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STANDARD OPERATING PROCEDURE: 01 / 2012 MAINTENANCE OF MICROLIGHTS IN NCC

 

References:

  1. Standard Operating Procedure 01/2008.
  1. IAP 1501.

List of Appendices:

  • Format for Demand of Item.
  • Format for calling of Quotation.
  • List of Authorised Firms for procurement of Spares/ Repairs.
  • Format for Supply Order.
  • Format for Acceptance Certificate.
  • Format for Defect Report.
  • Duties and Responsibilities.
  • Format for External Issue and Receipt Voucher.
  • Format for CRV.
  • Format for Internal Issue and Receipt Voucher.
  • Format for Internal Return and Receipt Voucher.
  • Extract of Zen Air Airframe OEM Manual.
  • Extract of Rotax 912A Engine OEM Manual.
  • Extract of X- Air Airframe OEM Manual.
  • Extract of Jabiru Engine OEM Manual.
  • SOP on Defect Reporting and Analysis.

 

INTRODUCTION

1. National Cadet Corps (NCC) Air Wing Flying Squadrons are equipped with Microlight aircraft for imparting flying training and instilling a sense of adventure amongst the Air Wing cadets. There are presently 45 Microlight aircraft in 50 Air Squadrons of NCC and 110 more Microlight aircraft are likely to be inducted into NCC in the near future. To enable effective utilization of these flying machines it is necessary to put in place a robust maintenance practices including provisioning, procurement and equipment accounting systems that would not only ensure timely availability of spares and high serviceability of aircraft but also enable proper accounting of the costly spares purchased/consumed.

AIM

2. The aim of this SOP is to lay down guidelines for the maintenance practices of Microlight aircraft in NCC including Provisioning/Procurement of spares, their accounting and repairs.

PROVISIONING AND PROCUREMENT OF SPARES

  1. JD Lgs (Air) at HQ DGNCC is responsible for Provisioning and Procurement of spares for the MICROLIGHT aircraft. Towards this end, the recurring requirement of spares, servicing kits, overhaul/servicing arising need to be worked out keeping in view the following:
  1. Annual training task.
  1. Present life of airframe/aero engine/component.
  1. Lifing policy/servicing/overhaul periodicity specified in the relevant OEM manuals /Service Bulletins/Policy directives.
  1. Mandatory spares/changes recommended in the relevant servicing schedules/ manuals/policy directives.
  1. Last two years consumption data.
  1. Float of fast moving spares/servicing kits authorized to be held at various units wherever applicable.
  1. In addition to the above, non-recurring requirements/arising at units due to unserviceabilities, defects etc would also need to be consolidated and procurement action initiated.
  2. Procurement of Spares. In order to effectively utilize the collated data and to provision the recurring requirements, the procurement / servicing / repairs would be regulated on a Centralised Local Purchase basis. HQ DG NCC Lgs Dte is designated as the central LP agency for this purpose wherein one commissioned Officer from Lgs Air Cell would be detailed as the Purchase Officer for all such purchases and associated documentation / aspects. The particulars and specimen signatures of the designated Officer would be forwarded to CDA and all concerned.
  1. Requirement of spares giving Part No. (indicating whether the part pertains to Airframe or Engine) will be projected by Units to Lgs Dte (Lgs Air Cell) at HQ DGNCC as per format attached as Appendix `A’. The demands of each Air NCC Sqn would be serially numbered for proper linking and follow up.
  1. Lgs (Air) Cell at HQ DG NCC will check availability of stock of demanded item at their store and if available, issue the items directly to the demanding unit.
  1. Lgs (Air) Cell at HQ DG NCC will examine and compile non-recurring demands received from various Air NCC Sqns. Quotations from the OEM / supplier for items or / and services not in the annual price catalogue of the firm would be called for. The format for calling of quotations is attached as Appendix `B’. The price called for / submitted by the firm would be on F.O.R. basis for direct supply to the demanding unit and installation, in situ (if required). The quotations / price list would be called for only from the OEM or their authorized supplier on PAC basis. The list of these firms is given at Appendix `C’. In case of dealing with firms other than OEM / authorized supplier, quotations from at least three firms would be invited and only L-1 (lowest) would be accepted until valid reasons for accepting quotations other than L-1 are endorsed by the CFA. The procedure for recurring requirements worked out by Lgs (Air) would also be the same as for demands received from user units.
  1. Sanction of CFA would be obtained for the finalized price (including Taxes, Charges, installation, commissioning, etc., if any) from `Angle of Necessity (AON)’.
  1. HQ DG NCC (Lgs Dte) will allot funds for centralized local purchase / repairs under code head 1/544/01 on earmarked basis for Air assets.
  1. The Purchase Officer would, on the basis of total financial effect obtain AON sanction and place Supply Order as per Appendix `D’ and forward copy of the same to all concerned. Requisite funds would be earmarked for the Supply Order.
  1. On receipt of stores, DGNCC Lgs Air Stores/ the consignee Air NCC Sqn will immediately issue `Acceptance Certificate’ duly annotated with RV (Receipt Voucher) No. and the Ledger Folio Page No. to the Firm. A copy of the same would be faxed to Lgs (Air) Cell at HQ DG NCC followed by ink signed copy by Speed Post. In case installation / commissioning is mentioned in the Supply Order, the `Acceptance Certificate’ would be issued only after satisfactory completion of installation / commissioning by the firm for claiming the payment as well as installation / commissioning charges, if any. Fitment of all spares and consumables is to be entered in Form 700D/ Logbook/ Expense Book. COs of Air Sqns are to ensure the same. Format of`Acceptance Certificate’ is attached as  Appendix `E’.
  2. The firm, after dispatch of item (with certification), will prepare the bill and forward it to HQ DG NCC Lgs Air Section along with a copy of the Purchase Order and requisite documents. The Purchase Officer will obtain CFA Sanction on the basis of AON Sanction and the actual Bill Amount. Thereafter, he will process the bill and forward it to CDA Tigris Road.
  3. CDA Tigris Road after receipt of duly certified and countersigned bill (with requisite documents) will make payment directly to the firm.

Repair of Microlights.

  1. At Site. The following procedure is to be adopted for repairs at site:
  1. Units will project details of repair / servicing required along with spares required giving Cat Part No. ( indicating whether the part pertains to Airframe or Engine) to Lgs Dte (Air Section) at HQ DG NCC. The format of Report is attached as Appendix `F’.
  1. Lgs (Air) Section at HQ DG NCC will examine the feasibility of repair / servicing within the expertise available at the unit. In case of the required facility / expertise not being available at unit level, would forward RFQ to the firm advising the nature of defect. The firm would furnish quote for complete repairs (at site) inclusive of items required to be replaced and charges for routing their representative to the unit.
  1. Sanction of CFA would be obtained for the finalized price (including Taxes, Charges, installation, commissioning, etc., if any) from `Angle of Necessity (AON)’.
  1. The Purchase Officer would place Work / Repair Order as per Appendix `D’ and forward copy of the same to all concerned. Requisite funds would be earmarked for the Work / Repair Order.
  1. The firm would carry out the repairs / servicing, certify the repairs having been carried out and offer the Microlight (after repair) for Ground and Air Test to the Commanding Officer of the user unit. If the user is satisfied (after the Air Test) then Certificate of fitness and acceptance (Appendix `E’) is to be signed by the user unit and handed over (two copies) to the firm’s representative. A copy of the same would be faxed to Lgs (Air) Section at HQ DG NCC followed by an ink signed copy by speed post. The repair including major spares replaced is to be entered in Form (T)700D / Log Book and countersigned by the CO, Unit.
  1. The firm will prepare the bill and forward it to HQ DG NCC (Lgs Air Cell) along with a copy of the Repair Order and Certificate of fitness and Acceptance (received from the unit) to the Purchase Officer for claiming payment. The Purchase Officer will process the bill and forward along with requisite documents to CDA Tigris Road Delhi.
  1. CDA Tigris Road after receipt of duly certified and countersigned bill will make payment directly to the firm under intimation to Lgs (Air) Section at HQ DG NCC, and the recipient unit.

7. At Repair Agency. The following procedure is to be adopted for undertaking repairs at repair agency:

  1. Units will project details of repair / servicing required to Lgs Dte (Air Section) at HQ DG NCC clearly certifying that the nature of defect is such that repair at site is not feasible. The format of Report is attached as Appendix `F’.
  1. Lgs (Air) Section at HQ DG NCC will float RFQ to the concerned Firm for disassembly of the ML and transportation to their premises advising the nature of defect. The firm would furnish quote for disassembly and transportation clearly certifying that the repairs cannot be undertaken at site.
  1. Sanction of CFA would be obtained for disassembly and transportation of the Microlight from `Angle of Necessity (AON)’.
  1. The Purchase Officer would, on the basis of total financial effect place Order as per Appendix `D’ and forward copy of the same to all concerned including NCC Liaison Cell.
  1. On receipt of the Microlight at the Firm’s premises, a joint survey will be carried out by the NCC Liaison Cell, representatives from concerned unit and the Firm. The Firm will forward their quote to JD Lgs (Air) at HQ DG NCC covering repair work, transportation back to the unit and re assembly at the unit along with a copy of the survey report.
  1. Additional Sanction of CFA would be obtained for the repair work, transportation back to the unit and re assembly at the unit of the Microlight from `Angle of Necessity (AON)’. The Purchase Officer would, on the basis of total financial effect place Work / Repair Order as per Appendix `D’ and forward copy of the same to all concerned including NCC Liaison Cell.
  1. On receipt of the Repair Order, the Firm will commence repair. All the unserviceable items replaced would be returned to the NCC Liaison Cell who will ensure proper accounting of all such items. All these items will be returned to the Unit for further disposal when the Microlight is dispatched back on completion of repair.
  2. NCC Liaison Cell will monitor progress of repair on a daily basis and furnish report to HQ DG NCC. On completion of repair, Air Test will be carried out both by the Firm as well as NCC Pilot. On completion of successful Air Test, joint acceptance is to be carried out by the NCC Liaison Cell, representatives from concerned unit and the Firm. The repair including major spares replaced is to be entered in Form (T)700D/Log Book and countersigned by the CO, Air NCC Sqn.
  1. The Microlight thereafter will be dismantled and transported back to the unit. On receipt at the unit, it will be reassembled by the representatives of the Firm and Air Tested by the CO of the unit in their presence. The CO will satisfy himself that the repairs have been carried out as per the Order and sign the Acceptance Certificate.
  1. Preparation of Bills by the Firm and payment by CDA will be as per para 6 (e) and (f) above.
  1. OEMs are to submit Annual Price List and particulars of their authorized signatory along with their specimen signatures to the Lgs (Air) Section at HQ DG NCC. The Purchase Officer would forward a copy of the same to CDA for their records. In case of non-availability / non-submission of Price List by any firm, the procedure for calling of quotations is to be resorted to.
  1. All certificates / CRVs (certificate receipt vouchers) issued by the user / receiving unit are to be signed by the CO/Commissioned Officer only.
  1. The Purchase Officer is to :-
  1. Place Supply / Repair / Work Order only for items / repairs / servicing on firm.
  1. Earmark funds for those purchases / Repairs / servicing.
  1. Obtain sanction of CFA.
  1. Progress Invoices for payment.
  1. The procurement / repair of commonly available items / low value items / non-proprietary items viz. Batteries, Araldite, measuring cans, chamois leather, etc., are to be procured / repaired locally by respective Air NCC Sqns from the funds allotted to each Directorate under related code head so as to obviate the air assets being on ground / unserviceable for trivial items and avoidable procedural delays through central provisioning. The bills for these purchases would be cleared through respective CsDA. Similarly the requirement of items pertaining to other code heads would be procured under the respective code head from the funds allotted to the state Dtes or a Statement of Case would be forwarded through concerned Dte to respective section at HQ DG NCC for consideration.
  1. The duties and responsibility of all agencies are listed at Appendix `G’.
EQUIPMENT ACCOUNTING

13. Issue from DGNCC Lgs Air Stores. Issues from DGNCC Lgs Air Stores will be made only on allocation from JD Lgs Air. Before effecting issue, the condition and life of the item is to be checked and item with sufficient life is to be issued. DGNCC Lgs Air Stores will raise an issue voucher as per Appendix `H’ annotating all the relevant details. Each issue voucher will be allotted an EX/IV Number from the manifold maintained for the purpose. The numbering will start from 01 Apr and end on 31 Mar of each year (Financial year wise). Issue Vouchers will be raised in five copies. The distribution will be as under:

  1. 1st copy: Advance copy from DGNCC Lgs Air Stores to the Air Sqn by post. To be returned to DGNCC Lgs Air Stores by the Sqn on receipt of item annotating EX/RV No. (External Receipt Voucher No.).
  1. 2nd copy:  To travel along with the item.
  1. 3rd copy:  DGNCC Lgs Air Stores Audit Copy.
  1. 4th copy: Accounting copy for posting on Ledger. To be maintained at DGNCC Lgs Air Stores for subsequent audit.
  1. 5th copy:  LAO Air Sqn copy.

14. Each issue will be meticulously entered in the Ledger prior to despatch of the item. The Store in-charge will certify and sign on the Issue Voucher stating that proper Ledger entries have been made. JD Lgs Air will carry out Snap Checks of store (at least ten items) once in three months to ensure that physical stock tallies with the Ledger Balances. Records of all Snap Checks are to be maintained in a separate folder.

Receipt at Air Sqns.

  1. From DGNCC Lgs Air Stores. Whenever an item is received at an Air Sqn from the DGNCC Lgs Air Stores, the same is to be brought on charge by annotating an EX/RV No. (External Receipt Voucher No.) to the Issue Voucher raised by DGNCC Lgs Air Stores. The numbering will start from 01 Apr and end on 31 Mar of each year (Financial year wise).
  1. From OEM/Other Agencies. Whenever an item is received at an Air Sqn from OEM/ Other agencies, the same is to be brought on charge by raising a CRV (Certified Receipt Voucher) as per Appendix `J’ annotating all the relevant details. Each CRV will be allotted an EX/RV/CRV Number from the manifold maintained for the purpose. The numbering will start from 01 Apr and end on 31 Mar of each year (Financial year wise). CRVs will be raised in six copies. The distribution will be as under:
  1. 1st copy:  To be retained at Air Sqn for Ledger action.
  2. 2nd, 3rd and 4th copy: To be forwarded to the Firm with EX/RV/CRV No. The Firm will retain 2nd copy. The 3rd and 4th copies will be attached along with bills and other documents and forwarded to HQ DG NCC for payment action. On accordance of CFA sanction at HQ DG NCC, 3RD copy will be passed to CDA along with Bills for payment action. 4th copy will be retained at HQ DG NCC for record purpose.
  3. 5th copy: To be sent by the Air Sqn to DGNCC Lgs Air Stores for record/monitoring purpose.
  4. 6th copy:  LAO Air Sqn copy.
  1. The Ledger balance is to be updated before stacking/binning the item in store. The Ledger should indicate the location of the item in store for easy access and handling.

Transactions at Air Sqns.

  1. Internal Issues. Whenever a technician requires an item from store, a demand for the same is to be raised by the Inventory Holder of the Sqn, specifically detailed by the CO (Should be of the rank Sgt and above). The format of Demand is placed at Appendix `K’.
  1. Each demand is to be serially numbered during the Financial Year and raised in three copies. The third copy will be retained as the Pad copy.
  1. First and Second copies are to be submitted to the Store Keeper who will annotate an IN/IV No.(Internal Issue Voucher) before issuing the demanded items to the Inventory Holder. The second copy will be returned along with the item. The Inventory Holder will annotate the IN/IV No. on the Pad copy of the voucher from the second copy for record purpose.

21. The Store Keeper will use the first copy to adjust the Ledger Balance and maintain it in a separate folder for records.

  1. Internal Returns. Whenever an item becomes unserviceable, the inventory holder will prepare a Return Voucher as per format placed at Appendix `L’ annotating all relevant details.
  1. The Return Voucher will be raised in three copies. The third copy will be retained as the Pad copy.
  1. First and Second copies are to be submitted to the Store Keeper along with the unserviceable item who will annotate an IN/RV No.(Internal Return Voucher) from the Manifold maintained for the purpose. The numbering will start from 01 Apr and end on 31 Mar of each year (Financial year wise). The second copy will be returned to the Inventory Holder duly signed by the Store Keeper as having received the unserviceable item. Inventory Holder will annotate the IN/RV No. on the Pad copy of the voucher from the second copy  for record purpose.
  2. The Store Keeper will maintain a separate Ledger for record of unserviceable items. Items meant for DI /PWR, when returned as unserviceable will be accounted for as EACH as well WEIGHT. These items are repairable/valuable/attractive in nature and therefore need higher inventory control. All other items on return will be converted to their basic raw materials and accounted for only in weight. (for eg. Metal Ferrous, Rubber, Leather etc.). He will use the first copy to update the Ledger Balance and maintain it in a separate folder for records. All items becoming unserviceable (other than consumables/expendables) are to be returned to store prior to issue of serviceable replacements. He will also ensure that the unserviceable items are kept in a separate store and not along with serviceable stock.
  3. All unserviceable items accumulated at Air Sqns other than those on DI/PWR action will be dispatched to their respective Dte at least once in three months. Each Dte will send a quarterly return of the unserviceable/salvage stock held with them. Directorates are to conduct a BOO annually in the month of April for auctioning the items and deposit the proceeds in govt. treasury through an MRO. A copy of the board proceedings and MRO are to be sent to HQ DGNCC Lgs Air Cell for information. All unserviceable arising at Air Sqns on DI /PWR action will be dispatched to NCCLC as per SOP on DI/PWR.
  4. The Store Keeper will make a list of salvage items before transfer to the Dte, obtain signature of the recipient and update his Ledger for salvage items accordingly. The list will be made in duplicate. One copy is to be retained by the Store Keeper and the second copy maintained at the concerned Dte.
MAINTENANCE ACTIVITIES

Inspection Procedures and Periodicity

28. Zen Air CH 701 Airframe. As per OEM manual for STOL Zen Air CH 701, prescribed periodicity between two consecutive servicing (of similar types) is either 25hrs or 100hrs only. An extract of the relevant pages of the manual is attached as Appendix `M’. There is no separate 50hrs servicing envisaged on the Zenair CH 701 aircraft. Accordingly, there would be three 25 hrs servicing between 0-100 AF hrs and the inspection carried out at 50 AF Hrs is nothing but a repeat 25 hrs servicing. There is no separate inspection/ servicing (200/ 400/600/1000/1500 hrs) required to be carried out on the Zen Air CH 701 aircraft and these are nothing but a repeat 100 hrs servicing.

  1. The following items are to be inspected for their condition during every 25 &100 hrs servicing and replaced wherever necessary:
  1. Bungee cord
  1. Fuel Filter
  1. Cushion Pad set.
  1. Nose Wheel Spacer
  1. Main Wheel Spacer
  1. Fuel Hose from filter to drain valve
  1. The basic maintenance philosophy is to carry out preventive maintenance checks every 25hrs and take corrective action based on condition. Items are to be changed ‘On Condition’ and not ‘Irrespective of Condition.’ If it is subsequently felt that certain items need to be changed, based on either failure data or feedback from operating units, the same will be introduced as an ‘Out of Phase Servicing’ event rather than as a new servicing cycle. Such requirements would be communicated separately to all Air NCC Sqns by HQ DG NCC.
  1. Rotax 912A Engine. In respect of Rotax engines, periodic inspections are to be performed at First 25hrs followed by 50, 100, 200, 600hrs intervals in accordance with Chap 05-20-00 Section 5.1 of Rotax 912 Maintenance Manual of October 2009. An extract of the relevant pages of the manual is attached as

Appendix `N’.

  1. X-Air airframe. In respect of the X-Air airframe, the servicing periodicities specified by OEM are every 50h/1 month, every 150h/6months, every 300 h/1year, every 600 h/2years and every 900h/5years. An extract of the relevant pages of the manual is attached as Appendix `P’.
  1. Jabiru engines. In respect of the Jabiru engines, the periodicity to be followed is initial 25 hrs check followed by every 50hrs , every 100hrs and 200hrs. The 200hrs check is to be treated as a 100hrs check with the addition of a fly wheel bolt check. An extract of the relevant pages of the manual is attached as

Appendix `Q’.

34. Defect Investigation Procedures. Despite an elaborate preventive maintenance program being followed, failures/defects do occur during the service life of a component leading to unserviceabilities/ premature withdrawal. In the interest of flight safety and to improve the serviceability and reliability, it is necessary that any such defect is immediately reported on appropriate form, investigated and prompt remedial measures instituted to prevent recurrence. This is particularly important in respect of component/system failures leading to accidents and incidents. A detailed SOP on the reporting, investigation and subsequent monitoring of defects both in respect of airframe and aero engine systems is placed at Appendix `R’.

  1. This SOP is applicable with immediate effect. All SOPs / instructions issued earlier on the subject stand cancelled.
  1. Any deviation to this procedure will be under the instructions of undersigned only.
  1. This has the approval of DG NCC.

Distribution:

CDA Tigris Road, Delhi

M/S AASAA, Bangalore

M/S Varman Aviation Pvt. Ltd, Bangalore

M/S Velocity Max Pvt. Ltd., New Delhi

M/S Raj Hamsa Ultra lights Pvt. Ltd., Bangalore

All NCC Dtes

All Air NCC Sqns

Internal Copy to:

All DDGs of HQ DG NCC