Start of September we had our only Cessna Caravan in for its phase check. The phase check system is a bit different to our other systems of maintenance we run. The Phase Check system runs over twelve checks at every two hundred flying hours, from check one all the way to Check twelve and then starts over again. In between each Phase Check is a smaller check called a mini phase which is every one hundred flying hours. Instead of having little checks and then really big checks after a longer period of time, it is spread out consistently. The aircraft is broken down into different areas with assigned work cards to each area involving inspections and servicing.
The one thing with having the Caravan over a year now, only having one in the fleet and the first ever operated by MAF in PNG means that for most of us we have not much experience on this aircraft type. Most of us have only done a few checks on it. But there are two guys that have a lot of experience on them when serving with other MAF programs. This check would be a Phase 1, the first time we would carry it out on this aircraft. There was a lot involved in the check, by far the biggest one to date we have done. Plus with defects requiring rectifying or items called up, some big ones like a flap track replacement and a prop change.
2. Phase Check 1
We were given a week to have the aircraft finished so that it could return to service the following week. I knew it was a real big ask, almost impossible. After we received the aircraft and it had been out and had the engine runs completed, it came into the hangar. We were destined different areas to look after. I was assigned area 2, which is the airframe all the way from the engine firewall to the tail. The largest area with a very large amount of inspections and servicing to be carried out. I had only worked in that area once before and by myself, but this time I would have someone helping me to get through it all.
3. Laz replacing a flap track, a big job
We would work back each evening till 1800, each day slowly making our way through the check. It seemed we were making little progress each day. Come Wednesday evening to some amazement we were close to finishing most scheduled stuff for the check. Thursday we would spend finishing defects and putting the aircraft back together. Planning to do the compressor wash, engine runs and a prop balance on Friday, and to have the aircraft ready to fly a program on Saturday. This was a huge achievement. One thing that helped was having people start some major jobs at the start of the check.
4. Looking down from the tail
Come Friday morning getting closer to the end after a big and intense week. A lot of us felt like we had hit a wall as it had been so intense and now had come to an almost halt, as the airframe was pretty much done with mainly the engine to be finished. As work continued there were problems with the new prop and in the end resulted in a few guys working into Friday night and throughout Saturday to get the aircraft ready for Monday morning. Despite the delay, it was a huge achievement by the team to get the aircraft out in a week, it is still a learning process for many of us and it was by far the most intense week I have experienced.
October 3rd, 2009 at 12:00 pm
Sounds like a hardcore week of work, really cool what you’re doing man.
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