A total capability

Citation

(2000), "A total capability", Aircraft Engineering and Aerospace Technology, Vol. 72 No. 1. https://doi.org/10.1108/aeat.2000.12772aaf.003

A total capability

Keywords Aviation support, Aircraft industry, Engineering, Maintenance

Part of the BWA Group, World Aviation Support (Plate 1) is a comprehensive aircraft engineering facility with its headquarters at Southend Airport. It has two hangars and 15 workshops with a total floor space in excess of 70,000ft sq. ft which can accommodate aircraft up to the size of a BAC 1-11. Apart from British World Airline (BWA) itself, recent clients have included British Aerospace Asset Management and Manx Airlines. As well as undertaking major airframe overhauls, World Aviation Support is one of the few companies in this field offering the full range of component and overhaul facilities. FAA, JAA and CAA approvals are held together with specific regional approvals, which enable a wide variety of components to be dealt with including those in the BAe 146, Fokker 100, Shorts 330/360, ATP, Boeing 707, 727 and 737, DC 8 and 10, Herald, Jetstream, Viscount, ATR 42 and 72, Dash 7, HS 125 and 748.

Plate 1 Colin Saunders, Managing Director of World Aviation Support

The extensive workshops are qualified to deal with auxiliary power unit, hydraulics, power generation, radar, communications and navigation instruments, composite manufacture and repair, aircraft interiors, power plant, pressurisation, electrical components, gearbox overhaul, machine shop and sheet metal manufacture and repair, welding, landing gear and non-destructive testing (NDT). The company's computer system integrates various modules ranging from inventory control through to workshop tracking, planning and technical records. Based on its experience of engineering medium sized jet and turboprop aircraft, World Aviation Support continues to develop its capability for a wide variety of customers and aircraft types. It is anticipated that the component overhaul activities of the company will form an even larger proportion of the work undertaken in the future.

Facilities available

The hangar complex has space for up to three medium-sized jet or turboprop aircraft and services available range from a simple reconfiguration, repair, maintenance and modification, to total engineering support for a whole fleet. Investment in information technology has enabled the company to integrate all aspects of its operations and the hangar operation is supported by the workshops and technical services to provide operators with a one-stop service.

The composite workshop has been established for over 20 years and has moved into the field of hot bond repair methods, using the latest computer-controlled ATAC Hot Bonders. This is a necessary facility for today's aircraft repairs with many components being made of carbon, Kevlar and glass epoxy. Hot bond repairs are called for to repair metal to metal bonded panels. The equipment can be used in the workshop or in situ on the aircraft. Examples of the components that can be repaired, either composite or metal to metal bonded include flap track fairings, honeycomb panels, wing to fuselage fairings, elevator, aileron, flap and trim tab structures, as well as some radomes. This facility also has the expertise acquired over many years, in the repair, overhaul and testing of a variety of aircraft radomes ranging in type and size from Shorts 330, Banderainte and Boeing 737 and 757 and DC 10. It can also undertake repairs to trim panels and ducting, can manufacture hard trim, and is able to carry out vacuum-bag repair techniques and the spraying of radome anti-erosion coatings.

Dedicated areas are available for DTD 585 and Skydrol components to eliminate the possibility of cross-contamination. This department is supported by a comprehensive NDT facility together with a machine shop capable of manufacturing to drawing and undertaking specific reworks. Specializing in the overhaul and repair of all manner of hydraulic components as well as wheels and brakes, this area is able to deal with selectors, valves, controls, actuators, motor driven pumps, spoiler controls and hydraulic brake units for a wide variety of aircraft. Rebuild and pressure testing of flexible hoses is also featured and static test equipment is available as well as power hydraulic rigs. The overhaul of aircraft wheels includes crack detection and tyre changes.

The sheet metal workshop undertakes overhaul and repair of primary flight control surfaces, trim and balance tabs, leading edges, galleys and accessories, as well as the fabrication and repair of floor panels, rolled skins and control surface balancing. Rolling, cutting, forming and binding of sheet metal can also be undertaken.

A section dealing with safety equipment carries out overhaul of adult and infant lifejackets, dinghy and escape slides and deals with inertia reels and harnesses, as well as the re-weighing of fire bottles. It is supported by the cylinder overhaul workshop.

The APU workshop is equipped with full tooling to perform overhaul and repairs on a wide range of auxiliary power units, sub-components and LRUs. It is also backed up with the services of the NDT and welding departments, both of these having the necessary approval to perform inspections. Attached to the main workshop is a test cell which has been purpose built to perform full overhaul serviceability functions.

The capability of the pressurisation department includes controllers and amplifiers, discharge and safety valves, cabin relief and outflow valves, PRRVs, butterfly and temperature control valves, air system valves, switches and gauges for a wide range of aircraft and pressure transmitters. Two universal test panels are also situated here to provide an efficient test facility and the department is supported by comprehensive tooling and test facilities including a mass flow compressor and test cell.

The power plant section is capable of QEC overhaul and Dart power plant strip and rebuild, with approval to overhaul heat exchangers, air intakes, starter clutches, exhaust units, electrical harnesses, thrust reversers, engine bearer bolts, trunnion assemblies, jet pipe repairs and repair and replacement of propeller overshoes, auxiliary and secondary flap gearboxes, jack heads, flap control shafts and various winch assemblies. These repair and overhaul services are supported by in-house NDT, machine-shop and processing departments. Recent capability additions include the overhaul of propeller control units.

In the welding and fabrication field, approval for welding using the TIG process is available, as well as repair of jet pipes and general work on aircraft sub-components. Fabrication of tooling and ground equipment can be undertaken and there is also a service for portable welding for steels.

The machine shop has the capability for manufacture of various high precision components, sub-assemblies and specialist tools for aircraft and related industries, using approved manuals or drawings, while adhering to all the associated process specifications. This department actively works with other workshops within the company by offering its facilities and providing an efficient backup machining service. The facilities include milling, turning, grinding, fitting, inspection, and dalic plating.

There is an established NDT facility for aircraft structures, components and assemblies. Portable X-ray, ultrasonic and eddy current services are available to carry out on-site inspections, complemented by base facilities for magnetic particle inspections.

There is a cylinder overhaul workshop which offers the capacity to purge, charge, hydrostatic test and overhaul many kinds of portable and fixed cylinders and nitrogen reservoirs. These can be cylinders of up to 14in. in diameter and 36in. high.

A new capability is that of mass flow, which enables the overhaul or rework of the majority of valves. Typical types include starter valves, shut-off valves, pressure reducing valves, and temperature control valves as fitted to a wide range of aircraft.

Instrument, radio and electrical

The instrument workshop is situated within a controlled clean room, which has a multi-stage, temperature controlled absolute filtered air system. Clean air laminar flow work cabinets supplement this facility, providing Class 100 conditions for working with high precision gyros, etc. This department has been in operation for a number of years and is staffed by a team of engineers experienced in the overhaul and repair of components which include:

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  airspeed, altitude and Mach speed equipment;

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  air data computers and transducers;

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  directional, vertical and rate gyros;

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  compass systems;

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  autopilot components;

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  engine indicating systems; and

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  general instruments.

A service facility comprises the radio workshop, with a working area of some 2,000 sq. ft. It contains a well-equipped area using modern and comprehensive test equipment for the overhaul, repair and modification of a wide range of radio and aircraft equipment. It has been designed for efficiency, safety and convenience and has recently added the Primus 90 colour radar system to its capability.

The electrical department undertakes repairs to units and components for various types of equipment. These include those for power supplies, emergency, rotary and static inverters, switching devices and relay contactors. Also, amplifiers, controllers and galley equipment. Landing lights and emergency lighting are dealt with, as well as rotary and linear actuators, autopilot, primary and trim actuators, AC and DC cooling fans, and a wide range of high energy ignition units.

The generator facility covers a wide range of electrical components and possesses a low-pressure fuel flow test rig, two variable-speed drive units for testing AC and DC generators, voltage regulators, generator control units, and associated equipment. There is also another rig which is purpose built for testing cabin superchargers. This shop is able to deal with an extensive range of components, including AC and DC generators, autopilot servomotors, cabin superchargers, fuel booster pumps, and APU sub-components, such as centrifugal switch assemblies starter motors, fuel control units and atomisers.

Overall, some 200 staff are employed, including licensed engineers at World Aviation Support which, as indicated, has a very wide capability for dealing with many kinds of equipment, and this is likely to extend in scope and numbers of customers in the future.