Testing aircraft pneumatic systems
Overview
This standard identifies the competences you need to test aircraft pneumatic systems, in accordance with approved procedures. It covers both fixed wing and rotary winged aircraft, and includes emergency blow-down systems, de-icing systems, air stairs, waste disposal systems, arrestor mechanisms, deck locks, air start systems, flying controls, weapon systems and other systems, as applicable to the aircraft type.
You will be required to select the appropriate tools and equipment to use, based on the operations to be performed and the systems to be tested. The complexity of tests involved will include the testing of both pressure and return lines, system flushing and systems with and without faults.
Your responsibilities will require you to comply with organisational policy and procedures for the aircraft pneumatic system tests undertaken and to report any problems with the testing activities that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision and instruction, taking personal responsibility for your own actions and for the quality and accuracy of the tests that you carry out.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying aircraft pneumatic system test procedures. You will understand the pneumatic system under test, and its application, and will know about the test equipment and test techniques, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the tested system performs to the required specification.
You will understand the safety precautions required when testing the aircraft pneumatic system and with its associated tools and equipment. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the appropriate procedures for use of tools and equipment to carry out the required tests
- set up and carry out the tests using the correct procedures and within agreed timescales
- record the results of the tests in the appropriate format
- review the results and carry out further tests if necessary
- leave the aircraft and work area in a safe and appropriate condition, free from foreign object debris on completion of the activities
Knowledge and Understanding
You need to know and understand:
- the specific safety practices and procedures that you need to observe when testing aircraft pneumatic systems (including any specific legislation, regulations/codes of practice for the activities, equipment or materials)
- the health and safety requirements of the work area where you are carrying out the activities and the responsibility these requirements place on you
- the safety procedures that must be carried out before work is started on the aircraft
- the hazards associated with testing aircraft pneumatic systems, and with the tools and equipment used, and how to minimise them and reduce any risks
- the protective clothing and equipment (PPE) to be worn whilst carrying out the testing activities
- where to obtain the necessary information regarding the testing of the aircraft pneumatic system being worked on (such as system drawings and circuit diagrams, engineering drawings and related standards)
- the terminology used in aircraft pneumatic system testing procedures, and the use of power diagrams and associated symbols
- test specifications of the systems you are working on; their interpretation and currency/issue checks
- the operating principles of the pneumatic system being tested and the performance characteristics of the testing equipment (such as looping out systems; performing specific testing activities; removal of foreign object debris; operating and test characteristics of the system and components being tested)
- the correct operating procedures of the system being tested and the pressures used
- electrical bonding specifications and their importance to the system
- the various types of pipe and component that make up the aircraft pneumatic test equipment (such as valves; looping out equipment; blanks; mating equipment; return and pressure lines; pneumatic pumps; pneumatic rigs; actuators; motors; specific-to-type equipment)
- methods of lifting, handling and manoeuvring test equipment to the desired location to aid test activities
- types of test equipment to be used and their selection for particular tests
- any required environmental controls relating to the testing
- methods of breaking down and testing systems, ensuring that: ingress and contamination of system is avoided; system equipment and surrounding airframe and components are not damaged; direction of flow indicators and max pressure labels are observed; blanks and plugs are used when accumulators, filters, pneumatic power supplies are disconnected
- reconnecting system equipment when testing is completed, ensuring that pipes and connections are tightened correctly; clearance is maintained between other components, including flying controls and aircraft surfaces; ensuring that pipework is not damaged and is located in correct positions; carrying out visual checks on all components; checking the security of joints and that the system is safe to pressurise
- the tools and equipment used in the test activities; calibration requirements; and care and control procedures for the tools and equipment
- the need for tool/equipment control and why you must be able to account for all the tools and equipment used on completion of the test activity
- the procedure for safe disposal of waste materials and testing fluid; what to do with leaks and pipe bursts; ensuring that contamination of other aircraft systems is kept within acceptable levels when leaks occur; cleaning procedures for aircraft and work area when leaks and contamination occurs
- the fault finding techniques to be used if the system fails the tests
- how to analyse test results
- displaying/recording test results and the documentation to be used
- authorisation procedures for changes to test procedures
- problems that may occur during the testing activities and how they can be overcome; errors that may affect test results
- the extent of your own authority and from whom to seek help if you have problems that you cannot resolve
Scope/range
Scope Performance
Carry out all of the following during the testing of the aircraft pneumatic systems:
- obtain and use the appropriate documentation (such as job instructions, aircraft pneumatic system test procedures, quality control documentation, history sheets, flight logbook, aircraft standards and specifications)
- adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide and maintain a safe working environment for the testing activities
- obtain the correct tools and equipment for the activity and check that they are in a safe, tested and usable condition and within current calibration date
- obtain clearance to work on the aircraft and observe all relevant safety procedures
- ensure that isolation procedures are followed and that safe working distance procedures are set up
- carry out the tests, using the specified techniques and procedures
- return all tools and equipment to the correct location on completion of the testing activities
Test two of the following aircraft pneumatic systems (either high or low pressure):
- emergency blow-down systems
- spoilers
- arrestor mechanisms
- de-icing systems
- slats
- deck locks
- air stairs
- flaps
- gun cocking
- waste disposal systems
- flying controls
- weapon bay doors
- engine air start
- nose wheel steering
- air intake shutters
- wheel braking
- other specific systems
Test aircraft pneumatic systems and equipment, using three of the following tools or test equipment:
- air pumps
- priming equipment
- connecting equipment
- pressure gauges/devices
- blanking equipment
- leak detection medium
- pneumatic test rigs
- bleeding equipment
- other specific test devices
Carry out four of the following types of test:
- system charging
- system sampling/taking results
- system priming and bleeding
- reduced system test
- system pressure test
- system components tests
- air line vapour tests
- leak test
- system functional tests
Deal with two of the following complexities during the testing activities:
- equipment with no faults
- equipment with faults
- equipment with intermittent faults
Use two of the following fault finding techniques during the tests:
- half-split technique
- input-to-output technique
- six point technique
Review and record fault symptoms and history of problems using four from:
- data sheets
- log cards/history sheet
- calibration records
- aircraft documentation
- fault records
- maintenance records
- other specific records
Carry out tests in compliance with one of the following standards:
- Civil Aviation Authority (CAA)/European Aviation Safety Agency (EASA)
- Ministry of Defence (MoD)
- Military Aviation Authority (MAA)
- Aerospace Quality Management Standards (AS)
- customer standards and requirements
- Federal Aviation Authority (FAA)
- company standards and procedures
- BS, ISO or BSEN standards and procedures
- specific equipment requirements
- manufacturers standards and procedures
Scope Knowledge
Values
Behaviours
You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:
- strong work ethic
- positive attitude
- team player
- dependability
- responsibility
- honesty
- integrity
- motivation
- commitment