Spotlight Award: 101 Maintenance Group (MXG), Maine ANG

by AMC FLIGHT SAFETY

2/5/2014 - Spring 2014 -- AMC FLIGHT SAFETY is proud to spotlight the 101 Maintenance Group (MXG), Maine ANG, for proactive mishap prevention efforts in identifying and mitigating C/KC-135 hydraulic system failures caused by chafing Air Refueling (AR) pump hydraulic lines. While troubleshooting an aircraft that had a hydraulic leak and was subsequently ground aborted at Bangor International Airport, hydraulic specialists discovered a leak caused by two AR pump hydraulic lines chafing each other. Rather than simply replacing the lines and closing out the discrepancy, the specialists took the initiative and looked deeper at the failure to determine if there were potential fleet-wide trends. Maintenance analysts searched historical records from other aircraft and discovered there had been similar events on other KC-135 aircraft. Additionally, technicians from the 101 MXG Inspection Dock analyzed an aircraft undergoing a Periodic Inspection and discovered chafing on its AR pump hydraulic lines.

The 101 MXG immediately initiated a One Time Inspection of all its aircraft and discovered 70 percent of their fleet had some chafed AR pump hydraulic lines. They up-channeled their findings to the ANG and AMC A4M communities so appropriate risk assessments and mitigation actions could be performed. After a coordinated effort with the KC-135 System Program Office, a 90-Day Routine Safety Time Compliance Technical Order was issued to inspect for and repair chafed AR pump hydraulic lines on all C/KC-135 aircraft in the AF inventory.

An in-depth review of inspection work cards identified improvement areas to mitigate future AR pump line chafing. The 101 MXG drafted and submitted an AFTO Form 22, Technical Manual Change Recommendation and Reply, to add inspection of all AR pump hydraulic lines to the 24-Month Periodic Inspection work cards.

As a direct result of the motivation and initiative exhibited by the 101 MXG, the entire C/KC-135 fleet flies safer today. We commend the Maineiacs of the 101st Air Refueling Wing Maintenance Group for their dedicated safety culture. Well done!