Naval Aviation Maintenance Oil Consumption Program

References:

1.  OPNAV 4790.2G, Volume V, Chapter 9: Establishes policy, responsibilities, and requirements for monitoring aircraft equipment condition.

2.  Aircraft/engine type Maintenance Instruction Manual (MIM) and Maintenance Requirement Cards (MRCs): Establishes specific T/M/S aircraft/engine requirements.

Objective:

The Oil Consumption Program

a. Establishes policy, responsibilities, and requirements for monitoring aircraft equipment condition in an effort to detect impending failures without equipment removal or extensive disassembly.

b. Provides Navy and Marine Corps Organizational-level maintenance activities the guidance necessary to achieve required performance, efficiency, and logistic support by establishing policy for integrated oil consumption requirements. All aspects of oil consumption/servicing, documentation, and trend analysis are critical to flight safety.

Background:

In 1994, as a result of the loss of two aircraft due to inadequate attention to engine oil consumption limits, a recommendation was made to formalize engine oil consumption as a NAMP program. Establishment of oil consumption as a formal NAMP process monitored by Quality Assurance, was the only alternative which would provide continuing routine attention and awareness of this vital subject. Effective monitoring of engine oil consumption is a critical indicator of engine integrity. Early detection of an abnormal usage trend can result in the repair or removal from service before a major component failure occurs.

Effectiveness:

The collective efforts between the Program Manager providing quality training, maintenance personnel performing the servicing/documentation requirements, Q/A monitoring/trend analysis, and Maintenance Control ensuring oil consumption rates are calculated and documented prior to release of aircraft as safe for flight ensure the effectiveness of the Oil Consumption Program. In addition, pilots/aircrew are also trained in oil consumption servicing /procedures and responsibilities. It helps identify those aircraft engines that normally have a low oil consumption rate per flight hour, as it provides a means of early detection in an effort to prevent loss of aircraft and engines.

The effectiveness of the oil consumption program is measured in the Navy Safety Center mishap program data. The oil consumption data was obtained from mishaps where aircraft had a history of high oil consumption. One Class A mishap in 1993 states as a causal factor that a “standard reporting program for monitoring aircraft model engine oil consumption was not established.” The majority of the mishaps queried revealed components failing due to absence of oil. The small number of mishaps indicate that the program is providing the attention necessary to prevent unnecessary mishaps.

Class of
Mishap / 1990 / 1991 / 1992 / 1993 / 1994 / 1995 / 1996 / 1997 / 1998 / 1999 / 2000
A / 1
B
C
HAZARD / 6 / 1 / 1 / 1 / 4 / 2 / 1

Analysis:

This program requires certain duties by several people in the Wing staff and squadron organizations as listed below. The responsibilities are listed by the individual within the activity who is responsible for completing the task and classified into the four categories requested. The manhour estimates are based on a 10-12 aircraft F/A-18C squadron with 180 sailors assigned to the Maintenance Department.

PROGRAM ELEMENT / ELEMENT IMPACT
Wing Staff:
Administrative:
-  Develop local command procedures
(1 time/chgs as required)
-  Develop T/M/S Oil Consumption Program CSEC questions. (1 time/chgs as required)
Operational:
- Monitor oil consumption requirements and provide a standardized method for Maintenance Control to ensure oil consumption limits are not exceeded prior to release of aircraft safe for flight. (3 hrs/qtr) / Manhours expended
Admin: <.001
Operation:
<.05
hours per day.
Maintenance Officer (MO):
Administrative:
-Designate, in writing, the Maintenance/Material Control Officer (MMCO) as the Oil Consumption Program Manager. (15min/yr)
-Coordinate with the NATOPS Officer to ensure all aircrew are thoroughly trained in oil consumption documentation requirements and procedures while operating away from home base.
-Develop local command procedures.
(one time/chgs as required) / Manhours expended
Admin:<.001 hours per day.
Program Manager:
Administrative:
-Be knowledgeable of applicable MIMs, MRCs, NATOPS procedures for their assigned aircraft, and the NAMP.
-Maintain a program file to include, applicable points of contact, program related correspondence and message traffic, and applicable references or cross reference locator sheets. (update monthly/5min)
-Ensure an Engine/Gearbox Oil consumption Record is retained in the Aircraft Discrepancy Book (ADB) until complete. Completed forms shall be placed with the applicable AESR and accompany the aircraft/engine when transferred. (as required)
-Ensure grade and quality of oil added to each engine is annotated in the Aircraft Inspection and Acceptance Record (OPNAV 4790/141).
Training:
- Provide indoctrination and follow-on training to personnel relating to their Oil Consumption Program responsibilities. (as required)
- Ensure personnel assigned duties of servicing engines and gearboxes are trained on proper servicing techniques and documentation requirements. (as required)
-Ensure safe for flight certified personnel receive adverse oil consumption values/trends certification training. (as required)
Operational:
- Ensure aircraft releasing authorities verify oil consumption limits have not been exceeded, per applicable MIMs/MRCs, prior to releasing aircraft safe for flight.
-Ensure oil consumption rates are calculated and documented prior to releasing aircraft safe for flight.
-Ensure appropriate action, per applicable MIMs, is taken when any consumption value or increase in consumption value exceeds the authorized limits.
-Ensure all pilots/aircrew taking aircraft on cross-country evolutions have been briefed on oil consumption/servicing procedures and responsibilities.
Assessment:
- Use CSEC information and reports to identify specific areas of concern and determine steps required for program/process improvement. / Manhours expended
Admin:<.1
Train:<.001
Operation:
<.1
Assessment:
<.001
hours per day.
Quality Assurance Officer:
-Designate, in writing, a Quality Assurance Representative (QAR) as the Oil Consumption Program Monitor. (15min/yr) / Manhours expended
ADMIN: <.001 hours per day.
Program Monitor:
-Perform annual audits using the Computerized Self-Evaluation Checklist. (1hr/yr)
-Assist in preparing NAMDRP reports.
-Screen oil consumption records weekly for completeness and accuracy with particular attention paid to abnormal trends and values. / Manhours expended
ASSESSMENT: <.1 hours per day.
Maintenance Control personnel:
-Ensure oil consumption rates are calculated and documented for engines/gearboxes prior to releasing aircraft safe for flight. (as required)
-Ensure an Engine/Gearbox Consumption Record is retained in the ADB until completed. Completed records shall be placed in the AESR and accompany the engine/gearbox when transferred. (as required) / Manhours expended
Operation: <.5 hours per day.
Work Center Supervisor:
Training:
-Provide Oil Consumption Program indoctrination and follow-on training. (as required)
Operational:
-Ensure oil servicing units are maintained free of contamination.
-Conduct oil servicing per applicable MIMs/MRCs. (10 min/engine) / Manhours expended
Train:
<.001
Operation:
<.1 hours per day
Aircrew:
Training:
-Be thoroughly familiar with oil servicing procedures. (as required)
Operational:
-Ensure oil consumption rates are calculated and documented on the Engine/Gearbox Oil Consumption Record prior to flight.
(5 min/flight) / Manhours expended
Train:<.001
Operation: <.3 hours per day
Total Admin: .103 Total Training: .003 Total Assessment:.101 Total Operational: 1.05 / Overall Total Manhours:
1.257 per day

Recommendations:

This is a program crucial to maintaining the condition of the aircraft and critical safety of flight components. It involves very little time on the part of any individual until a maintenance action is required due to adverse trends. Due to the safety of flight elements, the risk to personnel if the monitored components fail in flight, and the high cost to repair the weapons system, it is recommended that the Oil Consumption program be retained as specified in the NAMP. Applicable MIM's/MRC's to all T/M/S do not cite specific oil consumption monitoring processes. The MIM's/MRC's only address the oil consumption limitations and troubleshooting procedure(s) when engine/APU/gearbox consumption exceeds established consumption limits.

Current Initiatives:

OPNAV 881 has received and approved a request for deletion of a mandatory separate oil consumption chart for the T-56 engine in P-3 and C-130 aircraft because of aircraft systems capability, existing process monitoring checks, and the availability of monitoring trend data in other records. On these aircraft, the in flight oil quantities are monitored by flight station instruments. The Maintenance Instruction Manual (MIM) specifies explicit engine oil usage limits, leak limits, troubleshooting procedures and probable causes, and engine oil system checks. Any oil usage is documented on the post flight Inspection Record OPNAV 4790/38. The type commanders have readdressed this authorization to their respective fleets. Based on an average 50 flight hours/month and 240 aircraft, it is estimated that this change will save approximately 200 manhours/month fleetwide.

The NAMP Working Group has recommended that a review of the data compiled during the Integrated Maintenance Concept Studies (IMC) be conducted to determine if any other aircraft, engine and gearbox fit the above criteria.