一架巨型飛機的深度體檢

一架巨型飛機的深度體檢

A SUPER JUMBO’S IN-DEPTH CHECKUP

The world’s largest double-decked passenger plane, the A380, had its first 6-year check in China under the joint efforts of China Southern Airlines, GAMECO, and Airbus over 90 days and almost 100,000 working hours.

Text by Meng Yongning, Irene, Liu Yunpin, Cheng Yujiang & Wang Kai Photos by Zeng Jian & Tan Zhenyang Translation by Sonia

南航、GAMECO、空客三方聯手，90多個日日夜夜，近10萬工時，世界最大雙層客機A380在中國啟動第一次六年檢。

China Southern Airlines has been operating the A380 for 6 years. Since its operation, this super jumbo has been the center of attention around the globe for its smooth rides and large capacity. On March 1st, 2017, the first 3C-check of China's first A380 (B-6136) was officially activated in GAMECO's hangar and is scheduled to complete in June. The plane will take to the skies in a whole new condition after the checkup.

The 3C-check of the A380 is also called the 6-year check, which is a thorough, detailed, in-depth overhaul performed by the maintenance staff on the plane after 6 years of operation. The checkup includes major maintenance such as routine checkup, renovation, and cabin renewal. This is to ensure the reliability of plane operation and to level up the cabin comfort.

This A380 6-year check is the first time in China's aero maintenance history, and China Southern Airlines was faced with challenges never experienced before: enormous working hours and long AOG (aircraft on ground) period; difficult and numerous renovation items; many first-time work entries with very little experience to refer to. According to the plan, the first A380's 6-year check will take 94 days; nearly 100,000 working hours. In the cabin alone 2,500 parts will be removed; both decks of the cabin will be completely taken out; all parts are to be cleaned, checked, repaired, and painted. Compared with planes like the A320 and A330, the body of the A380 is not only massive but also 7 stories tall, all leading to huge maintenance difficulties. After the checkup, the plane will be completely repainted. The paint surface of an A380 exceeds 4,000 square meters, equivalent of five A320 planes.

Based on the maintenance scheme, the rest four A380s owned by China Southern Airlines will be hauled into the hangar for their 6-year checkswithin two years. Globally, there are many A380s due for the 3C-check. GAMECO plans to utilize the experience acquired and its competitive advantages to explore a larger A380 aircraft maintenance market.

＊GAMECO∶ Guangzhou Aircraft Maintenance Engineering Co. Ltd.

自引進國內首架A380，南航已運營該機型達6年之久。 投入使用以來，“空中巨無霸”以其平穩舒適、載客量大等特點，受到國內外廣泛關注。2017年3月1日，中國首架A380（B-6136）的首次3C檢在GAMECO機庫正式啟動，預計最終將在6月完工，屆時飛機將以全新狀態重返藍天，再展雄姿。

A380的3C檢也稱六年檢，就是在飛機運行6年之后，由機務人員進行的一次全面、詳細、深度的體檢。體檢中包括例行工作、改裝、客艙整新等一系列大型維修工作，以保證飛機的運行可靠性，并提升客艙舒適性。此次A380六年檢在國內航空維修史上屬首次。

6-year Check Process (94 Days)檢修流程（94天）

Day 1 to Day 14

Remove all parts of the double-decked cabin. Cabin renewal starts.

Wall panels are all opened. Complete most inspections.

Main components such as cabin doors, wing flaps, slats, and rails are all removed.

Inspections of items crucial to plane configuration, such as landing gear axles, slats, and engines, must be completed.

Nondestructive Testing (NDT) largely completed.

Major modifications start.

兩層客艙所有部件拆下，客艙整新全面開工

飛機蓋板全部打開，完成絕大多數檢查工作

客艙門、襟翼、縫翼、滑軌等大部件全部拆下

起落架小車樞軸檢查、縫翼檢查、發動機檢查等對飛機構型有嚴格要求的項目需完成

NDT檢查基本完成

重要改裝陸續開工

Day 15 to Day 45

Major modifications in tunnel bolsters, FR56, cabin doors, and pipelines completed.

Cabin renewal largely completed.

Non-routine work, such as cabin rail beam repair, largely completed.

鵝頸、FR56、客艙門、油管等重要改裝完成

客艙整新基本完成

客艙滑軌梁修理等非例行工作基本完成

Day 46 to Day 70

Install renewed cabin parts.

Recover and adjust wing flaps, slats, and cabin doors.

All-area cleaning, rot-resistance process, and panels put back.

Power test.

Test flight.

安裝整新后的客艙部件

恢復襟翼、縫翼、客艙門并調節

各區域的勤務、防腐以及蓋板恢復

飛機通電測試

試飛

Day 71 to Day 94

Whole body painting.

Weigh in after painting.

Test flight after painting.

Aircraft release.

整機噴漆

噴漆后稱重

（3）決策獨立，即獨立董事表達出的對決策的相關看法必須出自自己的意志，脫離大股東的控制，盡可能地減小公司管理者對其的影響。

噴漆后試車

放行

1

Wang Zhikun

Project Manager of A380 6-year check, GAMECO

王治坤

GAMECO A380六年檢項目經理

Q: What are the biggest challenges faced in the A380 6-year check?

A:There are many difficulties faced in this periodic inspection. Take the working hours for example: a total of 100,000 working hours are required for this 6-year check, compared to only 5,000 working hours in a routine C check and 30,000 in the most detailed D check. This means the processes have to be started in all areas at the same time. It really concerns me as a lot of what we're doing is for the first time.

問： A380六年檢遇到最大的挑戰在哪里？

答：此次定檢的困難非常多，單拿工時來說，本次六年檢大概需要100000工時，而平時做C檢基本上都是5000工時，做最深度的D檢，也就兩三萬小時。相當于四面開花，各個部位同時開工，每個工作量都比較大。很多東西第一次做，讓人很操心。

2

Bai Xuefeng

Assistant Engineer of Production Planning, Maintenance & Engineering Division, China Southern Airlines

白雪峰

南航股份機務工程部生產計劃助理工程師

Q: What preparation work did China

Southern Airlines and GAMECO do for this A380 6-year check?

A:China Southern Airlines' Maintenance & Engineering Division and GAMECO set up the mission team of 6-year check project in April 2016, to prepare the material, tools, equipment, and personnel training ahead of time. Since then, we have applied for the airworthiness permit from the authority, held many briefings with Airbus. Before commencing the checkup, 4,560 parts and 1,812 tools were all prepared, so were the tailor-made

scaffolding and the working platform for the A380.

問：南航和GAMECO為此次A380六年檢都做了哪些準備？

答：南航股份機務工程部和GAMECO等單位從2016年4月份就成立了六年檢項目籌備組，提前準備航材、工具、設備，對人員進行培訓，申請當局適航許可，并與空中客車公司技術代表召開多次碰頭會。開工前，4560項航材、1812項工具設備均已準備就緒，為A380量身定造的腳手架和接近平臺也已準備到位。

3

Jean-marc Braud

Technical Services Manager, Customer Support-SEOT4 Airbus

讓-馬克

空客公司技術服務經理

Q: What support does Airbus give to China Southern regarding this 6-year

check? What's your impression so far?

A:We are mainly responsible for two jobs: one is to optimize the working process in order to reduce the grounding time as much as possible. The other is to offer technical advice

for any other subjects during the C-check (structural modification, systems, etc. ). We have been working with Air France, Korean Air and Emirates on 6 - year checks before and I think this team is really good. They are well organized and disciplined. We are very happy with

what is going on. We expect that the grouding time (excluding painting) can be reduced to 60 days in the end.

問：空客給予南航哪些技術支持？空客對GAMECO的檢修水平怎么評價？

答：我們主要負責兩項工作，一是協助優化六年檢工作流程，盡量縮短停場時間。二是為結構改裝提供現場技術指導。這是A380在中國的第一次六年檢，南航也是中國唯一進行A380六年檢的航空公司。就我們的感受而言，南航的整體維修水平相當高，團隊組織性強，我們對工作進展非常滿意。我們預計到最后一架飛機的時候，停場時間（不包括噴漆）有望縮短到60天左右。

Q: How is the cabin renovation carried out?

A:Whole cabin renovation is an essential job in this A380 6-year check: almost all parts in the cabin have to be cleaned, repaired, or replaced. For example, the paddings in the back of the chairs are badly worn and need to be completely replaced; the arms of the chairs also need to be repainted. The panel walls and leather seat covers in both cabins have to be refurbished. Wallpaper is renewed: we use a vacuum laminating machine to paste a whole sheet of wallpaper seamlessly on the wall panel. The cabin parts are gradually reinstalled and a whole new A380 cabin will be seen.

問：客艙設備翻新是怎么進行的？

答：客艙整體翻新是本次A380六年檢的重要項目，幾乎客艙內所有的部件都要進行清潔、修復或更換。比如說經濟艙座椅靠背的海綿磨損得很厲害，需要全部更換，扶手也得噴漆整新，兩艙的板壁和真皮椅套都需要整新。壁紙全部更新，我們通過真空壓制車床，將整張壁紙無縫隙粘貼到壁板上。隨后客艙部件逐步安裝回去，旅客將會看到一個全新的A380客艙。

4

Wang Jue

Chief of Cabin Workshop Technology Team, 3rd Overhaul Division, GAMECO

王玨

GAMECO大修三部客艙車間工藝組主任

5

Tan Jinghua

Manager of Support Division, GAMECO

譚敬華

GAMECO支援部經理

Q: Are the standards for tools and equipment used in an A380 6-year check particularly high?

A:Yes. The body of A380 is huge and tall. The removal and transport of the chairs, toilets, kitchens, overhead compartments, and floor is massive work. Imagine moving a single kitchen weighing 350 kg off the airplane. To solve issues like this, we developed transport rails and lift trucks exchtsively for the A380s. Moving 3 kitchens at the same time takes less than 2 minutes.

問：A380六年檢對工具設備的要求是不是尤其高？

答：是的。A380機身又大又高，座椅、廁所、廚房、行李架以及地板的拆卸和運輸是巨量的工作。想象一下，一個廚房的重量是350公斤，怎樣才能從飛機上搬下來呢？為了解決這些問題我們專門研制出連接客艙與維修車間的滑軌運輸通道以及高達8.5米的自動升降平臺。三個廚房同時運下來，耗時不到兩分鐘。