Basic Indoc. Airframe and Powerplant Course

Prerequisite:

B.Sc.Mechanical Engineers newly hired

Duration:

(6)months

Course Objective

To introduce the new hire B. Sc. Mechanical Engineers to EgyptAir
and its'manner of conducting aircraft maintenance.
It specifically aquatints the student with EgyptAir's policies,
procedure frames, organization and administration practices and
ensure that the ·student has acquired basic maintenance engineer
knowledge. Also to ensure that the student is fully informed about
pr6cedure, techniques and new equipment in use and is. capable to
perform his duties as defined by ECARS 65 subpart B paragraph
65.37(B).

Content Course

Phase I EgyptAir's Specific Training Modules

Teclmical Procedure Manua

General, Why TPM, AOC Requirements
Technical Management and Quality System.
Personnel Qualification and Training.

Contents of MS Certification and Operation Specification

MS Technic:al Capabilities and Facilitie·s
MS Technical Document Control
Inspection (Quality Control)
Continuous Analysis and SurVeillance Program
Quality Records
Maintenance Reliability Program
Tools Test and Measuring Equipment
Identification and Tractability
Deferral of Discrepancy and Follow up
Short Term Escalation Program
Repeated Discrepancy Management
Non Conformity and Corrective Action
Planning
Procurement and Material Management
Engineering
Shop and Ramp Proces$ Control
Material Management
Safety Program
ETOPS Program

Field Trip 1 (Quality Records)
Field Trip 2 (Engineering)-"
Field Trip 3 (Hanger Maintenance)
Field Trip 4 (Shop Maintenance)
Exam I

Phase II Aeronautical Engineers Specific Training Modules

Aviation-Regulations

Introduction (ICAO & lATA).
Introdu'ction to ECARS:
Air Worthiness Certification
General Definitions and Abbreviations
Noise Certification
Air Worthiness Direction.
Nationality and Registration Marks.
Maintenance, Preventive Maintenance and Alternation
Certification: Airmen Other Flight Crewmembers.
Certification and Operation: Air-Carriers and Taxi Operators
Approyed Maintenance Organization and Repair Stations.
General Operating and Flight Rules
Standard Instrument Approach Procedures.
Transport ofDangerous Goods.
Exam 2

Inspection Procedure

Aircraft Materials
Heat Treatment.
Corrosion Protection.
Fasteners.
Control Cables
Tubing.
Welding
Non-Destructive test
Airframe Structure.
Structure Repair.

Field Trip 2

Unit shop.
Engine shop.
Electric/ElectroniG/Instruments/ Avionics/ ATEC.
Stores.

Exam 3 General Aeronautical Subjects

Aerodynamics
Jet Engines Performance
Jet Aircraft Performance Fundamentals
Weight and Balance
Digital Techniques
Exam4

Airframe Structure and Landing Gear Aircraft Structure

Light Alloys, Iron and Steel
Recognition and General Characteristics ofMetals Used
Identification of Corrosion
Corrosion Treatment During Repair
Commonly Used Fasteners and Joint Methods
Honey Comb
Reinforced Plastic I Epoxy Materials -Applications
Floors
Seats

Crew
Passenger
Crash" Situation

Main Structure - Fuselage I Wing
Stressed Skin - Diagrams and Longerons
Integral Fuel Tank
Load Paths

Aircraft Structure (Con't)

Empennage
Windows, Doors and Hatches
Fails-Safe Application
Fatigue Effects and Control
Bonded Type Construction
Sealing Compounds
Maintenance Programs - Structural Surveys
NDT Programs
Large Aircraft Paint and Protective Finishing
Processes
Venting and Draining - Sound Proofing

Landing Gear:

Wheels, Tyres, Shock Absorbers, Castering, Steering Methods
Multiple Axle and Wheels
Simple Hydraulic Brakes

Master cylinder to wheel
Brake unit

Brake Disks and Calipers
Main and Alternate Brake Provision
Landing and Braking Energy Conversion
Bogey Beams
Door Sequencing
Anti-skid System

Electronic and mechanical
Aquaplaning

Landing Gear Unsafe Protection
Alternate Lowering
A/eight ON I Weight OFF sensing
Fire Protection
Powered Steering, Retraction, Self Centering
Auto Braking

FTDl Exam 5 Aircraft Systems Hydraulic

Simple Systems

Powered pump
Reverse selection
Pressure relief
Pressure regulation
LP and HP filters

Types of Pumps
Control and Indication Methods
Variable Delivery Systems
Accumulator J Cut-out dependent systems
Pressure J Volume Control
Fire-Resistant Fluids, Temperature, Contamination,Compatibility.
Pressurized Reservoirs
Multiple System Provision
Alternate Systems - RAT J Hydraulic Motors
Electrically Powered and Air Driven Systems
Leak Protection System

System isolation
"Fused" systems
Priority control

Internal Leakage

Cause and effect
Acceptability

Flight Controls

Aileron, Elevator, Rudder
Operating Systems and Surfaces - Manually Operated
Trim Operating Systems and Surfaces - Manual and Electric
Flap Systems

Electrical
Hydraulic
Pneumatic
Manual

Flight Controls (Con't)

Asymmetric Protection
Slat Systems - Automatic and Manual
Hydraulic
Tab Systems

Trim
Balance
Servo
Anti-servo
Anti-balance
Spring servo

Stall Sensing and Warning- Simple System, e.g., Vane or Read Types
Basic Auto Pilots - Simple Systems
Inputs into Main Controls

Function testing
Attitude
Heading and Height sensing

Powered Controls
Spoilers, Air/Speed brake, Lift Dump
Lift Augmentation
Ailerons droop
Slats
Flaps
Flap Operating Systems- Large Transport Aircraft
Flap Asymmetric and Alternate Operation
Stall Sensing - Stick Shake
Stick Push I Nudge
Electronic Control Systems

FTD2 Toilets, Water and Waste, Galley Services

Toilets, Servicing Provisions
Toilets Flushing Systems - Pump Overheat Protection
Water

washing
Hot/cold
Potable

Ice and Rain Protection

Main Plane / Tail Hot Anti-ice Systems
Control and Indication
Leak / Overheat - Detection / Protection
Ice Protection
Rain Repellent
Wind screen Wipers
Laminated Wind Screen Heating
Waste Water Discharge
Pitot I Static Sensors

Air Conditioning

Cabin Blower I Bleed Air Supply
Heat Exchangers .
Cold Air Units I Air Cycle Machines
Vapor Cycle Systems
Humidity Control Systems
Mass, Flow, Pressure and Temperature Control and Indication
Leakage Detection and Protection
Ventilation Requirements
Passenger Service Unit Air Supply
Water Extraction
Re-circulation

FTD 3 Safety Equipment

Fire Extinguishers - Hand
Life Jackets
Life Rafts
Seat Belts I Harness -Passenger I Crew
Slides, Rafts, Dinghies
Loud Hailers
Survival Equipment
Portable Oxygen
Smoke Masks I Hoods
Notices I Placards

Oxygen System

Bottle Storage, Distribution Regulation
Masks - Passenger 1 Crew
Safety Features and Requirements
Drop-out Oxygen
Chemical Systems
Therapeutic Provisions
Bottle Checks and Precautions

Pressurization System

Outflow Control

Electric
Electronic
Pneumatic

Cabin Altitude and Rate of Change
Emergency Dump and Manual Control
Ditching
Cabin Altitude Warning
Entrance I Access I Baggage Door Sealing and Locking
Indication and Warning

Ground Handling Systems

Jacking, Trestling, Slinging, Towing and Tie Down
Servicing Activities
Storage
Painting·

Protective finish
External markings

Weighing and Center of Gravity Determination, Weighing Report

Aircraft Fuel System

Aircraft fuel tanks.
Refueling, De-fueling and Venting.
Cross feed, Dumping and Scavenging.
Fuel tank selector valves.
Low pressure valves.
High pressure valves.

Aircraft Fuel System (Con't)

Turbine fuels.
Pipelines and couplings.
Fuel system in pressurized areas.
Quantity Indication.
Leak assessment.
Filters.
Heaters.
Draining.

FTD 4 Exam 6 Aircraft Engines Basic Mechanics

Introduction
Principles of jet propulsion
Methods of jet propulsion

Working cycles and Airflow

Introduction
Working cycle
The relation between pressure, volume and temperature
Changes in velocity and pressure
Airflow

Compressors

introduction
Centrifugal flow compressor

Principles of operation
Construction
Impellers
Diffusers

Axial flow compressor

Principles of operation
Construction
Rotors
Rotors blades
Stator vanes

Operating conditions
Airflow control
Materials
Balancing

Combustion Chambers

Introduction
Combustion process
Fuel supply
Types of C. C.
Combustion chamber performance
Materials

Turbines

Introduction
Energy transfer from gas flow to turbine
Construction

Nozzle guide vanes
Turbine discs
Turbine blades
Contra-rotating turbines
Dual alloy discs

Compressor-turbine matching
Materials

Nozzle guide vanes
Turbine discs
Turbine blades

Balancing

Exhaust System

Introduction
Exhaust gas flow
Construction and materials

Accessory Drjves

Introduction
Gear boxes and drives
Construction and materials

Lubrication

Introduction
Lubricating systems
Oil system components
Lubricating oils

Internal Air System

Introduction
Cooling

Turbine cooling
Bearing chamber cooling
Accessory cooling

Internal Air System (Con't)

Sealing

Labyrinth seals
Ring seals
Hydraulic seals
Carbon seals
Brush seals
Hot gas ingestion

Control ofbearing loads
Surge protection
Aircraft services

Fuel System

Introduction
Manual and automatic control
Fuel control systems
Electronic engine control
Low pressure fuel system
Fuel pumps
Fuel spray nozzles
Fuel heating
Effect of a change of fuel

Starting and Ignition

Introduction
Methods of starting
Ignition
Re-lighting

Fire Protection

Introduction
Prevention of engine fire ignition (external cooling and ventilation)
Fire detection
Fire extinguishing
Engine overheat detection

Ice Prote~tion

Introduct1on
Hot air system
Electrical system

Control and instrumentation

Introduction
Controls
Instromentation

Engine thrust
Engine speed
Engine torque
Turbine gas temperature
Oil temperature
Oil pressure
Fuel temperature and pressure
Fuel flow
Vibration
Warning system

Thrust Reversal

Introduction
Principles of operation
Construction and materials

Noise Suppression

Introduction
Engine noise
Methods of suppressing noise
Construction and materials

Power Plant Installation

Introduction
Power plant location
Air intake
Engine and jet pipe
Mountings
Accessories
Cowlings

Auxiliary Power Units

Introduction
APU systems
Fire protection
Mountings

Maintenance

Introduction
On wing maintenance

Scheduled maintenance
Unscheduled maintenance
Condition monitoring
Maintenance precautions
Trouble shooting
Adjustments
Engine preservation
Ground testing

FTD 5
Exam 7

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