ETOPS MAINTENANCE REQUIREMENTS

AIRWORTHINESS NOTICE

VERSION
:
DATE OF IMPLEMENTATION :
OFFICE OF PRIME INTEREST :
11/06/2011

2.1
11-06-2011.
AIRWORTHINESS DIRECTORATE
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ETOPS MAINTENANCE REQUIREMENTS

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ETOPS MAINTENANCE REQUIREMENTS

A.

AUTHORITY:
A1.

B.

This Airworthiness Notice has been issued under the authority vested in DG CAA vide
rule 4, 5, 180 & 360 of Civil Aviation Rules 1994.

PURPOSE:
B1.

C.

Purpose of this Airworthiness Notice is to ensure the compliance with ETOPS

requirements for Twin Engine Turbine Powered Aircraft.

SCOPE:
C1.

The scope of this Airworthiness Notice is applicable to AOC holders who maintain and
operate aircraft on ETOPS.

D.

DESCRIPTION:

D1.

DEFINITIONS:
Nil

D2.

INTRODUCTION:
D2.1

D2.2

D3.

The requirements for ETOPS approval are defined in Air Navigation Order 91.0013 dated
18th May, 1999, which cover all regulatory aspects regarding Operation and Maintenance
of ETOPS approved aircraft.
Prior to ETOPS approval, the operator shall demonstrate that the ETOPS maintenance
checks, servicing and program are being properly conducted at representative departure
and destination aerodromes.

ETOPS MANUAL:

The operator shall develop a manual, in the light of Air Navigation Order No. 91.00013 dated 18th
May, 1999 and FAA Advisory Circular AC 120-42A. The ETOPS manual shall contain the following.
D3.1
D3.2
D3.3
D3.4
D3.5
D3.6
D3.7
D3.8
D3.9
D3.10
D3.11
D3.12
D3.13
D3.14

ETOPS Regulatory Requirements

ETOPS Approved Equipments
ETOPS Type Design Approval
ETOPS Program and Control
Documents and Report
Documents and control
Configuration Control
ETOPS Parts Control
Maintenance Program and Policy
Oil consumption Monitoring Program
Engine Condition Monitoring Program
Reliability Program
Propulsion Systems Monitoring Program
Training Program and Policy

The ETOPS manual shall be approved by PCAA (Director Airworthiness).

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D4.

D5.

ETOPS MAINTENANCE PROGRAMME:

D4.1

The basic maintenance programme for the aircraft being considered for ETOPS shall be
the continuing airworthiness maintenance programme currently approved for that
operator, for the make and model of airframe-engine combination. This programme shall
be reviewed to ensure that it provides an adequate basis for development of ETOPS
maintenance requirements. These shall include maintenance procedures to preclude
identical action being applied to multiple similar elements in any ETOPS critical system
(e.g. fuel control change on both engines).

D4.2

ETOPS-related tasks shall be identified on the operator's routine work forms and related
instructions.

D4.3

ETOPS-related procedures, such as involvement of centralized maintenance control, shall

be clearly defined in the operator's programme.

D4.4

An ETOPS service check (Task Card) shall be developed to verify that the status of the
aircraft and certain critical items are acceptable. This check shall be accomplished and
signed off by an ETOPS qualified maintenance person immediately prior to an ETOPS
flight.

D4.5

Logbooks shall be reviewed and documented as appropriate to ensure proper MEL

procedures, deferred items and maintenance checks and that system verification
procedures have been performed.

OIL CONSUMPTION PROGRAMME:

D5.1

D6.

ENGINE CONDITION MONITORING

D6.1

D7.

The operator's oil consumption programme shall reflect the manufacturer's

recommendations and be sensitive to oil consumption trends. It shall consider the
amount of oil added at the departing ETOPS stations with reference to the running
average consumption, i.e. the monitoring must be continuous up to, and including, oil
added at the ETOPS departure station. If oil analysis is relevant to this make and model,
it shall be included in the programme. If the auxiliary power-unit (APU) is required for
ETOPS operation, it shall be added to the oil consumption programme.

This programme shall describe the parameters to be monitored, method of data

collection and corrective action process. The programme shall reflect manufacturer's
instructions and industry practice. This monitoring shall be used to detect deterioration at
an early stage to allow for corrective action before safe operation is affected. The
programme shall ensure that engine limit margins are maintained so that a prolonged
single-engine diversion may be conducted without exceeding approved engine limits (i.e.
rotor speeds, exhaust gas temperatures) at all approved power levels and expected
environmental conditions. Engine margins preserved through this programme shall
account for the effects of additional engine loading demands (e.g. anti-ice. electrical.
etc.) which may be required during the single-engine flight phase associated with a
diversion.

RECTIFICATION OF AIRCRAFT DEFECTS:

D7.1

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The operator should develop a verification programme, or procedures shall be

established, to ensure corrective action following an engine shutdown, primary system
failure, adverse trends or any prescribed events, which require verification flight or other
action and establish means to assure their accomplishment. A clear description of who
must initiate verification actions and the section or group responsible for the
determination of what action is necessary shall be identified in the programme. Primary
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systems or conditions requiring verification actions shall be described in the operator's

ETOPS manual.
D8.

RELIABILITY PROGRAMME:
D8.1

An ETOPS reliability programme shall be developed or the existing reliability programme

supplemented. This programme shall be designed with early identification and
prevention of ETOPS-related problems as the primary goal. The programme shall be
event-orientated and incorporate reporting procedures for significant events detrimental
to ETOPS flights. This information shall be readily available for use by the operator and
the PCAA to help establish that the reliability level is adequate and to assess the
operator's competence and capability to safely continue ETOPS. It is recommended that
PCAA shall be notified within a short time (usually 96 hours) of events reportable through
this programme.

D8.2

Following items shall be included in the reliability programme:

D8.2.1
D8.2.2
D8.2.3
D8.2.4
D8.2.5
D8.2.6

D8.3

The report shall also identify the following:

D8.3.1
D8.3.2
D8.3.3
D8.3.4
D8.3.5
D8.3.6

D9.

Aircraft identification (make and serial number);

Engine identification (make and serial number);
total time, cycles and time since last shop visit;
for systems, the TSO or last inspection of defective unit;
phase of flight; and
Corrective action.

PROPULSION SYSTEM MONITORING:

D9.1

D10.

In-flight shut-downs;
Diversion or turn-back;
Uncommanded power changes or surges;
Inability to control the engine or obtain desired power;
Problems with systems critical to ETOPS; and
Any other event detrimental to ETOPS.

The operator's assessment of propulsion systems reliability for the extended range fleet
shall be made available to the PCAA (with the supporting data) on at least a monthly
basis to ensure that the approved maintenance programme continues to maintain a level
of reliability necessary for ETOPS. The assessment shall include, as a minimum, engine
hours flown in the period, in-flight shutdown rate for all causes and engine removal rate
computed on a twelve-month rolling average basis. Any adverse sustained trend would
require an immediate evaluation to be accomplished by the operator in consultation with
the State of the Operator. The evaluation may result in corrective action or operational
restriction being applied.

MAINTENANCE TRAINING:
D10.1 Maintenance training shall focus on the special nature of ETOPS. This programme shall
be included in normal maintenance training. The goal of this programme is to ensure that
all personnel involved in ETOPS are provided with the necessary training so that the
ETOPS maintenance tasks are properly accomplished and to emphasize the special
nature of ETOPS maintenance requirements. Qualified maintenance personnel are those
who have completed the operator's ETOPS training programme and have satisfactorily
performed ETOPS tasks under supervision, within the framework of the operator's
approved procedures for Personnel Authorization.

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D11.

ETOPS PARTS CONTROL:

D11.1 The operator shall develop a parts control programme that ensures the proper parts and
configurations are maintained for ETOPS. The programme includes verification that parts
placed on ETOPS aircraft during parts borrowing or pooling arrangements as well as
those parts used after repair or overhaul maintain the necessary ETOPS configuration for
that aircraft.

E.

EVIDENCES (ACRONYMS / RECORDS / REFERENCES):

E3.

ACRONYMS:
E1.1
E1.2
E1.3
E1.4
E1.5

E2.

APU
ETOPS
MEL
PCAA
TSO

AUXILIARY POWER UNIT

EXTENED TWIN ENGINES OPERATION
MINIMUM EQUIPMENT LIST
CIVIL AVIATION AUTHORITY
TIME SINCE OVERHAUL

RECORDS:
Nil

E3.

REFERENCES
E3.1

Air Navigation Order No. 91.0013

E3.2

FAA Advisory Circular AC 120-42A

IMPLEMENTATION:
This Airworthiness Notice shall be implemented with effect from 11th June, 2011 and repeals /
cancels / supersedes Airworthiness Notice No. AWNOT-064-AWXX-2.0 dated 1st June, 2010

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