9/22/2020

PAL EDTO (ETOPS)

MAINTENANCE PROGRAM 1

Objectives

Upon completion of the course, the participants will be able to:

 Identify the basic concepts of EDTO/ETOPS operation

 Review standards and references of EDTO/ETOPS Maintenance
Program
 Understand and map-out the processes involved in PAL EDTO/
ETOPS Maintenance Program

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Overview

During the session, the participants will be given an opportunity to:

 Identify the basic concepts of EDTO/ETOPS operation

 Realize the value of EDTO/ETOPS in aircraft operation
 Review standards and references of EDTO/ETOPS Maintenance
Program
 Brief introduction to Polar Operations
 Understand requirements of PAL EDTO/ETOPS Maintenance
Program

Definitions

EDTO means Extended Diversion Time Operations

ETOPS means Extended Operations

EDTO (ICAO) and ETOPS (FAA)

- Covers all aircraft fitted with all engines
- Any operation of an aircraft where the
diversion time to an en-route alternate
airport is greater than the threshold time
set by State of Operator.

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Definitions
ICAO – Concept of Threshold

There are sets of Certification & Operational requirements which apply

when an aircraft is operated beyond applicable threshold

Definitions
ICAO – Concept of Threshold

These Certification & Operational requirements, called EDTO or ETOPS

or LROPS also introduce the concept of Maximum Diversion Time, thus
defining an approved authorized area of operations

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EDTO (ETOPS) CERTIFICATION

and OPERATIONAL APPROVAL

OEM Certification Approval

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PAL Operational Approval:

GMM

PAL Operational Approval:

FOM

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PAL Operational Approval:

MEL

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EDTO (ETOPS) Benefits

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Benefits of EDTO(ETOPS) Operation

• Increased Operational Flexibility

• Simplified and Optimum
• More Reliable Operations
Operations
• Increased Passenger
• More Direct Routings
Satisfaction
• Twinjet Economics and Efficiency
• Reduced Economic Risk

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Benefits of EDTO(ETOPS) Operation

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Recall: Course Overview

During the session, the participants will be given an opportunity

to:

 Identify the basic concepts of EDTO/ETOPS operation

 Realize the value of EDTO/ETOPS in aircraft operation
 Review standards and references of EDTO/ETOPS Maintenan
ce Program
 Brief introduction to Polar Operations
 Understand requirements of PAL EDTO/ETOPS Maintenance
Program

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PAL EDTO (ETOPS)

Maintenance Program

Course Outline

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Course Outline

Topics

• Formal introduction on PAL EDTO (ETOPS) Operation

• Terminologies used in PAL EDTO (ETOPS) Maintenance Program

• PAL EDTO/ETOPS Maintenance Program, Policies, and Procedures

• Brief introduction on Polar Operations

• EDTO/ETOPS and POLAR Maintenance Documentation

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Basis for PAL EDTO(ETOPS)

Maintenance Program Training
 CAAP Advisory Circular 08-005:
 Provides guidance for operators to gain ETOPS operational approval
from CAAP.

 Outlines ETOPS Maintenance Training Requirement.

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Basis for PAL EDTO(ETOPS)

Maintenance Program Training
“...technical training or the specific airplane-engine
combination it intends to operate in ETOPS…”:
 B777-300ER with GE 90-115B

 A350-900 with Trent XWB-84

 A330-300 with Trent 772B-60

…. ETOPS specific training is in addition

to the AOC holder’s accepted
maintenance training program used to
qualify individuals for specific airplanes
and engines …”:

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Brief Intro on ETOPS Program

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PAL Maintenance Requirements

 EDTO (ETOPS) Maintenance Program

 Status Control and Technical Log Management
 Flights and Diversion
 Work on Parallel and Significant System
 Verification Program
 Parts Control
 Reliability Program (APU In-Flight Start)
 Oil Condition Monitoring
 Reportable Events

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Polar Operations for Line

Maintenance

A Brief Overview

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PAL Polar Operations

 All PAL B777-300ER and A350-900

are capable of operating in the polar
region.

Polar Operations
- GMM 5.1.90 that contains the
specific policies for direct
flights expected to be routed
via the North Polar Track
System

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PAL Polar Operations

 In case of diversion,
passenger recovery plan
needs to be in place

 Safe extraction of
passengers with 48 hours.

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PAL Polar Operations

PAL MEL shall be used to identify aircraft systems

with effect on polar operations capability of the
aircraft

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PAL Polar Operations

• There are two (2) winter suits onboard.

• Refer to MEL for the requirements in relation to
the use of Polar/winter suits

 A short term MEL relief may be granted provided the

company has arranged ground support provisions for
the protective clothing at alternate airports
 CAAP may also relieve PAL from this requirement
during seasonal periods that make the Polar Safety
Kit unnecessary.

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PAL Polar Operations

• The Polar Suit are located in:

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EDTO (ETOPS) Maintenance

Program and Documentation

Process and Procedures

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PAL Maintenance Program

Continuous Airworthiness Maintenance Program:
- GMM 3.2.3 that contains the set of policies and procedures to maintain PAL
aircraft and its equipment in airworthy conditions at the desired safety and
reliability levels

Maintenance Schedule
- Approved manual that contains minimum scheduled maintenance tasks to be
complied on the affected fleet.

- This document serve as means of compliance to PAL GMM 3.2.3 and CAR
Part 8 (Operations)

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PAL Maintenance Program

EDTO (ETOPS) Maintenance Program

- GMM 5.1.50 that contains the specific EDTO/ETOPS policies and
procedures for maintaining PAL EDTO/ETOPS aircraft.

Polar Operations

- GMM 5.1.90 that contains the policies and procedures for direct flights
expected to be routed via the North Polar Track System

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GMM 5.1.50 EDTO (ETOPS)

Maintenance Program

In compliance to the CAAP AC 08-005

EDTO (ETOPS) CAMP = GMM 3.2.3 + GMM 5.1.50

Identifies the maintenance requirements and

organizational responsibilities of PAL and its service
providers
Explains the program in detail with some cross-
references to other PAL GMM provisions and
documents

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GMM 5.1.50 EDTO (ETOPS)

Maintenance Program

 PAL Maintenance Schedule:

 As means of compliance to GMM 3.2.3 (CAMP)
 Contains tasks from two sources:
 MPD (Maint Planning Document)
 CMP (Configuration, Maintenance, and
Procedures)

 Pre-Departure Service Check (PDSC)

 Checklist to be accomplished by line maintenance
personnel prior to an EDTO (ETOPS) Flight

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Examples of PAL MS Tasks

 777 MPD / CMP TASKS :

 MPD Task 24-030-00
 Check BACKUP GENERATOR OIL Level and
add oil as required.
 Every 100 FH

 Pre-Departure Service Check (PDSC)

 MPD Task 35-400-00
 Check Crew Oxygen System for correct
pressure as required (use EICAS).
 To be accomplished prior to ETOPS flights

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Examples of PAL MS Tasks

 A330 MPD / CMP TASKS :

 MPD Task 242100-08-1
 IDG – discard the scavenge filter and replenish
the oil
 Every 800 FH

 Pre-Departure Service Check (PDSC)

 Perform an External Zonal Inspection (GVI) of all
visible exterior areas of the airplane
 To be accomplished prior to ETOPS flights

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Examples of PAL MS Tasks

 A350 MPD / CMP TASKS :

 MPD Task 502300-00M07-01
 CLS – Remove cargo drain valve for OPC
 Every 18 MO or 2000 FH

 Pre-Departure Service Check (PDSC)

 Perform an External Zonal Inspection (GVI) of
all visible exterior areas of the airplane
 To be accomplished prior to ETOPS flights

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GMM 5.1.50 EDTO (ETOPS)

Maintenance Program

 CMP Tasks:
 Cannot be escalated.

 Pre-Departure Service Check (PDSC)

 Verify the condition of all EDTO/ETOPS Significant
Systems;
 Verify the overall status of the airplane by reviewing
applicable maintenance records;
 Perform an interior and exterior inspection of the
airplane
 Determine engine and APU oil levels and consumption
rates

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PDSC

The PDSC is
signed-off by
an ETOPS
qualified
mechanic

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GMM 5.1.90 Polar Operations

Maintenance Program

To ensure capability of PAL aircraft to operate in

the polar region:
- an evaluation has to be made by the
authorized maintenance personnel to ensure
that the systems related to Polar Operations are
functioning reference to approved PAL MEL.

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GMM 5.1.90 Polar Operations

Maintenance Program

Due to nature of operation, a Polar Safety Kit

with two (2) winter suits is onboard.

For use by crew in order to coordinate with

ground services at the diversion airport.

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EDTO/ETOPS
STATUS CONTROL and
TECH LOG MGMT

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Return to Service

 Crew must be advised on current aircraft status.

 To indicate status in AML:

 An EDTO/ETOPS Status Stamp can be used;
or
 A similarly worded statement shall be written
in case of non-availability of status stamp.

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Return to Service

ETOPS Status Stamp

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Return to Service
Where EDTO/ETOPS status stamp is not available,
reflect either of the following (as applicable) in the
CORRECTIVE ACTION block of the AML for the RTS

• “Aircraft is certified for EDTO/ETOPS flight with

(indicate appropriate diversion time minutes
diversion time”.
• “Aircraft is NOT certified for EDTO/ETOPS flight
due to -----------------------“.
• “Aircraft is certified for EDTO/ETOPS subject to
verification of ---------- in the first 60 minutes of
flight”

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Return to Service

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Return to Service – Polar Operations

For a return to service of PAL B777-300ER aircraft for

Polar Operations, an AML logbook entry will be made
by a B777 ETOPS authorized maintenance personnel.

 “Polar Operations – OK” or a similarly worded

statement shall be made upon releasing a flight to
Polar Operations,
 otherwise,
 “Polar Operations – NOK. Refer to AML- XXX” or
a similarly worded statement shall be made in
conjunction with the AML Return To Service
Logbook entry. Refer to MEL.

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Return to Service – Polar Operations

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ETOPS Status Card

Location
- Inside the AML Folder, along with other aircraft status car
ds

Usage
- ETOPS status card is used to record the current syste
m status of the aircraft
- Accomplishment of ETOPS status card is to be perfor
med only during status change of aircraft (i.e. from ETO
PS capable to non-ETOPS capable or vice versa).
- Otherwise, the status card is to remain inserted in the AM
L.

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ETOPS Status Card

Usage
- No entry shall be made on th
e ETOPS Status Card if there
is no reason to change the pres
ent RVSM status of the aircraft

- Refer to GMM 6.0.0 for form an

d fill-up procedures
- Form AED-08-10-021

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ETOPS Status Card

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ETOPS Status Card

 Outstations must contact MANILA first prior to

changing EDTO/ETOPS status.
 An EDTO/ETOPS Focal/Coordinator will receive
PAL AED authorization to change the
EDTO/ETOPS Status
 Upon outstation receipt, status card must be
updated by EDTO/ETOPS authorized personnel
prior aircraft RTS.

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EXAMPLE – AML ENTRY

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A330 MEL

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CORRECTIVE ACTION ENTRY

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EDTO (ETOPS) STATUS CARD

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EDTO/ETOPS
FLIGHTS & DIVERSIONS

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Approved Diversion Time

PAL approval : 180 minutes

diversion time.
 B777-300ER with GE 90-115B

 A350-900 with Trent XWB-84

 A330-300 with Trent 772B-60

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Operational Dispatch Reference

 PAL Minimum Equipment List (MEL)

document shall be used as the dispatch authority
for all PAL A330-300, A350-900 and 777-300ER
EDTO/ETOPS flights.
The 777-300ER Dispatch Deviation Guide
(DDG) and A330-300 /A350-900 Configuration
Deviation List (CDL) shall be used as a
supplementary reference, as necessary.

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Flight Diversion

 For Non-Maintenance reasons: PDSC need not

be done.
 Maintenance reasons:
 if the reason affects a PAL EDTO/ETOPS
Significant System, PDSC is to be done.

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PAL Maintenance Requirements

 EDTO (ETOPS) Maintenance Program

 Status Control and Technical Log Management
 Flights and Diversion
 Work on Parallel and Significant System
 Verification Program
 Parts Control
 Reliability Program (APU In-Flight Start)
 Oil Condition Monitoring
 Reportable Events

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EDTO/ETOPS
Work on Significant &
Parallel Systems

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Significant Systems

 Any aircraft system that contains components

necessary for EDTO/ETOPS Flight.
 EDTO/ETOPS Significant Systems are identified in:
 A330: Attachment C of GMM 5.1.50
 A350: Attachment G of GMM 5.1.50
 B777: Attachment F of GMM 5.1.50
 All malfunctions or degradations in any of these
systems shall be subject to the verification of
maintenance action.

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Parallel Systems

 Any two significant system as listed in

attachments C, G and F of GMM 5.1.50
 EDTO/ETOPS Parallel Systems are identified in:
 A330: Attachment C of GMM 5.1.50
 A350: Attachment G of GMM 5.1.50
 B777: Attachment E of GMM 5.1.50

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Significant and Parallel Systems

A330 Example (Attachment C)

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Parallel Systems
 Work on two EDTO/ETOPS parallel systems
shall be avoided if possible.
Swapping of components related to
EDTO/ETOPS constitutes work on EDTO/ETOPS
parallel systems and must be addressed by
doing the following below:
 Assigning different persons to perform the task on the
two EDTO/ETOPS parallel systems during a single
maintenance visit
 Rescheduling maintenance / rectification on one of the
EDTO/ETOPS parallel systems, as applicable.

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Parallel Systems
If maintenance is done on EDTO/ETOPS parallel systems during a
single maintenance visit, then the following shall apply:
 Different individuals will perform maintenance on EDTO/ETOPS
parallel systems
• In addition, verification of maintenance will be done.

 The work will be inspected by a maintenance supervisor or an

aircraft inspector
• In addition, verification of maintenance action will be done

 If Option 1 or 2 is not available:

 A single maintenance personnel may perform the required
maintenance under the direct control of Maintenance Control
Center (MCC), followed by a verification flight.

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Parallel Systems
In cases that work packages need to be performed (at the
outstations):
 EDTO/ETOPS authorized person will get permission
from EDTO/ETOPS Coordinator (in MANILA)
 The EDTO/ETOPS authorized person who carries out
the work must contact the EDTO/ETOPS Coordinator
and describe the work carried out in detail.
 When the EDTO/ETOPS Coordinator is satisfied that
the work has been completed properly, the aircraft
shall be released for an EDTO/ETOPS flight.
• A record of such events shall be maintained by the
maintenance service provider.

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Parallel Systems
In cases that work packages need to be performed (at
the outstations), EDTO/ETOPS authorized person will :
 Get permission from EDTO/ETOPS Coordinator
(in MANILA)
 Comply the work package and describe the work
carried out in detail to EDTO/ETOPS Coordinator
 When the EDTO/ETOPS Coordinator is satisfied
that the work has been completed properly, the
aircraft shall be released for an EDTO/ETOPS
flight.
• A record of such events shall be maintained by
the maintenance service provider.

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Fluid Servicing

Servicing of fluids and gases

are not considered
maintenance on EDTO/ETOPS
parallel systems.

NEVERTHELESS, separate
individuals will perform such
servicing on EDTO/ETOPS
parallel systems because these
tasks, when done
IMPROPERLY, may adversely
affect EDTO/ETOPS
operations.

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EDTO/ETOPS
Verification Program

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Verification of Maintenance Action

 Initiated by the EDTO/ETOPS Authorized Personnel.

 To be done after working on ETOPS Significant
Systems or:
1. An EDTO/ETOPS Significant System failure;
2. An In-flight Shutdown, uncommanded power
change or surge, or inability to control an engine
or obtain desired power;
3. Failures of systems listed in GMM 4.6.5
4. Maintenance performed on EDTO/ETOPS
Parallel Systems

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Verification of Maintenance Action

5. Swapping components in EDTO/ETOPS

significant systems for purposes of
troubleshooting
6. An engine change
7. Discrepancies that occur only in flight and
cannot be verified on ground using existing
aircraft manuals.
8. Intermittent discrepancies w/c cannot be
verified by maintenance.
9. Engine fuel or oil system breakdown

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Verification of Maintenance Action

 Accomplished thru any of the following:

 Ground or function test (e.g. BITE test, via OPC/FUC tests per
applicable TSM/AMM)
 Verification flight
• Non-EDTO/ETOPS flight
• EDTO/ETOPS flight but verification done during the 1st 60 minutes
(prior to reaching the EDTO/ETOPS sector entry point
• A specific verification test flight, if any of the above are not an
option.

A verification flight is a revenue or non-revenue flight during

which the flight crew is asked to assist maintenance in order to
confirm that an EDTO/ETOPS significant system is operating
normally, or that an EDTO/ETOPS significant problem has been
resolved.

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Verification of Maintenance Action

 Examples:

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Verification Flight

 Maintenance Control shall be contacted to determine the

necessity for a verification flight.

 A verification flight should ONLY be used in the following

circumstances:
1) There is no effective ground check;
2) No Maintenance Manual check exists;
3) BITE checks do not adequately verify system operation or
effectiveness of the corrective action;

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PAL Maintenance Requirements

 EDTO (ETOPS) Maintenance Program

 Status Control and Technical Log Management
 Flights and Diversion
 Work on Parallel and Significant System
 Verification Program
 Parts Control
 Reliability Program (APU In-Flight Start)
 Oil Condition Monitoring
 Reportable Events

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EDTO/ETOPS
PARTS CONTROL

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Parts Control
Aircraft Illustrated Parts Catalog (IPC) – main source of
applicable parts to be used
 In addition to the IPC, parts must be in compliance with the CMP
which defines the minimum configuration standard for an
EDTO/ETOPS aircraft.

 PAL A330-300 / A350-900

 IPC
 EDTO/ETOPS Parts List for A330/A350 provides the
part numbers corresponding to the CMP configuration
requirements for all parts required for EDTO/ETOPS
 PAL B777
 IPC will indicate whether a part is not approved for
EDTO/ETOPS.

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A330 Example

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Parts Control

Aircraft Flight Kit

 The FK includes applicable EDTO/ETOPS and non-
EDTO/ETOPS parts, and such items as tires and a supply of
engine/APU oil.
Borrowed Parts
 Borrowed parts not verified per EDTO/ETOPS Parts List or IPC
cannot be used on EDTO/ETOPS Aircraft
 Procedures for borrowing parts are contained in PAL GMM
4.4.27, “Borrowed or Loaned Parts”.

Engine / APU Change

 The EDTO/ETOPS configuration status of the Engine or APU
must be confirmed.
 Otherwise, the aircraft must be operated NON-EDTO/ETOPS

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Parts Control

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EDTO/ETOPS
RELIABILITY PROGRAM:
APU In-Flight Start

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APU In-Flight Start (MNL/CEB)

Role of Maintenance
 Validates and checks corresponding AML entry of aircraft for
which APU needs to be sampled.

 The required In-flight APU starts by this program do not need to

be performed during EDTO/ETOPS flights.
 However, the APU must be in the EDTO/ETOPS configuration in
accordance with the appropriate CMP document.

 If the sampling of APU in-flight starting capabilities was not

performed within the required period:
 the affected aircraft’s EDTO/ETOPS capability status shall be
downgraded in accordance with the approved aircraft MEL until the
APU in flight start is performed

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APU In-Flight Start

Role of Maintenance
 Checks corresponding AML entry for successful / unsuccessful
APU in-flight start
 Confirms APU serviceability on ground after APU in-flight start
was attempted by the pilot and was unsuccessful.

 If APU does not start (within 3 attempts), but can be started on

the ground, then an in-flight start test should be performed as
soon as possible, typically within the next 4 flights.
 If the sampling of APU in-flight starting capabilities was not
performed within the required period:
 the affected aircraft’s EDTO/ETOPS capability status shall be
downgraded in accordance with the approved aircraft MEL until the
APU in flight start is performed

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APU In-Flight Start

If the inability to start in flight is confirmed:

 The APU should be considered as

unserviceable for EDTO/ETOPS
 until adequate troubleshooting and
corrective action have been performed

 The EDTO/ETOPS status of the aircraft

depends on the MMEL/MEL allowances
(dispatch with APU inoperative)

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EDTO/ETOPS
Oil Condition Monitoring

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Oil Condition Monitoring

 Determination of oil consumption rate is included in PAL

PDSC checksheets

 Monitored in Manila thru contracted service provider.

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Oil Condition Monitoring

 If the alert level is reached, the EDTO/ETOPS authorized

person responsible for the aircraft must advise the
EDTO/ETOPS Coordinator by fax or SITA, prior to release
of the aircraft for troubleshooting.

 Aircraft
RTS at the alert engine oil consumption level
must be noted in the AML by the EDTO/ETOPS
authorized personnel and remark to be forwarded to MNL.

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EDTO/ETOPS
Defect Rectification and
Reportable Events

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Defect Rectification

 All technical discrepancies for EDTO/ETOPS route/flight

which have been rectified or deferred must be reported to
the EDTO/ETOPS Coordinator.

 Contact
details are available in Attachment A of PAL
GMM 5.1.50

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REPORTABLE EVENTS

 Must be reported to PAL within 24 Hours (GMM 4.6.5)

 In-flight shutdowns (IFSD), except planned IFSDs performed for
flight training;
 Diversions or air turn backs due to technical difficulties;
 Un-commanded power changes or surges;
 Inability to control the engine or obtain desired power;
 Inadvertent fuel loss or unavailability, or uncorrectable fuel
imbalance in flight
 Problems with EDTO/ETOPS significant systems (EDTO/ETOPS
significant system failures);
 Any other event detrimental to EDTO/ETOPS.

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REPORTABLE EVENTS

 Report shall include the following information

 Airplane identification (type and registration number);
 Engine identification (make and serial number);
 For engines, total time, cycles, and time since last shop visit;
 Cause of the problems;
 Phase of flight (i.e., Takeoff, Climb, Cruise, Descent, Approach,
Landing);
 Corrective action;
 For systems, time since overhaul or last inspection of the
discrepant unit.

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Recall: Course Overview

During the session, the participants will be given an opportunity

to:

 Identify the basic concepts of EDTO/ETOPS operation

 Realize the value of EDTO/ETOPS in aircraft operation
 Review standards and references of EDTO/ETOPS Maintenan
ce Program
 Brief introduction to Polar Operations
 Understand requirements of PAL EDTO/ETOPS Maintenance
Program

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