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Engineering Design Capability
EXECUTIVE SUMMARY
Safe Air is a unique one stop service centre primarily set up to service the Royal New Zealand Air Force (RNZAF), and specifically for the Lockheed Martin C-130H Hercules and P-3K2 Orion (airframes, engines and propellers) and SH-2G Seasprite helicopter maintenance. Embodied in the organisation is a highly capable engineering design team rich in experience and expertise on these and other airframe types.
The Safe Air engineering design team draws its experience from its guardianship of the RNZAF’s fleet, as well as ongoing supplementation of Air New Zealand’s commercial aircraft engineering services requirements (having been a fully owned subsidiary of Air New Zealand until July 2015). Safe Air itself has achieved over 1.5 million maintenance hours on Lockheed Martin airframes and various helicopter types, all with the close support of the current engineering design team.
Safe Air’s engineering design expertise and experience includes;
» aircraft structural repair design and approval
» aircraft and component modification development and approval
» structural testing
» tooling and mechanical equipment design
» certification and approval of design data
» 3D data capture
» Documentation Services
Safe Air’s engineering design services are available either as a part of a wider engineering programme or as a discrete service including engineering liaison, consultancy or short term contract engineers. All Safe Air engineers are experienced at operating offsite within a customer’s facility.
Safe Air has the benefit of now being a wholly owned subsidiary of Airbus Helicopters and an integral part of Airbus Group Australia Pacific (AGAP). This substantially increases the total
engineering capability and capacity, which Safe Air is readily able to draw upon to meet the demands of, or provide support to, larger and more complex projects.
Safe Air operates under New Zealand Civil Aviation Authority (NZCAA) Part 146 and CASA Part 21M Design Approvals and holds design delegations from the NZCAA, the RNZAF and previously the Royal Australian Air Force (RAAF).
Through its Supply Chain the company is also able to tap into the resources and expertise of a number of national and international partners with complementary capabilities in manufacturing, component supply and repair services to provide value propositions into global aviation supply chains.
Our combined attributes and capabilities mean we can offer customers the opportunity to benefit from our ‘Kiwi Ingenuity’, our ‘Can Do Attitude’ and our passion for aviation. These make us ideal contenders for those smaller more complex niche projects that are typically too disruptive for larger mainstream aviation designers and manufacturers to consider.
Safe Air can demonstrate, through countless examples, the special focus and commitment to deliver totally compliant high standard results through:
» Well coordinated work-flow planning and supply chain management
» Design engineering expertise to innovate, develop and certify solutions
» A broad depth of manufacturing capability, competency and experience
» High levels of quality and conformance to required standards
» Available capacity to take on short lead-time work
» Flexibility to produce one-off prototyping, and small, medium or larger production runs.
A brief summary of a few notable recent project examples is provided below.
ENGINEERING SERVICES
Aircraft Structural Repair Design and Approval
Safe Air has particular structural experience with mature airframes such as the Lockheed Martin C-130H and P-3 Orion. Our team has developed over 500 repair schemes for a wide variety of commercial and military aircraft. Safe Air has accumulated over 1.5 million maintenance hours on Lockheed Martin airframes, much of which has been directly supported by our onsite engineering design team.
Structural Testing
Design, construction and operation of structural testing equipment to demonstrate compliance with specified loading conditions. Documentation of test plans and results.
Aircraft and Component Modification Development and Approval
Across both military and commercial airframes, the Safe Air engineering team has accumulated a range of modification experience including structural, avionic and aircraft interior. A sample of completed projects includes;
» Lockheed Martin P-3 Orion autopilot
installation
» Kaman SH-2G door jettison mechanism
design and installation
» Commercial aircraft galley equipment design
to manufacture
» C130 usage monitoring equipment installation
» Development of replacement radomes for P-3
Orion aircraft in conjunction with Cobham
Advanced Composites Ltd
» Design of major modifications for Boeing
Business Jet (737)
» Modification and installation of a Flight Data
Acquisition System on B1900 aircraft
» Development of a personnel rappelling device
for RNZAF NH90 helicopters
» Development of a Business Class Seat STC
for Air New Zealand’s 787-900
» Design of repair for RNZAF P-3 Engine
Nacelle Longerons
» Integration of FLIR Safire III to RNZAF P-3
Further details are provided for the four most
recent projects later in this document.
Tooling and Mechanical Equipment Design
The Safe Air engineering team’s experience
extends to the design of unique tooling to meet
specific technical requirements. Recent examples
of completed tooling include;
» Jigs for manufacture of helicopter weapons
pylon
» Rear fuselage removal stand for P-3 Orion
aircraft
» Adaptor for Rolls Royce T56 Mobile Engine
Test Stand (METS) to enable testing of
different engine configurations
Certification and Approval of Design Data
Expert advice and assistance with certification of
products to comply with airworthiness authorities
covering modifications, Type Certificates (TC’s),
Supplemental Type Certificates (STC’s), Parts
Manufacturing Approvals (PMA’s), and Technical
Standards Orders (TSO’s).
Includes development of technical data to meet
certification standards and compiling compliance
documentation. We can also issue Design
Statements of Compliance and Design Approvals
and assist with EASA, CAR 35 (Australia) and
FAA (USA) approvals through our global
engineering design network.
3D Data Capture
The Safe Air team employs advanced laser
tracking equipment to capture and display 3D
coordinates for the following applications:
» Aircraft symmetry and alignment checks
» Jig alignment checks
» Positional and planarity checks
» Mapping data (damage plots on aircraft
surfaces, modelling aircraft interior and
exterior surfaces)
» Reverse engineering
Documentation Services
Safe Air’s engineering service is
complemented by a comprehensive range of
documentation services including;
» Technical data packages
» Engineering drawings, illustrations (2D and
3D)
» Publications created to industry standards
including manual supplements
» Bulletins
» Engineering reports
Other Services
Preparation of aircraft trim charts to FAR
121 requirements
» Take off and landing charts for light
aircraft
» Aircraft weight and balance and
Centre of Gravity calculations
RECENT PROJECTS
NH90 Rappelling Device
OBJECTIVE
To produce a simple, reliable, robust and safe design that meets the requirements of the RNZAF.
Used for rapid troop deployment and training activities out of the NH90 Aircraft, similar to those currently undertaken using the RNZAF’s UH-1H Iroquois aircraft.
CAPABILITY
Max 8 Troopers in two groups of 4 in quick succession
Ropes are released after deployment
Rope release under load if necessary (emergency)
Troop extraction
Maximum weight for each person using the device (including their kit and equipment) is 180 kg
Max load of 2160 kg
(Includes Factor of Safety x 1.5 + Dynamic Factor x 2)
APPLICATIONS
This design can be modified to suit a much wider range of aircraft than just the NH90.
DESIGN FEATURES
Designed in conjunction with the RNZAF to suit their specific requirements
No modification to the aircraft required
Safety locks to avoid inadvertent release
Fabricated from lightweight welded aluminium box section
Optimized for structural efficiency & manufacturing simplicity
Transfers loads to the airframe
Can be easily and quickly installed by two people using quick release pins. No tools required to remove device
Mounted high into the roof of the cabin
Sturdy mechanical release mechanism
Simultaneous rope release
Single operation from the front or rear of device
Meets the applicable FAR 29 requirements
787-900 Business Class Seat STC
PROJECT INVOLVED:
- Successful collaboration with CAA NZ, Boeing, 3rd Party subcontracted design services & AIR NZ.
- Developing comprehensive Certification Plan to manage compliance to regulatory requirements & ensuring subsequent A/C on-time-delivery.
- Establish ELOS to certain regulatory rqmts acceptable to CAA NZ when certifying seat/bed actuation.
- Successful issuance of CAA NZ STC to Air NZ.
1. Regulatory
“Knowledge of requirements of the relevant aviation authorities”
2. Seats
“Safety levels established for authorising functionality”
3. Bed
“Understanding of end user and customer requirements and expectations”
4. Aircraft
“Liaison with customer from concept through to the installed product is fully functional”
P-3 FLIR Safire III Integration
OBJECTIVE
Design, integrate, validate and certify the installation of a stand alone FLIR EOIR Turret to a P3 Orioin
PROJECT INVOLVED
Structural design for component mounting
Electrical design for integration to aircraft and surveillance suite systems.
Radome modification
Aircraft modification and component installation
Installation testing / Acceptance testing
Tailored Certification & Approval
ENGINEERING DESIGN SERVICES
Structural testing
Aircraft repair design
Modification design
Documentation management
Certification & approval
Design to manufacture
3D CAD Modeling
Finite Element Analysis
LASER Tracking for highly accurate real time positional data
Recent modification of P3 with FLIR Mount.Recent modification of P3 with FLIR Mount.
P-3 Engine Nacelle Longeron Repair
OBJECTIVE
Determine a solution for cracking damage on RNZAF P-3K2 Orion Engine Nacelle Upper Longerons.
PROJECT INVOLVED
Design and substantiation of repairs to extensive cracking damage on the P-3 Engine Nacelle Upper Longerons.
Design of Longeron tooling to aid the removal & installation of replacement Longerongs during an aircraft servicing.
Organizing manufacture of the tool to meet stiffness and tolerance requirements.
Personnel Overviews
Refer table in Annex on following page showing a summary of experience of the senior engineering team.
Key Contact
David Goodwin
Engineering Design Manager
P: +64 3 572 7840
Mb: +64 21 221 3928
Fx: +64 3 572 7655
Email: [email protected]
PO Box 244
Blenheim
Marlborough 7240
New Zealand
Senior Engineering staff – Experience Summary
Name
Position
Basic
qualification
Delegations /
Authorizations
Previous Employment (years)
Strengths
Total
NZ/Intl OEM’s
Airline
support Other SAL
David Goodwin
ED Manager
CAANZ, CASA (AUS) and
RNZAF.
Previously held delegation from
DGTA (AUS)
13/10 Honeywell
Raytheon
Hawker Pacific
Beechcraft
6
Air NZ
Qantas
Design Engineer
– Hawker Pacific
5 » Team leadership
» Strategy development
» Operational oversight of the RNZAF Beech T6 program
» CAA senior person oversight of all design work
» engineering procedures, scheduling, finances, business
development and marketing, project management, tender
preparation, quoting, management liaison, mentoring and
development of Design Engineering and Ohakea staff
» Avionics related documents, design, review or approval for
both rotary and fixed wing aircraft
Damian Scott
Senior Design
Engineer
B.Eng Hons (Aero
Eng)
HNC (Mech Eng)
Safe Air , CAANZ , RNZAF
Air NZ. Previously BAE
Systems.
13/12 12 10 BAE Systems –
Airframe
Technology 1990-
2002
13 » Aircraft Structures, modifications / repairs, FEA
» Holds a SOC authorisation within ANZTO & RNZAF
approval delegation.
» Considerable experience of airline repair design.
» Specialist design of Role and Ground Support Equipment
Matthew Potts
BE Hons (Mech),
MEM
CAANZ , RNZAF
Air NZ, Altitude
16/1.5 1.25 L3-IS
0.25 Boeing
2 16 » Structures, modifications / repairs.
» Hold SOC approval with Air New Zealand Technical
Operations and Altitude Design.
Cameron
Ready
NZCE (Mech) RNZAF
Safe Air
18/1 -- --- --- 11 » Structures, mods/repairs.
» Specialise in Design for manufacture
» Experienced in Ground Support Equipment Design
» Extensive experience in 2D & 3D CAD design & Drafting.
» Management of customer technical design data
requirements during a/c heavy maintenance and mod work.
(MoD LEP Upgrade etc…….)
Senior Engineering staff – Experience Summary
David Goodwin (ED Manager)
David is a senior manager at Safe Air Ltd, with primary responsibilities as part of the leadership team; to develop strategy that both supports core business and promotes efficient and profitable growth. Keys to this are the management and development of the design engineering business unit and the operational oversight of the RNZAF Beech T6 program at Ohakea. As a CAA senior person David is responsible for oversight of all design, certification and test related activities for the company. He is responsible for engineering procedures, scheduling, finances, business development and marketing, project management, tender preparation, quoting, liaison with other managers and mentoring and development of Design Engineering and Ohakea staff. As a qualified engineer he is also responsible as the Chief Design Engineer for allocation of design delegation, review and approval of design data, preparation of test schedules, system safety analysis, failure mode and effect analysis, modification orders and instructions, technical assessment and design certification.
David holds delegation from NZCAA, CASA(AUS) and RNZAF. Having also previously held delegation from DGTA (AUS).
Previously David as Principle Design Engineer – Hawker Pacific David was responsible for avionics related documents, design, review or approval for both rotary and fixed wing aircraft for a variety of roles. He was responsible for mentoring and overseeing of the work and development of Graduate Design Engineers and Technical Officers.
He was Business Improvement Team member, responsible for the steering of the department with respect to adherence to regulations and approved guidance material, safety, configuration control, document management processes, procedures, business planning and recruiting. Project example include:
Project 1: Engineering and certification management of a bespoke, single ship, multi-role aircraft for use by the Malaysian Government for aerial mapping,
medivac and corporate transport. Very closely liaised with Malaysian DCA to acheive transfer from Australian civil register to the Malaysian civil register in
Australia prior to ferry flight.
Project 2: Full scope and engineering management of a full mission system integration to a King Air 350 for Malaysian Police. The final mission capable platform included; EO/IR, SAR Radar, COFDM secure Video Streaming, SatCOM, Drop Hole, Video Management system and jump seat.
Project 3: Application of 6Sigma principles and engineering experience to develop new design procedures for Safe Air engineering including a new document management system, new templates, new job induction and closure procedure, new numbering system and all applicable training and associated quality requirements with the production ‘go live’.
Senior Engineering staff – Experience Summary
Damian Scott
University of Manchester, England. Bachelor of Engineering (BEng) Honours.
Safe Air. Senior Design Engineer responsible of design changes (repairs and modifications) to aircraft structures, mechanical systems and components, including check and approval. Design of specialist Role Equipment and Ground Support Equipment and for use with aeronautical products, aircraft structures design and analysis, aircraft interiors design and development, Finite Element Analysis (FEA), computer aided design and liaison engineering.
BAE Systems (formerly British Aerospace (BAe) including 5 year sponsored Engineering Undergraduate Training Program. Graduate engineer, stress engineer/ structures engineer, Senior Structures Engineer. Experience included aircraft structures, in-service aircraft support, aircraft return to works and development, aircraft type record and fatigue type record development, fatigue check stress, structural analysis (FEA), structural test support, Aerodynamics support, design/drafting
Delegations and Authorities – Safe Air Limited authorized to check design change documentation, manual amendments, drawings, interim responses, test schedules (airworthiness and functional), reports, publication amendments and specifications/proposals. Authorized to approve design certificates, statements of compliance, design change documentation, manual amendments, drawing, validation of design software, approved technical information incorporation, interim response.
Civil Aviation Authority of New Zealand (CAANZ) authorized to approve aircraft modifications and repair i.a.w. Civil Aviation Rule 21.81 and Rule 21.433. Delegation may only be exercised in respect of work performed by Safe Air Limited under Design Organization Certificate Number DO12884. Delegation may be exercised for modifications and repairs to aircraft that are classified as Class B design changes as defined in Civil Aviation Rule Part 146.
Royal New Zealand Air Force (RNZAF) Delegated Engineering Authority (DEA) for Grade A Airframe and Grade B Mechanical Systems, Components and equipment including authorising; publication amendments, new drawings and drawing amendments, RNZAF concessions, New Zealand repair schemes, special local manufacture, and process deviations.
Air New Zealand letters of authorization to; check ANZES Technical Instructions and Technical Assessments, sign a Statement of Compliance (SOC) for aircraft design changes, and accept Technical Data on behalf of the Operator (Data Acceptance, CAANZ Part 119 activity).
Previously BAE Systems authorized to sign for checked; Technical Reports, Drawings (Stress), Stress and Fatigue calculations/reports, Fortran Programs, FEA and Accredited Structural Analyst (FEA).
Senior Engineering staff – Experience Summary
Matthew Potts
University of Canterbury ME in Management & BE Mech (Hons).
ANZES SOC, RNZAF DEA, Altitude SOC Approval
Safe Air. Two years production improvement projects for propeller overhaul facility. Prepared tenders for airframe and engine maintenance work. Fourteen
years designing repairs and modifications for aircraft structures and components, covering a wide range of aircraft types. Design of P3 METS adaptor.
Secondments:
Kaman Aerospace International Support Centre – KAISC (Nowra, Australia) Three months supporting the RAN Seasprite helicopters, defect
investigations, publication amendments, and potential structural modifications
Air New Zealand. Many secondments to Air New Zealand Liaison Engineering Group.
L-3/IS Communications (Texas) One year seconded for the RNZAF P-3K Systems Upgrade Project (SUP). Installation design Engineer for new systems. Conceptual design of tactical stations, weight and balance, & review of structural drawings.
Boeing Commercial Aircraft (Seattle) Three months designing & substantiating fuselage primary structure repair schemes for Boeing 737-series worldwide operators. Static strength and fatigue analysis using Boeing design tools.
Air New Zealand Engineering Services (Christchurch) - Project Engineer One year Evaluating & reviewing of tooling and test equipment for Boeing aircraft. Production and coordination of equipment manufacture. Technical validations for non OEM tooling.
Senior Engineering staff – Experience Summary
Cameron Ready
Secondments:
Air New Zealand Technical Operations, Auckland (February-August 2014 – B787-9 STC (Business Premiere Seat/bed re-activation).
Altitude Aerospace interiors (CHCH): Multiple secondments to support 2D & 3D CAD design and Drafting for projects:
- B737-8 BBJ A/C fitouts
- FAR23 A/C Cockpit Security Barrier
- A/C end of lease reconfigurations (B747)