一架巨型飞机的深度体检

一架巨型飞机的深度体检

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、空客三方联手，90多个日日夜夜，近10万工时，世界最大双层客机A380在中国启动第一次六年检。

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.

自引进国内首架A380，南航已运营该机型达6年之久。 投入使用以来，“空中巨无霸”以其平稳舒适、载客量大等特点，受到国内外广泛关注。2017年3月1日，中国首架A380（B-6136）的首次3C检在GAMECO机库正式启动，预计最终将在6月完工，届时飞机将以全新状态重返蓝天，再展雄姿。

A380的3C检也称六年检，就是在飞机运行6年之后，由机务人员进行的一次全面、详细、深度的体检。体检中包括例行工作、改装、客舱整新等一系列大型维修工作，以保证飞机的运行可靠性，并提升客舱舒适性。此次A380六年检在国内航空维修史上属首次。

6-year Check Process (94 Days)检修流程（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.

两层客舱所有部件拆下，客舱整新全面开工

飞机盖板全部打开，完成绝大多数检查工作

客舱门、襟翼、缝翼、滑轨等大部件全部拆下

起落架小车枢轴检查、缝翼检查、发动机检查等对飞机构型有严格要求的项目需完成

NDT检查基本完成

重要改装陆续开工

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.

鹅颈、FR56、客舱门、油管等重要改装完成

客舱整新基本完成

客舱滑轨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.

安装整新后的客舱部件

恢复襟翼、缝翼、客舱门并调节

各区域的勤务、防腐以及盖板恢复

飞机通电测试

试飞

Day 71 to Day 94

Whole body painting.

Weigh in after painting.

Test flight after painting.

Aircraft release.

整机喷漆

喷漆后称重

（3）决策独立，即独立董事表达出的对决策的相关看法必须出自自己的意志，脱离大股东的控制，尽可能地减小公司管理者对其的影响。

喷漆后试车

放行

1

Wang Zhikun

Project Manager of A380 6-year check, GAMECO

王治坤

GAMECO A380六年检项目经理

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.

问： A380六年检遇到最大的挑战在哪里？

答：此次定检的困难非常多，单拿工时来说，本次六年检大概需要100000工时，而平时做C检基本上都是5000工时，做最深度的D检，也就两三万小时。相当于四面开花，各个部位同时开工，每个工作量都比较大。很多东西第一次做，让人很操心。

2

Bai Xuefeng

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

白雪峰

南航股份机务工程部生产计划助理工程师

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.

问：南航和GAMECO为此次A380六年检都做了哪些准备？

答：南航股份机务工程部和GAMECO等单位从2016年4月份就成立了六年检项目筹备组，提前准备航材、工具、设备，对人员进行培训，申请当局适航许可，并与空中客车公司技术代表召开多次碰头会。开工前，4560项航材、1812项工具设备均已准备就绪，为A380量身定造的脚手架和接近平台也已准备到位。

3

Jean-marc Braud

Technical Services Manager, Customer Support-SEOT4 Airbus

让-马克

空客公司技术服务经理

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.

问：空客给予南航哪些技术支持？空客对GAMECO的检修水平怎么评价？

答：我们主要负责两项工作，一是协助优化六年检工作流程，尽量缩短停场时间。二是为结构改装提供现场技术指导。这是A380在中国的第一次六年检，南航也是中国唯一进行A380六年检的航空公司。就我们的感受而言，南航的整体维修水平相当高，团队组织性强，我们对工作进展非常满意。我们预计到最后一架飞机的时候，停场时间（不包括喷漆）有望缩短到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.

问：客舱设备翻新是怎么进行的？

答：客舱整体翻新是本次A380六年检的重要项目，几乎客舱内所有的部件都要进行清洁、修复或更换。比如说经济舱座椅靠背的海绵磨损得很厉害，需要全部更换，扶手也得喷漆整新，两舱的板壁和真皮椅套都需要整新。壁纸全部更新，我们通过真空压制车床，将整张壁纸无缝隙粘贴到壁板上。随后客舱部件逐步安装回去，旅客将会看到一个全新的A380客舱。

4

Wang Jue

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

王珏

GAMECO大修三部客舱车间工艺组主任

5

Tan Jinghua

Manager of Support Division, GAMECO

谭敬华

GAMECO支援部经理

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.

问：A380六年检对工具设备的要求是不是尤其高？

答：是的。A380机身又大又高，座椅、厕所、厨房、行李架以及地板的拆卸和运输是巨量的工作。想象一下，一个厨房的重量是350公斤，怎样才能从飞机上搬下来呢？为了解决这些问题我们专门研制出连接客舱与维修车间的滑轨运输通道以及高达8.5米的自动升降平台。三个厨房同时运下来，耗时不到两分钟。