Have you ever wondered what is involved in getting aircraft that have been sitting unused for months and sometimes even years airworthy again after an extended storage period? Storage facilities must begin intensive recovery and maintenance programs before signing off on a Certificate of Release to Service (CRS).
During the COVID-19 pandemic and the massive downturn in travel, airlines worldwide sent their aircraft to storage facilities. Because operators will seek areas of low humidity, places like Arizona, Southern California, Spain, the Middle East, and the Australian outback are common destinations for long-term aircraft storage. With dry conditions, the aircraft has less chance of surface erosion which is especially important for protecting engine blades.
Aircraft must be maintained while in long-term storage
It is not a question of just leaving the plane alone until it is ready to return to service, as aircraft in storage still need maintenance to keep them in decent condition. This was especially true during the pandemic, as nobody knew how long the aircraft would be in storage.
When a plane arrives at the facility, depending on its size, it can take as long as two weeks to prepare it for long-term storage. A facility must first ensure the aircraft is moored correctly and secured to prevent it from being damaged by high winds. All oils are removed from the plane and replaced with preservative liquids, while any openings and sensors are covered.
Also, because most of these locations are in hot sunny areas, covers are put on the wheels to protect the rubber from the effects of the sun. The aircraft’s interior is also protected with plastic sheeting and desiccants to absorb any water in the air.
Aircraft manufacturer guidelines help operators return a plane to service
Preparing a stored aircraft to return to service is a painstaking task that requires reversing everything done to prepare it for long-term storage. When an aircraft is ready to be returned to service, the storage facility follows aircraft manufacturers’ maintenance guidelines.
First, they remove all the protective covers and tape that kept the plane dry and stopped it from becoming a home for insects and animals. This is especially crucial concerning the pitot-static system to determine an aircraft’s airspeed and altitude. If an insect or insects were to find a way to get through the cover and into the tubing, it could result in erroneous data being sent to the crew. Storage facilities flush the system to ensure the pitot-static system is free of insects or any other debris before signing off on its readiness.
It takes around 100 working hours to return a widebody to service
The time to prepare a plane for service depends on the aircraft’s size. A widebody plane like an Airbus A380 takes around 100 man-hours, while a narrowbody Boeing 737 takes approximately 40. All the aircraft’s hydraulics must be refilled with oils, the plane’s electrical systems reconnected, and the engines turned on to ensure everything works correctly.
Adding pressure to the task is that airlines often give little notice when asking for their aircraft to be ready to return to service. The job can also be compounded when several airlines want their plan’s back at the same time.