A program to extend the life span of the twin engine Cessna 441 Conquest has been given the go ahead by CASA.
Approval has been given to an Australian supplemental type certificate (STC) for the Cessna Conquest which permits the aircraft to be operated for up to 40,000 hours flying time, almost doubling its life span.
Cessna set the Conquest’s life limit at 22,500 hours flying time in 2007 after the manufacturer decided not to develop an ageing aircraft maintenance program for the aircraft. This meant aircraft could not be safely flown after 22,500 hours and in Australia had to be grounded, with a small number of Conquests having been taken out of service as a result. There are currently 32 Cessna Conquests on the civil aircraft
register, with the baulk of them being utilised by charter and aerial
work operators.
Australian aerospace engineering company TAE began working on a life extension program for the Conquest in 2008. In collaboration with aeronautical design company Aeronautical Engineers Australia, TAE completed a detailed engineering analysis of the Conquest and its components.
The result was the development of a program of major modifications to be made to Conquests when they reach 22,500 hours. The program includes replacing major structural elements such as fuselage frames, reinforcement of other components and external straps to spread loads and provide redundant load paths. There is also a new, rigorous maintenance program which has been developed using modern damage tolerance philosophies.
“It's an example of genuine Aussie innovation and we are proud of the team in Adelaide that carried this project through the STC process over the past two years,” TAE General Manager Andrew Sanderson said. “We now look forward to modifying many Conquests for our customers from our base at Adelaide Airport. The first modified aircraft is due to return to the skies this month.”
Importantly, TAE’s maintenance schedule is also available to all Conquest operators, including those with aircraft below the 22,500 flight hour life limit
CASA was closely involved in the development of the life extension program to ensure safety will be maintained and type certification standards met up to 40,000 hours in flying time. CASA’s Director of Aviation Safety John McCormick said the development of the Conquest life extension program demonstrates the technical expertise and vision of the Australian aviation industry.
“Careful and detailed work by Australian aeronautical engineers, with safety oversight from CASA’s engineers, has created a program that will see the Conquest fly safely in our skies for many years to come," McCormick said. “This is a win for the Australian aviation industry and a win for air safety. I am proud of the role CASA has played in this project and congratulate TAE Group and Aeronautical Engineers Australia.”