How to keep a seaplane corrosion free | DHC-6 Twin Otter | Maldives

Summary

The Maldives is known for its stunning seaplane flights, which transport tourists to luxury resorts. However, maintaining these planes in a salty environment is a significant challenge. Saltwater corrosion is combated with regular washing, detailed inspections, and extensive repairs every 125 hours of flight. Seaplanes undergo major maintenance every three years, with corrosion removal, metal replacement, and repainting to ensure their safety. After thorough checks, including engine and wing assembly, the planes are reassembled and restored, ready for more flights. This video offers an inside look at how seaplanes are meticulously maintained to keep flying in the Maldives' unique conditions.

Takeaways

• 😀 Sea planes in the Maldives are exposed to saltwater, which causes corrosion and requires regular maintenance.
• 😀 Fresh water is used to wash away salt from the wings of the aircraft after each flight, but it's not enough for complete protection.
• 😀 Aircraft undergo a thorough inspection every 125 flight hours, which includes a photo inspection and a multi-day checkup.
• 😀 The sea plane engines feature complex components, including a governor and igniter, which must be carefully maintained.
• 😀 Due to the salty environment, sea planes in the Maldives undergo heavy maintenance every three years, compared to the usual five-year interval.
• 😀 During major inspections, parts like floats are rebuilt, and corrosion or cracks are addressed by replacing corroded metal.
• 😀 The painting process involves applying anti-corrosion primer to the aircraft after repairs, followed by a sticky sealant over the seams.
• 😀 The fuselage of the aircraft is moved to the paint shop using wheels, making the process easier and more efficient.
• 😀 Once repairs and painting are complete, the aircraft is reassembled, including the installation of the wings and engines.
• 😀 After reassembly, the sea plane is ready to resume operations, transporting tourists safely around the Maldives.
• 😀 Engineers and technicians play a crucial role in maintaining the sea planes, ensuring they remain in top condition despite the challenging environment.

Q & A

What is the primary challenge faced by seaplane operators in the Maldives?

The primary challenge is corrosion caused by saltwater, which affects the aircraft, particularly the metal components exposed to the salty sea environment.

How do seaplane maintenance crews protect aircraft from saltwater corrosion?

Maintenance crews use freshwater to wash away salt from the aircraft’s wings. However, this is only a preliminary measure, as further maintenance and inspections are needed.

What happens after a seaplane has flown 125 hours?

After 125 flight hours, the seaplane undergoes a photo inspection and is taken for a more detailed maintenance check, which can last a few days.

Why is seaplane maintenance conducted more frequently in the Maldives compared to other regions?

Due to the harsh salty environment, seaplanes in the Maldives undergo heavy maintenance every three years instead of the typical five-year interval, to address corrosion and other wear-and-tear issues.

What is involved in the heavy maintenance process for seaplanes?

Heavy maintenance includes stripping down the aircraft, inspecting every inch for corrosion and cracks, repairing or replacing damaged parts, and rebuilding the floats and wings.

How is corrosion managed during the maintenance process?

Corroded areas are removed and replaced with new metal. The repaired surfaces are then painted with an anti-corrosion primer and sealed to prevent further damage.

What role does the oil cooler play in the engine maintenance process?

The oil cooler helps to regulate the engine temperature by cooling the oil, which is crucial for maintaining engine performance during flight.

How are the aircraft wings and floats treated during maintenance?

The wings and floats are thoroughly inspected and rebuilt, with any corroded or damaged sections replaced. After repairs, the wings are painted, and the floats are treated for durability.

What is the significance of the 'dolphin' painted on the tail of the seaplane?

The dolphin design on the tail is a signature feature of the seaplane, symbolizing the airline’s brand and adding a unique aesthetic touch to the aircraft.

What happens once the seaplane has been fully repaired and painted?

Once the seaplane has been reassembled, painted, and had all small parts installed, it is ready to return to service, transporting tourists around the Maldives.