Sikorsky, a Lockheed Martin company has received the Federal Aviation Administration (FAA) certification for a one-time life extension on specific main gearbox housings of its S-92 helicopters. This approval allows operators to extend the operational life of their gearboxes beyond the standard 4,300 flight hours, leveraging data from the company’s extensive Health and Usage Monitoring Systems (HUMS).
Optimizing Component Lifespan with Data-Driven Insights
The S-92 fleet, comprising over 300 aircraft and amassing 2.3 million flight hours, has provided a robust data set for Sikorsky to develop a methodology that accurately determines the life limits of critical components. By analyzing HUMS data specific to individual gearbox housings, Sikorsky has effectively addressed ongoing supply chain challenges in the aviation industry, providing operators with a pathway to maintain and extend the service life of their helicopters.
Using this data, Sikorsky has developed a method to accurately determine the life limits of critical components. The extension is made possible through Sikorsky’s LifePlus methodology, which assesses the remaining life of components based on actual usage patterns rather than fixed time limits. This approach helps reduce downtime and increases the operational readiness of the fleet.
Safety and Reliability
Leon Silva, Vice President of Sikorsky’s Global Commercial and Military Systems, stated, “The FAA certification of the main gearbox housing earned life credit exemplifies Sikorsky’s ongoing commitment to the S-92 platform. Our decade-long investment in LifePlus is now transforming industry standards, providing significant value to operators.”
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This certification follows the FAA’s late 2023 approval of a life extension for the S-92’s main rotor hub, which increased its retirement limit from 9,000 to 15,000 hours or 45,000 ground-air-ground cycles. With LifePlus, Sikorsky is reshaping the industry’s approach to maintenance, prioritizing safety and reliability while supporting operators in maximizing their helicopter fleet’s capabilities. As additional FAA certifications are planned for 2025 and beyond, Sikorsky continues to lead in innovative solutions for helicopter maintenance and performance.
