Chromalloy. Borescope and Test Report. Prepared for. Triumph Air Repair A Triumph Group Company

Transcription

1 A Triumph Group Company Borescope and Test Report Prepared for Chromalloy Customer P.O.#: S2669 A.P.U. Model #: GTCP ER A.P.U. Serial #: P-2796 A.P.U. Part #: Triumph SRO #: S Received Date: March 1, 2013 Shipment Date: 1

2 Receiving Inspection Findings: Incoming APU Times and Cycles: TSN: CSN: 8493 TSR: 231 CSR: 154 TSO: 6010 CSO: 2778 Log Book Received: NO YES Customer Supplied: NO YES Shipping Container is a: Wooden foam drop in box S/N: Shipping Container damage: NO YES A.P.U. external damage: NO YES A.P.U. Missing parts: NO YES Missing Q.E.C. Items: NO YES None recieved Engine Rotation: Smooth Rough Seized Oil Condition: Normal Burnt No-Oil Contaminated I.G.V. Pull Test: Smooth Rough Seized 2.0 Pounds of pull Fan Gears: Normal Worn Damaged Delta P Indicators Oil Pump Delta P extended: NO YES Fuel Control Delta P extended: NO YES Gen. Scavenge Filter Delta P extended: NO YES Filters Oil Pump Contamination: None Light Moderate Heavy Fuel Control Contamination: None Light Moderate Heavy Gen. Scavenge Contamination: None Light Moderate Heavy Magnetic Chip Detectors Gearbox Chip Detector: None Light Moderate Heavy Mid Frame Chip Detector: None Light Moderate Heavy -250H Aft Scav. Pump Chip Detector: None Light Moderate Heavy -250H Generator Chip Detector: None Light Moderate Heavy -250H 2

3 A.P.U. Borescoped NO YES Borescope Findings: 1 st Stage Turbine Stator: X Acceptable Damaged 1 st Stage Turbine Wheel Blades: X Acceptable Damaged -Minor Tip Erosion 1 st Stage Compressor Impeller: X Acceptable Damaged 2 nd Stage Compressor Impeller: X Acceptable Damaged Load Compressor Impeller: X Acceptable Damaged 3 rd Stage Turbine Wheel: X Acceptable Damaged Combustion Chamber: X Acceptable Damaged -Minor Loss of TBC Load Compressor & Power Section Ball Bearings: X Acceptable Damaged Wheel Times: 1 st Stage Turbine Wheel: CSN: 8709 Cycles Remaining nd Stage Turbine Wheel: CSN: 8493 Cycles Remaining rd Stage Turbine Wheel: CSN: Cycles Remaining 7190 Data Plate Information: Gearbox Assembly Data plate: P/N: S/N: P-236 Load Compressor Data Plate: P/N: S/N: P-2281 Power Section Data Plate: P/N: S/N: P

4 Incoming Functional Test Results Complete detailed functional test results are available upon request. A.P.U. was not pre-tested. See remarks below. A.P.U. was not pre-tested due to major internal damage. A.P.U. was not pre-tested due to major external damage. A.P.U. was not pre-tested due to metal contamination in oil. A.P.U. was pre-tested. Results are within acceptable manual specifications. A.P.U. was pre-tested. The following results exceed allowable specifications: Recertified APU Customer Reason for Removal: Removed in Serviceable Condition for End of Lease Term Confirmation of Cause for Removal No Yes Customer Requested Workscope: Repair As Necessary Recommended Workscope: LRU Workscope: Load Compressor: Power Section: Gearbox Workscope: QEC Workscope: Misc. Workscope: 4

5 EVALUATION AFTER WORKSCOPE Gearbox Condition Metal Contamination Bearing Failure Gear Failure Oil Leak Liners Worn/Scored High Hours/Cycles Requires Modification Customer Request Other Gearbox Recommended Workscope: Repair Overhaul Visually Accept Not Disassembled Load Compressor Condition Strike Damage Bearing Failure IGV Wear/Failure Rub Damage Low Performance Surge Margin Oil Leak Other Load Compressor Recommended Workscope: Repair Overhaul Visually Accept Not Disassembled Power Section Condition Strike Damage Bearing Failure Blade Shift Rub Damage High Hours/Cycles Hot Section Deteriorated High EGT Oil Leak Other Power Section Recommended Workscope: Repair Overhaul HSI Visually Accept Not Disassembled Line Replaceable Units Route for Test and Repair as Necessary Metal In Oil Check Sheet GTCP /250 REV. A Auxiliary Power Unit Recommended Workscope: Repair No Fault Found Hot Section Inspection Overhaul Beyond Economical Repair / Part out Return As Is F/T Only 5

6 Analysis and Conclusion Chromalloy ER APU, P-2796 (S13678), was received at (TAR) April 19, 2013 with a reported time since overhaul of 6010 hours. The reason for removal was not given and the customer requested workscope was Repair as Necessary. Triumph relies on the results of the incoming inspection, as well as the return reason, to effectively disposition an APU. Results of the incoming inspection are critical in helping to verify the return reason or acceptability of the APU for a Pre Test. During incoming inspection the significant findings include: The engine rotation and IGV pull test was smooth with only 2.0 pounds of force needed. Oil Pump, Fuel Control, and Generator Scavenge Filter Delta P indicators were in the normal, un-extended position, the APU oil filter exhibited no contamination, the Generator and Fuel filters were free of debris, and the Magnetic Chip Detectors exhibited no contamination. The oil cooling fan is a sensitive reliability issue by design on the /-250 series APU s and Triumph inspects the cooling fan and mating idler gear closely. In this case the Cooling Fan Gear and Idler Gear were found acceptable for continued use. Borescope inspection revealed minor tip erosion to the 1st Stage Turbine Blades and some minor loss of thermal barrier coating in the Combustion Chamber. Both conditions are acceptable for continued use. The 1 st Stage Power Section Impeller blade leading edges were in servcieable condition. The trailing edges of the 1 st Stage Power Section Impeller can't be accessed during the borescope process. The 2 nd Stage Power Section Impeller trailing edges were viewed with the borescope and only showed minor flame spray build up on the blades, which was considered acceptable for a serviceable APU. The 2 nd Stage Power Section Impeller leading edges can't be accessed during the borescope process. The APU was found acceptable for a pre-test to determine the condition of the APU and LRU s. During test the APU met all OEM manual requirements. The Test sheet is attached below. 6

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8 Post Test Borescope Pictures Photo 1. APU data plate. Photo 2. Acceptable 3 rd Stage Turbine Blades Photo 3. Acceptable 1 st Stage Turbine Nozzle Photo 4. Minor and acceptable 1 st Stage Turbine Blade tip erosion Photo 5. Acceptable Combustion Chamber thermal barrier TARF coating delamination. (Rev. K, 11/10) Photo 6. Additional acceptable Combustion Chamber thermal barrier coating delamination. 8

9 Post Test Borescope Pictures Photo 7 2 nd Stage Power Section Impeller with minor rub and flame spray build up on the trailing edges Photo 8. 2 nd Stage Power Section Impeller and 2 nd Stage Diffuser-Minor rub and flame spray build up on impeller trailing edge. Photo 9. 1 st Stage Power Section Compressor Impeller leading edges-no defects noted Photo 10. Inlet Guide Vanes Photo 11. Load Compressor Impeller leading edges-no defects TARF noted (Rev. K, 11/10) 9