Engine/Module Repair Requirements /

Transcription

1 AIR CHINA TECHNICS Engine/Module Repair Requirements / ERR No. PW4K R0 Engine Type Engine S/N Executive Base Prepared By Checked By Approved By PW P Ameco EWR PW4K R0 Page1 CCA-ED-044

2 Engine Type PW Engine S/N P TSO/CSO / 7331/2650 TT/TC / 29817/7791 Engine Repair Requirements A/C Register No/Pos. / B-2557/1 Module S/N --- Reasons for Removal Oil Leakage Date of Removal Apr. 27, 2009 A. Engine History: 1. At TT/TC: 11426/3024, the engine was removed and was repaired on Jun.6, At TT/TC: 22486/5141, the engine was removed and was overhauled on May.25, B. Work-scope Requirements: 1.) Strip QEC/accessory components as necessary and disassemble engine into module condition. 2.) Inspect, repair or heavy maintenance all modules as followings: (01) LPC module- Module Level Inspection/Fan Blades- Heavy Maintenance a. Visual inspection LPC module per the instructions of P&W MPG P/N51A772, Part IV, Section 4.3 & 5.2, and repair on condition. (02) Turbine Coupling- Heavy Maintenance a. Disassemble, cleaning, detail inspection and repair turbine coupling module per the instructions of P&W MPG P/N51A772, Part IV, Section 6.3 (03) Fan case- Module Level Inspection a. Visual inspection Fan case module per the instructions of P&W MPG P/N51A772, Part IV, Section 7.2, and repair on condition. b. Repair 2.5 bleed valve assembly. (04) Intermediate case- Module Level Inspection a. Visual inspection Intermediate case module per the instructions P&W MPG P/N51A772, Part IV, Section 8.2, and repair on condition. b. Carry out SB (05) HPC module- Gas Path Restoration a. Disassemble, cleaning, inspection and repair HPC module per the instructions of P&W MPG P/N51A772, Part IV, Section 9.4 b. Measure and record tip clearance. c. Carry out SB , Carry out AD , if accessible. (06) Diffuser/combustor module- Heavy Maintenance a. Disassemble, cleaning, detail inspection and repair Diffuser/Combustor module per the instructions of P&W MPG P/N51A772, Part IV, Section 10.3 b. Carry out SB , (07) Turbine nozzle- Heavy Maintenance a. Disassemble, cleaning, detail inspection and repair Turbine nozzle module per the instructions of P&W MPG P/N51A772, Part IV, Section 11.3 b. Carry out SB , Prepared By: LiZhen Date: Jun. 1, 2009 Revision: R0 EWR PW4K R0 Page2 CCA-ED-044

3 Engine Repair Requirements (08) HPT module- Heavy Maintenance a. Disassemble, cleaning, detail inspection and repair HPT module per the instructions of P&W MPG P/N51A772, Part IV, Section 12.5 b. Carry out SB , SB72-736, AD (09) LPT module- Heavy Maintenance a. Disassemble, cleaning, detail inspection and repair LPT module per the instructions of P&W MPG P/N51A772, Part IV, Section 13.5 b. Carry out AD c. Once the LPT module pass the visual inspection, exchange LPT modules between and will be assembled LPT module. (10) Turbine exhaust case- Heavy Maintenance a. Disassemble, cleaning, detail inspection and repair Turbine exhaust case per the instructions of P&W MPG P/N51A772, Part IV, Section 14.3 (11) Main gearbox module- Module Level Inspection a. Visual inspection Main gearbox module per the instructions of MGB module per PW MPG P/N51A772, Part IV, Section 15.3, and repair on condition. (12) Angle gearbox- Module Level Inspection a. Visual inspection Angle gearbox module per the instructions of AGB module per PW MPG P/N51A772, Part IV, Section 16.2, and repair on condition. (13) Engine AFT/FWD mount- Heavy Maintenance (14) Main bearing- Heavy Maintenance (15) QEC/accessory components a. Visual inspection, functional test, modification or overhaul QEC/accessory components per the requirements of Engine Accessory Work Order, which will provided later. b. Carry out SB A75-51, , , , EO 747/ , 747/ , 747/ , 747/ , 747/ AD , AD ) Sub-assembly, balance and final assembly engine per the instructions of Engine Manual with ETOPS standard. 4.) Built-up QEC/accessory components per instructions of Engine Buildup Manual. 5.) Perform Engine test run at power rating 4052, 4056 in test-cell, service engine using BPTO 2197 oil. Perform C check, cleaning/insp. or replace all air/fuel/oil filters as necessary. 6.) Bore-scope inspection after engine test-run, a video of bore-scope inspection is required. 7.) Oil preservation for 60 days plus for engine storage. 8.) Fill out HPT airfoils rebuild summary form, Engine FAA DER/EASA DOA Repair Records and PMA Parts Installation Record. Prepared By: LiZhen Date: Jun. 1, 2009 Revision: R0 EWR PW4K R0 Page3 CCA-ED-044

4 Engine Repair Requirements C. Documentation Requirements After engine repair is accomplished, the following documents* and information must be provided: 1). Authorized Release Certificate(FAA8130-3, FAA-337 AAC-085 and AAC-038) 2). Life limit parts time report 3). Module time report 4). Engine accessory list 5). List of incorporated SBs 6). Engine test data sheet 7). Tip clearance report 8). Engine MAP III analysis report 9). Inspection report (Shop Finding Report) 10). Scrapped parts list 11). Engine FAA DER/EASA DOA Repair Records 12). PMA Parts Installation Record 13). All documents happened on this shop visit should be delivered to AIR CHINA. 14). Engine HPT blade and vane Rebuild Summary (see attachment form) 15). ETOPS Qualification Statement ** 16). Specific Obligations ** Note 1: ETOPS Qualification Statement Definition is a statement to clarify that ESN is in compliance with the requirement in the B767 CMP (D6T11604 Latest Revision) and no "non-etops parts or ETOPS restricted parts" are installed on subject engine according to B767 CMPS (D6T11605 Latest Revision) requirement. * Note 2: 1). Above item 1-6 documents must be provided as soon as the engine is release. A hard copy of the documents must be packed along with engine. 2).Complete copies of above documents must be available within four (4) weeks after the engine was delivered. Three copies of above repair documents are required to provide to Air China. Prepared By: LiZhen Date: Jun. 1, 2009 Revision: R0 EWR PW4K R0 Page4 CCA-ED-044

5 PW Engine HPT Vane/Blade Rebuild Summary Engine S/N Module S/N Date of Shop-visit Module TT Module TC Module TSO Module CSO Part Name Part No. Quantity Overhaul /New Part S/N. TSO CSO TT TC Stage 1 HPT Vane Stage 1 HPT Blade Stage 2 HPT Vane Stage 2 HPT Blade Remarks: Complied By: Date: Checked By: Date: EWR PW4K R0 Page5 CCA-ED-044

6 Engine S/N Engine Engine Shop Visit Workscope: Engine TSN FAA DER/EASA DOA Engine FAA DER/EASA DOA Repair Records Engine CSN SV Date Repair Vendor S/N Part Description Part Nr. Serial Nr. DER/DOA DER/DOA Repair Description FAA/EASA FAA/EASA Approval Nr. CCA Approval Nr. EWR PW4K R0 Page6 CCA-ED-044 Remarks

7 PMA PMA Parts Installation Records S/N Part Description PMA Part Nr. PMA Serial Nr. OEM Equivalent OEM P/N PMA Manufacturer Signature Title Date CCA-ED-035R1 EWR PW4K R0 Page7 CCA-ED-044 Remark