APU S/N : SP-E912042 AIRCRAFT REGISTRATION: EI-CZG APU P/N : 170101-106 CUSTOMER : Air One R/O N : 78202418 EVENT N : 1379 REVISION N : 685265 TSN : 16143 TSI : 2655 DATE OF REMOVAL: 18.04.07 CSN : 15386 CSI : 2839 DATE OF REPORT : 15.06.07 MODULE CONFIGURATION COMPRESSOR TURBINE GBX MODULE S/N AT ARRIVAL V42-C848 V26-HB017 SP-G 910140 S/N AT DEPARTURE V42-C848 HD441 SP-G 910227 SB CONFIGURATION : AS RECEIVED : O AFTER REPAIR (PLANNED) : X 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 o o o o o o o o o o o 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 o o o o o x x x x x 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 o o o o o o o o o o o o x o o 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 x o o o o o o o o x o o o x CUSTOMER`S REASON FOR REMOVAL : Combustion chamber distress REASON FOR REMOVAL CONFIRMED YES x NO PRIMARY FINDINGS : BEARING YES NO CARBON SEAL / FLOATING RING KNOWN FAILURE MODE x COMBUSTION CHAMBER x INVESTIGATION REPORT x GEARBOX INCOMING TEST RUN x FOD x CUSTOMER PRESENT x LRU`S PRELIMINARY FINDING REPORT x NO FAILURE FOUND ATTACHMENTS x FINAL FAILURE CONCLUSION: The removal reason could be confirmed. During borescope incoming inspection we found a "FOD" noticed on the compressor impeller. APU is a Non PI Version. The Compressor Impeller displayed impact marks on the leading edge. The nozzle guide vanes showed burnt and cracked trailing edges.the combustion chamber showed heavy damaged heatshiels and thermal cracks.the combustor housing inner seal broken and fuel nozzles showes damages and have to be repaired. Nearly all seal segments and the forward seal plate revealed wear. Nearly all Fuel Nozzles revealed wear marks. Note: Information above are subject to change pending further findings, inspection, test and repairs. WRITER APU PRODUCT ENGINEER Volker Kardel Thomas Mayer This report details the maintenance and repair service Lufthansa recently provided for your company. Included in this Shop Findings Report are the following information: 1. Technical Data 2. Picture Report Cover Sheet Page 1
FINDINGS UPON ARRIVAL: Shipping Container is a: Wood Box X Cardboard Box LHT Steel Container Shipping Container damage: X No Yes* Customer informed APU external damage: No X Yes* Customer informed Position 6 Bracket bent: No X Yes* Customer informed Bracket proper mounted No* X Yes Customer informed Combustor Housing cracked: No X Yes* Customer informed Oil Cooler contaminated: No Yes* Matrix dented Blocked Engine Rotation: Smooth X Rough Seized Oil Condition: X Normal No-oil Contaminated*** Burnt Oil Filter Condition: X Normal Chips**** Filter removed**** Light Fuel Filter Contamination: None X Light Moderate Heavy Generator installed: X No Yes Inlet Path inspected: No findings X Findings Engine Mount inspected: X No findings Findings Customer informed Starter Clutch defective: X No Yes***** Customer informed Igniter unit damaged: X No Yes Connector Box Fuel manifold seals leaking: X No Yes Not visible Muff bent, cracked: No X Yes Not visible Tubes chafed: X No Yes Harness damaged: X No findings Findings Connector damaged Cable * Take picture, inform customer support, inform Product engineering ** Trace missing parts on Missing Parts List (MPL), inform Customer Support *** Perform Oil analysis, inform customer support **** Check metal chip origin, check generator history, inform Product engineering and customer support ***** Check for proper installation, inform Product engineering, take picture THE FOLLOWING EXTERNAL HARDWARE WAS MISSING: None EMU Starter FCU Fire warning S.Clutch Cooling Fan LOP Switch TP Sensor X See table above** Generator is not installed Oil Cooler ist not installed Cooling Air Duct Assembly is not installed; see Missing Part List Add missing Parts + Partnumber Technical Data Page 2
BORESCOPE FINDINGS: APU borescoped x Yes No Compressor Impeller Normal x Damaged Soft FOD x Hard FOD Inlet Muff Normal x Damaged DOD Hard FOD Combustion Chamber Normal x Damaged NGV Normal x Damaged Compressor Turbine Wheel Normal x Damaged INCOMING FUNCTIONAL TEST RESULTS: x APU was not pre-tested due to major internal damage. APU was not pre-tested due to major external damage. APU was not pre-tested due to metal chips on MCD / contamination in oil. APU was pre-tested. Results are within acceptable manual specifications. APU was pre-tested. The following results exeed allowable specifications: EGT Margin Gearbox vibrations Power Section vibrations ECS-Mode EGT Functional Surge Check Oil Consumption Rundown time PERFORMED WORKSCOPE: x x x Remove, inspect, and repair applicable Line Replaceable Units as necessary. Remove, inspect, and repair applicable Line Replaceable Units per customer work scope. Remove, inspect, and repair Gearbox as necessary. Remove, inspect, and full refurbish Gearbox as necessary. Remove, inspect, and repair Compressor Section as necessary. Remove, inspect, and full refurbish Compressor Section as necessary. Remove, inspect, and repair Turbine Section as necessary. Remove, inspect, and full refurbish Turbine Section as necessary. Repair APU as necessary. Perform modifications in accordance with LHT Engineering baseline. Perform ATP Run in accordance with HSPS EM 170101-106:Series Perform all necessary AD-Notes. Perform necessary preservation for long time storage. APU HISTORY: Findings / Workscope: Last Shop Visit: Revision N : Aircraft Customer Removal Reason TSN / TSR: First shop visit at Lufthansa Technik Technical Data Page 3
GEARBOX SECTION: LUBE JET WEAR: YES NO x REINSTALLED x REPAIRED SCRAPPED & REPLACED BY NEW CLUSTER BUSHING YES NO x REINSTALLED x REPAIRED SCRAPPED & REPLACED BY NEW GEAR THEETH DAMAGE: YES NO x REINSTALLED x REPAIRED SCRAPPED & REPLACED BY NEW HOUSING DAMAGED: YES NO x REINSTALLED x REPAIRED SCRAPPED & REPLACED BY NEW BEARINGS WORN: YES NO x REINSTALLED x OVERHAU SCRAPPED & REPLACED BY NEW OIL PUMP SEIZED: YES NO x REINSTALLED x REPAIRED SCRAPPED & REPLACED BY NEW CHIPS IN SYSTEM: YES NO x CLEANED LIP`SEAL DAMAGED: YES x NO REINSTALLED REPAIRED SCRAPPED & REPLACED BY NEW x COMPRESSOR SECTION: BALL BEARING DAMAGED YES x NO REINSTALLED OVERHAU SCRAPPED & REPLACED BY NEW x CARBON SEAL DAMAGED YES x NO REINSTALLED REPAIRED SCRAPPED & REPLACED BY NEW x COMPR: IMPELLER DAMAGED YES x NO REINSTALLED REPAIRED x SCRAPPED & REPLACED BY NEW INTAKE HOUSING DAMAGED YES x NO REINSTALLED REPAIRED x SCRAPPED & REPLACED BY NEW DIFFUSER DAMAGED YES x NO REINSTALLED REPAIRED SCRAPPED & REPLACED BY NEW x QUILL SHAFT DAMAGED: YES NO x REINSTALLED x REPAIRED SCRAPPED & REPLACED BY NEW MUFF ASSY DAMAGED YES x NO REINSTALLED REP/MOD OLD VERSION / REPL. BY NEW x ROLL BEARING DAMAGED YES x NO REINSTALLED OVERHAU SCRAPPED & REPLACED BY NEW x POWER SECTION: NGV DAMAGED: YES x NO REINSTALLED REPAIRED x SCRAPPED & REPLACED BY NEW TURBINE WHEEL DAMAGED: YES x NO REINSTALLED REPAIRED SCRAPPED & REPLACED BY NEW x SCREEN DAMAGED: YES x NO REINSTALLED REPAIRED OLD VERSION / REPL. BY NEW x SEAL PLATE DAMAGED: YES x NO REINSTALLED REPAIRED SCRAPPED & REPLACED BY NEW x SEAL PLATE SEG. DAMAGED: YES x NO REINSTALLED REPAIRED 80% SCRAPPED & REP. BY NEW x SOUND ATTENUATOR YES NO x REINSTALLED x REPAIRED SCRAPPED & REPLACED BY NEW ROTOR COUPLING DAMAGED: YES NO x HOT SECTION: COMB.CHAMBER DAMAGED: YES x NO REINSTALLED REPAIRED x SCRAPPED & REPLACED BY NEW COMB.HOUSING DAMAGED YES x NO REINSTALLED REPAIRED x SCRAPPED & REPLACED BY NEW EXHAU.HOUSING DAMAGED: YES x NO REINSTALLED REPAIRED x SCRAPPED & REPLACED BY NEW THERMOCOUPLES DAMAGED: YES NO x REINSTALLED x REPAIRED SCRAPPED & REPLACED BY NEW 2 x IGNITION CABLE DAMAGED YES x NO REINSTALLED REPAIRED SCRAPPED & REPLACED BY NEW x MISCELLANEOUS: START FUEL NOZZLES WORN: YES x NO REINSTALLED REPAIRED SCRAPPED & REPLACED BY NEW x MAIN FUEL NOZZLES WORN: YES x NO REINSTALLED REPAIRED SCRAPPED & REPLACED BY NEW x FUEL MANIFOLD DAMAGED YES NO x REINSTALLED x REPAIRED SCRAPPED & REPLACED BY NEW ENGINE HARNESS DAMAGED YES NO x REINSTALLED x TESTED SCRAPPED & REPLACED BY NEW Technical Data 4
EVENT N 1379 REVISION N 685265 PICTURE 1 FOD - Plastik on inlet screen PICTURE 2 Cooling fan screen contaminated Picture Report 5
PICTURE 3 FOD - Compressor impeller PICTURE 4 Diffuser vanes shows impacts and inner diameter worn Picture Report 6
PICTURE 5 Combuster chamber heat shield heavy broken and outer liner cracked PICTURE 6 Turbine wheel blade damaged Picture Report 7
PICTURE 7 Air Intake Housing Plasma worn and bearing capsule support flange scratched and worn PICTURE 8 Seal plate worn Picture Report 8
EVENT N 1379 REVISION N 685265 PICTURE 9 Seal plate segments worn ( burned ) PICTURE 10 Combustion housing inner seal broken Picture Report 9
PICTURE 11 Gearbox housing contaminated PICTURE 12 EMU information Picture Report 10
EVENT N 1379 REVISION N 685265 PICTURE 13 Exhaust housing hole cracked PICTURE 14 Bearing support inner surface worn Picture Report 11
PICTURE 14 Muff Cover sreew missing PICTURE 15 very dirty air inlet aera ( Air intake / Screen ) Picture Report 12