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Ageing Gas Turbine Issues. C-130J Case Study
July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
Page 2
DISCLAIMER
This presentation, including any attachments or notes, is
confidential and intended solely for the use of the
individual(s) to whom it is presented. If you are not the
intended recipient, be advised that you have received this
presentation in error and that any use, dissemination,
forwarding, printing, or copying of this presentation is strictly
prohibited. If you have received this presentation in error,
please contact the sender and then delete it from your
system. Written consent is to be sought from StandardAero
prior to release to any third party organization, or person.
July 2018 I Information is Proprietary & Confidential To StandardAero Ltd.
Page 3
• The RAAF AE2100D3 Fleet consists of 58 Engines. (48 Installed, 10 Spare / above fit)
• AE2100D3 has an “On Condition” maintenance philosophy.
• On Condition philosophy managed by the RAAF as a “fly to failure” approach till 2010, then from 2014 through to 2016. Engines were still removed during this period for sustainment maintenance as well.
• High removal rate attributed to:
• Lack of Engine Fleet Planning.
• Poor MGT Margin
• Reduction in Preventative Maintenance actions
• Ageing engine components.
HISTORICAL OVERVIEW
July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
Page 4
• In flight events increased year over year culminating in 5 In Flight Shutdowns (IFSD) across a 5 week period in 2016 (Dual IFSD 5468)
• Inherent engine removal rate greater than repair turn around time.
• Unmanageably low serviceable engine asset levels.
• Budget overruns
• C-130J Powerplant operational confidence all time low.
RESULT….
jJuly 2018 Information is Proprietary & Confidential To StandardAero Ltd.
Page 5
• During the root cause investigation, StandardAero concluded
that poor engine MGT health and worn compressor module
components enabled the engine to be more susceptible to failure
with aircraft anti-ice engaged.
• Five resultant factors were discovered;
1. Weather. (Dual IFSD)
2. Operations in Middle East exposes the engines to High
Pressure Altitude operations, in extreme temperatures; as
well as dusty and sandy environments, leading to
accelerated wear on engine components.
3. The effects of Preventative Maintenance on the bleed air
system has on the overall performance of the engine.
4. No OEM limits on compressor blade Chord dimensions
5. Divergent Aircrew Behavior.
ROOT CAUSE ANALYSIS
July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
Page 6July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
5,500
6,000
6,500
7,000
7,500
Oct-
12
No
v-1
2D
ec-1
2Jan-1
3F
eb
-13
Ma
r-1
3A
pr-
13
Ma
y-1
3Jun-1
3Jul-1
3A
ug-1
3S
ep-1
3O
ct-
13
No
v-1
3D
ec-1
3Jan-1
4F
eb
-14
Ma
r-1
4A
pr-
14
Ma
y-1
4Jun-1
4Jul-1
4A
ug-1
4S
ep-1
4O
ct-
14
No
v-1
4D
ec-1
4Jan-1
5F
eb
-15
Ma
r-1
5A
pr-
15
Ma
y-1
5Jun-1
5Jul-1
5A
ug-1
5S
ep-1
5O
ct-
15
No
v-1
5D
ec-1
5Jan-1
6F
eb
-16
Ma
r-1
6A
pr-
16
Ma
y-1
6Jun-1
6Jul-1
6A
ug-1
6S
ep-1
6O
ct-
16
No
v-1
6D
ec-1
6Jan-1
7F
eb
-17
Ma
r-1
7A
pr-
17
Ma
y-1
7Jun-1
7Jul-1
7A
ug-1
7S
ep-1
7O
ct-
17
No
v-1
7D
ec-1
7Jan-1
8
AT
OW
(E
NH
R)
Propulsion System Maintenance SupportOPM-01: Average Time on Wing (ATOW) - A97J QECA
A97J QECA Target (Ave FTOW)
Page 7
INHERENT OFF WING DRIVERS
Reason 2005-2009 2010-2014 2015-2017Low MGT Margin 14 10 4
Vibration 18 4 6
P/S Oil Pressure 8 5 1
1st Stage Turbine Distress 7 4 3
PGB Metal on Mag Plug 5 3 3
#2 Bearing Rivets 4 8 3
Compressor Flooding 5 0 0
Integral Oil Leak / Impending Bypass 4 3 4
2nd Stage Turbine Distress 3 1 0
Smelly Bleed 2 0 0
4th Stage Turbine Smash Plates 2 2 0
Over Torque 1 0 2
QEC (Sheetmetal)* 29 16 6
High MGT Event 0 2 9
Total Removals ** 103 58 43
Average Removals Per Year ** 21 11 14
Total Removals for Performance Related
Fault49 26 23
Percentage of Removals for Performance
Related Fault47.57% 44.83% 53.49%
Percentage of Engine Fleet Removed 177.59% 100.00% 74.14%
* Maybe not Primary Reason for Removal, but Discovered during Removal / Inspection.
* * Excludes Removed for Access, Sustainment Maintenance, FOD, Serviceability Checks, etc.
July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
Page 8
HI MGT Event – 5468 – Compressor Blade Erosion
July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
Page 9
HI MGT Event – 5467 – Comp Blade Deformation
July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
Page 10
Compressor Blade Limits
July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
• Rolls Royce released Service Bulletins following the recent
surge events as they were attributed to eroded compressor
airfoils.
• AE2100D3-72-311 – 1st thru 14th Stage compressor blade
chord inspection.
• AE2100D3-72-312 – 1st thru 5th stage Variable vane chord
inspection.
•All RAAF engines that return to the AMC will have the
compressor split and blades measured, inspected and
replaced IAW the SB limits.
•28 Engines have already been through the Compressor
Remediation Program.
Page 11July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
80%
83%
85%
88%
90%
93%
95%
98%
100%
103%
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Ch
ord
-P
erc
en
tage
of N
ew
Compressor Stage
Propulsion System Maintenance SupportAE2100D3 Compressor Blade Chord Analysis
AE2100D3 EM Limit
AE2100D3 SB Limit
Average
>8,000 Bucket
>6,000 Bucket
<2,000 Bucket
Page 12
Middle East Operations
July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
Page 13
HI MGT Event – 5464 – Compressor Blade Erosion
July 2018 I Information is Proprietary & Confidential To StandardAero Ltd.
Page 14
Compressor Vane Erosion
July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
Page 15July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
C-130J Fleet Health
Page 16
Gas Generator Case Baffle Damage
July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
Page 17
2nd Stage Turbine Vanes – Distorted
July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
Page 18
Low MGT Margin – 1st Stage Turbine Damage
July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
Page 19
HI MGT Event – 5467 – 1st Stage Turbine Damage
July 2018 Information is Proprietary & Confidential To StandardAero Ltd.
Page 20
Goals
July 2018 I Information is Proprietary & Confidential To StandardAero Ltd.
• Fundamental Change required in the fleet management
of the AE2100D3
• Goals
• Maximize / Optimize time on wing
• Reduce in flight events.
• Contain / Reduce sustainment costs
• Increase serviceable spare asset levels
• Plan engine removals prior to failure or in-flight event.
• Restore C-130J Power Plant operational confidence.
Page 21
StandardAero Contact details
Andrew Wade, CSC
RAAF Program, Operations Manager
Richmond, Australia
Email: [email protected]
Chad Flowers
Director, Customer Programs
Winnipeg, Canada
Email: [email protected]
Matt Bell.
Manager, Engineering
Winnipeg, Canada
Email: [email protected]
July 2018 I Information is Proprietary & Confidential To StandardAero Ltd.
QUESTIONSJuly 2018 I Information is Proprietary & Confidential To StandardAero Ltd.