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PHENOM 300
TECHNICAL SESSION
SAMUEL PECCI | OCTOBER 14th, 2011
AGENDA PHENOM TECHNICAL SESSION
Electrical system contactors
Starter generator update
Pratt & Whitney Canada updates
Engine start failures
Engine inlets
Flap system updates
Tire wear update
Subject
Air Management System (AMS)
Ice and rain protection system
Brake system updates
AGENDA PHENOM TECHNICAL SESSION
Electrical system contactors
Starter generator update
Pratt & Whitney Canada updates
Engine start failures
Engine inlets
Flap system updates
Tire wear update
Subject
Air Management System (AMS)
Ice and rain protection system
Brake system updates
TECHNICAL ITEMS
New Solutions for Phenom 300:
Cabin Evaporator Module
Flow Control and Shut-off Valve (FCSOV)
Air Management System Controller (AMS CTRL)
AIR MANAGEMENT SYSTEM
CABIN EVAPORATOR MODULEAIR MANAGEMENT SYSTEM
Description
Cabin evaporator module low reliability
CABIN EVAPORATOR MODULEAIR MANAGEMENT SYSTEM
Investigation
Module was subject to failure due to low reliability of fan’s controller
Solution
More robust controller for the module (new P/N -4)
Action plan
SB 505-21-0004, “Replacement of the cabin evaporator”, issued on September 30, 2011
SB with retrofit campaign
FLOW CONTROL SHUTOFF VALVE
(FCSOV)
AIR MANAGEMENT SYSTEM
Description
FCSOV -2 has been presenting CAS messages “ECS 1(2) VLV FAIL”
FLOW CONTROL SHUTOFF VALVE
(FCSOV)
AIR MANAGEMENT SYSTEM
Investigation
Flow sensor robustness
Narrow margins for failure messages
Water ingression from bleed system
FLOW CONTROL SHUTOFF VALVE
(FCSOV)
AIR MANAGEMENT SYSTEM
Solution
FCSOV -7 introduces a more robust flow sensor, but does not address narrow margins for failure messages
FCSOV -9 corrects margins for failure messages
Water separator installation in the bleed system cold line
Action plan
FCSOV -7: available via AIPC (September 2011), replacement on attrition
FCSOV -9: SB with retrofit campaign (December 2011)
Water separator: SB with retrofit campaign (December 2011)
AMS CONTROLLERAIR MANAGEMENT SYSTEM
Description
SB 505-36-0001, Replacement of the AMS controller, introduced improved hardware for controller -202
Factory incorporated from S/N 505-00021
Retrofit campaign ongoing (82% - only 2 aircraft remaining)
CAS messages “BLEED 1(2) FAIL”
AMS CONTROLLERAIR MANAGEMENT SYSTEM
Investigation
CAS messages “BLEED 1(2) FAIL” are triggered due to logic to open/close the Fan Air Valve (FAV)
Solution
SB 505-36-0002, AMS controller software update, issued on June 07, 2011, introduces upgraded AMS controller -203 with software corrections to FAV open/close logic
Action plan
Factory incorporated from S/N 505-00050
SB with retrofit campaign (~28% done)
AGENDA PHENOM TECHNICAL SESSION
Electrical system contactors
Starter generator update
Pratt & Whitney Canada updates
Engine start failures
Engine inlets
Flap system updates
Tire wear update
Subject
Air Management System (AMS)
Ice and rain protection system
Brake system updates
WS HEATING CONTROL UNIT (WHCU)TECHNICAL ITEMS
Description
WHCU -2 presenting low reliability
WS HEATING CONTROL UNIT (WHCU)ICE & RAIN PROTECTION SYSTEM
Investigation
Root cause of issues is WHCU software (messages logic)
Solution
Improved part WHCU -3
Improved mechanical robustness
Correction of software logics (including CMC messages)
Action plan
Expected for December 2011
SB with retrofit campaign
AGENDA PHENOM TECHNICAL SESSION
Electrical system contactors
Starter generator update
Pratt & Whitney Canada updates
Engine start failures
Engine inlets
Flap system updates
Tire wear update
Subject
Air Management System (AMS)
Ice and rain protection system
Brake system updates
TECHNICAL ITEMS
BRAKE SYSTEM UPDATES
New solutions for Phenom 300
Brake Control Unit (BCU) -7
Brake pedal modifications
P300 In Service Request - Tech Reports Related to Failure
1 1 1
2 2
4
7
2
3
2 2
3
1
0
2
4
6
8
10
12
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP
2010 2011
ISR
Qty
0.0%
1.0%
2.0%
3.0%
4.0%
ISR
pe
r C
yc
le (
%)
BRAKE INOP / FAIL BRAKE INOP / FAIL (% Per Cycle)
BRAKE SYSTEM UPDATES
BRAKE CONTROL UNIT (BCU) -7
Description
BRK FAIL message on CAS, with associated loss of main brake system
BCU -06Retrofit
complete
BRAKE SYSTEM UPDATES
BRAKE CONTROL UNIT (BCU) -7
Investigation
Events failure modes were different, but all traced to BCU
Interim solution: SB 505-32-0005, Replacement of the brake control unit (BCU DAP00100-03/-04/-05 to BCU DAP00100-06), issued on February 23, 2011
Improved monitors and control logic
Subject to OB 505-001/11, Landing distance factor recommendation
BRAKE SYSTEM UPDATES
BRAKE CONTROL UNIT (BCU) -7
Solution
New BCU -7
Improved handling during brake application
Supersedes OB 505-001/11, landing distance factor recommendation
Action plan
SB with retrofit campaign
Expected availability in or before December 2011
BRAKE SYSTEM UPDATES
BRAKE PEDAL ASSEMBLY
Description
Reports of left/right tendency during main brake application
Investigation
Pedal ergonomics affects braking control
Same force applied to LH/RH pedals cause different pedal readings and different pressures applied to brakes
BRAKE SYSTEM UPDATES
BRAKE PEDAL ASSEMBLY
Solution
Modification of pedal position
Replacement of pedal feedback springs
Addition of a pedal end-of-course stop
BRAKE SYSTEM UPDATES
BRAKE PEDAL ASSEMBLY
Solution (cont.)
These modifications are complementary to SB 505-27-0003, “Modification of the pedal position transducer stops”, issued on October 14, 2010
Action plan
SB availability expected on or before December 2011
SB with retrofit campaign
AGENDA PHENOM TECHNICAL SESSION
Electrical system contactors
Starter generator update
Pratt & Whitney Canada updates
Engine start failures
Engine inlets
Flap system updates
Tire wear update
Subject
Air Management System (AMS)
Ice and rain protection system
Brake system updates
TIRE WEAR UPDATE
Description
Premature tire removals
Investigation
Service Letter (SL) 505-32-0002 was issued on March 04, 2011, with the intent of collecting more information on tire changes
Tire service life is mainly dependent on operational aspects
TECHNICAL ITEMS
TIRE WEAR UPDATE
Investigation
TECHNICAL ITEMS
TIRES REPLACEMENT
0
25
50
75
100
125
150
175
200
225
250
Jun-10 Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11
MONTH
CY
CL
ES
CUT DEFLATED N/A VIBRATION WEAR
Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11
TIRE WEAR UPDATE
Investigation (cont.)
TECHNICAL ITEMS
TIRES REPLACEMENT
0
25
50
75
100
125
150
175
200
225
250
Jun-10 Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11
MONTH
CY
CL
ES
CUT DEFLATED N/A VIBRATION WEAR
Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11
TIRE WEAR UPDATE
Investigation (cont)
TECHNICAL ITEMS
TIRE WEAR UPDATE
Investigation
TECHNICAL ITEMS
Underinflation (%)
Tire s
erv
ice
life
(%)
Test conditions:
35,000ft taxi cycles at 40mph, at standard load, with different tire sizes
Source: Goodyear –
Aircraft Tire Care and
Maintenance (Out/2004)
TIRE WEAR UPDATE
Solution
TECHNICAL ITEMS
Original average tire life Tire care
recommend
ations
New SLs
500-32-0007
505-32-0003
Revised
removal
criteria
AMM revised
Sep/2010 May/2011
AGENDA PHENOM TECHNICAL SESSION
Electrical system contactors
Starter generator update
Pratt & Whitney Canada updates
Engine start failures
Engine inlets
Flap system updates
Tire wear update
Subject
Air Management System (AMS)
Ice and rain protection system
Brake system updates
FCE -1009
Investigation
FLAP FAIL messages caused by flap power drive unit (PDU) brake
FLAP SYSTEM UPDATES
FCE -1009
Solution
Flight Control Electronics (FCE) software and hardware upgraded
Action plan
Retrofit campaign
Expected availability 1Q2012
FLAP SYSTEM UPDATES
AGENDA PHENOM TECHNICAL SESSION
Electrical system contactors
Starter generator update
Pratt & Whitney Canada updates
Engine start failures
Engine inlets
Flap system updates
Tire wear update
Subject
Air Management System (AMS)
Ice and rain protection system
Brake system updates
ELECTRICAL SYSTEM CONTACTORS
Description
Contactors P/N SM400D117 low reliability
TECHNICAL ITEMS
ELECTRICAL SYSTEM CONTACTORS
Investigation
Reports of unusual behavior in the electrical system
Displays blanking out during engine starts
Aircraft not entering electrical emergency during pre-flight test
Hot/hung starts
Engine not starting
Conflicting indications in the system synoptic page
TECHNICAL ITEMS
ELECTRICAL SYSTEM CONTACTORS
Solution
Upgraded contactor P/N SM400D117-1
SB 505-24-0006 – Replacement of LPDU, RPDU and EPDU contactors, issued on August 26, 2011
Action plan
Retrofit campaign will resume by the end of October 2011 (supplier parts availability)
TECHNICAL ITEMS
AGENDA PHENOM TECHNICAL SESSION
Electrical system contactors
Starter generator update
Pratt & Whitney Canada updates
Engine start failures
Engine inlets
Flap system updates
Tire wear update
Subject
Air Management System (AMS)
Ice and rain protection system
Brake system updates
STARTER GENERATOR UPDATES
Description
Reports of failed starter-generators were received in the Phenom100 fleet
Investigation
During removal and inspection of P100 starter-generators, a supplier commutator brazing quality escape has been identified that affects the Phenom 300 starter-generators as well
TECHNICAL ITEMS
STARTER GENERATOR UPDATES
Interim solution
SB 505-24-A005 – Replacement of the starter-generators, issued June 28, 2011
Starter-generators below 350FH shall be replaced before they reach 400FH
Starter-generators above 350FH shall be replaced in the next 50FH
Parts availability is defined by Embraer in accordance with aircraft utilization. Highest-time aircraft will have priority for the replacement of starter-generators
TECHNICAL ITEMS
STARTER GENERATOR UPDATES
Final solution
New starter-generators are under development
Availability scheduled for 3Q2012
TECHNICAL ITEMS
AGENDA PHENOM TECHNICAL SESSION
Electrical system contactors
Starter generator update
Pratt & Whitney Canada updates
Engine start failures
Engine inlets
Flap system updates
Tire wear update
Subject
Air Management System (AMS)
Ice and rain protection system
Brake system updates
ENGINE INLET CRACKS
Description
During a walk around inspection, cracks and missing rivet heads were found on the lip skin of Engine Air Inlet
Embraer Air Safety Department conducted a Risk Assessment and determined that this issue does not affect safety
TECHNICAL ITEMS
ENGINE INLET CRACKS
Description (cont.)
Lip Skin - Internal Rivet Line - Crack
TECHNICAL ITEMS
ENGINE INLET CRACKS
Description (cont.)
Inner Barrel - Aft Rivet Line - Pulled Rivet
TECHNICAL ITEMS
ENGINE INLET CRACKS
Investigation
Several airplanes inspected, yielding:
Cracks on Lip Skin over rivet line;
Cracks on Inner Barrel (internal skin) over rivet line;
Pulled rivets on Lip Skin and Inner Barrel attachments.
Supplier’s assembly line was audited by an Embraer team (Quality and Design engineers) to determine the possible root causes;
Detected deviations in the assembly procedures were corrected
TECHNICAL ITEMS
ENGINE INLET CRACKS
Solution
Interim Solution
SB 505-71-0001, issued on Jan 11th, 2011, provides instructions for repetitive visual inspections to be done on theinternal part of the inlet for cracks or pulled rivets;Effectivity: 50500004 thru 50500061.
Embraer Technical Disposition that provides repair instructions for the forward rivet line of Inner Barrel (Internal Skin).
ENGINE INLET CRACKS
Solution (cont.)
Final Solution
Engine Air Inlet Modules manufactured with an improved process (new Part Numbers);
L/H � PN = 505-36920-405
R/H � PN = 505-36930-405
ENGINE INLET CRACKS
Action plan
SB 505-71-0003 (Jul 2011) – retrofit campaign;
Factory-installed from S/N 062;
AIPC Revision (Jul 2011);
AMM Revision (Jul 2011);
Revision of SB 505-71-0001 (Jul 2011).
AGENDA PHENOM TECHNICAL SESSION
Electrical system contactors
Starter generator update
Pratt & Whitney Canada updates
Engine start failures
Engine inlets
Flap system updates
Tire wear update
Subject
Air Management System (AMS)
Ice and rain protection system
Brake system updates
ENGINE START FAILURES
Description
Difficulties to start the engines (on ground)
Two possible scenarios
Engine does not respond to start command
Hot start
TECHNICAL ITEMS
ENGINE DOES NOT RESPOND
TO START COMMAND
Investigation
When a start attempt is requested, there is no response from theengine
Generator Control Unit (GCU) hangs in initialization - PBIT
Solution
New GCU under development by the supplier, expected for November 2011
ENGINE START FAILURES
ENGINE DOES NOT RESPOND
TO START COMMAND
Solution (cont.)
Interim solution (recommendation)
De-energize aircraft and disconnect Ground Power Unit (GPU) cable
Re-energize aircraft and attempt to start the engine again
ENGINE START FAILURES
HOT START
Probable causes
1: Battery 2 low charge
2: Generator Control Unit – GCU failed
3: Contactor failed
ENGINE START FAILURES
HOT START
Investigation – Battery 2 low charge
Start is slow with N2 values taking too long to rise
Fuel flow and ITT rise too fast, which may lead to an ENG EXCEEDANCE event
Interim solution
FOL PHE505-013/11, Battery recommendations
SL 505-24-002, Batteries best practices manual
ENGINE START FAILURES
HOT START
Solution
Perform functional check in accordance with AMM and if the batterydoes not pass, replace the battery
Interim solution (recommendation)
Ensure the battery voltage is within specification for engine starts(minimum 24V)
ENGINE START FAILURES
HOT START
Investigation – Generator Control Unit – GCU failed
Normal start, with fuel flow, N2 and ITT rising normally
N2 starts to drop and fuel flow and ITT increase rapidly, which maycause an ENG EXCEEDANCE event
Solution
Replace the GCU for one bearing the same part number
Interim solution (recommendation)
Until the final solution is available, contact Embraer for troubleshooting assistance. Embraer will need the CMC data (CVDR data will speed up analysis)
ENGINE START FAILURES
AGENDA PHENOM TECHNICAL SESSION
Electrical system contactors
Starter generator update
Pratt & Whitney Canada updates
Engine start failures
Engine inlets
Flap system updates
Tire wear update
Subject
Air Management System (AMS)
Ice and rain protection system
Brake system updates
Pratt & Whitney Canada updates
Engine No Dispatch
Low Utilization Inspection (LUI)
Compressor wash recommendations
PRATT & WHITNEY CANADA
UPDATES
TECHNICAL ITEMS
ENGINE NO DISPATCH
Description
ENG NO DISPATCH CAS messages displayed
Investigation
On Avionics SW LOAD before version 4X ENG NO DISPATCH CAS message triggered by avionics logic.
Recent Issues related to FADEC HW (P&WC SB30438)
Solution
SB 505-31-0001, “Installation of G1000 load 43 avionics software and CMC load 9 software”, issued on February 17, 2011;
New Engine Electronic Control (EEC) hardware – P&WC SB30438
Action plan
Retrofit campaign ongoing
PRATT & WHITNEY CANADA UPDATES
LOW UTILIZATION INSPECTION (LUI)
Description
The PW535E Engine Maintenance Manual (EMM) requires Low Utilization Inspection (LUI) engines to be returned to an overhaul facility
Maintenance Update
On-wing Low Utilization Inspection (LUI) already available in the EMM. Additional requirements may be necessary based on inspection findings.
PRATT & WHITNEY CANADA UPDATES
COMPRESSOR WASH
RECOMMENDATIONS
Resistance to corrosion and recommendations
P&WC position – All P&WC engines meet industry standards for corrosion protection.
P&WC corrosion mitigation recommendations are appropriate and based on FAA AC 43-4A are similar to other engine manufacturers
Maintenance updates
Engine Maintenance Manual is being revised (Nov ‘11) to eliminate need to disconnect P3 during desalination wash to reduce procedure cost.
Compressor wash recommendations updated to provide more clarity to operators and maintenance facilities.
PRATT & WHITNEY CANADA UPDATES
THANK YOU!