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INTERNATIONAL HELICOPTER SYMPOSIUM 2005

INTERNATIONAL HELICOPTER SYMPOSIUM 2005. MONTREAL, QUEBEC CANADA SEPTEMBER 27-29, 2005. Gary Souza Chief Project Engineer Model 250 Helicopters & Small Gas Turbines Rolls-Royce Corporation. THE INFLUENCE OF ENGINE MAINTENANCE AND OVERHAUL ON ROTORCRAFT SAFETY. Safety Events.

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INTERNATIONAL HELICOPTER SYMPOSIUM 2005

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  1. INTERNATIONAL HELICOPTER SYMPOSIUM 2005 MONTREAL, QUEBEC CANADA SEPTEMBER 27-29, 2005 Gary Souza Chief Project Engineer Model 250 Helicopters & Small Gas Turbines Rolls-Royce Corporation

  2. THE INFLUENCE OF ENGINE MAINTENANCE AND OVERHAUL ON ROTORCRAFT SAFETY

  3. Safety Events Fleet Operating Risk Engine not Involved Engine Involved Cause Reduction (Effect of Mitigating Actions) Fleet Composition and Service Hours Cause Analysis Event Analysis Component & Mode Safety Assessments ROLLS-ROYCE MODEL 250 SAFETY & RISK ASSESSMENT - CAUSE & ANALYSIS Understanding of future safety event rates and associated risks can be gained by assessment of past fleet events and their causes Event Severity Historical Rates

  4. U.S. HELICOPTER ACCIDENT SUMMARY STATISTICS - 1996 -2004 Source: HAI Accident Summary

  5. MODEL 250 SAFETY & RISK ASSESSMENT Event Break-down of 1561 Events in Study Period Average No. of Engine-Involved Events per Year (1996-2004)Does not include Potential Hazards

  6. MODEL 250 SAFETY & RISK ASSESSMENTGeneral Causes of 234 Engine-Involved Events during Study Period

  7. 10.00% 9.00% 8.00% 7.00% 6.00% 5.00% % of All Reported Power Losses 4.00% 3.00% 2.00% 1.00% 0.00% Turbine Blade Off Loose B Nuts Corrosion Comp Fatigue Bearing #3 Fuel Contamination Erosion Comp Vane Solid Contamination Fatigue Tubes/ Lines Sulphidation Turbine Fuel Screen Collapse ECU Capacitor Failure Turb to Comp Coupling OvertemperatureTurbine Oil Starvation/Contam Blockage/FOD/Ingestion Comp Coupling Adapter MODEL 250 SAFETY & RISK ASSESSMENTMODEL 250 POWER LOSS MODES – ALL MODELS Fatigue Misalignment Wear TOP 15 MODES ACCOUNT FOR 56% OF POWER LOSS EVENTS

  8. REVIEW OF KEY MAINTENANCE INVOLVED EVENTS

  9. FUEL CONTAMINATION Failure to Properly Maintain and Inspect Fuel System Results In:

  10. FUEL CONTAMINATION • Fuel system contaminationwith the use of Jet A fuel and anti-icing inhibitor, Diethylene Glycol Monomethyl Ether (DIEGME). • DIEGME inhibitor draws water molecules from the fuel and over time forms an organic gel-like substance (coined Apple Jelly) in the bottom of fuel tanks. • When this gel-like material is detected in the aircraft fuel system or fuel storage tanks, inspection of the entire engine fuel system is required. • Inspect airframe / engine mounted fuel filters. • Separate, inspect / clean the fuel nozzle inlet screen • The formation of this gel-like material may result from: • Improperly maintained fuel storage tanks • Improper additive injection method or ratio

  11. FUEL CONTAMINATION FUEL SYSTEM CONTAMINATION WITH DIEGME

  12. FUEL CONTAMINATION FUEL STORAGE TANK CONTAMINATION WITH DIEGME (Apple Jelly)

  13. FUEL CONTAMINATION FUEL SYSTEM CONTAMINATION CAN RESULT IN RESTRICTED FUEL FLOW, CAUSING: • ENGINE STARTING STAGNATION • HUNG START OR VERY COOL, LONG START • ENGINE POWER LIMITING • INABILITY TO MAINTAIN Nr AT REQUIRED SETTING UNDER LOAD RESULTING IN Nr DROOP • IN-FLIGHT POWER LOSS • ENGINE FLAME-OUT OR CUT-BACK

  14. FUEL CONTAMINATION CLEAN FUEL NOZZLE INLET SCREEN DIRTY FUEL NOZZLE INLET SCREEN Nozzle Separated for Cleaning

  15. FUEL CONTAMINATION Collapsed contaminated screen resulting in loss of power in-flight

  16. COMPRESSOREROSION & CORROSION Failure to Inspect Compressor Cases and Blades Regularly for Erosion and/or Corrosion Results In:

  17. COMPRESSOR CORROSION & EROSION INSPECTIONS COMPRESSOR FAILURE

  18. COMPRESSOR CORROSION & EROSION INSPECTIONS COMPRESSOR BLADE FAILURE

  19. COMPRESSOR CORROSION & EROSION INSPECTIONS • Inspect Compressor Cases and Blades Regularly for Erosion and/or Corrosion • Minimum 300 Hours When Operating in Erosion and/or Corrosive Environment • As Required in Moderate Environments • Never Greater than Manufacturer’s Recommendation.

  20. COMPRESSOR CORROSION & EROSION INSPECTIONS COMPRESSOR CASE EROSION EXPOSED VANE BAND IS NOT ACCEPTABLE

  21. COMPRESSOR CORROSION & EROSION INSPECTIONS COMPRESSOR VANE EROSION NOTE EROSION UNDERCUT NEAR VANE ROOT AT PLASTIC LINE

  22. COMPRESSOR CORROSION & EROSION INSPECTIONS COMPRESSOR BLADE FAILURE NOTE PITS AT ROOT AREA OF BLADE

  23. SERIES II COMPRESSOR CORROSION & EROSION INSPECTIONS CRACK FORMING ON LEADING EDGE NEAR ROOT FROM CORROSION PIT

  24. ENGINE GAS PATH CONTAMINATION Failure to Regularly Remove Gas Path Contaminants Results In:

  25. 03FA8-113 TURBINE WHEEL HOT CORROSION FAILURE • TYPICAL MODEL 250 1ST STAGE TURBINE WHEEL HOT CORROSION • TYPICAL APPEARANCE AFTER IFSD EVENT • CORROSION DAMAGE REDUCES AIRFOIL CROSS-SECTIONAL AREA • BLADES FAIL IN OVERLOAD 98FA8-026

  26. Proper Contamination Removal (water rinse) Instructions Using Water Only 250-C18 CSL-141 250-C40 CSL-5017 250-C20 CSL-1135 250-C47 CSL-6004 250-C28 CSL-2082 250-C30 CSL-3085 250-C20R CSL-4018 The above CSL has been revised to remind operators the importance of doing a daily water rinse to all Rolls-Royce Model 250 Series engines that are flown in a corrosive environment WARNING:FAILURE TO PROPERLY FOLLOW THE WATER RINSE PROCEDURES COULD RESULT IN CORROSIVE ATTACK AND ENGINE FAILURE WARNING:SALT LADEN HUMIDITY AND CHEMICALS WILL CORRODE THE ENGINE AND COULD CAUSE IT TO FAIL. The highest quality of water must be used. Distilled or demineralized water is recommended

  27. TURBINE WHEEL HOT CORROSION • RECENTLY PUBLISHED REVISIONS • CSL141 PUBLISHED REQUIRING DE-MINERALIZED WATER FOR RINSE / WASH • CSL 205 PUBLISHED TO INSPECT FOR HOT CORROSION (SULFIDATION) OF 1ST STAGE TURBINE BLADES • REQUIRES 600 HR INSPECTION OF THE 1ST STAGE TURBINE BLADES FOR OPERATORS WHO ARE EXPOSED TO CONDITIONS WHICH PROMOTE HOT CORROSION • SAME AS COMPRESSOR INSPECTION • REQUIRES OPERATORS WHO DO NOT USE DE-MINERALIZED WATER OR ARE UNSURE OF LEVEL OF MINERAL CONTENT OF WATER USED FOR COMPRESSOR RINSE / WASH TO PERFORM 600 HR INSPECTION OF THE 1ST STAGE TURBINE BLADES

  28. MAINTENANCE OF FUEL, LUBE AND PNEUMATIC SYSTEM LINES Failure to Properly Maintain and Inspect Fuel, Lube and Pneumatic System Lines Results In:

  29. MAINTNENANCE OF FUEL, OIL AND AIR LINESMAINTENANCE WARNING – CONTROL SYSTEM PLUMBING 250-C18 CSL A-169 250-C20 CSL A-1166 250-C20R CSL A-4036 250-C28 CSL A-2113 250-C30 CSL A-3117 The above CSL has been issued to remind operators of the importance of proper alignment, clamping and torqueing of engine Control System Plumbing

  30. MAINTENANCE OF FUEL, OIL AND AIR LINES

  31. MAINTENANCE OF FUEL, OIL AND AIR LINES

  32. SUMMARY • Improper Engine Maintenance and Overhaul Affects Safety • Proper Maintenance in Accordance with Manufacturer’s Recommendations is Essential to the Safety of Engines Installed in Rotorcraft

  33. THANK YOU!QUESTIONS?

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