Presenter 2011 Honeywell Air Transport Operators Conference
Appendix APU131-9B
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Honeywell Confidential The enclosed technical data is export classified as EAR99. Its export is being transmitted under U.S. Export Administration Regulations designation “NLR” (No License Required) and is to be used solely by the individual / organization to whom it is addressed. Diversion contrary to U.S. export laws and regulations is prohibited. HONEYWELL CONFIDENTIAL: This copyrighted work and all information are the property of Honeywell International Inc., contain trade secrets and may not, in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All Rights Reserved.
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Appendix- APU131-9B, P/N 3800702-1 • Maintenance and Troubleshooting – – – – – – – –
Condition monitoring No APU bleed air APU no-start with fault 49-41010 No bleed air or generator after landing Load shed and speed droop APU on-wing vibration measurement Fuel manifold conical seals Safety wire chafing on fuel manifold
• Past Subjects / Closed – Eductor Erosion – Temporary Repair for Diffuser Housing Studs Pulled Out – Real Time Oil Level
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Maintenance and Troubleshooting • 131-9B APU Condition Monitoring Available – Some operators using this method of APU trend monitoring until PTMD is available. – Uses Cockpit Display Unit (CDU) to access CT5ATP • CT5ATP is T5 corrected for outside temperature, pressure, generator load and IGV position
– Boeing Fleet Team Digest Article (737NG-FTD-49-04005) provides method and parameters • Check CT5ATP at 45-90 day intervals • At 638C/1180F, reduce interval by 25% to 50% • At 653C/1207F, schedule APU for removal within next 200 hours
Values and Intervals Will Vary Based on Operator Requirements 4 Document control number
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Appendix- APU131-9B, P/N 3800702-1 • Maintenance and Troubleshooting – – – – – – – –
Condition monitoring No APU bleed air APU no-start with fault 49-41010 No bleed air or generator after landing Load shed and speed droop APU on-wing vibration measurement Fuel manifold conical seals Safety wire chafing on fuel manifold
• Past Subjects / Closed – Eductor Erosion – Temporary Repair for Diffuser Housing Studs Pulled Out – Real Time Oil Level
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Maintenance and Troubleshooting • Issue – No APU bleed air
• Background – APU started and ran but no bleed air • Maint Codes 49-52102, 49-52273 and 49-52303
• Findings – Corroded splice in P/N 3888449-1 APU wiring – Splice located on the bottom of the APU wrapped with heat shrink
• Corrective Action – Replace with P/N M81824-1-3 environmental splice using manual 49-11-01
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Appendix- APU131-9B, P/N 3800702-1 • Maintenance and Troubleshooting – – – – – – – –
Condition monitoring No APU bleed air APU no-start with fault 49-41010 No bleed air or generator after landing Load shed and speed droop APU on-wing vibration measurement Fuel manifold conical seals Safety wire chafing on fuel manifold
• Past Subjects / Closed – Eductor Erosion – Temporary Repair for Diffuser Housing Studs Pulled Out – Real Time Oil Level
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Maintenance and Troubleshooting • Issue – APU no-start with fault 49-41010
• Background – APU lights off but will not accelerate. • Usually after a long flight and cold soak
• Findings – Operators have found that fault 49-41010 coupled with high time on power section is most likely caused by a worn power section
• Corrective Action/ Recommendation – If the APU demonstrates no starts after cold soak and fault 49-41010, check the CT5ATP value in the CDU / APU DMM • If the value is above 653C/1207F, do not troubleshoot further, schedule the APU for replacement • If the value is below 653C/1207F, follow instructions in Aircraft FIM.
– See Condition Monitoring 8 Document control number
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Appendix- APU131-9B, P/N 3800702-1 • Maintenance and Troubleshooting – – – – – – – –
Condition monitoring No APU bleed air APU no-start with fault 49-41010 No bleed air or generator after landing Load shed and speed droop APU on-wing vibration measurement Fuel manifold conical seals Safety wire chafing on fuel manifold
• Past Subjects / Closed – Eductor Erosion – Temporary Repair for Diffuser Housing Studs Pulled Out – Real Time Oil Level
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Maintenance and Troubleshooting • Issue
Flow Divider
SOV
– No bleed air or generator after landing
• Prevents secondary fuel flow
– Low fuel flow causes speed droop • Speed droop disables generator and bleed air • ECU commands more fuel then resolver in FCU measures less than command.
– Fault 49-31171 / „Fuel Flow Disagrees With Command‟
Primary fuel flow
– Hydraulic lock holds SOV blade closed
Secondary fuel flow
• Background
• Corrective action – Shut down APU, allow hydraulic lock to dissipate and re-start APU. – LRU replacement WILL NOT resolve this issue.
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Appendix- APU131-9B, P/N 3800702-1 • Maintenance and Troubleshooting – – – – – – – –
Condition monitoring No APU bleed air APU no-start with fault 49-41010 No bleed air or generator after landing Load shed and speed droop APU on-wing vibration measurement Fuel manifold conical seals Safety wire chafing on fuel manifold
• Past Subjects / Closed – Eductor Erosion – Temporary Repair for Diffuser Housing Studs Pulled Out – Real Time Oil Level
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Maintenance and Troubleshooting • Issue – Load shed and speed droop
• Background – – – –
Started in-flight and gradually got worse Troubleshooting took six weeks Maintenance messages 49-11019, 49-31016, 49-41010 Troubleshooting included • • • • • •
Continuity test from APU Generator replaced FCU replaced IGV test was carried ou Surge Control Valve replaced ECU replaced
• • • • • •
IGV replaced SCU replaced Inlet Pressure Sensor replaced Total Pressure Sensor replaced Differential Pressure Sensor replaced Fuel Flow Divider Solenoid replaced
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Maintenance and Troubleshooting • Findings – Plastic in the inlet found after APU was removed – Bag was removed and the APU was re-installed into the A/C with no further problems
• Recommendation – Be aware of the close proximity between the APU inlet and the R/H aft cabin door – When checking the inlet for obstructions, check the whole inlet – From the A/C skin all the way down to the APU . . . carefully
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Appendix- APU131-9B, P/N 3800702-1 • Maintenance and Troubleshooting – – – – – – – –
Condition monitoring No APU bleed air APU no-start with fault 49-41010 No bleed air or generator after landing Load shed and speed droop APU on-wing vibration measurement Fuel manifold conical seals Safety wire chafing on fuel manifold
• Past Subjects / Closed – Eductor Erosion – Temporary Repair for Diffuser Housing Studs Pulled Out – Real Time Oil Level
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131-9B APU Vibration Survey Program • Issue – Operator has requested Honeywell develop an On-Wing Vibration Survey Capability
• Background – Two detection methods evaluated for viability • Case mounted accelerometer • Laser Vibrometer
– Laser Vibrometer method preferred due to ease of setup and test repeatability which would result in higher probability of success
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131-9B APU Vibration Survey Program • Solution – Hardware selected: • Laser Vibrometer: Polytec PDV-100
– Features: • Non-contact velocity measurement from 0 to 22 kHz • Variable working distance from 0.2 m up to 30 m • Digital signal processing
– Benefits: • Non-contacting measurement system – No need to physically mount accelerometers to APU
• Portability • Simplicity of use and setup • Accuracy
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131-9B APU Vibration Survey Program • Solution (cont‟d) – Laser Vibrometer PDV-100 Operation: 1. 2. 3. 4. 5.
Open APU Access Door Position PDV-100 on the ground below the APU Aim the PDV-100 at APU Gearbox Record data with a laptop Review results to identify if the APU vibration is within the “blade walking” limits
• Status – Awaiting operator review
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Appendix- APU131-9B, P/N 3800702-1 • Maintenance and Troubleshooting – – – – – – – –
Condition monitoring No APU bleed air APU no-start with fault 49-41010 No bleed air or generator after landing Load shed and speed droop APU on-wing vibration measurement Fuel manifold conical seals Safety wire chafing on fuel manifold
• Past Subjects / Closed – Eductor Erosion – Temporary Repair for Diffuser Housing Studs Pulled Out – Real Time Oil Level
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Conical Seal Option for Fuel Manifold Leaks • Issue – Fuel manifold leaks at the Atomizer
• Background – Leaks result in over tightening – Seals used on 331 Turboprop
• Status – Honeywell incorporating into Manual for the 131-9B
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Appendix- APU131-9B, P/N 3800702-1 • Maintenance and Troubleshooting – – – – – – – –
Condition monitoring No APU bleed air APU no-start with fault 49-41010 No bleed air or generator after landing Load shed and speed droop APU on-wing vibration measurement Fuel manifold conical seals Safety wire chafing on fuel manifold
• Past Subjects / Closed – Eductor Erosion – Temporary Repair for Diffuser Housing Studs Pulled Out – Real Time Oil Level
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Safety Wire Chafing on Fuel Manifold • Issue – Safety wire chafing on fuel manifold
• Background – Operators and shops have found heat shield safety wire chafing on fuel manifold
• Solution – Separate the safety wire from the fuel manifold during maintenance – Operators /shops notified in SIL D200907000007 – Safety wire removal made optional
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Appendix- APU131-9B, P/N 3800702-1 • Maintenance and Troubleshooting – – – – – – – –
Condition monitoring No APU bleed air APU no-start with fault 49-41010 No bleed air or generator after landing Load shed and speed droop APU on-wing vibration measurement Fuel manifold conical seals Safety wire chafing on fuel manifold
• Past Subjects / Closed – Eductor Erosion – Temporary Repair for Diffuser Housing Studs Pulled Out – Real Time Oil Level
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Eductor Wear • Issue – Operators have found Cracks / Holes in Eductor at 07:00 position
• Background – Boeing AMM task 49-81-41-200 Item 2. F. b) 1) states that no cracks are permitted and that the eductor housing must be replaced if cracks are present – Materials Analysis shows the wear to be due to long term particulate erosion • Considered Normal Wear
– Repairs are available, but only after the APU is removed from service and the eductor is removed from the APU
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Appendix- APU131-9B, P/N 3800702-1 • Maintenance and Troubleshooting • • • • •
Condition monitoring No APU bleed air APU no-start with fault 49-41010 No bleed air or generator after landing Load shed and speed droop
– APU on-wing vibration measurement – Fuel manifold conical seals – Safety wire chafing on fuel manifold
• Past Subjects / Closed – Eductor Erosion – Temporary Repair for Diffuser Housing Studs Pulled Out – Real Time Oil Level
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Diffuser Housing Studs Pulled Out • Issue – Studs pull out over time
• Background – Insufficient material remains for use of oversized stud – Temporary Repair Authorized by Boeing • Bolt P/N MS9557-14 • Washer NAS1149C0432R, 2 each, • Self locking nut MS21043-4 • FTD Article 737NG-FTD-49-11005
– Shop Incoming / Outgoing Inspection of Inserts Implemented – Once in Shop, Flange Requires Repair
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Appendix- APU131-9B, P/N 3800702-1 • Maintenance and Troubleshooting – – – – – – – –
Condition monitoring No APU bleed air APU no-start with fault 49-41010 No bleed air or generator after landing Load shed and speed droop APU on-wing vibration measurement Fuel manifold conical seals Safety wire chafing on fuel manifold
• Past Subjects / Closed – Eductor Erosion – Temporary Repair for Diffuser Housing Studs Pulled Out – Real Time Oil Level
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Real Time Oil Level • Issue – Oil Level Does Not Update
• Background – In the Version 2,4, and 5 software, the oil level registered during start does not update. – During interrogation of the LOQ sensor, the ECU can register one of three possible oil levels on CDU: 1. FULL 2. ADD 3. LOW
– In the version 2 software reading on CDU remains unchanged – In the version 4-5 software CDU registers UNKNOWN after 1 hour
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