22 November 2016—7 February 2017

1485

ALLISON 501 D13–ATA 7261 TURBINE ENGINE OIL SYSTEM–O RING–DAMAGED. DR 611649327
Inflight, high oil consumption was reported. Defect traced to damaged O ring in the rear turbine scavenge pump. O ring was replaced. Ground run confirmed nil leakage.

IAE V2527 A5–ATA 7230 TURBINE ENGINE COMPRESSOR SECTION–TURBINE ENGINE–HPC blades cracked. DR 611649363
HPC stage 6 and 7 blades cracked on engine SN XX as reported by engine overhaul facility. Investigation continuing.

GENERAL ELECTRIC GENX1B64 P2–ATA 7200 ENGINE (TURBINE/TURBOPROP)–TURBINE ENGINE–BIRDSTRIKE. DR 611649366
Bird hit resulted in damage to acoustic panels and X2 fan blades. Core ingestion also noted along with fan blade rub. BSI inspection completed with no internal damage.

ROLLS ROYCE RB211 972 84–ATA 7250 TURBINE ENGINE TURBINE SECTION–TURBINE DISC–grinding. DR 611649394
During disassembly of module 41 (Post Service Bulletin 72-G308 PT.1), the following items were found:

  • five of twenty BOLTS (P/N: FW82729) were found missing. Bolts sheered of and the rest of the pieces remained in the self-locking shank nuts (P/N: AS63542).
  • the SEAL, RIM (former retaining ring; P/N: FW80860) was found damaged on approx. 45 cm length of missing material, one end with sharp edges is standing up high (approx. 2 cm).
  • the SEAL, RIM (P/N: FW80860) was held in position by the missing bolts (P/N: FW80860).
  • probably, the loosen part of the SEAL, RIM (P/N: FW80860) grinded on the HPT retaining front plates (P/N: KH14504; KH14505) of the HPT Disc (P/N: FW77435) and HPT blades (P/N: KH18203).
  • the SEAL, RIM material also removed on a length of approx. 45cm.
  • the HPT disc (FW77435) damaged by grinding contact with the SEAL, RIM (P/N: FW80860).
  • base (fir tree) of the HPT blades (P/N: KH18203) damaged by grinding contact with the SEAL, RIM (P/N: FW80860).
  • some PINs (P/N: FW86128) were missing.

OEM investigation is continuing.

ROLLS ROYCE RB211 524G2 19–ATA 7314 ENGINE FUEL PUMP–Fuel pump–UNSERVICEABLE. DR 611649431
On application of take-off thrust, #3 engine failed to reach desired thrust. Take-off aborted. After parking, it was decided to replace fuel pump and FMU. Fuel pump and governor installation completed. Idle engine ground runs carried out satisfactory. The type certificate holder/OEM has been notified.

ALLISON 250 C20B–ATA 7230 TURBINE ENGINE COMPRESSOR SECTION–TURBINE ENGINE–FOD. DR 611749477
Whilst conducting 100-hourly inspections it was found that the compressor had suffered foreign object damage (source inconclusive) beyond limits. The compressor was repaired by approved overhaul facility. Strip report confirms FOD has disintegrated on impact.

CFM CFM56 7B 26–ATA 7830 THRUST REVERSER–SWITCH–FAULTY. DR 611749501
During climb out, passing approximately 7000 feet, master caution annunciator illuminated with ‘ENG’ and the number 2 ‘REVERSER’. Air turn back planned with ‘REVERSER ‘ light remained on for the rest of the flight. During the course of troubleshooting, ‘L sleeve lock sensor’ S835 was found to faulty. Harness assembly eng No. 2, inboard sleeve P/N 286A1082-005 require replacement.

ALLISON 250 C40B–ATA 7240 TURBINE ENGINE COMBUSTION SECTION–Combustion chamber–Lining cracked. DR 611749518
During inspection, spot welding failure detected. Rectifications planned.

TURBOMECA ARRIEL1 E2–ATA 7200 ENGINE (TURBINE/TURBOPROP)–Residual fuel–Ignited. DR 611749542
Residual fuel in engine exhaust ignited on engine start during post maintenance activities. Engine was immediately shut down and the fire extinguished by the fire guard using a portable fire extinguisher. Engineers performing the task were unaware of extant information in the airframe maintenance manual relating to engine cleaning process. Engineers were following the instructions of the engine maintenance manual. Technical Notice to Engineers issued highlighting the incident and existence of applicable maintenance instructions. Company incident report completed.

GENERAL ELECTRIC GENX1B64–ATA 7250 TURBINE ENGINE TURBINE SECTION–HOT SECTION–BSI findings. DR 611749549
Engine removed for HPT stage 1 blade retainer inspection. GVI of removed engine noted damage to stage 7 LPT blade trailing edge. BSI of LPT section detailed nicks and dents to all stages of LPT blades and nozzles. Inspection of stage 2 LPT blades detailed significant rubbing on blade tip trailing edge. Inspection of stage 2 HPT shrouds found, it has moved AFT and protruded into the flow path area causing significant stage 2 HP turbine blade tip rubbing. BSI of combustor did not reveal any abnormal findings. Performance shift was noted but was within the warning threshold.

PRATT AND WHITNEY PW118–ATA 7200 ENGINE (TURBINE/TURBOPROP)–TURBOPROP ENGINE-BIRDSTRIKE. DR 611749598
Evidence of birdstrike found on RH propeller. Birdstrike special inspections completed with no damage found.

ROLLS ROYCE RB211 535E4 37–ATA 7250 TURBINE ENGINE TURBINE SECTION–TURBINE ENGINE–EGT exceedance. DR 611749606
RH engine exceeded limits on take-off. EGT reached 874 degrees for approx. 2 seconds. It was a full power take-off due to wind shear conditions. Could be possibly due to temperature inversion. FIM task 71-05-8X carried out, airflow control test satisfactory and take-off power parameters within limits. Relevant electrical checks completed for EGT ballast resistor code, resistor block connections and EGT cables.

ROLLS ROYCE TAY650 65015–ATA 7200 ENGINE (TURBINE/TURBOPROP)–TURBINE ENGINE–Hi Vibes. DR 611749625
L/H engine N1 speed 95.7% with engine anti-ice switched on. Subsequent N1 HI VIB alert occurred several times. Air return to departing port initiated.

GENERAL ELECTRIC CF34 3B–ATA 7200 ENGINE (TURBINE/TURBOPROP)–TURBINE–FIRE. DR 611749639
While rectifying defect of high idle N2 RPM, fuel control unit was replaced. During post-replacement ground runs (as defect persisted), while starting engine on the 3rd time, ITT indication rapidly increased from approx. 90C to around 760C without movement of the thrust lever. Uncommanded ignition ‘light-off’ occurred, where the ITT increased to approx. 990C. Start was aborted and ‘fire switch’ activated on report from ground crew that fire was visible in the tail pipe. Relevant engine ground fire procedure carried out.

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