apu55 131-9b appendix - final
DESCRIPTION
apuTRANSCRIPT
Appendix APU131-9B
Presenter
2011 Honeywell Air Transport Operators Conference
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Honeywell Confidential
The enclosed technical data is export classified as EAR99. Its
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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,
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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
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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
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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 bleed air or generator after landing
• Background
– Hydraulic lock holds SOV blade closed
• 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‟
• Corrective action
– Shut down APU, allow hydraulic lock to
dissipate and re-start APU.
– LRU replacement WILL NOT resolve this
issue.
Prim
ary
fue
l flow
Se
co
nd
ary
fue
l flow
Flow Divider SOV
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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. Open APU Access Door
2. Position PDV-100 on the ground below the APU
3. Aim the PDV-100 at APU Gearbox
4. Record data with a laptop
5. 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