APS 2000 Shop Findings Report

APU S/N :

SP-E912042

AIRCRAFT REGISTRATION:

APU P/N :

170101-106

CUSTOMER :
EVENT N

78202418

R/O N :

1379

685265

REVISION N:

TSN :

16143

TSI :

2655

DATE OF REMOVAL:

18.04.07

CSN :

15386

CSI :

2839

DATE OF REPORT :

15.06.07

COMPRESSOR

TURBINE

GBX MODULE

S/N AT ARRIVAL

V42-C848

V26-HB017

SP-G 910140

S/N AT DEPARTURE

V42-C848

HD441

SP-G 910227

SB CONFIGURATION :

26

Air One

MODULE CONFIGURATION

EI-CZG

27

28

29

AS RECEIVED : O
5

30

31

32

33

o
51

52

76

77

53

78

54

55

79

80

56

57

58

82

83

AFTER REPAIR (PLANNED) : X

11

37

13

14

38

39

35

59

60

61

62

63

85

86

87

88

84

36

12

34

o
81

10

64

89

15

16

17

18

42

43

40

41

65

66

67

91

92

93

90
o

19

20

21

23

24

25

47

48

49

50

71

72

73

74

75

96

97

98

99

100

o
44

45

46

x
68

22

69

94

70

95
o

Combustion chamber distress

CUSTOMER`S REASON FOR REMOVAL :

REASON FOR REMOVAL CONFIRMED

YES

NO

PRIMARY FINDINGS :
BEARING

YES NO

CARBON SEAL / FLOATING RING

COMBUSTION CHAMBER

GEARBOX
x

FOD

KNOWN FAILURE MODE

INVESTIGATION REPORT

INCOMING TEST RUN

x
x

CUSTOMER PRESENT

LRU`S

PRELIMINARY FINDING REPORT

NO FAILURE FOUND

ATTACHMENTS

x
x

FINAL FAILURE CONCLUSION:

The removal reason could be confirmed. During borescope incoming inspection we found a "FOD" noticed
on the compressor impeller. APU is a Non PI Version. The Compressor Impeller displayed impact marks on
the leading edge. The nozzle guide vanes showed burnt and cracked trailing edges.The combustion
chamber showed heavy damaged heatshiels and thermal cracks .The combustor housing inner seal broken
and fuel nozzles showes damages and have to be repaired. Nearly all seal segments and the forward seal
plate revealed wear. Nearly all Fuel Nozzles revealed wear marks.

Note: Information above are subject to change pending further findings, inspection, test and repairs.
WRITER

APU PRODUCT ENGINEER

Volker Kardel

Thomas Mayer

This report details the maintenance and repair service Lufthansa recently provided for your company.
Included in this Shop Findings Report are the following information:
1. Technical Data
2. Picture Report

The information contained herein is proprietary to Lufthansa Technik and shall not be reproduced or disclosed in whole or in part without the expressed written consent of Lufthansa Technik AG.

Cover Sheet Page 1

APS 2000 Shop Findings Report

EVENT N

1379

685265

REVISION N

FINDINGS UPON ARRIVAL:

Shipping Container is a:
Shipping Container damage:
APU external damage:
Position 6 Bracket bent:
Bracket proper mounted
Combustor Housing cracked:
Oil Cooler contaminated:
Engine Rotation:
Oil Condition:
Oil Filter Condition:
Fuel Filter Contamination:
Generator installed:
Inlet Path inspected:
Engine Mount inspected:
Starter Clutch defective:
Igniter unit damaged:
Fuel manifold seals leaking:
Muff bent, cracked:
Tubes chafed:
Harness damaged:

X
X

X
X
X
X

X
X

Wood Box
No
No
No
No*
No
No
Smooth
Normal
Normal
None
No
No findings
No findings
No
No
No
No
No
No findings

X
X
X
X

Cardboard Box
Yes*
Yes*
Yes*
Yes
Yes*
Yes*
Rough
No-oil
Chips****
Light
Yes
Findings
Findings
Yes*****
Yes
Yes
Yes
Yes
Findings

LHT Steel Container

Customer informed
Customer informed
Customer informed
Customer informed
Customer informed
Matrix dented
Seized
Contaminated***
Filter removed****
Moderate

Blocked
Burnt
Light
Heavy

Customer informed
Customer informed
Connector
Not visible
Not visible

Box

Connector damaged

Cable

* Take picture, inform customer support, inform Product engineering

** Trace missing parts on Missing Parts List (MPL), inform Customer Support
*** Perform Oil analysis, inform customer support
**** Check metal chip origin, check generator history, inform Product engineering and customer support
***** Check for proper installation, inform Product engineering, take picture

THE FOLLOWING EXTERNAL HARDWARE WAS MISSING:

None

EMU

Starter

FCU

Fire warning

S.Clutch

Cooling Fan

LOP Switch

TP Sensor

X See table above**

Generator is not installed

Oil Cooler ist not installed
Cooling Air Duct Assembly is not installed; see Missing Part List

Add missing Parts + Partnumber

The information contained herein is proprietary to Lufthansa Technik and shall not be reproduced or disclosed in whole or in part without the expressed written consent of Lufthansa Technik AG.

Technical Data Page 2

APS 2000 Shop Findings Report

EVENT N

1379

REVISION N

685265

BORESCOPE FINDINGS:
APU borescoped
Compressor Impeller
Inlet Muff
Combustion Chamber
NGV
Compressor Turbine Wheel

Yes
Normal
Normal
Normal
Normal
Normal

x
x
x
x
x

No
Damaged
Damaged
Damaged
Damaged
Damaged

Soft FOD
DOD

Hard FOD
Hard FOD

INCOMING FUNCTIONAL TEST RESULTS:

x

APU was not pre-tested due to major internal damage.

APU was not pre-tested due to major external damage.
APU was not pre-tested due to metal chips on MCD / contamination in oil.
APU was pre-tested. Results are within acceptable manual specifications.
APU was pre-tested. The following results exeed allowable specifications:
EGT Margin
Gearbox vibrations
Power Section vibrations
ECS-Mode

EGT
Functional Surge Check
Oil Consumption
Rundown time

PERFORMED WORKSCOPE:
Remove, inspect, and repair applicable Line Replaceable Units as necessary.
Remove, inspect, and repair applicable Line Replaceable Units per customer work scope.
x Remove, inspect, and repair Gearbox as necessary.
Remove, inspect, and full refurbish Gearbox as necessary.
Remove, inspect, and repair Compressor Section as necessary.
x Remove, inspect, and full refurbish Compressor Section as necessary.
Remove, inspect, and repair Turbine Section as necessary.
x Remove, inspect, and full refurbish Turbine Section as necessary.
Repair APU as necessary.
Perform modifications in accordance with LHT Engineering baseline.
Perform ATP Run in accordance with HSPS EM 170101-106:Series
Perform all necessary AD-Notes.
Perform necessary preservation for long time storage.

APU HISTORY:
Findings / Workscope:
Last Shop Visit:
Revision N:
Aircraft
Customer
Removal Reason
TSN / TSR:

First shop visit at Lufthansa Technik

The information contained herein is proprietary to Lufthansa Technik and shall not be reproduced or disclosed in whole or in part without the expressed written consent of Lufthansa Technik AG.

Technical Data Page 3

APS 2000 Shop Findings Report

EVENT N

1379

REVISION N

685265

GEARBOX SECTION:
LUBE JET WEAR:

YES

NO

REINSTALLED

REPAIRED

SCRAPPED & REPLACED BY NEW

CLUSTER BUSHING

YES

NO

REINSTALLED

REPAIRED

SCRAPPED & REPLACED BY NEW

GEAR THEETH DAMAGE:

YES

NO

REINSTALLED

REPAIRED

SCRAPPED & REPLACED BY NEW

HOUSING CRACKED:
DAMAGED:

YES

NO

REINSTALLED

REPAIRED

SCRAPPED & REPLACED BY NEW

BEARINGS WORN:

YES

NO

REINSTALLED

OVERHAU

SCRAPPED & REPLACED BY NEW

OIL PUMP SEIZED:

YES

NO

REINSTALLED

REPAIRED

SCRAPPED & REPLACED BY NEW

CHIPS IN SYSTEM:

YES

NO

CLEANED

LIP`SEAL DAMAGED:

YES

NO

REINSTALLED

REPAIRED

SCRAPPED & REPLACED BY NEW

YES

NO

REINSTALLED

OVERHAU

SCRAPPED & REPLACED BY NEW

SCRAPPED & REPLACED BY NEW

COMPRESSOR SECTION:
BALL BEARING DAMAGED
CARBON SEAL DAMAGED

YES

NO

REINSTALLED

REPAIRED

COMPR: IMPELLER DAMAGED

YES

NO

REINSTALLED

REPAIRED

INTAKE HOUSING DAMAGED

YES

NO

REINSTALLED

REPAIRED

DIFFUSER DAMAGED

YES

NO

REINSTALLED

REPAIRED

NO

REINSTALLED

SCRAPPED & REPLACED BY NEW

SCRAPPED & REPLACED BY NEW
SCRAPPED & REPLACED BY NEW

QUILL SHAFT DAMAGED:

YES

REPAIRED

SCRAPPED & REPLACED BY NEW

MUFF ASSY DAMAGED

YES

NO

REINSTALLED

REP/MOD

OLD VERSION / REPL. BY NEW

ROLL BEARING DAMAGED

YES

NO

REINSTALLED

OVERHAU

SCRAPPED & REPLACED BY NEW

POWER SECTION:
NGV DAMAGED:

YES

NO

REINSTALLED

REPAIRED

TURBINE WHEEL DAMAGED:

YES

NO

REINSTALLED

REPAIRED

SCRAPPED & REPLACED BY NEW

SCREEN DAMAGED:

YES

NO

REINSTALLED

REPAIRED

OLD VERSION / REPL. BY NEW

SEAL PLATE DAMAGED:

YES

NO

REINSTALLED

REPAIRED

SCRAPPED & REPLACED BY NEW

SEAL PLATE SEG. DAMAGED:

YES

NO

REINSTALLED

REPAIRED

80% SCRAPPED & REP. BY NEW

SOUND ATTENUATOR

YES

NO

REPAIRED

SCRAPPED & REPLACED BY NEW

ROTOR COUPLING DAMAGED: YES

NO

REINSTALLED

SCRAPPED & REPLACED BY NEW

HOT SECTION:
COMB.CHAMBER DAMAGED:

YES

NO

REINSTALLED

REPAIRED

SCRAPPED & REPLACED BY NEW

COMB.HOUSING DAMAGED

YES

NO

REINSTALLED

REPAIRED

SCRAPPED & REPLACED BY NEW

EXHAU.HOUSING DAMAGED:

YES

NO

REPAIRED

SCRAPPED & REPLACED BY NEW

THERMOCOUPLES DAMAGED: YES

2 x IGNITION CABLE DAMAGED YES

NO
x

REINSTALLED
x

NO

REINSTALLED

REINSTALLED

REPAIRED

SCRAPPED & REPLACED BY NEW

REPAIRED

SCRAPPED & REPLACED BY NEW

MISCELLANEOUS:
START FUEL NOZZLES WORN: YES

NO

REINSTALLED

REPAIRED

SCRAPPED & REPLACED BY NEW

MAIN FUEL NOZZLES WORN:

NO

REINSTALLED

REPAIRED

SCRAPPED & REPLACED BY NEW

YES

FUEL MANIFOLD DAMAGED

YES

NO

REINSTALLED

REPAIRED

SCRAPPED & REPLACED BY NEW

ENGINE HARNESS DAMAGED

YES

NO

REINSTALLED

TESTED

SCRAPPED & REPLACED BY NEW

Technical Data 4

APS 2000 Shop Findings Report

EVENT N

1379

REVISION N

685265

PICTURE 1

FOD - Plastik on inlet screen

PICTURE 2

Cooling fan screen contaminated

The information contained herein is proprietary to Lufthansa Technik and shall not be reproduced or disclosed in whole or in part without the expressed written consent of Lufthansa Technik AG.

Picture Report 5

APS 2000 Shop Findings Report

EVENT N

1379

REVISION N

685265

PICTURE 3

FOD - Compressor impeller

PICTURE 4

Diffuser vanes shows impacts and inner diameter worn

The information contained herein is proprietary to Lufthansa Technik and shall not be reproduced or disclosed in whole or in part without the expressed written consent of Lufthansa Technik AG.

Picture Report 6

APS 2000 Shop Findings Report

EVENT N

1379

REVISION N

685265

PICTURE 5

Combuster chamber heat shield heavy broken and outer liner cracked

PICTURE 6

Turbine wheel blade damaged

The information contained herein is proprietary to Lufthansa Technik and shall not be reproduced or disclosed in whole or in part without the expressed written consent of Lufthansa Technik AG.

Picture Report 7

APS 2000 Shop Findings Report

EVENT N

1379

REVISION N

685265

PICTURE 7

Air Intake Housing Plasma worn and bearing capsule support flange scratched and worn

PICTURE 8

Seal plate worn

The information contained herein is proprietary to Lufthansa Technik and shall not be reproduced or disclosed in whole or in part without the expressed written consent of Lufthansa Technik AG.

Picture Report 8

APS 2000 Shop Findings Report

EVENT N

1379

REVISION N

685265

PICTURE 9

Seal plate segments worn ( burned )

PICTURE 10

Combustion housing inner seal broken

The information contained herein is proprietary to Lufthansa Technik and shall not be reproduced or disclosed in whole or in part without the expressed written consent of Lufthansa Technik AG.

Picture Report 9

APS 2000 Shop Findings Report

EVENT N

1379

REVISION N

685265

PICTURE 11

Gearbox housing contaminated

PICTURE 12

EMU information
The information contained herein is proprietary to Lufthansa Technik and shall not be reproduced or disclosed in whole or in part without the expressed written consent of Lufthansa Technik AG.

Picture Report 10

APS 2000 Shop Findings Report

EVENT N

1379

REVISION N

685265

PICTURE 13

Exhaust housing hole cracked

PICTURE 14

Bearing support inner surface worn

The information contained herein is proprietary to Lufthansa Technik and shall not be reproduced or disclosed in whole or in part without the expressed written consent of Lufthansa Technik AG.

Picture Report 11

APS 2000 Shop Findings Report

EVENT N

1379

REVISION N

685265

PICTURE 14

Muff Cover sreew missing

PICTURE 15

very dirty air inlet aera ( Air intake / Screen )

The information contained herein is proprietary to Lufthansa Technik and shall not be reproduced or disclosed in whole or in part without the expressed written consent of Lufthansa Technik AG.

Picture Report 12