B8 Air Turbine Starter

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China Technical Review Meeting Suzhou, 18-20 November 2014

Air Turbine Starter

2 / CFM Proprietary Information subject to restrictions on the cover China Technical Review Meeting, Suzhou, 2014

– Reliability Trends

– Anniston Shop Findings Data

• Low Time Removals

• All Removals

– Top Removal Drivers

• Seal Leakage

• Inadvertent Decoupling

• Turbine Radial Bearing Failure

– Soft Time Approach

– Starter Clamp

– Conclusions

ATA 80: Air Turbine Starter (ATS) Air Turbine Starter uses high pressure air from APU, Ground Cart, or Cross Bleed to start main engine.

Agenda


ATS Reliability Trend

MTBUR, 44646

MCBUR, 23769

0

5000

10000

15000

20000

25000

30000

35000

40000

45000

500006

/1/2

00

8

8/1

/20

08

10

/1/2

00

8

12

/1/2

00

8

2/1

/20

09

4/1

/20

09

6/1

/20

09

8/1

/20

09

10

/1/2

00

9

12

/1/2

00

9

2/1

/20

10

4/1

/20

10

6/1

/20

10

8/1

/20

10

10

/1/2

01

0

12

/1/2

01

0

2/1

/20

11

4/1

/20

11

6/1

/20

11

8/1

/20

11

10

/1/2

01

1

12

/1/2

01

1

2/1

/20

12

4/1

/20

12

6/1

/20

12

8/1

/20

12

10

/1/2

01

2

12

/1/2

01

2

2/1

/20

13

FH

/FC

737NG Air Turbine Starter 3505945

MTBUR/MCBUR

ATS Reliability Stable, Varying with Each Operator


Low Time ATS Removals

• CFM SB 80-0015 (HW SB 80-1865) Key driver

• Overall low number of low time removals

• Radial Bearing Failures - HW offering Commercial solution

• Seal leakage typically high time failure mode – monitoring for future LTR’s

0

1

2

Radial Bearing Failure NFF Seal Leakage

Starter Low Time Removals (<3000hrs) Anniston R&O Shop Jan 2013to Apr 2014


Honeywell Anniston Shop Data

Prod fix

OCT10


Seal Leakage

Seal Case

Seal Rotor

Spring

O-Ring

Carbon

Leakage path During start, oil leaks across seal and exits

starter through exhaust screen

• Pitting of carbon seal surface known to cause minor leaks (Average TSO/TSN 24K hrs)

• Preventative Action: Accomplish On-Condition Starter Inspection for Oil Leakage,

• MRB 70-802-01/70-812-02

• CMM 80-11-79, January 9, 2013 revision


Inadvertent Decoupling

• Decoupler prevents back driving of turbine wheel, if clutch fails to disengage

• Inadvertent decoupling - Disengages despite normal starter operation

• Improved design uses Wear Resistant Steel Shaft with Spring Loaded Torsion Bar decoupler

• Torsion decoupler design used with other starters with no Inadvertent decoupling events

• Zero field starter inadvertent decoupling events on other engine applications with over 30 million flight hours

• CFM SB 80-0014/Honeywell SB 3505945-80-1861 released Apr13

• Production introduction April 2013

• 544 spare kits sold/installed globally


Turbine Radial Bearing Failure

Turbine radial bearing failure occurrence independent of starter age

• Most failures exhibit blade liberation prior to rub event ~90%

• Some units returned show radial bearing failure without blade loss ~10%

• Failures experienced are random in hours/cycles

Honeywell Offers Commercial Solution to Customers when a confirmed event transpires

Extensive testing and analysis, yet no root cause indented


• ATA 80 Status:

• No. 9 on 737NG Top (10) D/C Driver List

• No. 4 Cost Driver

• Soft-Time Benefits:

• Mitigates unscheduled removals (Operational D/C’s)

• Reduced LRU cost

• Reduced unscheduled Line Maintenance/AMT cost

• Addresses Primary Failure Modes, before incurring service interruption

• Mitigates passenger frustration

• Customizable to operators Approved Maintenance Program

• Schedule during Engine Shop Visit/C-Check Intervals

• Cycles/hrs vary per operator

Soft-Time Maintenance Approach

Analysis Conclusions/Recommendations

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Starter Clamp


Starter Clamp

• Starter v-band clamp attaches ATS to gearbox QAD adapter

• Clamp failure leads to engine oil loss through starter • 2 IFSD’s due to clamp failures within last

12 months

• Clamps fail in high cycle fatigue in heat

affected zone (HAZ) of spot weld • Alternative design selected

• Target EIS 1Q 2015


Conclusion

• Air Turbine Starter reliability Stable

• Failure modes understood with product or process improvements established

• Seal leakage

• Inadvertent decoupling

• Radial bearing failures will receive commercial solution • Soft Time Program will reduce service interruptions

Operators with significant ATS D&C’s Might consider soft-time approach

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Closing

B8 Air Turbine Starter

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