Cf6-80c2 Reliability Scorecards -monthly - Mar2017-r1.pdf

CF6-80C2 Fleet Reliability Update

Brandon Endres, CF6 Product Leader March 2016

Export Data Jurisdiction ECCN / ITAR Designation Export License (if applicable)

DoC 9E991 NLR

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Fleet Scorecard Fleet Reliability Statistics

31 years in service

(12 mo. rolling average – thru February 2017)

IFSD

ATO

(Events/1000 EFH)

(Events/1000 Departures) (Events/1000 Departures)

0.004 0.006

Interruptions

0.021

0.008

0.050

0.060

Departure Reliability

UER

(% On-Time Departures)

(Events/1000 EFH)

99.93

0.079 0.050

0.090

99.85

Statistics Engines in Operation: (includes installs & spares)

99.50

KEY ISSUES 3,771

0.036 0.030

0.040

Total Rates

AD Fuel Manifold: IFSD & Fire Event Driver. Introduced New Fuel Manifold System in SB 73-0371 – AD issued October 2014 – 45% Compliant

Aircraft in Operation:

1,127

Total No. of Operators:

170

Total Engine Time:

224,916,108

CRF Oil Manifold Leaks: IFSD & UER Driver. New Design Manifold SB 72-1516 issued on September 1, 2015 – 6% Compliant

Total Engine Cycles:

51,822,521

Fleet Hours per month:

663,284

IGB Teflon Seal Removal: IFSD & Interruption Driver. Rework incorporates press fit & welded-in ring with nickel-graphite seal to replace PTFE seal per SB 72-1186 Cat 3 - 53% Compliant

Fleet Cycles per month:

146,537

Departures per month:

59,390

Shop visits per month:

42

Average Restored TOW

2900

AGB Heat Shield TBC Improvement: SB 72-1520, incorporates 7 new

AD Thermal Barrier Coated Fire Shields as an Improvement to previously sump fire protection – AD issued April 2016, AMOC issued July 2016

Mid Outer Liner Panel Liberation Events: Three 80C2 events since Dec 2013. Cat.2 SB 72-1506 in Jan 2015 for On-Wing Inspection, Cat.5 SB 72-1511 in Jan 2015 for Engine Shop Repair Limits

= Control Plan & Final Fix in place = Control Plan in place, working final fix = No control or field plan in place

GE Proprietary Information Use or disclosure of data contained on this sheet is subject to restrictions on cover

IFSD & ATO Scorecard IFSD Rates*

(Events / 1000 EFH)

0.008

0.07

IFSD Rate 12 M - Total IFSD Rate 12 M - Engine Caused

(Events / 1000 Aircraft Departures)

0.01

ATO Rates*

0.08

0.06

TOA Rate 12 M - Total TOA Rate 12 M - Engine Caused

0.05

0.006

0.04 0.03

0.004

0.02

0.002 0 Jan-12

0.01

Jan-13

Jan-14

Jan-15

Jan-16

Jan-1

0 Jan-12

Updated Through March 1, 2017

Jan-13

Jan-14

Jan-15

Jan-16

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Jan-17

(Events / 1000 Aircraft Departures)

Significant Event Scorecard (Thru OCT 2016)

102* 69* * 12-month count

Updated Through March 1, 2017

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B747 Rates

CF6-80C2B1/B1F/B5F

Utilization

In-Flight Shutdown Rate

16 Events

Take-Off Abort Rate

4 Events

Updated Through March 1, 2017

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B767 Rates

CF6-80C2B2/B2F/B4/B4F/B6 B6F/B7F/B8F

Utilization

In-Flight Shutdown Rate

5 Events

Take-Off Abort Rate

5 Events

Updated Through March 1, 2017

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MD11 Rates CF6-80C2D1F

In-Flight Shutdown Rate

5 Events

Utilization

Take-Off Abort Rate

3 Events

Updated Through March 1, 2017

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A300-600 Rates

In-Flight Shutdown Rate

CF6-80C2A1/A3/A5/A5F/A8

1 Event

Utilization

Take-Off Abort Rate

2 Event

Updated Through March 1, 2017

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A310-300 Rates

In-Flight Shutdown Rate

CF6-80C2A2/A8

0 Events

Utilization

Take-Off Abort Rate

0 Events

Updated Through March 1, 2017

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Fuel Manifold Changes

Ref. C.I. No. 2

Old Configuration

New Configuration (released 2010)

24 Damper Brackets

8 Sheet Metal Brackets

P CLAMPS

BRAZED STRAPS

BLOCK CLAMPS

Recurring 7500 hour inspections of block clamps and P-clamps are terminated when new fuel manifold design is installed CF6-80C2 SB 73-0371 AD 2014-21-01 GE Proprietary Information Subject to restrictions on the cover or first page

10 3/29/2017

CF6-80C2 AGB Heat Shield Expanded TBC Plates •

Expanded TBC plate coverage resulting from NTSB safety recommendation to the FAA

•

Category 3 service bulletins released on 09/22/2015

•

S/B 72-1520 CF6-80C2

•

Weight addition of 5.2 lbs (2.4 kg) per engine

•

AD 2016-08-10 effectivity is June 1, 2016

•

GE business plan provide backend discount for material, please contact your customer support manager (CSM) for details

AD 2016-08-10

Ref. C.I. No. 19

11 3/29/2017

CRF Oil Manifold Program Plan

Ref. C.I. No. 33

New Design Released to Field  80C SB 72-1516 & 80E SB 72-0523 issued on Sep. 1, 2015  315 engines complied as of Oct 5, 2016  Performing well in the field  80C2 Quick-turn programs for faster implementation GE Proprietary Information Subject to restrictions on the cover or first page

12 3/29/2017

CF6-80C HPT S1 Blade Improvement 80C SB 72-1444 / 1538M90P22 • •

Fillet radius increased to reduce stress

New High Chrome Corrosion Coating applied to the shank

New design fills in pockets and lowers stress

Increased wall thickness reduces stress where corrosion related cracking occurs & reduces pocket that traps dirt

• Reduces stress in the Aft Damper Pocket to address scrap rate • Four (4) visual changes to blade are introduced with new blade design 1. 2. 3. 4.

Convex and Concave platform to shank fillet radius is increasing Aft shank has a machined dimple Bottom of dovetail root is rounded off Convex and concave aft seal body lugs is shorter

Ref. C.I. No. 30

Baseline Redesign

Shortened AFT seal body lugs

Dimple Rounded root bottom

GE Proprietary Information Subject to restrictions on the cover or first page

FWD 13 3/29/2017

HPT S2 Seal Body

Ref. C.I. No. 45

The 80C fleet has reported >20 broken & liberated seal body since 2005

Old

New

• Shop Visit Findings • UERs - BSI findings of blades or N2 Vibes

Liberated material can cause damage to adjacent hardware • Stage 2 HPT Blade Airfoil • Thermal Shield • Stage 2 Disk

Old

Failure Causes • Broken Tab • Cracking in high stress area

Design Changes Address: • Stress • Retention Tab Durability

New

Peak stress locations Peak stress locations

Part Numbers • P/N 1957M35P05 • P/N 1957M35P06

Hardware now available S/B 72-1527 GE Proprietary Information Subject to restrictions on the cover or first page

Page 14

*** APPENDIX *** CRITICAL ITEMS LIST (for your reference)

GE Proprietary Information Use or disclosure of data contained on this sheet is subject to restrictions on cover

Critical Items List CF6-80C2 Critical Items consist of 3 levels of high priority actions: • Priority A – Safety or Airworthiness Directive related – Control plans or corrective actions for issues that are deemed safety items by GE’s safety board and/or items that are mandated by the FAA or other agency

• Priority B – Top Reliability Related – Control plans & corrective actions for issues that are top causes of fleet unreliability

• Priority C – Key Product Improvements and Historical items (still applicable) – Key product improvements (recently released) – Control plans & corrective actions for issues that were top causes of fleet unreliability (mostly complete in the fleet but some engines may still not be in compliance)

GE recommends that you review records for each of your engines to ensure critical items have been implemented GE Proprietary Information Use or disclosure of data contained on this sheet is subject to restrictions on cover

CF6-80C2 Fleet Scorecard – Fleet Critical Items Safety or Airworthiness Directive Related No.

Critical Item

Documents

Metric(s) Affected

1

HPT S1 Disk Dovetail

SB 72-1089 SB 72-1217

Safety

2

LPT Case Debris Deflectors

SB 72-1171

Airworthiness Directive

3

4 5

Fuel Manifold Programs Fuel Manifold Supply Tube to Fuel Nozzle Retaining Clip HPC S11-14 Seal Wire Groove Repair

SB 73-0326R1 SB 73-0414R0 SB 73-0365 SB 73-0371

Safety

SB 73-0337

Safety

SB 72-1052

Airworthiness Directive Airworthiness Directive

6

3R Packing

SB 72-A1385

7

HPC 10-14 Spool

SB 72-A1122

IFSD/UER

8

Cast Forward Mount Platform or Yoke With Weld Repairs

SB 72-1206 SB 72-1207

Safety

9

Engine Inclement Weather Flameout and Boeing FADEC FMV Fault Accommodation Logic Improvement

SB 73-0375 SB 73-0351

Airworthiness Directive

SB 73-0352

Priority A

Action Description

SB Category

Mandatory rework of disk dovetail breakedge (AD 2006-16-06) Disk Inspection for Slot Edge Anomalies and Re-identification Rework LPT case to install debris deflectors at stg 5 for improved containment capability (AD 2008-21-11) Inspection and clamp replacement program (AD 2009-05-02) Inspect wear-sleeve area & block clamp CAT2 SB 73-0414R0 (AD 2014-21-01) Application of PTFE tape under loop clamps New design fuel manifold - terminates AD inspection requirement New snap ring for improved fuel manifold supply tube in case of manifold break - prevent undercowl fuel leak and possible fire (AD 2007-11-20 )

2 2

Inspect and repair seal wire grooves of affected spools (AD 2005-17-05)

2

Replace nonconforming packings (AD 2012-03-12)

2

Spool inspection (shop level and module level) (AD 2009–07–03)

3

Replace 13 affected platforms within 500 cycles or 6 months (AD 2007-05-14) Replace 59 affected yokes at next shop visit (AD 2007-05-14) FADEC software version 8.2.R for B747/B767 with enhanced flameout prevention for high and middle altitudes. (AMOC for AD 2007-12-07 ) FADEC software version 8.3.K for MD-11 with enhanced flameout prevention for high and middle altitudes. (AD 2007–22–07) FADEC software version 8.4.F for A300 with enhanced flameout prevention for high and middle altitudes. (AD 2007-21-06) Airbus Service Bulletins to add thrust reverser actuation system locks as a third line of defense against inadvertent thrust reverser deployment (DGAC AD F-2004-165)

2 3

10

A300/A310 Thrust Reverser Actuation System Locks

A300-78-6024 A300-78-6025 A310-78-2023

Safety

11

Thrust Reverser Actuator Inspection and Rod End Replacement

SB 78-A1162

Safety

Replacement of actuator 3/8 inch rod ends and other inspections to prevent rod end breakage and potential partial transcowl liberation (AD 2009-21-07)

12

HPC 3-9 Spool

SB 72-0937

Safety

Inspection (AD 2002-25-08) Spool replacement with improved design GE Proprietary Information Use or disclosure of data contained on this sheet is subject to restrictions on cover

4 2 2 3 5 3

3

N/A

2 N/A 7

CF6-80C2 Fleet Scorecard – Fleet Critical Items Safety or Airworthiness Directive Related No.

Critical Item

Documents

Metric(s) Affected

SB 72-1152

Safety

Action Description

SB Category

Repair cutback of LPT nozzle

5

IFSD/UER/TOW

On-wing inspection (AD 2004-22-07) Redesigned (TechCF6) Nozzles

2 7

High Cost Event

Service Bulletins for improved thrust reverser latches. (AD 2006-06-08)

2

13

LPT Overspeed Protection

14

HPT Stage 2 Nozzle Guide Vanes

15

MD11 Thrust Reverser Half Liberation

16

Thrust Reverser Improved Flex Shaft

SB 78-1168R1

Reliability

17

ECU Front Panel Improvement

SB 72-0386

IFSD

18

IDG Oil Cooler Fuel Tube Flange Spray Shield

SB 73-0242

IFSD / A.D.

19

AGB Heat Shield - Expansion of TBC Plates

SB 72-1520

Safety / A.D.

SB 72-0952 SB 72-1291 SB 78-1068 SB 78-1077 SB 78-1078 SB 78-1088

Priority A

Improved flex-shaft to improve reliability (747 and 767 applications only Boeing cover SB 747-78A2185 and SB 767-78A0100) (AD Pending) Improved front panel design to address potential uncommanded engine shutdown due to electrical interference (AD 2012-04-05)

2 2

Improved bracket design to integrate the function of both the IDG bracket and spray shield into one part. (AD 2013-08-20)

3

Expand surface area coverage of Thermal Barrier Coated plates (AD 2016-08-10)

3

GE Proprietary Information Use or disclosure of data contained on this sheet is subject to restrictions on cover

CF6-80C2 Fleet Scorecard – Fleet Critical Items Top Reliability Related No.

Critical Item

Documents

Metric(s) Affected

20

Fan Forward Inner Liner Brackets Inspection and Replacement

SB 72-1223R1 SB 72-1374

High Cost Event

Training

IFSD

SB 72-1265

IFSD/UER

SB 77-0050

IFSD/High Cost Event

CESM 204

IFSD/UER

SB 72-1230

IFSD/UER

21 Maintenance Related Reliability CRF Sump Vent Oil Impingement Tube Rework and Improvements EGT Thermocouple Probe On-Wing 23 Inspection 22

24 No. 4 Ball Bearing 25

Oil Manifold for IGB Horizontal Drive Shaft Spline Wear

26 Oil Pressure Transmitter Tube 27 IGB Gearshaft Teflon Seal

SB 79-0086 SB 79-0082 SB 72-1186 SB 72-1193

IFSD IFSD/UER

28 TRF Oil Tube Coking

SB 72-0001 CESM 09

IFSD/UER

29 HPT Thermal Shield

Eng.Manual WSPG

IFSD/ATO/TOW

72-1444 (S1-R142)

COO/IFSD/ATO

30

HPT Blade Redesign & Shank Corrosion Coating

31 Bleed Flow Sensor (PMC Engines)

SB 75-0202

IFSD/UER

32 Fan Mid-Outer Liner Panels

SB 72-1506 SB 72-1511

ATO / INTERRUPTION

33 CRF Oil Manifold System

SB 72-1516

IFSD/UER

Priority B

Action Description Improved fan forward inner liner bracket Inspection of fan forward inner liner bracket (pre-SB 72-1223) Awareness and training, Maintenance Newsletters, Blogs Improved design or rework instructions for CRF sump vent oil impingement tube to prevent tube cracking and oil loss On-wing resistance check of older EGT probes to avoid tip separation and downstream LPT damage CESM204 (bearing handling best practices). Enhanced oil filter fault isolation procedures in AMMs. New oil supply manifold with debris screen to prevent oil nozzle blockage and resulting IGB horizontal drive shaft spline wear Improved oil pressure tube system Improved tube support brackets and clamps Service Bulletin defining welded ring repair replacement of Teflon seal Spare part Service Bulletin releasing solid metal gear (production config.) SB 79-001 (High Thermal Stability Oils) Engine Manual (72-58-01 Repair 01) Tube Cleaning Trend Monitoring Engine manual changes - open seal clearance, strip/inspect seal teeth; specified min. seal tooth thickness

SB Category 3 2 N/A 5 2 N/A 5 3 3 6 8 9 N/A N/A N/A

Shank redesign & corrosion coating to prevent corrosion on blade shanks

5

Replace stainless steel bleed flow sensor with new part made of Inconel

3

Service Bulletin defining on-wing inspection/repair criteria Service Bulletin defining in-shop inspection/repair criteria

2 5

Redesigned CRF Oil Manifold System, oil supply tubes, HP recoup tubes

3

GE Proprietary Information Use or disclosure of data contained on this sheet is subject to restrictions on cover

CF6-80C2 Fleet Scorecard – Fleet Critical Items Key Product Improvements and Historical Reliability Items (still applicable) No.

Critical Item

34 Improved LPT Shrouds 35 S5 VSV Lever Arms 36 HPC S11 Vane Rail Wear 37 Stage 11 Air System 38 HPC Stages 3-5 Blades 39 HPT Stage 2 Blades 40 Fuel Nozzle Welded Heat Shield 41 HP Recoup Ducts 42 CRF B/C Sump O-Rings 43

HPT S1 Disk Inner Transition Radius Erosion

44 Fan Case Corrosion 45 HPT S2 Seal Body

Documents

Metric(s) Affected

SB 72-1006

Airworthiness Directive

SB 72-1081 CESM 205 SB 72-1117 SB 72-1118 SB 72-1125 SB 75-0156 SB 75-0200 SB 72-1060 SB 72-0982 SB 72-1283 SB 73-0287 SB 73-0289 SB 75-0167 SB 75-0168 SB 72-1107 SB 72-1195 72-1313 Eng manual and AMMs SB 72-1527

IFSD/ATO/TOW IFSD/UER IFSD IFSD/ATO/UER IFSD/TOW IFSD/UER IFSD UER/TOW COO COO UER/TOW

Priority C

Action Description Improved design LPT shrouds with improved containment capability (AD 2003-02-07) Improved design stage 5 lever arm system VSV lever arms and bushings maintenance On-wing borescope inspection of affected engines. Replacement of S11 vanes with Al-Br coating Twin pipe design

SB Category 4 N/A 3 2/4 3

Introduced FOD tolerant airfoils for HPC stages 3-5 blades. Maintains improved dovetail geometry. R80 material blade retirement Tech CF6 Blades Standard (non-dribble flow) fuel nozzles with welded heat shield Dribble flow fuel nozzles with welded heat shield Redesigned duct support for FADEC engines+F24 Redesigned duct support for PMC engines

4 7 3 3 4 4

AFLAS material O-rings (more tolerant of high temperatures)

5

Introduction of baffle ring to prevent erosion New HPT S1 disk design Engine manual and Aircraft Maintenance manual changes - improved limits and repairs Engine manual and Aircraft Maintenance manual changes - improved limits and repairs

5 7

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3

N/A N/A

CF6-80C2 HPT S1 Disk Dovetail

Ref. C.I. No. 1

Inco 718 Rotors

Disk event in June 2006 Resulted in update to HPT stage 1 disk field plan Background Breakedge

• Service bulletin 72-1089 - P/Ns 1531M84G10, 9392M23G10, 9392M23G12, 9392M23G21, 1531M84G02, 1531M84G06, and 1531M84G08

Non Chamfered (Breakedge) Disk

Chamfer

• Require the machining of a chamfer, FPI, and eddy current inspection at the aft edge of the 80 dovetail slots • Incorporate completion dates • AD 2006-16-06 for new field program

S/B Field Rework Disk Chamfer (.036-.056”)

GE Proprietary Information Subject to restrictions on the cover or first page

21 3/29/2017

CF6-80C2 - New HPT 1 Disk Design Service Bulletin 72-1313 Inco 718 Rotor

Ref. C.I. No. 1 Ref. C.I. No. 43

Disk redesign program initiated after June 2006 event • Eliminate the high stress in dovetail slot bottom • Increase resistance to potential damage in the slot bottom region • Chapter 5 life limits 15K for all thrust levels Enhanced Durability

Not subject to AD 2006-16-06

GE Proprietary Information Subject to restrictions on the cover or first page

22 3/29/2017

CF6-80C2 LPT Case Debris Deflectors

Ref. C.I. No. 2

AD 2008-21-11… Service Bulletins 72-1170 or 72-1171

Addresses S5 LPT blade plane LPT case breach caused by blade fragmentation • Rub-through / “machine” through mechanism – New design with a rework for the field LPT cases: » SB 72-1170 (December 2004) released the new production LPT case with integral debris stops » SB 72-1171 (May 2005) released the field rework definition to add “bolt in” debris stops 24 bolted in debris stops to prevent fragment entrapment

Doubler welded on LPT case

GE Proprietary Information Subject to restrictions on the cover or first page

23 3/29/2017

Fuel Manifold Clamp Chafing

Ref. C.I. No. 3

AD 2009-05-02 … CF6-80C2 - Service Bulletin 73-0326 R4

Inspect fuel manifold and replace clamps

HOLE

• Clamps that appear to be serviceable with visual inspection can contain contaminants which accelerate tube wear • SB affects both drained and drainless systems • Taped fuel manifolds also require inspection until it demonstrates effectiveness

Repeat fuel manifold inspections includes clamp replacement GE Proprietary Information Subject to restrictions on the cover or first page

24 3/29/2017

CF6-80C2 Periodical Inspection Service Bulletins

Ref. C.I. No. 3

Fuel manifold inspection on epoxy wear-sleeve area and block clamp is required by CAT2 SB 73-0414R0 / AD 2014-21-01 • •

•

Perform first inspection within 6 months of SB issuance. Repetitive inspections at same interval time (7500 flight hours) as fuel manifold cushion clamps inspection Allowable ESM wear depth is .0035”. Wear from .0035-.010” depth, may continue 50 additional cycles, then replace manifold.

GE Proprietary Information Subject to restrictions on the cover or first page

25

Epoxy wear sleeve area. 3/29/2017

Fuel Manifold Supply Tube Shroud Retaining Clip

Ref. C.I. No. 4

AD 2007-11-20 … CF6-80C2 - Service Bulletin 73-0337

O-ring fitting

Liberated Retaining Ring

Incorporation of snap ring improves retention of fuel manifold feeder tube in event of a severed tube • Plug load on o-ring fitting can exceed retention capability of the retainer ring • Results in loss of fuel containment • 2 fire events caused by this problem • Retainer ring replaced with snap ring • Snap ring installation is not recommended while the fuel manifold is installed on the engine • AD 2007-11-20 requires incorporation of the snap ring at next shop visit for drainless manifolds

GE Proprietary Information Subject to restrictions on the cover or first page

26 3/29/2017

HPC S11-14 Seal Wire Groove Repair

Ref. C.I. No. 5

AD 2005-17-05… S/B 72-1052 (80C2)

Seal wires installed in stages 6-14

S11-14 Spool Seal Wire Grooves

• Installed in grooves in outer diameter of dovetail slots • Two grooves per stage, one forward, one aft of dovetail slot • Intended to reduce air backflow under blade platforms

AD requires repair to eliminate wear notches

Typical Seal Wire Wear

• Affects S11-14 spool/shafts with circumferential cut repairs

GE recommends HPCR seal wires be left out at engine overhaul

GE Proprietary Information Subject to restrictions on the cover or first page

27 3/29/2017

CF6-80C2 3R Packing (Gasko Seal)

Ref. C.I. No. 6

AD 2012-03-12… Service Bulletin 72-A1385 (Category 2)

No 3R packing between fan frame and 3R Stationary oil seal

• Multiple holes in packing meter pressurization and bore cooling air from booster

Fifty (50) nonconforming parts shipped as spare parts • 5 holes were manufactured undersized… reduces cooling flow to rotor bores • Increased thermal stress in HPC & LPT LLP • Prolonged operation with nonconforming packing lowers Ch 5 life of certain parts: – LPT Stage 3 Disk PN 9373M53P05 – LPT Stage 4 Disk PN 9373M54P03 – All Stage 10-14/Stage 11-14 HPC Spools

3R Packing Undersize d Holes Locations

Control program and corrective action per SB 72-A1385 (end date 31-Jan-2017)

• If engine has LPT S3 disk PN 9373M53P05, replace nonconforming 3R packing at next shop visit, not to exceed 2,550 cycles • Replace nonconforming 3R packing at next shop visit not to exceed 5,500 cycles • Alternatively, nonconforming seal can be confirmed by borescope inspection (but requires removal of one flowpath fairing to gain access) GE Proprietary Information Subject to restrictions on the cover or first page

28 3/29/2017

HPC Module, Rotor: 10-14 Spool Shaft Inspection AD 2009–07–03 … Service Bulletin 72-A1122 (80C2)

Ref. C.I. No. 7

Circumferential cracking of S14 disk web • • • •

Cracks initiated by vibration induced by inertia weld Part numbers 1703M49G02, 1703M49G03 and 1509M71G10 740 spool shafts affected , last build 2002 Cracking results in very high N2 vibration

Inspect affected spools at first (next) engine shop visit Inertia Weld Location

CF6 10-14 HPC Spool Cross-Section (1703M49)

Crack Locations in Stage 14 Web GE Proprietary Information Subject to restrictions on the cover or first page

29 3/29/2017

CF6-80C2 Cast Forward Mount Platform or Yoke With Weld Repairs Ref. C.I. AD 2007-05-14 … Service Bulletins 72-1206 and 72-1207 Yoke

Platform

No. 8

Removal of Yokes/Platforms • New-make welds in structurally critical areas. Cracks may originate from weld • Not all hardware affected, see SBs for specific serial numbers • Platforms: 1292M13G06/1846M24G04 1301M28G08/1459M70G07 • Yokes: 9383M43G14/9383M43G16 • AD 2007-05-14 issue 5 Mar 2007 • Hardware replacement program in place

GE Proprietary Information Subject to restrictions on the cover or first page

30 3/29/2017

CF6-80C2 Inclement Weather Flameout

Ref. C.I. No. 9

AD’s on VBV schedule changes issued on recent FADEC software Service Bulletins B767/B747 8.2.R SB SB 73-0375R1 issued Dec ‘09

• FAA AD 2007-12-07 effective July 11, ’07 for 8.2.Q1 • AMOC to AD 2007-12-07 issued Jan ’10 to allow 8.2.R to be installed

A300 CF6-80C2A5F 8.4.F SB 73-0352 issued Feb, ’07

• FAA-NE AD 2007-21-06, effective Nov 15, ’07 (>30% complied)

MD-11 CF6-80C2D1F SB 73-0351 8.3.K issued Apr, ’07 • FAA-NE AD 2007-22-07, effective Nov 28, ’07

A330 CF6-80E1 SB 73-0091 E.1.O issued May ‘07

• EASA AD 2007-0215 … terminating action for bleed procedure • FAA AD 2007-17-01, effective Aug 29, ’07 (100% complied Jan ’08)

GE Proprietary Information Subject to restrictions on the cover or first page

31 3/29/2017

CF6-80C2 A300/A310 Thrust Reverser Actuation System Locks DGAC Airworthiness Directive F-2004-165

CF6-80C2 Thrust Reverser TLOD* Modification

Ref. C.I. No. 10

New Locking Actuator Assembly

• Replacement of the lower end actuator with one that includes integral locking locking actuator and gearbox assembly • Addition of pneumatic supply tube from the Y- check valve • New electrical harness from pylon junction box to reverser • Modification of the Hold Open Rod bracket

* TLOD - Third Line of Defense for the A/C to guard against an inadvertent deployment (IAD)

Locking Actuator and Gearbox Assembly (LAGA) 3272636 or 3272638 GE Proprietary Information Subject to restrictions on the cover or first page

32 3/29/2017

CF6-80C2 Thrust Reverser Actuator Inspection and Rod End Replacement

Ref. C.I. No. 11

Service Bulletin 78A1162 and AD 2009-21-07 Purge the fleet of older 3/8” dia KBE-59 rod ends and replace them on-wing with improved M81935/16 rod ends The SB recommends that operators eventually upgrade adjustable length end actuators to 7/16” dia rod ends within 11,000 FC

3/8” dia threads

NO ACTION REQUIRED PER SB 78A1162

7/16” dia threads

Initial:

ON WING REPLACEMENT 3/8” dia WITHIN 500 FC

Follow on:

• This can be incorporated SHOP UPGRADE to 7/16” dia WITHIN 11,000 FC on attrition during normal shop visits of end actuators or thrust reversers If feasible, operators could install 7/16” adjustable or fixed

length actuators within 500 FC to preclude follow on action

GE Proprietary Information Subject to restrictions on the cover or first page

33 3/29/2017

HPC Module, Rotor: 3-9 Spool AD Inspection AD 2002-25-08 – CF6-80C2 SBs 72-A0812, 72-A0848, 72-A0937

Ref. C.I. No. 12

Ultrasonic and eddy current inspection for melt conditions and dwell fatigue,1998, revised in 2003 Affects older (pre-1995) material

CF6-80C2 Total Engines

13" & 9/10" Billet Spools

Repeat inspection intervals get smaller as part CSN increases

4000

Number of Spools

3500 3000 2500

• 2000 CSLI for spools over 8000 CSN • Will limit engine time on wing

2000 1500 1000 500

Quarter / Year

1/08

2/07

3/06

4/05

1/05

2/04

3/03

4/02

1/02

2/01

3/00

4/99

1/99

2/98

3/97

4/96

1/96

2/95

0

Spools subject to 10,500 CSN re-use limit

Adding notes to EM 05-11-02 identifying affected spools New 5-piece spools not affected • SB 72-0937 (80C2)

Replace old material spools at ESV if over 8000 CSN GE Proprietary Information Subject to restrictions on the cover or first page

34 3/29/2017

CF6-80C2 LPT Overspeed Protection Category 5 Service Bulletin 72-1152 (November 2004)

Ref. C.I. No. 13

If fan midshaft would separate, design intent is for axial translation of LPT rotor to clash with LPT stator • Clashing would break airfoils and act as a “brake” to slow rotor to avoid free-running rotor and possible overspeed Unmodified Part

Analysis determined S4/S5 LPT nozzles inner platform could provide “false bearing” • Possible delay in clashing and fragmentation of the blades • Unloaded free rotor could continue to run to overspeed

Cut off inner band lip

GE Safety Board directed corrective redesign cutback of LPT S4/S5 nozzle inner platform • RD 934-234-S2 or later – Set incorporation is required GE Proprietary Information Subject to restrictions on the cover or first page

Modified Part

35 3/29/2017

CF6-80C2/E1 HPT Stage 2 Nozzle

Ref. C.I. No. 14

AD 2004-22-07 – CF6-80C2 SBs 72-0952

For R80 Phase 1 HPT Stage 2 Nozzle :

• Repetitive BSI per SB 72-0952 and AD 2004-22-07 Phase 2 design not subject to repetitive inspection per Airworthiness Directive

• CF6-80C2 SB 72-0978 (R80)or SB 72-1099 (N5) • CF6-80E1 SB 72-0244 (N5) • Phase 2 airfoil replacement repair for either R80 or N5 – CF6-80C2 SB 72-1169

GE Proprietary Information Subject to restrictions on the cover or first page

36 3/29/2017

CF6-80C2 HPT Stage 2 Nozzle

Ref. C.I. No. 14

Tech CF6 - HPT Stage 2 Nozzle (80C2/80E1) CF6-80C2 SB 72-1291 and –80E1 SB 72-0385 INCREASE TRAIL VANE SUCTIONSIDE COOLING

INCREASE TRAIL VANE PRESSURESIDE COOLING

REDUCE LEAD VANE SUCTIONSIDE COOLING

Custom cooling air inserts

REDUCE LEAD VANE PRESSURESIDE COOLING

• Custom cooling insert improves part durability, scrap rate and lifecycle cost with no impact to performance. • Reduced thermal stresses in nozzle segment by improved distribution of cooling air • Directly addresses top scrap rate driver for the Phase 2 HPT nozzle • Can be incorporated at FAB repair or new make, SB 72-1286 • Successful endurance testing completed 2004 and 2006 • Piece-part interchangeable with current design

GE Proprietary Information Subject to restrictions on the cover or first page

37 3/29/2017

CF6-80C2/MD-11 Thrust Reverser Half Liberation AD 2006-06-08 … MD-11 Aircraft

Ref. C.I. No. 15

Recommends mandatory incorporation of 78-1068R2 OR 78-1077R1 with compliance time “at next normally scheduled maintenance period or within 1,200 flight hours time-in-service (TIS) after the effective date of AD, whichever occurs first.” Recommends mandatory incorporation of 78-1088R5 AND 78-1078R1 with compliance time “at the next normally scheduled maintenance period or within 6,000 flight hours TIS after the effective date of AD, whichever occurs first.” This AD is intended to prevent liberation of thrust reverser hardware at landing, which can result in runway debris and a possible hazard to other aircraft GE Proprietary Information Subject to restrictions on the cover or first page

38 3/29/2017

CF6-80C2 747/767 Thrust Reverser Flex Shaft Service Bulletin 78-1168R2 (Category 2) Previous flex shaft design prone to overload failure • High impact speeds during thrust reverser actuation exceeds design capability • Compromises thrust reverser third line of defense Improved flex shaft design improved durability • Manufacturer change • Core material change and diameter increase • Flex shaft braid winding change • End fitting change • Attachment of end fitting to core change 78-1168R2 released April 2011 with installation record/ torque inspection data sheets added. • Torque inspection required every 1000 hours • Send data sheets to MRAS

Ref. C.I. No. 16

Flex Shaft

Flex Shaft

Failed Flex Shaft

TRAS Lock Upper End Actuator

GE Proprietary Information Subject to restrictions on the cover or first page

Wire Wound Core

End Fitting 39 3/29/2017

CF6-80C2 ECU Front Panel Improvement

Ref. C.I. No. 17

SB 73-0386 & 73-0395 – Introduced Front Panel Assembly rework Event fault reports and QAR/DFDR data point to ignition excitation occurring at the time of the IFSD or GSD •

Cycle of the ignition system resulted in electrical noise within the ECU due to ignition system relay contact bounce

SB73-0386 Issued to rework the ECU hardware containing the latest PSS & FPA assemblies •

ECU P/N’s involved: 2121M38P01/P02, 2121M41P01/P02

•

Jumper wire added across low side of the ECU ignition relays

•

Ferrite bead added to high side of the ECU ignition relays

•

Ignition relay noise is suppressed, so CPU faults no longer set

FAA Issued AD 2012-04-05 to mandate introduction of reworked PN with the latest improvements. SB 73-0396 issued to apply the same rework as in SB 73-0386 to ECU’s containing the latest FPA assemblies that addressed ECU removals due to single channel EEC C1 EICAS message •

ECU PN’s 1471M63P42, 1519M89P32, 1820M33P15 40 3/29/2017

Ref. C.I. No. 18

CF6-80C2 IDG Oil Cooler Fuel Tube Flange Spray Shield

AD 2013-08-20… SB 73-0242 – Improve maintainability of flange joint Three reports of incorrectly installed spray shields at the IDG Cooler bracket since 2006 • Two fires – 2006 & 2012 • One fuel leak – 2012 SB 73-0242 introduced in 1996 • Integrates the function of both the IDG bracket and spray shield into one part • Changed to a Cat 3 after the 2006 event • 73-A0401 (Cat 2) replaces only F/O HX forward flange spray shield and support bracket • AD Pending for 1-piece bracket

Spray Shield

Spray Shield FLANGE

FLANGE

IDG BRACKET

TOP VIEW Incorrect assembly – improper seating of bolts  Inspect seal for damage  Clean flange surface to ensure no debris and proper seating  Ensure proper positioning of components

Correct assembly

 Make sure tube flange is not hung-up on the ferrule shoulder  Torque bolts in diagonal pattern to ensure proper seating  Use proper torque on bolts per AMM

IDG oil cooler bracket

IDG oil cooler bracket

IDG oil cooler IDG oil cooler Spray shield Spray shield incorrectly installed under IDG bracket

Spray shield Spray shield correctly installed over IDG bracket 41 3/29/2017

CF6-80C2 AGB Heat Shield Expanded TBC Plates AD 2016-08-10 •

Expanded TBC plate coverage resulting from NTSB safety recommendation to the FAA

•

Category 3 service bulletins released on 09/22/2015

•

S/B 72-1520 CF6-80C2

•

Weight addition of 5.2 lbs (2.4 kg) per engine

•

AD 2016-08-10 effectivity is June 1, 2016

•

GE business plan provide backend discount for material, please contact your customer support manager (CSM) for details

Ref. C.I. No. 19

42 3/29/2017

CF6-80C2 Fan Forward Inner Liner Bracket

Ref. C.I. No. 20

SB 72-1223 R2 – Improved Brackets SB 72-1374 – On-Wing Inspection of Pre SB 72-1223 Brackets Forward inner liner support bracket can crack in operation • Several events of bracket separation and liner liberation • Has caused significant thrust reverser transcowl damage

New design improves bracket durability • Introduced by SB 72-1223 • SB category revised to Cat 3 in SB 72-1223 R2 after increase in significant liberation events

On-wing inspection program introduced to reduce chance of liner liberation Cracked Bracket

• Bracket inspection introduced by SB 72-1374 Transcowl Damage (Cat 2)… 400 cycle repetitive interval (Secondary) • Only applies to pre-SB 72-1223 brackets GE Proprietary Information Subject to restrictions on the cover or first page

43

3/29/2017

Maintenance Related Reliability Maintenance Newsletters

Ref. C.I. No. 21

GE has published a series of Maintenance Newsletters • Issued with Fleet Highlights • Topics selected based on fleet reliability data

Maintenance Newsletters inform maintainers of best practices to avoid maintenance errors • Training aid with suggested ways to prevent errors

Newsletters are available for your use • Some customers use these letters in training or as maintenance bulletins • If you need a PowerPoint version, please let us know

Line Maintenance Lessons Learned Blogs are now available! • Highlighting maintenance lessons learned, the proper way to perform a maintenance action, and the consequences for doing it incorrectly https://geaviation.widencollective.com/c/jpokfntw GE Proprietary Information Subject to restrictions on the cover or first page

44 3/29/2017

Maintenance Newsletter Example

GE Transportation

Training Newsletter Issue C F680C21005 • O ctober 2005

CF6-80C2 & 80E Flanged Tube Installation

Ref. C.I. No. 21

Loose Bolts and damaged seals… High Speed Take-Off Abort During t ake-off pri or to rotati on a CF6 -80C2 en gine had a loss of thrust. The cre w a borted the take-off and three t ires were dam aged du ring deceler ation . Investigati on r evealed a fue l le ak at the flang e jo int of the fue l d ischarge t ube between the fuel pump and main eng ine c ontrol. The flange attachin g bo lts were found with l ow t orque. The bo lts were re-torq ued but the fue l le ak remained. The fu el tu be g asket seal was inspected and foun d to have damage to t he o -ring portion of the seal. This eve nt resulted in a 37 hr fl ight delay. The tubi ng a nd fl ange construction is the same for the CF6-8 0C2 and CF6 -80E1 engi nes.

Preventing these Errors  When c hang ing accessories both ends of tubin g shou ld be l oose − Slight differences in accessory alignme nt will lead to t ubin g alignme nt differences.

Instal lation Coupling Flange

Tube

Tu b e Fe rru l e

Training N ewsletter

Accessory Housing

 No brackets shou ld b e loc ated between tube fl ange and accessory housing. Leaks wi ll occ ur.  Evenly tighte n b oth en ds of tu be while ensuring fl ange remai ns centered on tube en d. Use cross-pattern seque nce when t ighten ing & app lying torqu e.

Seal Close-up

Correct

 Ensure all bo lts pass throu gh th e gasket holes befo re thre adin g i nto the accessory housing.

 Finger ti ghten all bo lts first.

Instal lation with incorrect Flange seating

is published by GE Transportation Customer Training Services. Copyright, 2005 General Electric Company Product Support Engineering 1-877-GEAE-CSC [email protected] m

Flange Close-up

Flange not centered

For procedure steps or further information, Reference EM Task 72-00-05 or contact your GE Field Rep or CSC (1-877-GEAE-CSC) or [email protected] m.

 Do not use tubi ng attach p oints to force ali gnment of accessories an d tubing. −

Engine location: Right hand side, Acces sory Gearbox

Damage to g asket seal mater ial can result. Inspect inserts and gasket seal material

− Damage to accessory inserts can result. − Tube flan ge may not ce nter around tube end.

Brackets on tube side of flange

 Check torq ues after fi nal assembly. Post-maintena nce le ak checks do not always detect loose c onnecti ons.

GE Proprietary Information Subject to restrictions on the cover or first page

This document is for training purposes only.

GE PROPRIETARY INFORMATION The information contained in thisdocument is GE proprie tary information and is disclo sed in confidence. It is the property of GE and shallnot be used,disclosed to others or reproduced without the express written consent of GE, inclu din g, but without limit ation, it isnot to be used in the creatio n, manufacture, development, or derivation of any repair s, modificatio ns, spare parts, designs, or configuratio n changes or to obtain FAA or any other government or regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part. The info rmation contained in this document may also be controlle d bythe U.S.export control laws. Unauthorized export or re-export is prohibit ed.

45 3/29/2017

Maintenance newsletters – complete list • • • • • • • • • • • • • • • • • • • • • • • • • • •

CF6-80C2 Oil Pressure Sensing Tube Installation CF6-80E1 Tolerance Take-Up Unit & Stage 14 Tubes Installation CF6-80C2/-80E1 Flanged Tube Installation CF6-80C2/-80E1 FADEC Fuel Filter Pressure Differential Switch Installation CF6-80C2/-80E1 Oil Tank Cap Installation CF6-80C2/-80E1 Accessory Gearbox Drive Pad Cover Installation CF6-80C2/-80E1 HPT Stage 1 Nozzle Borescope Plug Installation CF6-80C2/-80E1 Self-Locking Nuts Torque Check for Re-use CF6-80C2/-80E1 Electrical System Cable Connector Maintenance CF6-80C2/-80E1 Accessory Gearbox Carbon Seal Installation CF6-80C2 EGT Probe Maintenance CF6-80C2/-80E1 LRU Drive Shaft O-Ring Installation CF6-80C2/-80E1 VSV Actuator Rod End Installation CF6-80E1 7th Stage Differential Pressure Switch CF6-80C2 IDG Oil Cooler Fuel Tube Flange Spray Shield CF6-80C2/-80E1 V-Band Clamp Coupling Assembly CF6-80C2/-80E1 4-Bolt Flange Fastener Condition CF6-80C2/-80E1 Tube System Clamps CF6-80E1 Fuel Pump Strainer CF6-80C2/-80E1 Abnormal Engine Operation Following Water Wash CF6-80C2/-80E1 Starter Oil Servicing CF6-80C2 Best Practices to Avoid FOD through VBV Doors CF6 All Fluid Line B-Nut Fittings Best Practices CF6-80C2 Fan Trim Balance CF6-80C2 FADEC Questions & Answers CF6-80C2/-80E1 Thrust Reverser Maintenance CF6-80C2 MFP Fuel Supply and Return Tubes GE Proprietary Information Subject to restrictions on the cover or first page

Ref. C.I. No. 21

All Maintenance Newsletters are available on the GE Customer Web Center (CWC) or from the GE Aviation Operations Center ([email protected])

46 3/29/2017

GE Maintenance Minutes

Ref. C.I. No. 21

Reduce Human Factors related events • Seminars • GE Maintenance Minute Videos

https://geaviation.widencollective.com/c/jpokfntw

• Re-branded from Line Maintenance Lessons Learned Blogs to GE Maintenance Minute • Located on the GEAviation youtube website https://www.youtube.com/user/GEAviation/videos 47 3/29/2017

CRF Sump Vent Oil Impingement Tube

Ref. C.I. No. 22

CF6-80C2 SB 72-1265 Category 5 April 2007 CF6-80E1 SB 72-0367 Category 5 June 2007 Impingement tube cracks result in Caution oversized dovetails blade High Oil Consumption shims required

• 14 confirmed UER’s • 5 confirmed In Flight Shut Downs

Redesign removes stress concentration • Removes the foil and tack welds from tube • Removes the heat shield

CRF impingement tube recommended repair at first exposure Production Introduction Engines: CF6-80C2: ESN 706-876 CF6-80E1: ESN 811-443 Impingement tube reliability is increased when stress concentrations are removed GE Proprietary Information Subject to restrictions on the cover or first page

48 3/29/2017

CF6-80C2 EGT Thermocouple Probe On-Wing Inspection

Ref. C.I. No. 23

CF6-80C2 Cat 2 SB 77-0050 Revision 4 Probe tip liberation has led to significant secondary damage to the LPT including airfoil separation On-wing resistance check inspection repeated every 500 cycles or concurrently with HPT borescope inspection Begin at EGT probe age threshold of 2800 CSN Applies to P/N 9373M91P03/P05 and also 1696M81P10/P12/P16 • P/N 1696M81 probes are alternate supplier introduced in 1996 (same support design as P/N 9373M91 probes)

Shop inspection no longer terminates inspection * 80E1 only has later standard EGT probes GE Proprietary Information Subject to restrictions on the cover or first page

49 3/29/2017

No. 4 Ball Bearing – CESM 204

Ref. C.I. No. 24

4B bearing is highest loaded bearing • Core thrust bearing operating at N2 speed • Made from M50 NIL (vs. just M50) • M50 NIL material for improved fatigue life • More sensitive to hard particle type damage • Surface defects significantly affect the bearing life • Requires the stringent inspection / handling etc. criteria

Most fleetwide failures occurred shortly after shop visit • Contamination likely introduced at the shop visit

CESM 204 revision 1 issued Jan 2002

• Provides best practice recommendations that will help extend the serviceable life of bearings and help prevent costly operational events due to bearing failures -

Bearing Inspection Bearing Cleaning Bearing Assembly Engine Transportation

- Bearing Refurbishment - Bearing Handling - Bearing Preservation - More GE Proprietary Information Subject to restrictions on the cover or first page

50 3/29/2017

IGB Horizontal Gearshaft Spline Wear

Ref. C.I. No. 25

Service Bulletins 72-1230 (-80C2) and 72-0333 (-80E1)

Worn splines

IGB gear shaft spline wear leads to decoupling of gearbox from core • IFSD, ATB, UER can result

Clogged oil nozzles are the leading cause of IGB spline wear • BSI of nozzle and backlash check

Introduced a screen in the nozzle • Prevents contamination of oil jets at #3R and IGB spline lube nozzle

New oil nozzle

New nozzle improves reliability of the gearshaft splines GE Proprietary Information Subject to restrictions on the cover or first page

51 3/29/2017

IGB Gearshaft PTFE Seal Debonding Service Bulletins

Ref. C.I. No. 27

72-1186 (-80C2)

Piece of seal found in pump inlet from TGB

Inlet gearbox (IGB) gear shaft PTFE (Teflon®) seal adhesion loss (debond) can result in oil hiding and oil leakage IFSD, ATB, UER can result

Two Service Bulletins

cancelled • Repetitive replacement of the PTFE seal • Rework of IGB horizontal gearshafts

ID of gear shaft with damaged seal

New design removes PTFE and replaces with nickel graphite Old design – must replace PTFE with nickel-graphite

Inspecting gear shafts via the limits in the service bulletin or reworking/replacing seals to nickel-graphite reduces significant events GE Proprietary Information Subject to restrictions on the cover or first page

52 3/29/2017

TRF Oil Tube Coking CF6-80C2 and 80E1 CESM 09

Ref. C.I. No. 28

TRF Tubes

No. 6 Oil Nozzle

TRF tubes are in close proximity to the struts

Oil Scavenge

• Results in rapid heat transfer to the tubes

CESM 09 Issued for CF6-80C2 & -80E1 • Oil servicing recommendations

No. 6 Sump

2x .046

Oil Supply

dia.

– Changing or mixing of brands – Use of HTS oils recommended – Inspection recommendations

Detached coke particles obstruct oil jets

• Operational recommendations – Idle a minimum of 3 minutes prior to shutdown 1x .035 dia. – Tube cleaning recommendations – Oil pressure trending recommended Cross section through nozzle GE Proprietary Information Subject to restrictions on the cover or first page

53 3/29/2017

CF6-80C2 Thermal Shield

Ref. C.I. No. 29

Thermal shield cracking continues in field • Scrap stage 1 and stage 2 HPT disks if thermal shield crack remains axial • Extensive HPT airfoil and LPT damage if crack turns circumferential and part of thermal shield is liberated (chunk-out) • To date, all occurrences were on older parts subjected to hard rubs during test cell break-in run

Recommendations Perform eddy current inspections define in engine shop manual at piece part opportunity • FPI alone may not find all cracks

Retire high cycle thermal shields • Especially those manufactured with tight clearances (pre-1997) … thermal shield serial numbers that begin with “BTA” GE Proprietary Information Subject to restrictions on the cover or first page

54 3/29/2017

CF6-80C2 HPT S1 Blade Improvement SB 72-1444 in Dec.2010 / 1538M90P22 • •

Fillet radius increased to reduce stress

New High Chrome Corrosion Coating applied to the shank

New design fills in pockets and lowers stress

Increased wall thickness reduces stress in regions where corrosion related cracking occurs and reduces pocket that traps dirt

• Addresses Aft Damper Pocket Scrap cause by reducing the stress at this location

Ref. C.I. No. 30

Baseline Redesign

Shortened AFT seal body lugs

• Four (4) visual changes to blade are introduced with new blade design 1. 2. 3. 4.

Convex and Concave platform to shank fillet radius is increasing Aft shank has a machined dimple Bottom of dovetail root is rounded off Convex and concave aft seal body lugs is shorter

Dimple Rounded root bottom

GE Proprietary Information Subject to restrictions on the cover or first page

FWD 55 3/29/2017

CF6-80C2 Bleed Flow Sensor (PMC Engines)

Ref. C.I. No. 31

Service Bulletin 75-0202 (Category 3)

G01 Sensor housings cracking in high cycle fatigue (HCF) mode • Cause Fire Warnings, IFSD & Engine overheat message Contributing factors determined to be V-band clamp over-torque and duct misalignment leading to clamp yielding Corrective Action: • Material change from 300 series stainless steel to INCO 718 – Originally released as Cat 8, SB 72-1044 May 2001 – Cat 3 , SB 75-0202 issued July 2006 • Introduction of V-Band coupling standard practices GE Proprietary Information Subject to restrictions on the cover or first page

56 3/29/2017

CF6-80C/E Fan Liner Panels

Ref. C.I. No. 32

Field Plan: Cat 2 SB (area exposure) – Do at next C-Check or at next ESV if panels are not removed - Jan 2015 – Inspect per current AMM Shop Plan: Cat 5 SB ( piece part exposure) – Do at next shop visit if panel is removed- Jan 2015 •

Grading system used to assess current state of liner. Allows operator to determine if liner is repair or replace. GE Proprietary Information Subject to restrictions on the cover or first page

57 3/29/2017

CRF Oil Manifold Program Plan

Ref. C.I. No. 33

New Design Program Launched  Engineering Tech Review – 1Q 2014  Laboratory Shake Table Testing – June 2014  Detailed Design Review – July 2014  SB 72-1516 issued on September 1, 2015 GE Proprietary Information Subject to restrictions on the cover or first page

58 3/29/2017

CF6-80C2 Improved LPT Shrouds

Ref. C.I. No. 34

AD 2003-02-07… Service Bulletin S2-1006 LPT shrouds per SB 72-1006 provide the required improvement (stages 2, 3, and 4): • Address any future unknown / special causes of blade fragment liberation • Address the variation in compliance to the prime root cause programs • Airworthiness Directive (AD) 2003-02-07 was effective on the 3rd March 2003: – Mandates the incorporation of the LPT shrouds having the improved containment capability at next piece part exposure but no later than the 31st July 2010 – Stages 1 and 5 are not affected.

GE Proprietary Information Subject to restrictions on the cover or first page

59 3/29/2017

HPC Module, Stator: VSV S5 Long Lever Arm

Ref. C.I. No. 35

CF6-80C2 SB 72-1081; CF6-80E1 SB 72-0237 Improved Stage 5 lever arm system ~80% incorporated System is performing significantly better than old system GE recommends replacing lever arms at SV

New VSV System

• Issued 2003 with Revision in Sept. 2007 • Leading Indicators program to review improved reliability

New Stage 5 Lever Arm System is Performing Well GE Proprietary Information Subject to restrictions on the cover or first page

60 3/29/2017

11th Stage Air Tube – FADEC Engines CF6-80C - Service Bulletin 75-0156 for Post 75-0060 engines CF6-80C - Service Bulletin 75-0200 for Pre 75-0060 engines Ruptured 11th stage duct on original FADEC system

Twin pipe (PMC style) design

Ref. C.I. No. 37

The 11th stage air tubes on FADEC engines are changed to a twin pipe, PMC type design • Stress in the original FADEC system caused tube ruptures resulting in IFSD • The PMC style design is more reliable

Twin pipe 11th stage system has eliminated reliability issues GE Proprietary Information Subject to restrictions on the cover or first page

61 3/29/2017

HPT Module

Blade corrosion coating Tech CF6-80C2 New stage 2 blades: CF6-80C2 SB 72-1283

Ref. C.I. No. 39

S2 HPT blade with corrosion coatings • Reduces shank corrosion with no impact to performance • Reduces blade scrap rates… lowers overall lifecycle cost • Piece-part interchangeable with current design

Corrosion Coating GE Proprietary Information Subject to restrictions on the cover or first page

62 3/29/2017

HP Recoup Tube

Ref. C.I. No. 41

CF6-80C – Service Bulletin 75-0167 (FADEC) CF6-80C – Service Bulletin 75-0168 (PMC) Cracking and rupture of right side HP recoup air tube have caused high undercowl temperatures • Some resulted in in-flight shutdowns • Caused by high cycle fatigue A bracket and retaining strap are added at the CRF/HPT flange • This new bracket supports the HP recoup air tube and eliminates HCF • The new hardware is easier to install Category 4 SB – do when part is exposed

GE Proprietary Information Subject to restrictions on the cover or first page

63 3/29/2017

CRF Module – AFLAS O-Rings Ref. C.I. No. 42

CF6-80C2 SB 72-1107 CF6-80E1 SB 72-0314

Oil wetting is sometimes seen on the CRF case, external tubes and heat shield at the 6:00 location • Problem may be due to “crystallized” Orings in the B-sump area

AFLAS material was chosen as best combination of performance and cost • Result of CF6-80C2 Field Service Evaluation (FSE) Program that was conducted to identify valid O-ring materials that were more tolerant of high temperatures

GE Proprietary Information Subject to restrictions on the cover or first page

64 3/29/2017

HPT Stage 1 Disk Inner Transition Radius Erosion Current Released Programs - In718 Rotors

Ref. C.I. No. 43

CF6-80C2 - Service Bulletin 72-0816 Background

Erosion PTSN: PCSN: P/N: S/N:

Baffle installed in disk

42769 Hours 6682 Cycles 1531M84 RPMCM155

• SB 72-0816, issue Aug 2005 • One configuration fits field disks and new production components • Flow baffle can be installed either way (no “fwd” mark required) • No effect on life limiting locations of disk • No impact on the chapter 5 disk lives in the engine manual • A one run expendable component • New HPT stage 1 disk design (SB 721313) eliminates inner transition feature so it is not subject to erosion

GE Proprietary Information Subject to restrictions on the cover or first page

65 3/29/2017

Fan Case Corrosion

CF6-80C2 – Service Bulletin 72-1196 Fan Case P/N 1821M34G10/11 is latest design

Ref. C.I. No. 44

Increasing reports of corrosion: • OD where Kevlar cover meets the Al fan case • ID under forward outer liners and/or doubler plates • Some operators have reported more than others due to corrosion awareness Recommend taking preventive corrosion measures at next SV, Green Polyurethane protection on ID and OD of case G10/G11 Design Improvements: • Polyurethane added to ID and OD for additional protection between forward flange and Kevlar containment • Doublers are zinc-chromate coated for corrosion resistance 66 3/29/2017

HPT S2 Seal Body

Ref. C.I. No. 45

The 80C fleet has reported >20 broken & liberated seal body since 2005

Old

New

• Shop Visit Findings • UERs - BSI findings of blades or N2 Vibes

Liberated material can cause damage to adjacent hardware • Stage 2 HPT Blade Airfoil • Thermal Shield • Stage 2 Disk

Old

Failure Causes • Broken Tab • Cracking in high stress area

Design Changes Address: • Stress • Retention Tab Durability

New

Peak stress locations Peak stress locations

Part Numbers • P/N 1957M35P05 • P/N 1957M35P06

Hardware now available SB72-1527 GE Proprietary Information Subject to restrictions on the cover or first page

Page 67