CFM56-7 Hydromechanical Unit
**** Hidden Message ***** This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 267<BR>WTT CFM56-7B - Seattle<BR>May 2004<BR>CFM56-7 Hydromechanical Unit<BR>CFM56-7 HMU<BR>Reliability & Support<BR>• Fleet Statistics<BR>• Removal Drivers<BR>• Modification Effectiveness<BR>• Performance Analysis<BR>• Field Support<BR>Bob Chojnacki<BR>Manager, Customer & Product Support (Honeywell)<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 269<BR>Fleet Statistics - Operational Impact<BR>HHMMUURReelliiaabbiilliittyyiissCCrriittiiccaallttooDD&&CCRRaattee<BR>SOURCE: GE/CFMI SMART2000 Database<BR>Delays and Cancellations<BR>HMU Caused<BR>Feb 1998 through Mar 2004<BR>173<BR>100 97<BR>71<BR>66<BR>41 39<BR>31 30<BR>25<BR>20 20<BR>12<BR>4 4 2 2<BR>0<BR>20<BR>40<BR>60<BR>80<BR>100<BR>120<BR>140<BR>160<BR>180<BR>200<BR>HPSOV<BR>TBV DMD and POS Disagree (SAC)<BR>FMV POS Out of Range<BR>FMV POS Disagree<BR>Unknown<BR>VBV Current Out of Range<BR>TBV DMD and POS Disagree (DAC)<BR>Vibration<BR>Leak<BR>No Start/Hung Start<BR>Flameout Uncommanded Throttle<BR>LPTACC DMD and POS Disagree<BR>Engine Control Light<BR>Precautionary<BR>Service Bulletin<BR>No Fault<BR>Mech Ovespd Protec Out of Range<BR>* * * * * * * * *<BR>* Denotes modification in place<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 270<BR>0<BR>2,000<BR>4,000<BR>6,000<BR>8,000<BR>10,000<BR>12,000<BR>14,000<BR>16,000<BR>18,000<BR>Apr-00<BR>Jun-00<BR>Aug-00<BR>Oct-00<BR>Dec-00<BR>Feb-01<BR>Apr-01<BR>Jun-01<BR>Aug-01<BR>Oct-01<BR>Dec-01<BR>Feb-02<BR>Apr-02<BR>Jun-02<BR>Aug-02<BR>Oct-02<BR>Dec-02<BR>Feb-03<BR>Apr-03<BR>Jun-03<BR>Aug-03<BR>Oct-03<BR>Dec-03<BR>Feb-04<BR>P08<BR>"New HPSOV"<BR>(Feb-02)<BR>P09<BR>"FMV/TBV/BSV"<BR>(Jun-03)<BR>P07<BR>"Rumble"<BR>(May-99)<BR>Fleet Statistics - Reliability Performance<BR>RReelliiaabbiilliittyyPPeerrffoorrmmaanncceeCCoonnttiinnuueessttooIImmpprroovvee<BR>MTBUR: 15,266 hrs.<BR>MTBUR = (12 Month Flight Hours) / (12 Month Removals)<BR>“On-wing”<BR>HPSOV Switch<BR>Replacements<BR>(Mar-00)<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 271<BR>CFM56-7 HMU - Time to First Removal<BR>PPoossiittiivveeTTrreenndd<BR>Average Hours at First HMU Removal<BR>0<BR>1,000<BR>2,000<BR>3,000<BR>4,000<BR>5,000<BR>6,000<BR>7,000<BR>8,000<BR>9,000<BR>10,000<BR>1998 1999 2000 2001 2002 2003 2004<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 272<BR>3012<BR>177<BR>300<BR>P07/P08<BR>New P09<BR>Upgraded to P09<BR>70,000<BR>336,000<BR>27,844,000<BR>Total Fleet<BR>3,489 HMU抯<BR>28,250,000 Hours<BR>( 86%)<BR>( 9%)<BR>( 5%)<BR>Fleet Statistics - Fielded Configurations<BR>CFM56-7 HMU Fleet<BR>By Part Number<BR>CFM56-7 HMU Fleet<BR>By Part Number<BR>CFM56-7 HMU Fleet hours<BR>By Part Number<BR>CFM56-7 HMU Fleet hours<BR>By Part Number<BR>EEaarrllyyiinn““PP0099””PPeenneettrraattiioonn<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 273<BR>• High Pressure Shutoff Valve (HPSOV) Switch<BR>• Wire Chafing Resulting in Wrap Faults<BR>• Burner Staging Valve (BSV) &Main Staging Valve (MSV) Faults<BR>• Fuel Leakage<BR>– Increased Removals Partially Due to AFSO Switch Replacement<BR>• Fuel Metering Valve (FMV) Feedback Faults<BR>– Fuel Metering Valve Resolver<BR>• Demand / Feedback Faults<BR>– Transient Bleed Valve (TBV) EHSV<BR>CFM56-7 HMU Removal Drivers<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 274<BR>0<BR>10<BR>20<BR>30<BR>40<BR>50<BR>60<BR>70<BR>80<BR>Jan-00<BR>Mar-00<BR>May-00<BR>Jul-00<BR>Sep-00<BR>Nov-00<BR>Jan-01<BR>Mar-01<BR>May-01<BR>Jul-01<BR>Sep-01<BR>Nov-01<BR>Jan-02<BR>Mar-02<BR>May-02<BR>Jul-02<BR>Sep-02<BR>Nov-02<BR>Jan-03<BR>Mar-03<BR>May-03<BR>Jul-03<BR>Sep-03<BR>Nov-03<BR>Jan-04<BR>Mar-04<BR>0<BR>100,000<BR>200,000<BR>300,000<BR>400,000<BR>500,000<BR>600,000<BR>700,000<BR>800,000<BR>Unknown / Misc.<BR>Chafing / Wrap Fault<BR>BSV<BR>Leakage<BR>HPSOV Switch<BR>DMD/FDBK (TBV)<BR>FMV F/B<BR>Monthly Usage (Right Axis)<BR>CFM56-7 HMU - Removal Drivers<BR>RReemmoovvaallssDDeeccrreeaassiinnggDDeessppiitteeIInnccrreeaasseeddUUttiilliizzaattiioonn<BR>Monthly Removals<BR>(12 Month Rolling Average)<BR>Monthly Removals<BR>(12 Month Rolling Average)<BR>Monthly Removals<BR>Monthly Usage (hours)<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 275<BR>Removal Driver - HPSOV Switch<BR>• Indication: “ENG VLV CLSD” light bright on shutdown<BR>• Issue: “Sticking” of the Reed & Contact<BR>– SPDT switch reed always in contact during flight<BR>– Pump vibration (20KHz) = resonant frequency of reed switch<BR>• Impact: D&C & Removal<BR>• Monthly Failures (Peak): ~70 per month<BR>• Containment Action: FOC on-wing replacement support<BR>– 10 day MEL reduced D&C’s and HMU Removals<BR>– Allowed operators to schedule replacement<BR>• Modification Action: Introduced SPST Switch (Feb 2002)<BR>– Eliminated reed contact in flight<BR>– Required change to P-5 panel in the cockpit<BR>– FOC on-wing replacement support<BR> HON FSE’s performed<BR> Trained operators to perform themselves<BR> Performed at repair facility on request<BR>““OOnn--wwiinngg””rreeppllaacceemmeenntt rreedduucceeddiimmppaacctt ttooooppeerraattiioonnss<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 276<BR>0<BR>5<BR>10<BR>15<BR>20<BR>25<BR>30<BR>35<BR>40<BR>Jan-00<BR>Mar-00<BR>May-00<BR>Jul-00<BR>Sep-00<BR>Nov-00<BR>Jan-01<BR>Mar-01<BR>May-01<BR>Jul-01<BR>Sep-01<BR>Nov-01<BR>Jan-02<BR>Mar-02<BR>May-02<BR>Jul-02<BR>Sep-02<BR>Nov-02<BR>Jan-03<BR>Mar-03<BR>May-03<BR>Jul-03<BR>Sep-03<BR>Nov-03<BR>Jan-04<BR>Mar-04<BR>0<BR>100,000<BR>200,000<BR>300,000<BR>400,000<BR>500,000<BR>600,000<BR>700,000<BR>800,000<BR>HPSOV Switch<BR>Monthly Usage (Right Axis)<BR>Allowed<BR>On-wing<BR>Switch<BR>Replacement<BR>SPST Switch<BR>Introduction<BR>HPSOV Caused Delays by Year<BR>12<BR>26<BR>40<BR>49<BR>21<BR>1<BR>0<BR>10<BR>20<BR>30<BR>40<BR>50<BR>60<BR>1999 2000 2001 2002 2003 2004<BR>HPSOV Caused Delays by Year<BR>12<BR>26<BR>40<BR>49<BR>21<BR>1<BR>0<BR>10<BR>20<BR>30<BR>40<BR>50<BR>60<BR>1999 2000 2001 2002 2003 2004<BR>Monthly Removals<BR>揘on-HMU?Causes for Switch Removals:<BR>•P5-2 Card Issue<BR>•Harness & Connectors<BR>•Throttle Quadrant Switches<BR>•Circuit Breakers<BR>揘on-HMU?Causes for Switch Removals:<BR>•P5-2 Card Issue<BR>•Harness & Connectors<BR>•Throttle Quadrant Switches<BR>•Circuit Breakers<BR>Monthly Usage (hours)<BR>Effectiveness Review - HPSOV Switch<BR>HHPPSSOOVVSSwwiittcchhIIssssuueeRReessoollvveedd<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 277<BR>Removal Driver - Wire Chafing<BR>• Indication: Various Fault Codes (Dependent on signal shorted)<BR>Visual Inspection during HPSOV change<BR>• Issue: Sub-optimal wire bundling<BR>• Impact: D&C & Removal<BR>• Monthly Removals (Peak): 11 per month<BR>• Modification Action: Introduced wire retention bracket and<BR>shortened wire lengths (Sep 2001)<BR>– Provided FOC at next shop return<BR>New bracket<BR>Wire tiedowns<BR>IImmpprroovveeddAAsssseemmbbllyyPPrroocceessssCCoonnttrrooll<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 278<BR>0<BR>5<BR>10<BR>15<BR>20<BR>25<BR>30<BR>35<BR>40<BR>Jan-00<BR>Mar-00<BR>May-00<BR>Jul-00<BR>Sep-00<BR>Nov-00<BR>Jan-01<BR>Mar-01<BR>May-01<BR>Jul-01<BR>Sep-01<BR>Nov-01<BR>Jan-02<BR>Mar-02<BR>May-02<BR>Jul-02<BR>Sep-02<BR>Nov-02<BR>Jan-03<BR>Mar-03<BR>May-03<BR>Jul-03<BR>Sep-03<BR>Nov-03<BR>Jan-04<BR>Mar-04<BR>0<BR>100,000<BR>200,000<BR>300,000<BR>400,000<BR>500,000<BR>600,000<BR>700,000<BR>800,000<BR>Chafing / Wrap Fault<BR>Monthly Usage (Right Axis)<BR>Allowed<BR>On-wing<BR>Switch<BR>Replacement<BR>SPST Switch<BR>Introduction<BR>Improved<BR>Wire<BR>Retention<BR>Monthly Removals<BR>Monthly Usage (hours)<BR>Effectiveness Review - Wire Chafing<BR>CChhaaffiinnggRReemmoovvaallsshhaavveeSSttaabbiilliizzeedd<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 279<BR>Removal Driver - BSV/MSV Solenoid<BR>• Indication: BSV Failed Open (SAC Engines)<BR>MSV Failed Closed (DAC Engines)<BR>• Issue: Built-in contamination caused intermittent “sticky”<BR>solenoid actuation & reduced force margin<BR>• Impact: Aborted Take-off, D&C & Removal<BR>• Monthly Removals (Peak): 7 per month<BR>• CFMI Action: Dual Channel Solenoid Excitation (7.B.N Software)<BR>• Containment Action: BSV Solenoids replaced with overhauled<BR>solenoid when removed for cause (May 2002 - Jun 2003)<BR>– Overhauled solenoids have a modified cleaning procedure<BR>– Returned for cause replaced regardless of confirmation<BR>– Operator must provide appropriate fault code<BR>• Modification Action: Improved BSV / MSV Solenoid - Increased<BR>force margin (June 2003)<BR>– Provided FOC if failed at next shop visit<BR>– Provided FOC if returned with appropriate fault code<BR>– SIL No. 8 provides discount for proactive replacement<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 280<BR>Effectiveness Review - BSV/MSV<BR>BBSSVVSSoolleennooiiddIIssssuueeRReessoollvveedd<BR>0<BR>5<BR>10<BR>15<BR>20<BR>25<BR>30<BR>35<BR>40<BR>Jan-00<BR>Mar-00<BR>May-00<BR>Jul-00<BR>Sep-00<BR>Nov-00<BR>Jan-01<BR>Mar-01<BR>May-01<BR>Jul-01<BR>Sep-01<BR>Nov-01<BR>Jan-02<BR>Mar-02<BR>May-02<BR>Jul-02<BR>Sep-02<BR>Nov-02<BR>Jan-03<BR>Mar-03<BR>May-03<BR>Jul-03<BR>Sep-03<BR>Nov-03<BR>Jan-04<BR>Mar-04<BR>0<BR>100,000<BR>200,000<BR>300,000<BR>400,000<BR>500,000<BR>600,000<BR>700,000<BR>800,000<BR>BSV<BR>Monthly Usage (Right Axis)<BR>Began 100%<BR>BSV/MSV Solenoid<BR>Replacement if Fault<BR>Code Provided<BR>Introduced<BR>New BSV<BR>Solenoid<BR>CFM56-7 T/O Aborts Due To BSV<BR>2 2<BR>9<BR>2<BR>0 0 0<BR>2<BR>4<BR>6<BR>8<BR>10<BR>1999 2000 2001 2002 2003 2004<BR>CFM56-7 T/O Aborts Due To BSV<BR>2 2<BR>9<BR>2<BR>0 0 0<BR>2<BR>4<BR>6<BR>8<BR>10<BR>1999 2000 2001 2002 2003 2004<BR>CFMI Introduced<BR>7.B.N Software<BR>Monthly Removals<BR>Monthly Usage (hours)<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 281<BR>Removal Driver - Leakage<BR>• Indication: Fuel discovered in switch cavity<BR>External Inspection of HMU<BR>• Issue: Insufficient o-ring squeeze - Metering Valve (MV) Set Screw<BR>• Impact: D&Cs & Removals<BR>• Monthly Removals (Peak): 12 per month<BR>• Modification Action: Introduced MV Set Screw & Leak Check<BR>(Jun 2003)<BR>– Decreased groove depth on the set screw<BR>– Introduced low pressure leak check into acceptance test<BR>Original Metering<BR>Valve Set Screw<BR>Modified Metering<BR>Valve Set Screw<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 282<BR>0<BR>5<BR>10<BR>15<BR>20<BR>25<BR>30<BR>35<BR>40<BR>Jan-00<BR>Mar-00<BR>May-00<BR>Jul-00<BR>Sep-00<BR>Nov-00<BR>Jan-01<BR>Mar-01<BR>May-01<BR>Jul-01<BR>Sep-01<BR>Nov-01<BR>Jan-02<BR>Mar-02<BR>May-02<BR>Jul-02<BR>Sep-02<BR>Nov-02<BR>Jan-03<BR>Mar-03<BR>May-03<BR>Jul-03<BR>Sep-03<BR>Nov-03<BR>Jan-04<BR>Mar-04<BR>0<BR>100,000<BR>200,000<BR>300,000<BR>400,000<BR>500,000<BR>600,000<BR>700,000<BR>800,000<BR>Leakage<BR>Monthly Usage (Right Axis)<BR>Allowed<BR>On-wing<BR>Switch<BR>Replacements<BR>SPST Switch<BR>Introduction<BR>Switch Cavity<BR>Wetting<BR>Allowance<BR>External leakage due to<BR>搇ife-limited fluorosilicone seals<BR>will be covered in<BR>Engineering Initiatives<BR>External leakage due to<BR>搇ife-limited fluorosilicone seals<BR>will be covered in<BR>Engineering Initiatives<BR>Modified MV<BR>Set Screw<BR>Introduction<BR>Monthly Removals<BR>Monthly Usage (hours)<BR>Effectiveness Review - Leakage<BR>SSwwiittcchhCCaavviittyyLLeeaakkaaggeeAAddddrreesssseedd<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 283<BR>Removal Driver - FMV Feedback<BR>• Indication: FMV signal out of range or channel disagreement<BR>Engine Control Light<BR>• Issue: FMV Feedback channel tracking & voltage signal anomalies<BR>• Impact: D&Cs & Removals<BR>• Monthly Removals (Peak): 21 per month<BR>• Containment Action (Resolver): FMV Resolver replaced with new when<BR>removed for cause (May 2002 - Jun 2003)<BR>– Resolver replaced with new regardless of confirmation<BR>– Operator must provide appropriate fault code<BR>• Modification Action (Linkage): FMV Linkage Modifications (Sep 2002)<BR>– Tightened tolerances & reduced the potential for binding<BR>– 100% incorporation at next shop visit<BR>• Modification Action (Resolver): New part number introduced with<BR>design/process modifications (Jun 2003)<BR>– Provided FOC if failed at next shop visit<BR>– Provided FOC if returned with appropriate fault code<BR>– SIL No. 8 provides discount for proactive replacement<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 284<BR>FMV Faults - Resolver Related<BR>Estimated P09 Impact Prior to Incorporation of Change<BR>UNCONFIRMED<BR>60% CONFIRMED<BR>38%<BR>CONFIRMED<BR>(Unknown Causes)<BR>2%<BR>ALREADY<BR>ADDRESSED VIA<BR>DESIGN CHANGES<BR>30%<BR>ADDRESSED BY<BR>ECP 4866<BR>8%<BR>7.B.O.<BR>Temperature<BR>Compensation for<BR>Out-of-Range<BR>Faults May<BR>Reduce<BR>Unconfirmed<BR>Removals<BR>11 Independent<BR>Class 2 changes:<BR>Improved Resolver<BR>magnet wire<BR>robustness & FMV<BR>linkage<BR>Class I change (P09)<BR>Two (2) additional changes<BR>to further improve magnet<BR>wire longevity.<BR>8%<BR>CONFIRMED<BR>(Known Causes)<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 285<BR>Effectiveness Review - FMV Resolver<BR>IImmpprroovveeddFFMMVVRReessoollvveerrRReelliiaabbiilliittyy<BR>0<BR>5<BR>10<BR>15<BR>20<BR>25<BR>30<BR>35<BR>40<BR>Jan-00<BR>Mar-00<BR>May-00<BR>Jul-00<BR>Sep-00<BR>Nov-00<BR>Jan-01<BR>Mar-01<BR>May-01<BR>Jul-01<BR>Sep-01<BR>Nov-01<BR>Jan-02<BR>Mar-02<BR>May-02<BR>Jul-02<BR>Sep-02<BR>Nov-02<BR>Jan-03<BR>Mar-03<BR>May-03<BR>Jul-03<BR>Sep-03<BR>Nov-03<BR>Jan-04<BR>Mar-04<BR>0<BR>100,000<BR>200,000<BR>300,000<BR>400,000<BR>500,000<BR>600,000<BR>700,000<BR>800,000<BR>FMV F/B<BR>Monthly Usage (Right Axis)<BR>Began 100%<BR>FMV Resolver<BR>Replacement<BR>if Fault Code<BR>Provided<BR>CFMI Introduced<BR>7.B.O Software<BR>揟emp Compensation Introduced<BR>Modified<BR>Resolver<BR>Monthly Removals<BR>Monthly Usage (hours)<BR>Introduced<BR>FMV Linkage<BR>Modifications<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 286<BR>Removal Driver - TBV EHSV<BR>• Indication: TBV Demand / Feedback Disagree &<BR>Engine Control Light<BR>• Issue: Vibration-induced fretting wear of armature due to contact with<BR>stop screw<BR>– Results in EHSV “latching” in energized or de-energized positions<BR>• Impact: D&Cs and Removals<BR>• Monthly Removals (Peak): 19 per month<BR>• Containment Action: TBV EHSV replaced with zero-time overhauled<BR>EHSV when removed for cause (May 2002 - Jun 2003)<BR>– ESH replaced with new regardless of confirmation<BR>– Operator must provide appropriate fault code<BR>• Modification Action: Addition of feedback wire<BR>eliminated armature contact (Jun 2003)<BR>– Provided FOC if failed at next shop visit<BR>– Provided FOC if returned with appropriate fault code<BR>– SIL No. 8 provides discount for proactive replacement<BR>Area of dimpling wear:<BR>fretting between armature<BR>and stop screws (both sides)<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 287<BR>Effectiveness Review - TBV EHSV<BR>CClloosseellyyMMoonniittoorriinnggNNeewwTTBBVVEEHHSSVVPPeerrffoorrmmaannccee<BR>0<BR>5<BR>10<BR>15<BR>20<BR>25<BR>30<BR>35<BR>40<BR>Jan-00<BR>Mar-00<BR>May-00<BR>Jul-00<BR>Sep-00<BR>Nov-00<BR>Jan-01<BR>Mar-01<BR>May-01<BR>Jul-01<BR>Sep-01<BR>Nov-01<BR>Jan-02<BR>Mar-02<BR>May-02<BR>Jul-02<BR>Sep-02<BR>Nov-02<BR>Jan-03<BR>Mar-03<BR>May-03<BR>Jul-03<BR>Sep-03<BR>Nov-03<BR>Jan-04<BR>Mar-04<BR>0<BR>100,000<BR>200,000<BR>300,000<BR>400,000<BR>500,000<BR>600,000<BR>700,000<BR>800,000<BR>DMD/FDBK (TBV)<BR>Monthly Usage (Right Axis)<BR>Began 100%<BR>TBV EHSV<BR>Replacement if<BR>Fault Code<BR>Provided<BR>Introduced<BR>New TBV<BR>EHSV<BR>TBV DM B Po sitio n Disag re e Cau se d De lays b y Y e ar<BR>3 2<BR>7<BR>20<BR>52<BR>16<BR>0<BR>10<BR>20<BR>30<BR>40<BR>50<BR>60<BR>199 9 2000 200 1 200 2 2003 2004<BR>TBV DM B Po sitio n Disag re e Cau se d De lays b y Y e ar<BR>3 2<BR>7<BR>20<BR>52<BR>16<BR>0<BR>10<BR>20<BR>30<BR>40<BR>50<BR>60<BR>199 9 2000 200 1 200 2 2003 2004<BR>Monthly Removals<BR>Monthly Usage (hours)<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 288<BR>Field Performance - P09 Configuration<BR>P09 Removals to Date<BR>WWiillllCCoonnttiinnuueettooMMoonniittoorrPP0099PPeerrffoorrmmaanncceeCClloosseellyy<BR>• Pareto of removals: 14 HMUs<BR>– 16 occurrences<BR> Two had multiple failures<BR>– 3 confirmed<BR> FMV 73-20341 fault (rotor magnet<BR>wire open within windings)<BR> 2 mechanical overspeed protection<BR>signal out of range (isolated to dirty<BR>magnet retainer and installation<BR>damage of OSG switch)<BR>– 13 unconfirmed<BR> 3 FMV feedback faults: (1) x034n,<BR>(1) x035n, (1) both x034n & x035n<BR> 2 TBV demand/feedback faults<BR> 2 external leaks<BR> 2 engine control lights<BR> 1 each: N1 split, flame-out<BR>protection signal, VSV wrap fault,<BR>HPSOV bright after start<BR>~ 247 OE HMUs fielded (380 shipped)<BR>~ 177 R&O HMUs fielded<BR>Est. 396,000 hours accumulated to date on P09<BR>P09 Removal Pareto<BR>0<BR>1<BR>2<BR>3<BR>4<BR>FMV F/B<BR>TBV DMD F/B<BR>External Leak<BR>OSG Signal OOR<BR>ECL<BR>N1 Split<BR>Flame-Out Protect...<BR>VBV Wrap Fault<BR>AFSO Light Bright ...<BR>Unconfirmed<BR>Confirmed<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 289<BR>MTBUR Assessment<BR>HMU Reliability Assessment & Projection<BR>• HMU MTBUR trending up from<BR>12,000 hours<BR>– MTBUR numbers include all<BR>removals except “precautionary”<BR>• MTBUR projection for CFM56-7<BR>HMU incorporating latest and<BR>proposed ECPs<BR>– Projections derived using a<BR>Crowe-AAMSA (Duane growth)<BR>curve<BR>– Projections are estimates based<BR>on known failure modes with<BR>constant failure rates based on<BR>the latest monthly removal rates<BR>– P09 and P11 projected to drive to<BR>20,000 hour MTBUR within 4 and<BR>3 years, respectively<BR>P07 & P08 - ‘recent’ incorporations = wire grid & SPST switch<BR>P09 = FMV resolver module, TBV EHSV, BSV solenoid modifications<BR>P10 = proposed BSV solenoid elimination<BR>P11 = proposed fluorocarbon fuel-to-air seals<BR>CFM56-7 MTBUR<BR>0<BR>1000<BR>2000<BR>3000<BR>4000<BR>5000<BR>6000<BR>7000<BR>8000<BR>9000<BR>10000<BR>11000<BR>12000<BR>13000<BR>14000<BR>15000<BR>16000<BR>17000<BR>18000<BR>19000<BR>20000<BR>7/24/1998<BR>2/9/1999<BR>8/28/1999<BR>3/15/2000<BR>10/1/2000<BR>4/19/2001<BR>11/5/2001<BR>5/24/2002<BR>12/10/2002<BR>6/28/2003<BR>1/14/2004<BR>8/1/2004<BR>2/17/2005<BR>9/5/2005<BR>3/24/2006<BR>10/10/2006<BR>4/28/2007<BR>Month/Year<BR>MTBUR (Hours)<BR>Projected: No Changes<BR>Duane Growth Model<BR>12 Month Actual<BR>Projected: 'P09 Changes<BR>Projected: 'P0' and P11<BR>Crowe AAMSA Model - MTBUR to Date and Projected<BR>Actual 12 Month MTBUR<BR>Crow-AAMSA Model<BR>P08<BR>P11<BR>Target 20,000 EFH to 1st Overhaul<BR>P09<BR>CCFFMM5566--77HHMMUURReelliiaabbiilliittyyEExxcceeeeddiinnggPPrroojjeeccttiioonnss<BR>Field Support<BR>• SIL 8 Provisions<BR>• Support Locations<BR>• Customer Management<BR>• R&O Performance (PEI)<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 291<BR>Service Information Letter 8 - Overview<BR>What’s Included:<BR>• Free of Charge (FOC) Replacement of TBV EHSV, FMV Resolver<BR>and BSV/MSV Solenoid upon failure<BR>– Coverage for failures includes “in the field” or “in the shop”<BR>– Replaced with new design parts<BR>– FOC regardless of HMU warranty status<BR>– FOC regardless of failure confirmation<BR> Corresponding fault code(s) must be provided<BR>• Discounted HMU overhaul (zero-time restoration) price<BR>– Price reduced 16.4% from $38.3K to $32K<BR>– Includes incorporation of the (3) product modifications<BR>– Includes all previous service bulletins (as required)<BR>• Discounted pricing for proactive incorporation of modifications.<BR>– Priced for rapid return on airline investment.<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 292<BR>SIL 8 - Pricing for Proactive Modification<BR>Modification<BR>Included<BR>Customer<BR>Price<BR>(USD)<BR>Comment<BR>FMV Resolver Only 3,707 FOC if returned for an FMV fault<BR>TBV EHSV Only 6,619 FOC if returned for an TBV fault<BR>BSV Solenoid Only 3,379 FOC if returned for an BSV fault<BR>TBV FOC<BR>(FMV & BSV Charge) 5,500 TBV is FOC if the HMU is returned for a TBV fault<BR>FMV FOC<BR>(TBV & BSV Charge) 7,800 FMV is FOC if the HMU is returned for a FMV fault<BR>BSV FOC (FMV & TBV Charge) 7,800 BSV is FOC if the HMU is returned for a BSV fault<BR>FMV & TBV Only<BR>(BSV disabled) 7,800 Option for operators with the BSV disabled<BR>All 3<BR>(Returned for other reason) 9,500 Price for all 3 on a proactive basis<BR>PPrriicceeBBrreeaakkddoowwnnAAlllloowwssffoorrCCuussttoommiizzeeddIInnccoorrppoorraattiioonn<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 293<BR>0<BR>20<BR>40<BR>60<BR>80<BR>100<BR>120<BR>140<BR>160<BR>Jul-03<BR>Aug-03<BR>Sep-03<BR>Oct-03<BR>Nov-03<BR>Dec-03<BR>Jan-04<BR>Feb-04<BR>Mar-04<BR>Apr-04<BR>May-04<BR>Jun-04<BR>Jul-04<BR>Aug-04<BR>Units<BR>Receipts<BR>Shipments<BR>Backlog<BR>Forecast<BR>Year End Goal (Backlog/Year End Goal (Backlog/UUnniittssIInn--HHoouussee)):: 2200UUnniittss<BR>CFM56-7 HMU - R&O Performance (PEI)<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 294<BR>0<BR>10<BR>20<BR>30<BR>40<BR>Aug-03<BR>Sep-03<BR>Oct-03<BR>Nov-03<BR>Dec-03<BR>Jan-04<BR>Feb-04<BR>Mar-04<BR>Apr-04<BR>May-04<BR>Jun-04<BR>Jul-04<BR>Aug-04<BR>Days in House<BR>Monthly<BR>Target<BR>CFM56-7 HMU - R&O Performance (PEI)<BR>YYeeaarrEEnnddGGooaall((DDaayyssiinnHHoouussee//TTAATT)):: 1100DDaayyss<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 295<BR>SR Technics<BR>Zurich, Swit<BR>KLM Technik<BR>Amsterdam<BR>Lufthansa Technik<BR>Hamburg<BR>Prince Edward Island<BR>Canada<BR>Xaimen<BR>China<BR>Legend-<BR>HON Owned Operational Facilities<BR>HON Owned Non-Certified Facilities<BR>3rd Party Operational Facilities<BR>3rd Party Non-Certified Facilities<BR>SR Technics<BR>Zurich, Swit<BR>KLM Technik<BR>Amsterdam<BR>Lufthansa Technik<BR>Hamburg<BR>Prince Edward Island<BR>Canada<BR>Xaimen<BR>China<BR>Legend-<BR>HON Owned Operational Facilities<BR>HON Owned Non-Certified Facilities<BR>3rd Party Operational Facilities<BR>3rd Party Non-Certified Facilities<BR>Support Center Locations<BR>This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not,<BR>in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved 296<BR>CFM56-7 HMU Reliability Modifications aarreeEEffffeeccttiivvee<BR>CFM56-7 HMU Performance Summary<BR>• R&O Support Performance Continues to Improve<BR>• HPSOV Switch Issue - Resolved<BR>• Wire Chafing Issue - Stabilized<BR>• BSV/MSV Issue - Resolved<BR>• Fuel Leakage Issues<BR>– HPSOV Switch Cavity Related - Resolved<BR>– Life-Limited Fluorosilicone Seals Related - Alternative Pending<BR>• FMV Feedback Faults<BR>– Fuel Metering Valve Resolver Related - Resolved<BR>– FMV System Level Related - Addressed/Watch<BR>• Demand / Feedback Faults<BR>– Transient Bleed Valve (TBV) EHSV - Addressed/Watch :victory: :victory: CFM56-7 Hydromechanical Unit
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