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    72.61.00.045 26-MAR-2020 08-DEC-2021 Closed A319-100N, A320-200N, A321-200N, A321-200NX, A321-200NY 72-61 Iae LLC Pratt & Whitney TFU Update

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    jivomir
    Fractures were found in the main gearbox of some aircraft, including the main oil pump/integrated drive generator gear. The fractures were from high cycle fatigue caused by higher excitation at a specific engine speed during flight. Software and hardware changes were made to address this, including modifying gear geometry to reduce responses and adjusting engine control software to minimize time at critical frequencies. The changes have been incorporated through production and retrofits.

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    72.61.00.045 26-MAR-2020 08-DEC-2021 Closed A319-100N, A320-200N, A321-200N, A321-200NX, A321-200NY 72-61 Iae LLC Pratt & Whitney TFU Update

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    jivomir
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    Fractures were found in the main gearbox of some aircraft, including the main oil pump/integrated drive generator gear. The fractures were from high cycle fatigue caused by higher excitation at a specific engine speed during flight. Software and hardware changes were made to address this, including modifying gear geometry to reduce responses and adjusting engine control software to minimize time at critical frequencies. The changes have been incorporated through production and retrofits.

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    72.61.00.045

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    Fractures were found in the main gearbox of some aircraft, including the main oil pump/integrated drive generator gear. The fractures were from high cycle fatigue caused by higher excitation at a specific engine speed during flight. Software and hardware changes were made to address this, including modifying gear geometry to reduce responses and adjusting engine control software to minimize time at critical frequencies. The changes have been incorporated through production and retrofits.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    117 views9 pages

    72.61.00.045 26-MAR-2020 08-DEC-2021 Closed A319-100N, A320-200N, A321-200N, A321-200NX, A321-200NY 72-61 Iae LLC Pratt & Whitney TFU Update

    Uploaded by

    jivomir
    Fractures were found in the main gearbox of some aircraft, including the main oil pump/integrated drive generator gear. The fractures were from high cycle fatigue caused by higher excitation at a specific engine speed during flight. Software and hardware changes were made to address this, including modifying gear geometry to reduce responses and adjusting engine control software to minimize time at critical frequencies. The changes have been incorporated through production and retrofits.

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    © All Rights Reserved
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    of 9

    PW1100G-JM: Main Gearbox events - MOP/IDG Gear Fracture

    Reference: 72.61.00.045 Issue date: 26-MAR-2020 Last check date: 08-DEC-2021 Status: Closed
    A/C type/serie: A319-100N, A320-200N, A321-200N, A321-200NX, A321-200NY ATA: 72-61
    Engine manufacturer: IAE LLC Supplier: PRATT & WHITNEY
    Purpose / Reason for revision: TFU update
    Engineering Support Status: Closed

    Description / Operational Impact

     Operators reported commanded In-flight Shut-Down or


    Rejected Take-Off end of 2018 and in 2019, with OIL LO PR
    ECAM warning.
     Metal chips found in MGB magnetic chip collectors.
     Damage to the main gearbox, including fractures of the Main
    Oil Pump (MOP)/Integrated Drive Generator (IDG) Gear.

    Root Cause / Investigation Terminating Action

     Fracture features are consistent with High Cycle Fatigue (HCF) EEC Keep out Zone (FCS5.0 – AI SB 73-1136)
     No manufacturing or material anomalies found.  EEC software logic to minimize time spent at critical frequencies
     Root cause testing completed: the MOP/IDG gear shows a high
    level of gear responses observed during flight with higher New MOP/IDG Gear (P&W SB 72-00-0129)
    excitation at 18,900 rpm, with levels consistent with gear  Gear hardware modifications to de-tune responses.
    failure mode.  Production incorporation (A/C level) since Q4 2019.
     MRO Incorporation since July 2019.
     On-wing incorporation for non-ETOPS operators: P&W training
    available, contact P&W.
    Additional Information

    1. Description

    There have been reported In-flight Shut-Down events and Rejected Take-Offs with OIL LO PR ECAM warning, end of 2018 and in
    2019. Metal chips were found in MGB magnetic chip collectors.
    Damage to the external main gearbox, including fractures of the Main Oil Pump (MOP)/Integrated Drive Generator (IDG) Gear.

    2. Consequence

    Gear fracture can lead to OIL LO PR ECAM Warning. Per Flight Operations procedure, the engine shutdown is commanded by pilots.

    3. Investigation Status

    Fracture features are consistent with High Cycle Fatigue (HCF).


    No manufacturing or material anomalies were found
    Root cause testing was completed in February 2019 (Instrumented Gearbox testing).

    The MOP/IDG gear shows a high level of gear responses observed during flight with higher excitation at 18,900 rpm, with
    levels consistent with gear failure mode.

    4. Mitigation / Interim Plan


    Airbus and PW explained that this gear fracture is not predictable with aircraft/engine data, and repetitive inspection of gear is not
    considered.

    5. Maintenance Information

    When this event occurs, an engine replacement is required. In case of re-installation of the IDG and EDP, below actions are
    recommended:
    1- For IDG (ATA24), the inspection of the IDG/QAD installation prior IDG removal is recommended.
    A check of QAD tension bolt (torque and distance) before IDG removal is also recommended as follows: AMM task 24-21-41-200-
    802-A Torque Check of the IDG Quick Attach/Detach (QAD) Adapter Tension-Bolt.

    2- For the EDP (ATA29), the inspection of the EDP shaft/spline and the four corners where it is fixed on the AGB is recommended
    before its re-installation on another engine. Then, after re-installation on engine, the AMM task 29-13-51-860-001-A shall be
    performed as required by AMM task 71-00-51-400-802-A, Installation of Powerplant.

    6. Repercussions on A/C Operations

    Commanded In-Flight is required as per FCOM PRO-ABN-ENG.


    In-Flight Turn-Back or Diversion can be performed by crew.

    7. Permanent Solutions

    EEC Keep out Zone


    • EEC software logic to minimize time spent at critical frequencies (Flight tested in Airbus).
    • Introduced through EEC FCS5.0 – Available through AI SB 73-1136 and P&W SB 73-00-0037.
    • EIU S4.1 (Airbus SB 73-1132) is a pre-requisite of EEC FCS5.0.

    New MOP/IDG Gear


    • Gear hardware modifications have been released that allows to de-tune responses:
    • The rim & web thickness of the MOP/IDG gear are being increased to improve the durability of the gear.
    • This post-MOD gear was flight tested on Airbus Flight Test aircraft.

    • MRO Incorporation has started since July 2019 through P&W SB 72-00-0129.
    • On-wing retrofit was completed for ETOPS operators to comply with the FAA AD. On-wing retrofit for non-ETOPS operators has been studied
    and will be available by 4Q 2019: the airlines can contact P&W to attend trainings at P&W Training Centre; and to get the P&W
    material/documentation to allow this change.

    • Production incorporation (A/C level) since Q4 2019. POE available in the P&W SB.

    Each of above modifications is aimed at preventing HCF fracture separately.

    FAA Airworthiness Directive – FAA AD 2019-11-08


    • PW AOC-042 provides more information.
    • From 28 June 2019,
    • FCS 5.0 must be incorporated within
    • 120 days for engines without new gear.
    • ETOPS – New Gear must be incorporated within
    • 90 days for 180 minute operation
    • 120 days for 120 minute operation.

    FAA AD was superseded by FAA AD 2020-05-028 (effective date 21 APR 20):


    • FCS 5.0 must be incorporated within
    • 120 days from 28 JUN 19 or before further flight after the effective date of this AD, for engines without new gear.
    • ETOPS – New Gear must be incorporated
    • before further flight after the effective date of this AD, for 180 minute operation
    • withing 120 days from 28 JUN 2019 or before further flight after the effective date of this AD, for 120 minute
    operation.

    Survey for the Engineering Support section


    Retrofits Monitoring Status: Closed Retrofit Information Letter: YES
    AIRBUS Monitored Retrofit has ended.
    Standard commercial conditions from SB/VSB now apply.
    Please contact AIRBUS Warranty Manager or AIRBUS Customer Support Director for further support.
    For a complete list of monitored retrofits applicable to your fleet, please contact monitored.retrofit@airbus.com.
    Survey for the Retrofits Monitoring section
    Annex

    General Information
    Potential impact: Maintenance, Operational Reliability, Specific Operations - ETOPS/EDTO/Others
    Key information: In-Service Issue, Linked Items - MISP
    Solution benefit: Top Fleet Solution
    First issue date: 08-APR-2019 Issue date: 26-MAR-2020 Last check date: 08-DEC-2021

    Technical parameters
    ATA: 72-61
    A/C type/serie: A319-100N, A320-200N, A321-200N, A321-200NX, A321-200NY
    Engine: PW1127G-JM, PW1130G-JM, PW1133G-JM
    Engine manufacturer: IAE LLC
    Fault code/ECAM
    ENG 1 OIL LO PR, ENG 2 OIL LO PR
    warning:
    FIN: 1000EM1, 1000EM2
    Part Number:
    Supplier: PRATT & WHITNEY

    Attachments
    Retrofits Monitoring:
    - RIL SA73M19002740 R00.pdf

    Links
    N/A
    © Airbus SAS, 2021. All rights reserved. Confidential and proprietary document.The technical information provided in this article is for convenience and information purposes only. It
    shall in no case replace the official Airbus technical or Flight Operations data which shall remain the sole basis for aircraft maintenance and operation. These recommendations and
    information do not constitute a contractual commitment, warranty or guarantee whatsoever. They shall not supersede the Airbus technical nor operational documentation; should
    any deviation appear between this article and the Airbus or airline's official manuals, the operator must ensure to cover it with the appropriate document such as TA, FCD, RDAS.
    Access to WISE is supplied by Airbus under the express condition that Airbus hereby disclaims any and all liability for the use made by the user of the information contained in
    WISE. It shall be used for the user's own purposes only and shall not be reproduced or disclosed to any third party without the prior consent of Airbus.

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