PHENOM 300 TECHNICAL SESSION - Embraer Jet / Welcome€¦ · PHENOM 300 TECHNICAL SESSION SAMUEL...

PHENOM 300

TECHNICAL SESSION

SAMUEL PECCI | OCTOBER 14th, 2011

AGENDA PHENOM TECHNICAL SESSION

Electrical system contactors

Starter generator update

Pratt & Whitney Canada updates

Engine start failures

Engine inlets

Flap system updates

Tire wear update

Subject

Air Management System (AMS)

Ice and rain protection system

Brake system updates

TECHNICAL ITEMS

New Solutions for Phenom 300:

Cabin Evaporator Module

Flow Control and Shut-off Valve (FCSOV)

Air Management System Controller (AMS CTRL)

AIR MANAGEMENT SYSTEM

CABIN EVAPORATOR MODULEAIR MANAGEMENT SYSTEM

Description

Cabin evaporator module low reliability

CABIN EVAPORATOR MODULEAIR MANAGEMENT SYSTEM

Investigation

Module was subject to failure due to low reliability of fan’s controller

Solution

More robust controller for the module (new P/N -4)

Action plan

SB 505-21-0004, “Replacement of the cabin evaporator”, issued on September 30, 2011

SB with retrofit campaign

FLOW CONTROL SHUTOFF VALVE

(FCSOV)


Description

FCSOV -2 has been presenting CAS messages “ECS 1(2) VLV FAIL”


(FCSOV)


Investigation

Flow sensor robustness

Narrow margins for failure messages

Water ingression from bleed system


(FCSOV)


Solution

FCSOV -7 introduces a more robust flow sensor, but does not address narrow margins for failure messages

FCSOV -9 corrects margins for failure messages

Water separator installation in the bleed system cold line

Action plan

FCSOV -7: available via AIPC (September 2011), replacement on attrition

FCSOV -9: SB with retrofit campaign (December 2011)

Water separator: SB with retrofit campaign (December 2011)

AMS CONTROLLERAIR MANAGEMENT SYSTEM

Description

SB 505-36-0001, Replacement of the AMS controller, introduced improved hardware for controller -202

Factory incorporated from S/N 505-00021

Retrofit campaign ongoing (82% - only 2 aircraft remaining)

CAS messages “BLEED 1(2) FAIL”

AMS CONTROLLERAIR MANAGEMENT SYSTEM

Investigation

CAS messages “BLEED 1(2) FAIL” are triggered due to logic to open/close the Fan Air Valve (FAV)

Solution

SB 505-36-0002, AMS controller software update, issued on June 07, 2011, introduces upgraded AMS controller -203 with software corrections to FAV open/close logic

Action plan

Factory incorporated from S/N 505-00050

SB with retrofit campaign (~28% done)






Engine inlets

Flap system updates

Tire wear update

Subject




WS HEATING CONTROL UNIT (WHCU)TECHNICAL ITEMS

Description

WHCU -2 presenting low reliability

WS HEATING CONTROL UNIT (WHCU)ICE & RAIN PROTECTION SYSTEM

Investigation

Root cause of issues is WHCU software (messages logic)

Solution

Improved part WHCU -3

Improved mechanical robustness

Correction of software logics (including CMC messages)

Action plan

Expected for December 2011







Engine inlets

Flap system updates

Tire wear update

Subject




TECHNICAL ITEMS

BRAKE SYSTEM UPDATES

New solutions for Phenom 300

Brake Control Unit (BCU) -7

Brake pedal modifications

P300 In Service Request - Tech Reports Related to Failure

1 1 1

2 2

4

7

2

3

2 2

3

1

0

2

4

6

8

10

12

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP

2010 2011

ISR

Qty

0.0%

1.0%

2.0%

3.0%

4.0%

ISR

pe

r C

yc

le (

%)

BRAKE INOP / FAIL BRAKE INOP / FAIL (% Per Cycle)


BRAKE CONTROL UNIT (BCU) -7

Description

BRK FAIL message on CAS, with associated loss of main brake system

BCU -06Retrofit

complete



Investigation

Events failure modes were different, but all traced to BCU

Interim solution: SB 505-32-0005, Replacement of the brake control unit (BCU DAP00100-03/-04/-05 to BCU DAP00100-06), issued on February 23, 2011

Improved monitors and control logic

Subject to OB 505-001/11, Landing distance factor recommendation



Solution

New BCU -7

Improved handling during brake application

Supersedes OB 505-001/11, landing distance factor recommendation

Action plan


Expected availability in or before December 2011


BRAKE PEDAL ASSEMBLY

Description

Reports of left/right tendency during main brake application

Investigation

Pedal ergonomics affects braking control

Same force applied to LH/RH pedals cause different pedal readings and different pressures applied to brakes



Solution

Modification of pedal position

Replacement of pedal feedback springs

Addition of a pedal end-of-course stop



Solution (cont.)

These modifications are complementary to SB 505-27-0003, “Modification of the pedal position transducer stops”, issued on October 14, 2010

Action plan

SB availability expected on or before December 2011







Engine inlets

Flap system updates

Tire wear update

Subject




TIRE WEAR UPDATE

Description

Premature tire removals

Investigation

Service Letter (SL) 505-32-0002 was issued on March 04, 2011, with the intent of collecting more information on tire changes

Tire service life is mainly dependent on operational aspects

TECHNICAL ITEMS

TIRE WEAR UPDATE

Investigation

TECHNICAL ITEMS

TIRES REPLACEMENT

0

25

50

75

100

125

150

175

200

225

250

Jun-10 Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11

MONTH

CY

CL

ES

CUT DEFLATED N/A VIBRATION WEAR

Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11

TIRE WEAR UPDATE

Investigation (cont.)

TECHNICAL ITEMS

TIRES REPLACEMENT

0

25

50

75

100

125

150

175

200

225

250

Jun-10 Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11

MONTH

CY

CL

ES

CUT DEFLATED N/A VIBRATION WEAR

Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11

TIRE WEAR UPDATE

Investigation (cont)

TECHNICAL ITEMS

TIRE WEAR UPDATE

Investigation

TECHNICAL ITEMS

Underinflation (%)

Tire s

erv

ice

life

(%)

Test conditions:

35,000ft taxi cycles at 40mph, at standard load, with different tire sizes

Source: Goodyear –

Aircraft Tire Care and

Maintenance (Out/2004)

TIRE WEAR UPDATE

Solution

TECHNICAL ITEMS

Original average tire life Tire care

recommend

ations

New SLs

500-32-0007

505-32-0003

Revised

removal

criteria

AMM revised

Sep/2010 May/2011






Engine inlets

Flap system updates

Tire wear update

Subject




FCE -1009

Investigation

FLAP FAIL messages caused by flap power drive unit (PDU) brake

FLAP SYSTEM UPDATES

FCE -1009

Solution

Flight Control Electronics (FCE) software and hardware upgraded

Action plan

Retrofit campaign

Expected availability 1Q2012

FLAP SYSTEM UPDATES






Engine inlets

Flap system updates

Tire wear update

Subject




ELECTRICAL SYSTEM CONTACTORS

Description

Contactors P/N SM400D117 low reliability

TECHNICAL ITEMS


Investigation

Reports of unusual behavior in the electrical system

Displays blanking out during engine starts

Aircraft not entering electrical emergency during pre-flight test

Hot/hung starts

Engine not starting

Conflicting indications in the system synoptic page

TECHNICAL ITEMS


Solution

Upgraded contactor P/N SM400D117-1

SB 505-24-0006 – Replacement of LPDU, RPDU and EPDU contactors, issued on August 26, 2011

Action plan

Retrofit campaign will resume by the end of October 2011 (supplier parts availability)

TECHNICAL ITEMS






Engine inlets

Flap system updates

Tire wear update

Subject




STARTER GENERATOR UPDATES

Description

Reports of failed starter-generators were received in the Phenom100 fleet

Investigation

During removal and inspection of P100 starter-generators, a supplier commutator brazing quality escape has been identified that affects the Phenom 300 starter-generators as well

TECHNICAL ITEMS


Interim solution

SB 505-24-A005 – Replacement of the starter-generators, issued June 28, 2011

Starter-generators below 350FH shall be replaced before they reach 400FH

Starter-generators above 350FH shall be replaced in the next 50FH

Parts availability is defined by Embraer in accordance with aircraft utilization. Highest-time aircraft will have priority for the replacement of starter-generators

TECHNICAL ITEMS


Final solution

New starter-generators are under development

Availability scheduled for 3Q2012

TECHNICAL ITEMS






Engine inlets

Flap system updates

Tire wear update

Subject




ENGINE INLET CRACKS

Description

During a walk around inspection, cracks and missing rivet heads were found on the lip skin of Engine Air Inlet

Embraer Air Safety Department conducted a Risk Assessment and determined that this issue does not affect safety

TECHNICAL ITEMS

ENGINE INLET CRACKS

Description (cont.)

Lip Skin - Internal Rivet Line - Crack

TECHNICAL ITEMS

ENGINE INLET CRACKS

Description (cont.)

Inner Barrel - Aft Rivet Line - Pulled Rivet

TECHNICAL ITEMS

ENGINE INLET CRACKS

Investigation

Several airplanes inspected, yielding:

Cracks on Lip Skin over rivet line;

Cracks on Inner Barrel (internal skin) over rivet line;

Pulled rivets on Lip Skin and Inner Barrel attachments.

Supplier’s assembly line was audited by an Embraer team (Quality and Design engineers) to determine the possible root causes;

Detected deviations in the assembly procedures were corrected

TECHNICAL ITEMS

ENGINE INLET CRACKS

Solution

Interim Solution

SB 505-71-0001, issued on Jan 11th, 2011, provides instructions for repetitive visual inspections to be done on theinternal part of the inlet for cracks or pulled rivets;Effectivity: 50500004 thru 50500061.

Embraer Technical Disposition that provides repair instructions for the forward rivet line of Inner Barrel (Internal Skin).

ENGINE INLET CRACKS

Solution (cont.)

Final Solution

Engine Air Inlet Modules manufactured with an improved process (new Part Numbers);

L/H � PN = 505-36920-405

R/H � PN = 505-36930-405

ENGINE INLET CRACKS

Action plan

SB 505-71-0003 (Jul 2011) – retrofit campaign;

Factory-installed from S/N 062;

AIPC Revision (Jul 2011);

AMM Revision (Jul 2011);

Revision of SB 505-71-0001 (Jul 2011).






Engine inlets

Flap system updates

Tire wear update

Subject




ENGINE START FAILURES

Description

Difficulties to start the engines (on ground)

Two possible scenarios

Engine does not respond to start command

Hot start

TECHNICAL ITEMS

ENGINE DOES NOT RESPOND

TO START COMMAND

Investigation

When a start attempt is requested, there is no response from theengine

Generator Control Unit (GCU) hangs in initialization - PBIT

Solution

New GCU under development by the supplier, expected for November 2011


ENGINE DOES NOT RESPOND

TO START COMMAND

Solution (cont.)

Interim solution (recommendation)

De-energize aircraft and disconnect Ground Power Unit (GPU) cable

Re-energize aircraft and attempt to start the engine again


HOT START

Probable causes

1: Battery 2 low charge

2: Generator Control Unit – GCU failed

3: Contactor failed


HOT START

Investigation – Battery 2 low charge

Start is slow with N2 values taking too long to rise

Fuel flow and ITT rise too fast, which may lead to an ENG EXCEEDANCE event

Interim solution

FOL PHE505-013/11, Battery recommendations

SL 505-24-002, Batteries best practices manual


HOT START

Solution

Perform functional check in accordance with AMM and if the batterydoes not pass, replace the battery


Ensure the battery voltage is within specification for engine starts(minimum 24V)


HOT START

Investigation – Generator Control Unit – GCU failed

Normal start, with fuel flow, N2 and ITT rising normally

N2 starts to drop and fuel flow and ITT increase rapidly, which maycause an ENG EXCEEDANCE event

Solution

Replace the GCU for one bearing the same part number


Until the final solution is available, contact Embraer for troubleshooting assistance. Embraer will need the CMC data (CVDR data will speed up analysis)







Engine inlets

Flap system updates

Tire wear update

Subject





Engine No Dispatch

Low Utilization Inspection (LUI)

Compressor wash recommendations

PRATT & WHITNEY CANADA

UPDATES

TECHNICAL ITEMS

ENGINE NO DISPATCH

Description

ENG NO DISPATCH CAS messages displayed

Investigation

On Avionics SW LOAD before version 4X ENG NO DISPATCH CAS message triggered by avionics logic.

Recent Issues related to FADEC HW (P&WC SB30438)

Solution

SB 505-31-0001, “Installation of G1000 load 43 avionics software and CMC load 9 software”, issued on February 17, 2011;

New Engine Electronic Control (EEC) hardware – P&WC SB30438

Action plan

Retrofit campaign ongoing

PRATT & WHITNEY CANADA UPDATES

LOW UTILIZATION INSPECTION (LUI)

Description

The PW535E Engine Maintenance Manual (EMM) requires Low Utilization Inspection (LUI) engines to be returned to an overhaul facility

Maintenance Update

On-wing Low Utilization Inspection (LUI) already available in the EMM. Additional requirements may be necessary based on inspection findings.


COMPRESSOR WASH

RECOMMENDATIONS

Resistance to corrosion and recommendations

P&WC position – All P&WC engines meet industry standards for corrosion protection.

P&WC corrosion mitigation recommendations are appropriate and based on FAA AC 43-4A are similar to other engine manufacturers

Maintenance updates

Engine Maintenance Manual is being revised (Nov ‘11) to eliminate need to disconnect P3 during desalination wash to reduce procedure cost.

Compressor wash recommendations updated to provide more clarity to operators and maintenance facilities.


THANK YOU!

PHENOM 300 TECHNICAL SESSION - Embraer Jet / Welcome€¦ · PHENOM 300 TECHNICAL SESSION SAMUEL...

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