UUL AIR PROPULSION TEST - NASA
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UUL AIR PROPULSION TEST TRENTON. NEW JERSEY O8628 NAPTC-PEjJ NASA-CR-t 135304 MAY 1977 ROTOR BURST PROTECTION PROGRAM: STATISTICS ON AIRCRAFT GAS TURBINE ENGINE ROTOR FAILURES THAT OCCURRED IN U.S. COMMERCIAL AVIATION DURING 1975 By R. A. DeLUCIA & G. J. MANGANO APPROVED FOR PUBLIC RELEASE: DISTRIBUTION UNLIMITED
Transcript of UUL AIR PROPULSION TEST - NASA
UUL AIR PROPULSION TESTTRENTON. NEW JERSEY O8628
NAPTC-PEjJNASA-CR-t
135304
MAY 1977
ROTOR BURST PROTECTION PROGRAM: STATISTICS ON AIRCRAFT
GAS TURBINE ENGINE ROTOR FAILURES THAT OCCURRED IN U.S.
COMMERCIAL AVIATION DURING 1975
By R. A. DeLUCIA & G. J. MANGANO
APPROVED FOR PUBLICRELEASE: DISTRIBUTIONUNLIMITED
UNCLASSIFIEDSECURITY CLASSIFICATION OF THIS PAGE (When De»« Entered)
REPORT DOCUMENTATION PAGE READ INSTRUCTIONSBEFORE COMPLETING FORM
1.. REPORT NUMBER
NAPTC-PE-106
2. GOVT ACCESSION NO 3. RECIPIENT'S CATALOG NUMBER
4. TITLE (end SubtlHe)
ROTOR BURST PROTECTION PROGRAM: STATISTICS ONAIRCRAFT GAS TURBINE ENGINE ROTOR FAILURES THATOCCURRED IN U. S. COMMERCIAL AVIATION DURING 1975
S. TYPE OF REPORT ft PERIOD COVERED
Final Report, 1974-1975
6. PERFORMING ORG. REPORT NUMBER
t. CONTRACT OR GRANT NUMBER^;
NASA DPR C-41581-B, Mod. 6
7. AUTHORf*;
R. A. DeLucia and G. J. Mangano
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Commanding OfficerNaval Air Propulsion Test Center (PE42)Trenton, New Jersey 08628"
10. PROGRAM ELEMENT, PROJECT, TASKAREA « WORK UNIT NUMBERS
None
11. CONTROLLING OFFICE NAME AND ADDRESS
National Aeronautics and Space AdministrationLewis Research CenterCleveland. Ohio 44135
12. REPORT DATEMay 1977
13. NUMBER OF PAGES
3014. MONITORING AGENCY NAME & AODRESSfff dlfferonf from Controlling Office; IS. SECURITY CLASS, (ol thlm report)
UNCLASSIFIEDI3«. DECLASSIFICATION/DOWNGRADING
SCHEDULE
16. DISTRIBUTION STATEMENT (ol Oil* Report;
APPROVED FOR PUBLIC RELEASE: DISTRIBUTION UNLIMITED
17. DISTRIBUTION STATEMENT (ol ttie fbttrtct entered In Block 30, It dl/ferenf tram Report;
IB. SUPPLEMENTARY NOTES
Aerospace Safety Research and Data Institute, Lewis Research CenterCleveland, Ohio 44135, Advisor, A. G.. Holms." 'Other report 'designation: NASA-CR-
19. KEY WORDS (Continue on r»v»r*» tldf II n»c*tt*ry mtd
Aircraft HazardsAircraft SafetyGas Turbine Engine Rotor Failures
block number;
20. ABSTRACT (Continue on nvnte eld* II nec*mm*tr and Identify by Mock number;
DD 1 JAN 73 1473 EDITION OP 1 MOV 65 18 OBSOLETES/N 0102-014-6601 | -
UNCLASSIFIEDSECURITY CLASSIFICATION OF THIS PAOE (When DM* Altered;
UNCLASSIFIEDCLASSIFICATION OF THIS PAGEfWhm Dmlm Bnt«*d;
UNCLASSIFIEDSECURITY CLASSIFICATION OF THIS
NAVAL AIR PROPULSION TEST CENTER
TRENTON, NEW JERSEY 08628
PROPULSION TECHNOLOGY AND PROJECT ENGINEERING DEPARTMENT
NAPTC-PE-106 . MAY 1977
135304
ROTOR BURST PROTECTION PROGRAM: STATISTICS ON AIRCRAFT
GAS TURBINE ENGINE ROTOR FAILURES THAT OCCURRED IN U. S.
COMMERCIAL AVIATION DURING 1975
Prepared by:R. A. DeLUCi
Approved by:'R. K. BRUMWELLCommander, USNDirector, PE
APPROVED FOR PUBLIC RELEASE;DISTRIBUTION UNLIMITED
AUTHORIZATION: NASA DPR C-41581-B, MOD. 6
NAPTC-PE-106
ACKNOWLEDGEMENTS
We thank the Flight Standards National Field Office, Federal Aviation
Administration, Oklahoma City, Oklahoma, for their cooperative effort
in providing the basic data used for this report.
TABLE OF CONTENTS
REPORT DOCUMENTATION PAGE — DD Form 1473
TITLE PAGE
TABLE OF CONTENTS.
LIST OF FIGURES
INTRODUCTION . ,
RESULTS
CONCLUSIONS . :
Figures 1 through 6
APPENDIX A
DISTRIBUTION LIST
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Page
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ii
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3
4-9
A-l to A-14
Inside rear cover
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LIST OF FIGURES
Figure No. Title Page
1 Incidence of Rotor Failure/Burst in 4Commercial Aviation - 1975
2 Component and Fragment Type Distribution 5for Contained and Uncontained Rotor *Bursts - 1975
3 The Incidence of Rotor Burst in '6Commercial Aviation According toEngine Type Affected - 1975
4 • • Rotor Failure/Burst Cause Categories - 71975
5 Flight Condition at Rotor Failure/Burst - 81975
6 The Incidence of Uncontained Rotor Burst 9in U. S. Commercial Aviation -1962-1975
ii
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INTRODUCTION
This report has been prepared as part of the Rotor Burst ProtectionProgram (RBPP),'which is sponsored by the National Aeronautics andSpace Administration (NASA)l and conducted by the Naval Air PropulsionTest Center (NAPTC). The objective of the RBPP is to develop criteriafor the design of devices that will be used on aircraft to protectpassengers and the aircraft structure from the lethal and devastatingfragments that are generated-by gas turbine engine rotor bursts.
Presented in this report are statistics on gas turbine rotorfailures that, have occurred in U. S. commercial aviation during 1975.These statistics are based on data compiled from the Flight StandardsService Difficulty Reports (SDR) that were published by the Departmentof Transportation, Federal Aviation Administration (FAA). The compileddata were analyzed to establish:
1. The incidence of rotor failures and the number of containedr\
and uncontained rotor bursts.
. 2. The distribution of rotor bursts with respect to enginerotor component; i.e., fan, compressor or turbine.
3. The type of rotor fragment (disk, rim or blade) typicallygenerated at burst.
4. The cause of failure.
5. The type of engines involved.
6. The flight condition at the time of failure.
RESULTS
1. "The data used for analysis are contained in APPENDIX A. The resultsof these analyses are shown in Figures 1 through 6.
a. Figure 1 shows that 193 rotor failures occurred in 1975.These rotor failures accounted for approximately 8.4% of the 2305shutdowns experienced by the gas turbine powered U. S. commercialaircraft fleet during 1975. Rotor fragments were generated in 104
DPR C-41581-B, Mod. 6
2An uncontained rotor burst is defined as a rotor failure that producesfragments which penetrate and escape the confines of the engine casing.
NAPTC-PE-106
of the failures experienced and, of these, 14 (13.5% of the rotorbursts) were uncontained. This represents an uncontained rotorburst rate of 2.4 per million gas turbine engine powered aircraftflight hours, or 0.73 per million engine operation hours. 'Approximately6.0 million and 19.2 million aircraft flight and engine operatinghours, respectively, were logged by the U. S. commercial aviationfleet in 1975. Because of the potentially catastrophic consequenceof such bursts, these rates are considered to be significantly high.
b. Figure 2 shows the distribution of rotor bursts (rotorfailures that produced fragments) according to the engine componentinvolved — fan, compressor, turbine; the types of fragments that weregenerated; and the percentage of uncontained failures according to thetype fragment generated. These data indicate that:
(1) The incidence of turbine rotor burst was slightly morethan twice that of compressor rotor burst; these corresponded to65.4% and 30.8%, respectively, of the total number of rotor bursts.Fan rotor bursts accounted for 3.8% of the bursts experienced.
(2) Blade fragments were generated in 90.4% of the rotor bursts;7.4% of these were uncontained. The remaining rotor bursts (9.6%)produced disk, rim and seal fragments, of which 70% were uncontained.
c. Figure 3 shows the rotor burst distribution among the typesof engines that were affected, and the total number of engines in useof the type that experienced rotor failures. It appears that the morerecently introduced, larger turbofan engines have experienced thehighest rate of rotor burst.
d. Figure 4 shows what caused the rotor failures to occur. Ofthe known causes of failure*, the dominant causal factors were: (1)Foreign Object Damage (42.6%); (2) Secondary Causes (36.4%); and (3)Design and Life Prediction Problems (18.6%).
e. Figure 5 shows the flight conditions that existed when thevarious rotor failures or bursts occurred. Approximately 81% of the193 rotor failures occurred during the takeoff, climb, and cruisestages of flight. Eighty-seven percent of the rotor bursts, andapproximately 79% of the uncontained rotor bursts, occurred duringthese same stages of flight. The highest percentage of uncontainedrotor bursts (43%) were experienced during climb.
f. Figure 6 shows the annual incidence of uncontained rotor burstsin commercial aviation for the years 1962 through 1975. There appearsto be a decreasing trend in the incidence of uncontained rotor failures
*Because of the high .percentage of unknown causes of rotor failure/burst, the analysis was based on the total number of known causes.
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during the past three years. The rate of uncontalnment with respect toengine operating hours has also decreased during this same period(1.2, 1.1 and 0.73 uncontained bursts per million engine operatinghours for the years 1973, 1974 and' 1975) .
CONCLUSIONS ;
1. The incidence of rotor failure and uncontained burst is stillsignificantly high enough to warrant continuation of the experimentaland analytical efforts that constitute the Rotor Burst ProtectionProgram.
2. Of all the types of fragments generated at rotor burst, disk andfan blade fragments, because of their size, high energy content andhigh rate of uncontainment, continue to be the major threat that mustbe addressed in the RBPP.
3. The number of uncontained blade failures has diminished during1975 but is still surprisingly high considering that, under FAAregulations, rotor blade containment is required for enginecertification.
4. It appears that causes beyond the control or scope of presenttechnology such as FOD, structural life and integrity prediction,and secondary effects, are still primarily responsible for most ofthe rotor failures that occur. . ,
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, APPENDIX. A
Data on Rotor Failures in U. S. Commercial Aviation
for 1975. Compiled from the Federal Aviation
Administration Service Difficulty Reports.
A-l
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DATA COMPILATION KEY;
Submitter Code (single letters only)
A - Air Carrier Operator
B - Certificated Repair Station
C.- Operator
D - Mechanic ..
E - Air Taxi Operator .
F - Manufacturer
G - FAA Inspector
H - Other
Component Code;
F - Fan
C - Compressor
T - Turbine
Fragment Type Code;
D - Disk
R - Rim
B - Blade
S - Seal
N - None
A-2
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Cause Code;
1 - Design and Life Prediction Problems
2 - Secondary Causes
3 - Foreign Object Damage
4 - Quality Control
5 - Operational
6 - Assembly and Inspection Error
7 - Unknown
Containment Condition Code:
C - Contained
NC - Not Contained
Flight Condition Code: . .
1 - -Insp/Maint
2 - Taxi/Grnd Hdl
3 - Takeoff
4 - Climb
5 - Cruise
6 - Descent
7 - Approach
8 - Landing
9 - Hovering
10 - Unknown
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DISTRIBUTION LIST
Activity Copies
Commander, Naval Air Systems Command (AIR-50174), Department 9of the Navy, Washington, DC 20361
Intra-command Addressees:
AIR-330A (1) AIR-5361 (1)AIR-530 (1) AIR-5362 (1)AIR-536 (1) MAT-03L (1)AIR-5360 (1) AIR-330 (1)
Commander, Naval Air Development Center, Warminster, PA 118974
Commanding Officer, Naval Air Engineering Center, 1Lakehurst, NJ 08733
Commanding Officer, Naval Aviation Safety Center, 1Naval Air Station, Norfolk, VA 23511
Director, Eustis Directorate, U. S. Army Air Mobility Research 1and Development Laboratory (SAVDL-EU-TAP), Fort Eustis,VA 23604
Commanding General, U. S. Army Aviation Systems Command 1(AMSAV-ERP), 12th and Spruce Streets, St. Louis, MO 63166
Commander, Air Force Aero-Propulsion Laboratory (AFSC), 1Wright-Patterson Air Force Base, Ohio 45433
National Aeronautics and Space Administration (MS6-2, 12MS49-1, MS60-3, MS5-5, MS3-19, MS500-302), Lewis ResearchCenter, 21000 Brookpark Road, Cleveland, OH 44135
National Aeronautics and Space Administration (RF, R0(2), 4RLC), Washington, DC 20546
Federal Aviation Administration (RD-723), Washington, 1DC 20553
Defense Documentation Center for Scientific and Technical 12Information, Building No. 5, Cameron Station,Alexandria, VA 22314
Aeroelastic Laboratory, Massachusetts Institute of 4Technology, Cambridge, MA 02139
