MRO || QUESTIONS WITH COMPLETE
SOLUTIONS!!
GP7200 Air Turbine Starter correct answers GP7200 ATS Oil Seal has a history of 'coking'
Lift off seal has improved performance, but some low time removals due to coking
Project is implementing a non-contact 'restrictor ring'
This Teflon ring configuration has extensive history
Teflon ring will avoid coking due to the non-contact design
We have an accepted design
A field implementation of the seal change has been developed, but we want this to ONLY be
done at Emirates (>80% of the fleet)
This situation necessitates two SB: one for Emirates, one for everyone else
Hardware is on order
Program concerns:
GP7200 ATS Program Concerns correct answers Program concerns:
Second SB is not in scope, not in budget
We need GE to fund the second SB, as a SB specific to a field implementation was not part of
our scope
Spend is high on this program, we cannot afford the cost of additional SB
Working with Anniston, Tempe and RAU to insure adequate capacity, but EA and Emirates
wants an 18 month schedule...that means 30/month
GP7200 ATS Design correct answers Design
• Drawing has been released in Honeywell system, awaiting EA approval expected at the end
of Oct.
• Every time I speak with EA, and they push for all of the above requests, they come back to
"well you have to support the customer". What they weren't aware of, and I informed them of
at the WTT, is that Emirates has yet to pay for a repair of a -5 unit that had coking present -
HON has covered all cost (over $2mil as I last remember) of repairs/overhauls
• Emirates continues to claim that the -4 to -5 mod didn't fix the problem, despite the fact as
Ghiya said that the intent was never to entirely eliminate coking
o Based on Emirates data:
TSO (-4): 5857 hrs (21 units in data)
TSO (-5): 12036 hrs (25 units in data)
If you were able to make it through all that rambling and have questions let me know.
GP7200 ATS SB Options (from CJ) correct answers Service Bulletin
• Presented criteria for Emirates to be able to perform mod yesterday to the EA team
o To avoid additional risk Honeywell recommends performing upgrade in Authorized Service
Centers. However, if adherent coke is only present on the seal rotor and the seal assembly
then the modification is possible at Emirates. Small traces of coke in the oil is not means of
concern as long as the system is flushed with oil.
, • 2 options currently being discussed on releasing design to the field
o Release 2 SBs
• General SB released to field that outlines shop procedure in breaking the starter open and
performing the modification. This SB can only be performed at HON Authorized Service
Center
• Limited Release SB just to Emirates, which outlines the work that Emirates will perform
within their shop to replace the seal/rotor.
*This is the plan I like best, because we don't have to inform the other operators at all that a
field modification is available - BUT we do not have funding for 2 SBs, so we would need to
claim scope change to EA and ask for $$$ to write 2nd SB.
o Release SB & CMM
• SB would be released to all operators, but would have workscope to perform the mod in the
field. We would need to write in something to preclude operators other than EK to perform
the work - "Significant tooling and training required", or something, but based on what I
know of Middle East operators we will have a hard time deterring them with statements like
that.
• CMM - either TR or actual revision, to include and show installation of new parts, which
could then be used at an Authorized shop. Concern on this item is timing associated, as
anything related to the CMM usually takes significantly longer than SB release.
• EA wants to release as Cat 2 ("Do as soon as possible without effect on revenue service or
before specific end date"
GP7200 Rotables Situation from CJ correct answers Rotables
• EA has requested a total of 30 rotables in the field to support the 30 units/mo we will have
to mod. Interesting to note here that their perception is we should be providing ALL rotables,
and operators should not have to contribute anything...
o Current Status - 10 past due retables at Emirates, none available for other operators
• Argument from EA and Emirates is that the 10 rotables previously supplied were enough to
allow for the last mod to take place over 3 years, with a fleet of half the size - so they think
they need more...
• We have been pushing EA to agree that Emirates is under provisioned
o EA initial provisioning, based on current fleet size, shows EK should have ~21 rotables, but
does not take into account all the outstations (line stations)
o HON initial provisioning (which isn't really used anymore) shows they should have ~44 to
support all their operations
• Emirates operations map (may be a bit outdated) below
•
• EA is not aware that we are currently pursuing a PBC with Emirates, which may require us
to support a number of these rotables.
GP7200 ATS Hardware from CJ correct answers Hardware
• Approval from CSB to enter demand at risk (as EA has not approved dwg) for 80 pc of 2
new components needed for MOD
o Breakdown of Parts
• Production - 12 units
• PROs (from EA or BA) - 8 units
• Unclear now as to whether we would be able to pre-build -6 ATS to provide as advanced
exchanges (as EA requested), but should be able to support PRO returns for upgrade
• AM - 60 units
SOLUTIONS!!
GP7200 Air Turbine Starter correct answers GP7200 ATS Oil Seal has a history of 'coking'
Lift off seal has improved performance, but some low time removals due to coking
Project is implementing a non-contact 'restrictor ring'
This Teflon ring configuration has extensive history
Teflon ring will avoid coking due to the non-contact design
We have an accepted design
A field implementation of the seal change has been developed, but we want this to ONLY be
done at Emirates (>80% of the fleet)
This situation necessitates two SB: one for Emirates, one for everyone else
Hardware is on order
Program concerns:
GP7200 ATS Program Concerns correct answers Program concerns:
Second SB is not in scope, not in budget
We need GE to fund the second SB, as a SB specific to a field implementation was not part of
our scope
Spend is high on this program, we cannot afford the cost of additional SB
Working with Anniston, Tempe and RAU to insure adequate capacity, but EA and Emirates
wants an 18 month schedule...that means 30/month
GP7200 ATS Design correct answers Design
• Drawing has been released in Honeywell system, awaiting EA approval expected at the end
of Oct.
• Every time I speak with EA, and they push for all of the above requests, they come back to
"well you have to support the customer". What they weren't aware of, and I informed them of
at the WTT, is that Emirates has yet to pay for a repair of a -5 unit that had coking present -
HON has covered all cost (over $2mil as I last remember) of repairs/overhauls
• Emirates continues to claim that the -4 to -5 mod didn't fix the problem, despite the fact as
Ghiya said that the intent was never to entirely eliminate coking
o Based on Emirates data:
TSO (-4): 5857 hrs (21 units in data)
TSO (-5): 12036 hrs (25 units in data)
If you were able to make it through all that rambling and have questions let me know.
GP7200 ATS SB Options (from CJ) correct answers Service Bulletin
• Presented criteria for Emirates to be able to perform mod yesterday to the EA team
o To avoid additional risk Honeywell recommends performing upgrade in Authorized Service
Centers. However, if adherent coke is only present on the seal rotor and the seal assembly
then the modification is possible at Emirates. Small traces of coke in the oil is not means of
concern as long as the system is flushed with oil.
, • 2 options currently being discussed on releasing design to the field
o Release 2 SBs
• General SB released to field that outlines shop procedure in breaking the starter open and
performing the modification. This SB can only be performed at HON Authorized Service
Center
• Limited Release SB just to Emirates, which outlines the work that Emirates will perform
within their shop to replace the seal/rotor.
*This is the plan I like best, because we don't have to inform the other operators at all that a
field modification is available - BUT we do not have funding for 2 SBs, so we would need to
claim scope change to EA and ask for $$$ to write 2nd SB.
o Release SB & CMM
• SB would be released to all operators, but would have workscope to perform the mod in the
field. We would need to write in something to preclude operators other than EK to perform
the work - "Significant tooling and training required", or something, but based on what I
know of Middle East operators we will have a hard time deterring them with statements like
that.
• CMM - either TR or actual revision, to include and show installation of new parts, which
could then be used at an Authorized shop. Concern on this item is timing associated, as
anything related to the CMM usually takes significantly longer than SB release.
• EA wants to release as Cat 2 ("Do as soon as possible without effect on revenue service or
before specific end date"
GP7200 Rotables Situation from CJ correct answers Rotables
• EA has requested a total of 30 rotables in the field to support the 30 units/mo we will have
to mod. Interesting to note here that their perception is we should be providing ALL rotables,
and operators should not have to contribute anything...
o Current Status - 10 past due retables at Emirates, none available for other operators
• Argument from EA and Emirates is that the 10 rotables previously supplied were enough to
allow for the last mod to take place over 3 years, with a fleet of half the size - so they think
they need more...
• We have been pushing EA to agree that Emirates is under provisioned
o EA initial provisioning, based on current fleet size, shows EK should have ~21 rotables, but
does not take into account all the outstations (line stations)
o HON initial provisioning (which isn't really used anymore) shows they should have ~44 to
support all their operations
• Emirates operations map (may be a bit outdated) below
•
• EA is not aware that we are currently pursuing a PBC with Emirates, which may require us
to support a number of these rotables.
GP7200 ATS Hardware from CJ correct answers Hardware
• Approval from CSB to enter demand at risk (as EA has not approved dwg) for 80 pc of 2
new components needed for MOD
o Breakdown of Parts
• Production - 12 units
• PROs (from EA or BA) - 8 units
• Unclear now as to whether we would be able to pre-build -6 ATS to provide as advanced
exchanges (as EA requested), but should be able to support PRO returns for upgrade
• AM - 60 units
