Quarterly Review

October, 2008
C-17 APU Organic Capability
Contract
 Agenda
8:00 Welcome and Introductions
Contract Review
Progress Update
Power Section and Electrical
Component Module
Update
Technical Manual Update
Drawing Update
11:00 Open Discussion
12:00 Dismissal
2
 Attendees

• Triumph Air
Repair
• The Boeing
Company
• OO-ALC
• WR-ALC

3
 Contract Review

• Deliver Depot Level C-17 APU Maintenance

Capability at OO-ALC by June 2009
– Facility Modifications
– SE - Support Equipment
– TD - Technical Data
– MD&T - Maintenance Demonstration &
Training
– FA - First Article ( Validation / Verification )
– Drawings and Documentation

4
 Contract Review

• Facility Modifications
– Fuel-Oil-Pneumatic-APU
– Routing Utilities (power
& air supply)
– Floor space allocation
– Test Cell # 4
– Future – Electrical Dept.

5
 Contract Review

• Facility
Modifications -Test
Cell # 4
– Load Bank
– Start Power Unit
– Airflow Measuring
Section
– Inlet Air Handler &
air deflector
– Data Acquisition &
Control
– Software – Sytronics
6
–
 Contract Review

• Support Equipment
– Test Stands
– Test Adapters
– Overhaul Tools
– Shipping Containers
– COTS items
• Over 400 pieces of
SE designed/fabricated to
date + ~80 more for power
and electrical sections
7
 Contract Review

• Support
Equipment
– Test stands
• Maintenance
Stands
• Transport
Stands
• Oil Components
• Fuel
Components
• Pneumatic
Components
• Future - 8
 Contract Review

• Support
Equipment
– Test adapters
• Fuel
Components
• Oil Components
• Pneumatic
Components
• Test Cell dress
equipment
• Future -
Electrical
Components 9
 Contract Review

• Support
Equipment
– Overhaul tools
• Provided for all
oil, fuel,
pneumatic
components
• Provided for
engine test,
gearbox, load
compressor
modules
• Designed/most
10
ready to ship for
 Contract Review

• Support
Equipment
– Shipping
Containers
• Overall APU
• Modules–
Gearbox , Load
Compressor
• Line Replaceable
Units ( LRU’s )
• Power section
module
11
 Contract Review

• Support
Equipment
– COTS items
• Hand Tools
• Gages - measuring
• Exceptions per
“Responsibility
Matrix”

12
 Contract Review

• Technical Orders
• Derivative of existing
Component Maintenance
Manuals
• 23 T.O.’s produced and
accepted including APU,
gearbox, load compressor,
and fuel, oil, pneumatic
LRU’s
• Validation “built in” during
maintenance and
demonstration/1st Article
• Development of 14
additional T.O.’s in 13
progress
 Contract Review

• Maintenance
Demonstrations
& Training
– Hands on
training
– Onsite at Hill
AFB w/Triumph
lead technicians
and engineering
– Proper use of
tools
– Validation of 14
 Contract Review

• First Article
– Validation
and
Verification
– Acceptance
of
training/tech
data
– OO-ALC is
ready to
repair
– Final version 15
 Contract Review

• Drawings and
Documentati
on
– Support
Equipment
drawings
and
documentati
on delivered
to WR-ALC
following
OO-ALC 16
 Contract Review

• Engine
modules
– Fuel
Components
– Oil Components
– Gearbox
– Load
Compressor
– Pneumatic
Components
– Overall APU
– Power Section
– Electrical 17
Contract Review Questions?

18
Break

19
 Progress Report

• Completed
activities
– Gearbox Module:
• SE delivered Feb
2005
• TD delivered June
2005
• MD&T completed
June 2005
• FA completed Aug
2005
• Additional training 20
 Progress Report

• Completed
Activities
– Fuel Components
• SE delivered March
2005
• TD delivered Oct
2005
• MD&T completed
Nov 2005
• FA completed Dec
2005

21
 Progress Report

• Completed Activities
– Load Compressor
• SE delivered April
2006
• TD delivered March
2006
• MD&T completed May
2006
• FA completed June
2006
• Additional training
provided May 2008 22
 Progress Report

• Completed
Activities
– Oil Components
• SE delivered June
2006
• TD delivered June
2006
• MD&T completed
Aug 2006
• FA completed Sept
2006

23
 Progress Report

• Completed Activities
– Pneumatic
Components
• SE delivered Oct 2007
• TD delivered Sept 2007
• MD&T completed Dec
2007
• FA completed 01 Feb
08
• Delivery of Drawings
initial submittal
01 May 08
• OO-ALC Process
Engineer reviewed all
24
drawings 27 June 08
 Progress Report

• Completed Activities
– Overall APU
• SE delivered 07 Dec 08
• TD delivered 07 Dec 08
• MD&T completed 14
Mar 08
• FA completed 28 Mar
08
• Delivery of manual 30
May 08 – received 07
July 08
• Delivery of Drawings
initial submittal 15 July
08
25
 Power Section & Electrical
Components Update
• Power Section Module
– SE – Nov 2008
– TD - Nov 2008
– MD&T – Jan 2009 [12 weeks]
– FA - April 2009 [12 weeks]
• Electrical Components
– SE - Dec 2008
– TD - Dec 2008
– MD&T – Jan 2009 [4 weeks]
– FA – Feb 2009 [4 weeks]

26
 Power Section Module Status

• Special Tooling
– Design – 100%
completed
– Fabrication – 90%
completed
– Design/Fab
Verified – 75 %
completed
– Drawings @ 80%
– Tech data @ 50%

27
 Electrical Components Status

• Electrical
Components
– Starter Motor
Run-In Stand
– Starter Dyno Test
Stand
– Wiring Harness
Test Stand

28
 Electrical Components Status

• Electrical
Components
– Starter
Motor Run-In
Stand
– Starter Dyno
Test Stand
– Wiring
Harness Test
Stand

29
 Electrical Components Status

• Electrical
Components
– Starter Motor
Run-In Stand
– Starter Dyno Test
Stand
– Wiring Harness
Test Stand

30
 Technical Order Update

• Complete engine overhaul requires 37 technical

orders
– All are identified and catalogued by WR-ALC
– 23 are compete/in the system/in use
– Remaining 14 submitted to Boeing
• Minimum 50% complete
• Major changes completed in Gearbox and Load
Compressor manuals
– Will be submitted 10/08
• Annual in-house review program established to
ensure currency
– Program shown on next three slides
31
 T.O. Review/Change Log (Page 1 of
3)
Annual
Review Month T.O. Number T.O. Title Latest Version Change # Review Comments

Jan 2G-GTCP331-3 OVERALL APU 30-May-08 0

APU TEST CELL FAULT
Jan 2G-GTCP331-3-12-2 MATRIX 50% Submitted to Boeing 7/08
Jan 2G-GTCP331-3-12-1 APU RECEIVING PROCESS 50% Submitted to Boeing 7/08

Feb 2G-GTCP331-3-3 FUEL FLOW DIVIDER 16-Dec-05 0

Chg 1 IN
Feb 2G-GTCP331-3-2 FUEL CONTROL UNIT 22-Dec-05 WORK C/W Apr 08 Finalizing Change 1
Feb 2G-GTCP331-3-4 IGV ACTUATOR ASSEMBLIES 16-Dec-05 0

Mar 2G-GTCP331-3-5 FUEL MANIFOLD ASSEMBLY 22-Dec-05 0

Mar 34Y26-6-1-3 FUEL COLLECTION STAND 22-Dec-05 0
Mar 34Y26-6-1-4 HYDRAULIC SUPPLY CART 22-Dec-05 0
CALIBRATION for HYDRAULIC
Mar LDP-OO/ALC-15 SUPPLY CART 28-Feb-05 0

GEARBOX MODULE Chg 1 IN

Apr 2G-GTCP331-3-1 ASSEMBLY 25-Aug-05 WORK C/W Apr 08 Change 1 ready to submit

Chg 1 IN
May 2G-GTCP331-3-11 LOAD COMPRESSOR MODULE 28-Jul-06 WORK C/W Apr 08 Change 1 ready to submit

32
 T.O. Review/Change Log (Page 2 of
3)
Annual
Review Month T.O. Number T.O. Title Latest Version Change # Review Comments

Jun 2G-GTCP331-3-12 POWER SECTION MODULE 50% Submitted to Boeing 7/08

Jun 2G-GTCP331-3-12-3 PRESSURE RELIEF VALVE 50% Submitted to Boeing 9/08
Jun 34Y26-7-1-2 THERMOCOUPLE TESTER 50% Submitted to Boeing 9/08

Jul 33D2-9-10-3 PNEUMATIC TEST STAND 29-Feb-08 0 C/W Sep 08

Jul 7J14-9-3 FLOW SENSOR ASSEMBLY 29-Feb-08 0
Jul 7J6-21-3 SURGE CONTROL VALVE 29-Feb-08 0

Aug 7J6-6-17-3 LOAD CONTROL VALVE 29-Feb-08 0

COOLING FAN ASSEMBLY
Aug 7J15-9-3 3616959-6 29-Feb-08 0
COOLING FAN ASSEMBLY
Aug 7J15-10-3 3614416-1/-2 29-Feb-08 0

Sep 2G-GTCP331-3-13 STARTER MOTOR (-6) 50% Submitted to Boeing 7/08

Sep 2G-GTCP331-3-14 STARTER MOTOR (-7/-8) 50% Submitted to Boeing 7/08
Sep 34Y26-7-1-5 STARTER DYNO TEST STAND 50% Submitted to Boeing 9/08
Sep 34Y26-7-1-4 STARTER BREAK-IN STAND 50% Submitted to Boeing 9/08

33
T.O. Review/Change Log (Page 3 of
3)
Review Month T.O. Number T.O. Title Latest Version Change # Annual Review Comments

Oct 2G-GTCP331-3-15 IGNITION EXCITER 50% Submitted to Boeing 7/08

Oct 2G-GTCP331-3-17 IGNITER PLUG 50% Submitted to Boeing 7/08
Oct 2G-GTCP331-3-18 IGNITER PLUG LEAD 50% Submitted to Boeing 7/08
Oct 2G-GTCP331-3-16 WIRING HARNESS ASSEMBLY 50% Submitted to Boeing 9/08
Oct 34Y26-7-1-3 WIRE HARNESS TEST STAND 50% Submitted to Boeing 9/08

Nov 2G-GTCP331-3-6 LUBE PUMP ASSEMBLY 3-Nov-06 0

Nov 34Y26-2-3 OIL TEST STAND 3-Nov-06 0
GENERATOR FILTER
Nov 2G-GTCP331-3-7 ASSEMBLY 3-Nov-06 0
GENERATOR SCAVENGE
Nov 2G-GTCP331-3-8 PUMP ASSEMBLY 3-Nov-06 0

Dec 2G-GTCP331-3-9 OIL COOLER 3-Nov-06 0

Dec 34Y26-1-3 FLUSHING STAND 3-Nov-06 0
Dec 2G-GTCP331-3-10 OIL TEMP. CONTROL VALVE 3-Nov-06 0

34
 Drawing Update

• I need your help…

– And some more help…
– And some more….
– Remember—they’ll make an issue of lateness, so it
– Would be best to show the step-by-step progression
– (and headaches) to show this has been
– a full time tasking times 3 people

35
 Drawing Update

• I need your help…

– And some more help…
– And some more….
– Remember—they’ll make an issue of lateness, so it
– Would be best to show the step-by-step progression
– (and headaches) to show this has been
– a full time tasking times 3 people

36
FY08 Triumph Training @ HAFB
• Training breakdown is as follows:
• Feb 08—120 hours (2 technicians x 60 hours each): Cooling
Fan (both part numbers)
• Feb 08—240 hours (2 technicians, 1 at 150 hours, 1 at 90
hours): Load Control Valve, Surge Control Valve, Flow
Pallet
• Feb 08—120 hours (1 technician): Pneumatic Test Stand
introduction and testing of Load Control Valve, Surge
Control Valve, Flow Pallet
• Mar 08—160 hours (2 technicians x 80 hours each): Test
Cell operation
• Mar 08—180 hours (3 technicians x 60 hours each): Overall
APU (everything except Power Section)
• May 08—240 hours (3 technicians x 80 hours each):
Gearbox and Load Compressor requalification training
• Total hands-on training hours from above: 1060 hours
– Note that this does not include the time spent correlating the test cell
in Nov and Dec 07. This was approximately three weeks of engine run
time to solve the problems we encountered, and that entire time there 37
was a Hill AFB engineer and technician helping (and learning).
Next meeting discussion

Location: ?
Date: ?
Open Discussion

39