A330340 P18 Bleed Air System LS

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
A330/A340 Family symposium Berlin, 31 May - 03 June 2010
Presented by:
Laurent Seguy
Pneumatics, Ice & Fire Protection
Group Manager
Customer Services
Bleed air system

Content
Engine Bleed Air System

A330
– Dual Bleed Loss
– Operational reliability
A340-200/300
A330 & 340 OverHeat Detection System
SFAR88 impact
PTFE seals performance
A340-500/600
Operational reliability: Improved precooler
Dual Pack flow reduction
Conclusion
Bleed air system Page 3
Content

A330
– Dual Bleed Loss
A340-200/300
SFAR88 impact
A340-500/600
Conclusion
Engine Bleed Air System, A330
Dual Bleed Loss

Fleetwide events, action plan
20 2,5
15
Fleet FH, Million

10 1,25
Specific A/L
5
A330 Fleet
0 0
2003 2004 2005 2006 2007 2008 2009 2010*
MPD task, ThC filter Customized action plan ThC VSB

(specific A/L)
MISP Solutions

Dual Bleed Loss

Root cause for loss of 2nd bleed
Other
3 events
12%
Overtemperature
16 events
49%
39%
Overpressure
13 events

Dual Bleed Loss

Overtemperature scenario, 16 events
Item Events Status Target / Doc

ThC . Reduced FAV opening due to:
1 - internal mesh filter clogging
⇒Replace internal filter by pollution cover VSB, Sep/09
4 - external filter clogging
⇒Reinforce on-wing replacement or cleaning SIL, Nov/04
⇒Upgrade MPD task to MRB task MPD, Jan/11
3 . Clapper / guide wearing
⇒ Use of improved material VSB, Dec/10
FAV 1 . Limited opening due to air flow leakage TSM & AMM, 3Q10
⇒Include air flow criteria in FAV test

Contributing factor . Reduced pressure in case of overtemperature build-up
⇒Inhibit temperature limitation function (PRV, ThS) Decision by Jun/10
Remaining 7 events . Fault triggered by a combination of the above root causes

Dual Bleed Loss

Overpressure scenario, 13 events
Item Events Status Target / Doc
OPV 2 . Premature closure in case of pressure overshoot
⇒Secure higher closure threshold VSB, Dec/10
⇒Tighten test criteria AMM, Sep/10
PRV 2 . Pressure overshoot up to OPV closure threshold
⇒Decrease regulated pressure Decision by Jun/10
Sensor 5 . Faulty indication at high altitude CMM,TSM Sep/10
- Humidity accumulation & freezing suspected 3Q10
- In-service recording launched, May/10
Contributing factors . Increased demand with Pack-off take-off procedure

. Steep thrust increase at T/O leading to PRV overshoot SOP 3.03.12,
⇒Reinforce use of 2-step thrust increase available
Remaining 4 events . Fault triggered by a combination of the above root causes

Dual Bleed Loss, summary
Increased number of occurrences in 2008

Addressed by action plan at one specific airline
Increased number of occurrences in 2009

Fleetwide
action plan
MISP opened early 2009
Solutions available by end 2010

Operational Reliability
Significant Improvement since 2008
No. of OI for 100 take-off

0,05
9 HPV D09 for PW & RR
9New carbon seals for PRV, HPV
0,04 9 Bleed Not Closed mitigation
-25%
0,03
0,02
0,01
0
2007 2008 2009 2010*

Operational & System reliability

2009 breakdown
Bleed Fault
50%
HPV • Dual Bleed Loss solutions

28% • Continue introduction of

improved carbon seals
•Solution for HPV
damage on GE engine

HPV: GE engine, vibration-induced damage

Issue
High
removal rate with significant vibration-induced damage
MTBF 4,800 FH
Resolution
High vibration levels confirmed on affected fleet engine, Aug/09
HPV damage consistent with measured spectrum
Options for installation change identified, Jan/10
Way forward
Testing of improved installation, 3Q10
Industrial decision, 4Q10


2009 breakdown
Bleed Not
Closed
16%
• Ongoing investigation
Bleed Fault
50%
• Dual Bleed Loss solutions

HPV
• Continue introduction of
28% improved carbon seals
•Solution for HPV
damage on GE engine

Bleed Not Closed

Issue
No PRV closure indication at engine shut-down
AIR ENG BLEED NOT CLSD at cockpit, GO-IF
Contributes to unjustified PRV removals, MTBUR 10,800 FH
Investigation
Scenarionot reproduced in lab, even with suspected PRV’s
Dedicated ACMS set to record system status at time of failure
ACMS released to 3 operators, Jun/10
Way forward
Preliminary check in TSM to avoid unjustified action, May/09
Action plan depends on ACMS outcome, 3Q10


2009 breakdown
Bleed Not
Closed
16%
Action plans
• Ongoing investigation
Bleed Fault
ongoing 50%
for all drivers
• Dual Bleed Loss solutions
HPV
28% improved carbon seals
•Solution for HPV
damage on GE engine

Content

A330
– Dual Bleed Loss
A340-200/300
SFAR88 impact
A340-500/600
Conclusion
Continuous improvement since 2007
No. of OI for 100 take-off
0,12
9New carbon seals for PRV, HPV
9ThS B05 continued introduction
0,1
-25%
0,08
0,06
0,04
0,02
0
2007 2008 2009 2010*


2009 breakdown
Bleed Fault
80%
• Improve ThS senseline
installation

Improved ThS senseline installation
Issue
Cases of senseline breakage reported
Approx 60 spare parts ordered in 2009
AIR ENGi BLEED FAULT at cockpit, GO-IF
Resolution
Pre-loadingat installation is a contributor
FEM & tap test demonstrated that failure is vibration induced
Added attachment bracket proven effective: FEM, tap test and trial
Way forward
Airbus SB 36-4034, target 3Q10


2009 breakdown
HPV
13%
• Reduce not confirmed

removals Bleed Fault
• Increase lifetime 80%
installation

HPV, not-confirmed removals and reliability
Issue
High not-confirmed rate (50 %)
Reliability below expectations, MTBUR 10,000 FH
Resolution
Not-confirmed removals: 70 % of HPV messages cleared by action at
interface level or harness replacement
HPV failures: main driver is solenoid sub-assembly
Way forward
Check harness installation as per Rohr VSB
Higher attention to harness condition during T/S
Upgrade HPV to Amdt A with improved solenoid, Jan/09


2009 breakdown
HPV
13%
Improvement
• Reduce not confirmed plan Bleed Fault
removals
• Increase lifetime for main drivers 80%
installation

Content

A330
– Dual Bleed Loss
A340-200/300

SFAR88 impact
A340-500/600
Conclusion
OverHeat Detection System
Impact of SFAR88
Reinforced monitoring of APU leak detection
Loss of detection requires immediate maintenance action
– Software upgrade available, FOC monitored retrofit:
• A330: BMC M4 (done) and FWC T3 (on-going)
• A340: BMC L6 (done) and FWC L11 (on-going)
– Rule applicable 31st July 2010
Complete FWC upgrade
Airbus actions to protect A/C operations

Possibility of MMEL ‘GO-IF’ if no confirmed leak

• APU Check Valve to be replaced by blanking plate
Dual loop architecture available for retrofit
Consider MMEL option or dual loop retrofit

PTFE seal performance

A340-200/300 example, 30% retrofitted
No. of O.I. for 100 take-off

0,04
0,03
- 47%
0,02
0,01
0
pre SB post SB

PTFE seal performance

Business case evaluation tool, item RECO-LR-36-01
Pay-back
Pre-mod OR
Uptake 30% on A340 and 50% on A330

Content

A330
– Dual Bleed Loss
A340-200/300
SFAR88 impact
A340-500/600
Conclusion
A340-500/600
No. of O.I. for 100 take-off
0,08
A340-200/300, 2009
0,07
0,06
0,05
0,04
0,03
0,02
0,01
0
2007 2008 2009 2010*
Electro-pneumatic technology proven reliable & mature

OR improved by a factor 8 vs. fully pneumatic system (A340-200/300)

A340-500/600
Improved precooler
Issue
Heavy leakage developing around at 20,000 to 30,000 FH
AIR ENGi BLEED LEAK at cockpit – NO GO
Resolution
Periodic
check to mitigate exposure to on-wing failures
New precooler –C02 validated through back-to-back testing
Way forward
Spares situation to be secured until –C02 units availability
Airbus SB 36-5024 to be released Jun/10
New PCE available from Liebherr by Jan/11

A340-500/600
Improved precooler, Logistics

Objectives
Manufacturing PN transfer to avoid AOG stock shortage
Maintain the same level of support stock for C02 EIS
Total stock C02 EIS

~ Jan/11
OEM Exchange pool
OEM Safety stock
AOG stock (worldwide)

Forecast based on a steady removal rate equal to 2009 average
May/10 Sep/10 Dec/10
Stock sized for maximum security & flexibility

Bleed air system
Page 30
Content

A330
– Dual Bleed Loss
A340-200/300
SFAR88 impact
A340-500/600
Conclusion
A330 & A340, Dual Pack Flow Reduction
Improved Pack Controller logics
Issue
Cases of ECAM message ‘EXCESS CAB ALT’ in cruise
Resolution
Root cause:
– Humidity at high altitude contributes to icing of main heat exchanger
– Air flow through the pack is reduced
More robust Pack Controller logics required to prevent icing
Way forward
. Pack Controller software upgrade for all standards
. Monitored FOC retrofit started, 3 year objective

Content

A330
– Dual Bleed Loss
A340-200/300
SFAR88 impact
A340-500/600
Conclusion
Conclusion
A330
Significant OR improvement in 2009
Dual Bleed Loss: solutions available by end 2010
Additional improvement to come with solutions to
– PRV ‘Bleed Not Closed’ messages
– HPV on GE engine
A340-200/300
Continued OR improvement
– Improved installation of ThS senseline
PTFE seals, business case to be considered

A340-500/600
Electro-pneumaticsystem confirmed reliable & mature
New precooler available by Jan/11

Appendix
A330 Documentation
Subject Reference
Latest PN & interchangeability SIL 36-051
HPV, vibration induced damage on GE engine TFU 36.11.51.014
Dual Bleed Loss TFU 36.11.00.065

IPCV, low reliability on GE engine TFU 36.11.41.010
SB 36-3027, 36-3031,
PTFE Seals
36-3034
Bleed Not Closed messages TFU 36.11
HPV, marginal closure at high altitude TFU 36.11.51.015
Dual Loop for APU leak detection SB 36-3037

Appendix
A340-200/300 Documentation
Subject Reference
Latest PN & interchangeability SIL 36-053
ThS senseline, installation improvement TFU 36.11.00.064
HPV, High Not Confirmed removal rate TFU 36.11.00.058
VSB 6753-36-05
HPV, improved Solenoid
and 6753D-36-03
SB 36-4024, 36-4029,
PTFE Seals
36-4032
Dual Loop for APU leak detection SB 36-4033

Appendix
A340-500/600 Documentation
Subject Reference
Precooler Leakage TFU 36.11.00.063
Periodic inspection of Precooler –B01 and –C01 SB 36-5023
Improved Precooler –C02 SB 36-5024

Appendix
Other documentation
Subject Reference
Bleed Valves: new carbon seals VSIL LSF1958-13
ThC preventive action for external filter clogging SIL 36-055
OHDS reliability improvement and T/S SIL 36-049

Pack flow reduction, Pack Controller upgrade TFU 21.50.00.001

© AIRBUS S.A.S. All rights reserved. Confidential and
proprietary document.
This document and all information contained herein is the sole
property of AIRBUS S.A.S.. No intellectual property rights are
granted by the delivery of this document or the disclosure of
its content. This document shall not be reproduced or
disclosed to a third party without the express written consent
of AIRBUS S.A.S. This document and its content shall not be
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statements are not shown, AIRBUS S.A.S. will be pleased to
explain the basis thereof.
AIRBUS, its logo, A300, A310, A318, A319, A320, A321,
A330, A340, A350, A380, A400M are registered trademarks.

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© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

A330/A340 Family symposium Berlin, 31 May - 03 June 2010

Bleed air system

Engine Bleed Air System

Engine Bleed Air System

Dual Bleed Loss

Fleet FH, Million

MPD task, ThC filter Customized action plan ThC VSB

Bleed air system Page 5

Dual Bleed Loss

Bleed air system Page 6

Dual Bleed Loss

Item Events Status Target / Doc

⇒Include air flow criteria in FAV test

Bleed air system Page 7

Dual Bleed Loss

Contributing factors . Increased demand with Pack-off take-off procedure

Bleed air system Page 8

Dual Bleed Loss, summary

Increased number of occurrences in 2008

Increased number of occurrences in 2009

Solutions available by end 2010

Bleed air system Page 9

No. of OI for 100 take-off

Bleed air system Page 10

Operational & System reliability

HPV • Dual Bleed Loss solutions

28% • Continue introduction of

Bleed air system Page 11

HPV: GE engine, vibration-induced damage

Bleed air system Page 12

Operational & System reliability

• Dual Bleed Loss solutions

Bleed air system Page 13

Bleed Not Closed

Bleed air system Page 14

Operational & System reliability

Bleed air system Page 15

Engine Bleed Air System

Bleed air system Page 17

Operational & System reliability

Bleed air system Page 18

Improved ThS senseline installation

Bleed air system Page 19

Operational & System reliability

• Reduce not confirmed

Bleed air system Page 20

HPV, not-confirmed removals and reliability

Bleed air system Page 21

Operational & System reliability

Bleed air system Page 22

Engine Bleed Air System

A330 & 340 OverHeat Detection System

Airbus actions to protect A/C operations

Possibility of MMEL ‘GO-IF’ if no confirmed leak

Consider MMEL option or dual loop retrofit

Bleed air system Page 24

PTFE seal performance

No. of O.I. for 100 take-off

Possibility of MMEL ‘GO-IF’ if no confirmed leak