INTERNATIONAL HELICOPTER

SYMPOSIUM 2005

MONTREAL, QUEBEC
CANADA
SEPTEMBER 27-29, 2005
Gary Souza
Chief Project Engineer
Model 250
Helicopters & Small Gas Turbines
Rolls-Royce Corporation

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THE INFLUENCE OF ENGINE

MAINTENANCE AND OVERHAUL
ON ROTORCRAFT SAFETY

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ROLLS-ROYCE MODEL 250 SAFETY & RISK

ASSESSMENT - CAUSE & ANALYSIS
Understanding of future safety event rates and associated risks can
be gained by assessment of past fleet events and their causes
Fleet
Operating
Risk

Fleet
Composition
and Service
Hours

Engine not
Involved

Safety
Events

Engine
Involved

Cause
Reduction
(Effect of Mitigating
Actions)

Event
Severity
Historical
Rates

Cause
Analysis

Component &
Mode Safety
Assessments

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Event
Analysis

Percentage of Total

U.S. HELICOPTER ACCIDENT SUMMARY

STATISTICS - 1996 -2004
80.00%
70.00%
60.00%
50.00%
40.00%
30.00%
20.00%
10.00%
0.00%
1996 1997 1998 1999 2000 2001 2002 2003 2004
Year
Engine Involved
Structural

Human Factors
Weather

Mechanical
Wirestrike
Source: HAI Accident Summary

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MODEL 250 SAFETY & RISK ASSESSMENT

5%

3% 1%

Event Break-down of
1561 Events in Study
Period

No EI / Not Established

6%
4%

EI Potential Hazard
EI Incident
EI Accident - No Injury
EI Accident - Injury
EI Accident - Fatalities
81%

30
25

Average No. of EngineInvolved Events per Year

(1996-2004)
Does not include Potential
Hazards

20
EI Incident & Accidents
15

EI Accidents
EI Accidents with Fatalities

10
5

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l
Al

8
T6
3
C2
0
C2
8
C3
0/
S
C3
0P
C3
0
C3 R
0R
/3
C4
0
C4
7

C1

B1

MODEL 250 SAFETY & RISK ASSESSMENT

General Causes of 234 Engine-Involved Events during Study Period
15%
Maintenance &
Overhaul
Operational
48%
Quality (factory)

23%

Engine Systemic
(basic)
Unknown

4%
10%

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Fatigue Bearing #3

Turb to Comp Coupling

Comp Coupling Adapter

ECU Capacitor
Failure
Misalignment

Sulphidation Turbine
Wear

Erosion Comp Vane

Turbine Blade Off

Fatigue
OvertemperatureTurbine

Fuel Screen Collapse

Solid Contamination

Oil Starvation/Contam

Loose B Nuts

Fatigue Tubes/ Lines

Corrosion Comp

Blockage/FOD/Ingestion

Fuel Contamination

% of All Reported Power Losses

MODEL 250 SAFETY & RISK ASSESSMENT

MODEL 250 POWER LOSS MODES ALL MODELS

10.00%

9.00%

8.00%

7.00%

6.00%

5.00%

4.00%

3.00%

2.00%

1.00%

0.00%

TOP 15 MODES ACCOUNT FOR 56% OF POWER LOSS EVENTS

REVIEW OF KEY MAINTENANCE

INVOLVED EVENTS

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FUEL CONTAMINATION
Failure to Properly Maintain and Inspect
Fuel System Results In:

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FUEL CONTAMINATION
Fuel system contamination with the use of Jet A
fuel and anti-icing inhibitor, Diethylene Glycol
Monomethyl Ether (DIEGME).

DIEGME inhibitor draws water molecules from the fuel

and over time forms an organic gel-like substance
(coined Apple Jelly) in the bottom of fuel tanks.
When this gel-like material is detected in the aircraft
fuel system or fuel storage tanks, inspection of the
entire engine fuel system is required.
Inspect airframe / engine mounted fuel filters.
Separate, inspect / clean the fuel nozzle inlet screen
The formation of this gel-like material may result from:
Improperly maintained fuel storage tanks
Improper additive injection method or ratio

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FUEL CONTAMINATION
FUEL SYSTEM CONTAMINATION WITH DIEGME

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FUEL CONTAMINATION
FUEL STORAGE TANK CONTAMINATION WITH DIEGME
(Apple Jelly)

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FUEL CONTAMINATION
FUEL SYSTEM CONTAMINATION CAN RESULT IN
RESTRICTED FUEL FLOW, CAUSING:

ENGINE STARTING STAGNATION

HUNG START OR VERY COOL, LONG START
ENGINE POWER LIMITING
INABILITY TO MAINTAIN Nr AT REQUIRED SETTING
UNDER LOAD RESULTING IN Nr DROOP
IN-FLIGHT POWER LOSS
ENGINE FLAME-OUT OR CUT-BACK

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FUEL CONTAMINATION
CLEAN FUEL
NOZZLE INLET
SCREEN

DIRTY FUEL
NOZZLE INLET
SCREEN
Nozzle Separated for Cleaning

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FUEL CONTAMINATION
Collapsed contaminated screen resulting in loss
of power in-flight

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COMPRESSOR
EROSION & CORROSION
Failure to Inspect Compressor Cases
and Blades Regularly for Erosion and/or
Corrosion Results In:

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COMPRESSOR CORROSION & EROSION

INSPECTIONS

COMPRESSOR
FAILURE

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COMPRESSOR CORROSION & EROSION

INSPECTIONS
COMPRESSOR BLADE FAILURE

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COMPRESSOR CORROSION & EROSION

INSPECTIONS

Inspect Compressor Cases and Blades Regularly

for Erosion and/or Corrosion
Minimum 300 Hours When Operating in Erosion
and/or Corrosive Environment
As Required in Moderate Environments
Never Greater than Manufacturers
Recommendation.

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COMPRESSOR CORROSION & EROSION

INSPECTIONS
COMPRESSOR CASE EROSION

EXPOSED VANE
BAND IS NOT
ACCEPTABLE

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COMPRESSOR CORROSION & EROSION

INSPECTIONS
COMPRESSOR VANE EROSION

NOTE EROSION
UNDERCUT
NEAR VANE
ROOT AT
PLASTIC LINE

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COMPRESSOR CORROSION & EROSION

INSPECTIONS
COMPRESSOR BLADE FAILURE

NOTE PITS AT
ROOT AREA OF
BLADE

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SERIES II COMPRESSOR CORROSION &

EROSION INSPECTIONS

CRACK
FORMING ON
LEADING EDGE
NEAR ROOT
FROM
CORROSION
PIT

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ENGINE GAS PATH CONTAMINATION

Failure to Regularly Remove Gas
Path Contaminants Results In:

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TURBINE WHEEL HOT CORROSION FAILURE

TYPICAL MODEL 250 1ST STAGE TURBINE WHEEL HOT CORROSION
TYPICAL APPEARANCE AFTER IFSD EVENT
CORROSION DAMAGE REDUCES AIRFOIL CROSS-SECTIONAL AREA
BLADES FAIL IN OVERLOAD

03FA8-113

98FA8-026

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Proper Contamination Removal (water

rinse) Instructions Using Water Only
250-C18 CSL-141

250-C40 CSL-5017

250-C20 CSL-1135

250-C47 CSL-6004

250-C28 CSL-2082

250-C30 CSL-3085

250-C20R CSL-4018

The above CSL has been revised to remind operators the

importance of doing a daily water rinse to all Rolls-Royce Model
250 Series engines that are flown in a corrosive environment

WARNING: FAILURE TO PROPERLY FOLLOW THE WATER RINSE

PROCEDURES COULD RESULT IN CORROSIVE ATTACK AND ENGINE FAILURE

WARNING: SALT LADEN HUMIDITY AND CHEMICALS WILL CORRODE THE

ENGINE AND COULD CAUSE IT TO FAIL.
The highest quality of water must be used. Distilled or demineralized water is
recommended

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TURBINE WHEEL HOT CORROSION

RECENTLY PUBLISHED REVISIONS

CSL141 PUBLISHED REQUIRING DE-MINERALIZED

WATER FOR RINSE / WASH
CSL 205 PUBLISHED TO INSPECT FOR HOT
CORROSION (SULFIDATION) OF 1ST STAGE
TURBINE BLADES
REQUIRES 600 HR INSPECTION OF THE 1ST STAGE
TURBINE BLADES FOR OPERATORS WHO ARE EXPOSED
TO CONDITIONS WHICH PROMOTE HOT CORROSION
SAME AS COMPRESSOR INSPECTION

REQUIRES OPERATORS WHO DO NOT USE DEMINERALIZED WATER OR ARE UNSURE OF LEVEL OF
MINERAL CONTENT OF WATER USED FOR COMPRESSOR
RINSE / WASH TO PERFORM 600 HR INSPECTION OF THE
1ST STAGE TURBINE BLADES

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MAINTENANCE OF FUEL, LUBE

AND PNEUMATIC SYSTEM LINES
Failure to Properly Maintain and Inspect
Fuel, Lube and Pneumatic System Lines
Results In:

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MAINTNENANCE OF FUEL, OIL AND AIR LINES

MAINTENANCE WARNING CONTROL SYSTEM PLUMBING
250-C18 CSL A-169
250-C20 CSL A-1166
250-C20R CSL A-4036
250-C28 CSL A-2113
250-C30 CSL A-3117

The above CSL has been issued to remind operators of the

importance of proper alignment, clamping and torqueing of engine
Control System Plumbing

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MAINTENANCE OF FUEL, OIL AND AIR LINES

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MAINTENANCE OF FUEL, OIL AND AIR LINES

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SUMMARY

Improper Engine Maintenance and

Overhaul Affects Safety
Proper Maintenance in Accordance with
Manufacturers Recommendations is
Essential to the Safety of Engines Installed
in Rotorcraft

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THANK YOU!
QUESTIONS?

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