Service difficulty report · Blade · Boeing 777222

Difficulty date
March 19, 2004
Submitted
March 30, 2004
Operation
Air carrier
Aircraft
N783UA
Make and model
Boeing 777222
Aircraft serial
26950
Aircraft time
31,309 hours, 4,809 cycles
Engine
Pwa PW4090
Part
Blade
Condition
Cracked
Location
Nr 2 Engine
Stage of operation
CR
How discovered
O
Nature of condition
R
Precautionary procedure
A

As reported to the FAA. Reports are unverified, and codes are left as the FAA publishes them.

What was found

NR 2 ENGINE COMPRESSOR STALLED IN CRUISE. POWER REDUCED TO IDLE. THE 6TH STAGE HPC INNER SHROUD ASSEMBLIES (PW IPC 72-35-00-17-001/-010) WERE FOUND TO HAVE BEEN INSTALLED BACKWARDS. THIS ALLOWED THE SEAL LAND TO MAKE INTERMITTENT CONTACT WITH THE TRAILING EDGE OF ALL OF THE 6TH STAGE BLADES NEAR THE AIRFOIL ROOT. A CRACK STARTED IN THE TRAILING EDGE OF ONE OF THESE BLADES, AND PROGRESSED IN FATIGUE TO THE AIRFOIL MID-CHORD. AT THAT POINT, THE REMAINDER OF THE BLADE FAILED IN STRESS RUPTURE. ALL 6TH STAGE BLADES, AND ALL OTHER HPC BLADES DOWNSTREAM OF THE 6TH STAGE, SUFFERED HEAVY RESULTANT DAMAGE.