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ENGINE - Service Life Limits for Rotating Parts
GE PROPRIETARY INFORMATION The information contained in this document is GE proprietary information and is disclosed in con- fidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modi fications, spare parts, designs, or configuration changes or to obtain FAA or any other government or regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part.
This technical data is considered EAR controlled pursuant to 15 CFR Parts 730-774 respectively.
Transfer of this data by any means to a Non-US Person, whether in the United States or abroad, without the proper U.S. Government authorization (e.g., License, exemption, NLR, etc.), is strictly prohibited.
GEAE authorizes the Federal Aviation Administration to incorporate this document by reference in an Airworthiness Directive.
Copyright (2015) General Electric Company, U.S.A.
July 09, 1979 CT58 S/B 72-A0162 Revision 16, January 07, 2015 PAGE 1 of 27
ENGINE - Service Life Limits for Rotating Parts
TRANSMITTAL INFORMATION REVISION 16 TO ALERT SERVICE BULLETIN 72-A0162 Revision 16 is issued to update paragraphs 1., P LANNING INFORMATION,3 . ,ACCOMPLISHMENT INSTRUCTIONS, and 4., A PPENDIX A.
Revision 15 was dated January 09, 2014. Revision 14 was dated April 29, 2013. Revision 13 was dated June 13, 2012. Revision 12 was dated April 18, 2008. Revision 11 was dated March 01, 2005. Revision 10 was dated December 11, 2003. Revision 9 was dated October 06, 1998.
Revision 8 was dated June 16, 1997. Revision 7 was dated April 25, 1997. Revision 6 was dated June 19, 1995. Revision 5 was dated May 12, 1994. Revision 4 was dated August 31, 1993.
Revision 3 was dated May 19, 1993. Revision 2 was May 22, 1985. Revision 1 was dated June 27, 1980. The original was dated July 09, 1979. Revision bars in the left margin identify changes.
1. PLANNING INFORMATION A. Effectivity This Alert Service Bulletin is applicable to the following engines:
CT58-100-2 CT58-110-1 CT58-110-2 CT58-140-1 CT58-140-2 B. Concurrent Requirements None.
C. Description Operators are required to maintain the service records of engine life-limited rotating parts. Service hours and cycles (calculated according to paragraph 3., ACCOMPLISHMENT INSTRUCTIONS), must be compared to the limits in T ables I, II, III, IV of this Alert Service Bulletin. Parts must be removed from service before the life limits are exceeded.
NOTE: T ables I, II, III, and IV in this Alert Service Bulletin supersedes and replaces the Airworthiness Limitations Section (ALS) of the Overhaul Manuals SEI-102 and SEI-183 contained in section 72-00. Future changes to the limits will continue to be made by revisi on of this Alert Service Bulletin.
For a copy of the Overhaul Manual SEI-102, contact CT58 Program Manager. Refer to the address listed at the end of paragraph 3.B.(2) of ACCOMPLISHMENT INSTRUCTIONS of this Alert Service Bulletin.
(1) Definitions:
(a) Cycle: de fined as any engine operating sequence involving an engine start, one acceleration to takeoff power, and shutdown.
July 09, 1979 CT58 S/B 72-A0162 Revision 16, January 07, 2015 PAGE 2 GE PROP RIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Service Life Limits for Rotating Parts
(b) Non-Repetitive Heavy-Lift (Non-RHL) operations: de fined as an engine start, acceleration to takeoff power, an average of less than two additional landings or lift-carry-drop sequences per hour, and shutdown.
(c) Utility operations: de fined as an engine start, acceleration to takeoff power, an average of two to ten additional landings or lift-carry-drop sequences per hour, and shutdown.
(d) Repetitive Heavy-Lift (RHL) operations: de fined as an engine start, acceleration to takeoff power, an average of more than ten additional landings or lift-carry-drop sequences per hour, and shutdown.
(e) CSN: Cycles Since New
(f) TSN: Time Since New
(g) Shop Visit: de fined as the induction of an engine into a shop or facility for maintenance in accordance with Overhaul Manual SEI-183.
D. Compliance Category 1 GE recommends you do this Alert Service Bulletin to ensure safe operation of CT58 engines in service.
Upon receipt of this bulletin, refer to T ables I, II, III, IV for life limits on all rotating parts.
(1) The change of the Multiplying Factor for Utility and RHL Operations from 6.0 to 3.0 and reducing cycle life limit from 26,000 to 12,800 cycles, affecting compressor spools P/N 5124T94G02, P/N 6010T57G04, P/N 6010T57G07, and P/N 6010T57G08 can be complied with by utilizing the Field Management Plan described in paragraph 4.A. of A PPENDIX A of this Alert Service Bulletin, in order to minimize the operational impact on their fleets.
(2) Utility operators can utilize the Fi eld Management Plan described in paragraph
4.B. of A PPENDIX A of this Alert Service Bulletin, in order to minimize the operational impact on their fleets.
E. Reason
(1) Objective:
This Alert Service Bulletin provides service life limits for rotating parts in all operations and a method of counting cycles of life-limited parts for RHL and Utility operations.
(2) Condition:
Engines primarily engaged in RHL or U tility operations have experienced premature, low-cycle fatigue damage to some parts.
July 09, 1979 CT58 S/B 72-A0162 Revision 16, January 07, 2015 PAGE 3 GE PROP RIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Service Life Limits for Rotating Parts
(3) Cause:
The conventional basis for determining the number of cycles accumulated on rotating parts has been de fined as a start, accelerate to takeoff power, and shutdown in a speci fic time frame. The use and applications of CT58 powered helicopters in Non-RHL operations have evolved to a much wider variety of operations than originally taken into account.
(4) Improvement:
Evaluation of operator input has led to an update of the operational pro file for Non-RHL operations to re flect the current operations of the Non-RHL fleet. This revision of the Alert Service Bulletin has also been updated with clarification of conversion factors for T able IV and examples of its use.
(5) Substantiation:
An analysis of the usage and inspection data of compressor spool parts used in Non-RHL operations has shown that usage exceeds analytical models. A risk assessment was conducted using a validated life approach for active compressor spools with a conservative operational pro file as de fined during the operator survey. The risk assessment indicated a need to reduce the cycle life limit for Non-RHL operators. The updated limits in T able I and paragraph
4.A. of A PPENDIX A must be applied in accordance with paragraph 1.D., Compliance.
F. Approval This Alert Service Bulletin has been reviewed by the FAA and the repair(s) and modification(s) herein comply with the appl icable Federal Aviation Regulations and are FAA APPROVED for installation in the model(s) listed in this Alert Service Bulletin.
Revision 16 of this Alert Service Bulletin is approved by the Manager, Engine Certification Office, ANE-140, by letter dated December 30, 2014, as an Alternative Method of Compliance (AMOC) to Airworthiness Directives (AD) 2001-18-06 and 2008-22-16.
G. Manpower No additional man-hours are required when compliance with this Alert Service Bulletin is performed during normal overhaul.
H. Weight and Balance Weight and balance are not changed.
July 09, 1979 CT58 S/B 72-A0162 Revision 16, January 07, 2015 PAGE 4 GE PROP RIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Service Life Limits for Rotating Parts I. References (Use the latest version of any document) Airworthiness Directive (AD) 2001-18-06 Airworthiness Directive (AD) 2008-22-16 SEI-102, CT58-100/-110 Overhaul Manual SEI-183, CT58-140 Overhaul Manual J. Publications Affected Not applicable.
K. Previous Modification Service Bulletin Number Service Bulletin Title CT58 S/B 72-0078 (CEB-136) Rework of Stage 2 Compressor Rotor Disk.
CT58 S/B 72-0084 (CEB-147) Compressor Rotor Spool Rework (Life Limit Extension).
CT58 S/B 72-A0124 (CEB-204) Reduction of Life Limits on Stage 2 Compressor Rotor Disk Shaft.
CT58 S/B 72-A0125 (CEB-205) Reduction of Life Limits for Stage 1 and Stage 2 Turbine Wheels and Introduction of New Stage 1 and Stage 2 Turbine Wheels.
CT58 S/B 72-A0126 (CEB-206) Inspection of Stage 1 and Stage 2 Turbine Wheels.
CT58 S/B 72-A0132 (CEB-216) Reduction of Life Limits on Stage 1 Disk, Front Disk Shaft, Rear Shaft, and Rear Seal of the Compressor Rotor.
CT58 S/B 72-A0146 (CEB-240) Reduction of Service Life Limits of Compressor Rear Shaft for External Lift Operators Only.
CT58 S/B 72-A0159 (CEB-255) Inspection of Stage 1 Turbine Wheels.
CT58 S/B 72-A0173 (CEB-275) Identification and Inspection of Suspect Gas Generator Turbine Rotor Assembly Parts and Power Turbine Wheels that may have been Inadvertently Shotpeened.
L. Interchangeability Not applicable.
July 09, 1979 CT58 S/B 72-A0162 Revision 16, January 07, 2015 PAGE 5 GE PROP RIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Service Life Limits for Rotating Parts
2. MATERIAL INFORMATION A. Material - Price and Availability
(1) Parts necessary to do this Alert Service Bulletin:
If serviceable spare parts with serviceable life remaining are not available for replacement, the operator may purchase new parts from GE Aircraft Engines or authorized distributor. Part numbers and names are shown in T ables I, II, III, and IV.
(2) Consumables:
None.
B. Industry Support Information Not applicable.
C. Configuration Chart Not applicable.
D. Parts Disposition T erminate replaced parts.
E. Tooling - Price and Availability No special support equipment beyond that normally used during overhaul is required for compliance with this Alert Service Bulletin.
3. ACCOMPLISHMENT INSTRUCTIONS A. Perform the following on all installed and spare rotating parts listed in T ables I, II, and III:
(1) Determine component part number and its t otal time (in hours) and cycles for installed and spare parts as follows:
(a) For engines that have not been involved in RHL or Utility operations, compare total hours and accumulated cycles to the limits for that part number listed in T ables I, II, and III. Then, remove parts that exceed total hours or cycle limits from service.
(b) For engines that have been involved in RHL or Utility operations, determine calculated total cycles for each part in T ables I, II, and III.
Then, remove parts that exceed total hours or cycle limits from service as follows:
July 09, 1979 CT58 S/B 72-A0162 Revision 16, January 07, 2015 PAGE 6 GE PROP RIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Service Life Limits for Rotating Parts 1 Perform calculations with Multiplying Factor for Utility and RHL Operations for T ables I, II, and III as follows:
a If a part has been in RHL or Utility operations (paragraph 1.C.(1) of Description), multiply the total hours in RHL or Utility operation by the Multiplying Factor for Utility and RHL Operations (found in T ables I, II, and III) for that part. The resulting product is the cycles for that part in RHL or Utility operation:
FORMULA FOR DETERMINING CALCULATED CYCLES IN RHL OPERATIONS
CALCULATED
CYCLES IN RHL
OPERATIONS = HOURS FLOWN INRHL OPERATIONS X
MULTIPLYING FACTOR FOR
UTILITY AND RHL
OPERATIONS
FORMULA FOR DETERMINING CALCULATED CYCLES IN UTILITY OPERATIONS
CALCULATED
CYCLES IN UTILITY
OPERATIONS = HOURS FLOWN INUTILITY OPERATIONS X
MULTIPLYING FACTOR FOR
UTILITY AND RHL
OPERATIONS b Sum the cycles calculated in the above paragraph as well as those accumulated during Non-RHL operations. The resulting sum is the calculated total cycles:
FORMULA FOR DETERMINING CALCULATED TOTAL CYCLES
CALCULATED TOTAL CYCLES =
CALCULATED CYCLES
IN UTILITY
OPERATIONS +
CALCULATED
CYCLES IN RHL OPERATIONS + CYCLES
ACCUMULATED
IN NON-RHL
OPERATIONS 2 Compare calculated total cycles to the cycle limits for that part (found in T ables I, II, or III). If the part calculated total cycles exceeds its cycle limit, remove the part from service.
(2) Examples for determining expended life of rotating parts:
(a) Stage 1 compressor disk P/N 5001T20P01 with no history of RHL or Utility operation and 3,000 hours and 2,500 accumulated cycles in Non-RHL service:
1 Part can be evaluated based solely on the accumulated cycles.
July 09, 1979 CT58 S/B 72-A0162 Revision 16, January 07, 2015 PAGE 7 GE PROP RIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Service Life Limits for Rotating Parts 2 Disposition:
Continue in service and apply a Multiplying Factor for Utility and RHL Operations of 2.4 when determining cycle life during RHL or Utility service until 4,000 hours or 9,900 cycles, whichever occurs first (T able I).
(b) Stage 1 compressor disk P/N 5001T20P01 with 2,000 hours in RHL operations and 1,000 hours and 800 accumulated cycles in Non-RHL service:
1 Calculated total cycles result is determined as follows:
a Calculated Cycles in RHL Operations = 2,000 (RHL hours) X
2.4 (Multiplying Factor for Utility and RHL Operations) (Refer to T able I) = 4,800 Calculated Cycles in RHL Operations.
b Calculated T otal Cycles = 800 (accumulated cycles) + 4,800 (Calculated Cycles in RHL Operations) = 5,600 Calculated T otal Cycles.
2 Disposition:
Continue in service and apply a Multiplying Factor for Utility and RHL Operations of 2.4 when determining cycle life during RHL or Utility service. Remove the stage 1 compressor disk from service at, or prior to reaching a life limit of 4,000 hours or 9,900 cycles, whichever occurs first.
(c) Compressor spool P/N 6010T57G04 with 2,000 hours in RHL service and 2,000 hours and 2,000 accumulated cycles in Non-RHL service:
1 Calculated T otal Cycles is determined as follows:
a Calculated cycles in RHL Operations = 2,000 (RHL hours) X
3.0 (Multiplying Factor for Utility and RHL Operations) = 6,000 Calculated Cycles in RHL Operations.
b Calculated T otal Cycles = 2,000 (accumulated cycles) + 6,000 (Calculated Cycles in RHL Operations) = 8,000 Calculated T otal Cycles.
2 Disposition:
Continue in service and apply a Multiplying Factor for Utility and RHL Operations of 3.0 when determining calculated total cycles during RHL or Utility service. Remove the compressor spool from service at, or prior to reaching a life limit of 10,000 hours or 12,800 cycles, whichever occurs first.
July 09, 1979 CT58 S/B 72-A0162 Revision 16, January 07, 2015 PAGE 8 GE PROP RIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Service Life Limits for Rotating Parts B. Perform the following on all installed and spare stage 1 and stage 2 turbine wheels l i s t e di nT a b l eI V :
(1) Determine the component part number and its total time in hours for each type of operation (Non-RHL, Utility, RHL) on installed and spare parts and then convert to the selected operation to determine the total equivalent hours:
(a) Perform Calculations for Turbine Wheel Conversion Factor for T able IV as follows:
1 If a part has been in one type of operation, compare accumulated hours in that operation to the hourly life limit in T able IV. Remove parts from service that exceed life limits.
2 If a part has been in multiple types of operation, select a single operation type for the part. Any one of the three operations can be selected as there is no difference in impact on the life consumption.
Use the Turbine Wheel Conversion Factor (found in T able IV), convert the hours of each operation type to the selected operation type. Sum all the converted hours to obtain the total hours of the selected operation.
3 Divide RHL and Utility converted hours by five to obtain the cycles and Non-RHL converted hours by two to obtain the cycles.
(b) Compare total hours to the operational life limits for the part number in T able IV. Remove parts from service that exceed life limits.
(2) Examples for determining expended life for stages 1 and 2 turbine wheels:
(a) Stage 1 turbine wheel P/N 4002T17P06 with 300 hours RHL and 500 hours Non-RHL:
1 If RHL is selected, sample calculations for the hours and cycles for RHL:
a Convert Non-RHL to RHL (Turbine Wheel Conversion Factor = 0.46):
0.46 x 500 = 230 hours T otal converted hours = 230 + 500 = 730 hours b Converted cycles = 730/5 = 132 cycles 2 If Utility is selected, sample calculations for hours and cycles for Utility operation:
a Convert RHL to Utility (Turbine Wheel Conversion Factor = 1.07):
1.07 x 300 = 321 hours July 09, 1979 CT58 S/B 72-A0162 Revision 16, January 07, 2015 PAGE 9 GE PROP RIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Service Life Limits for Rotating Parts b Convert Non-RHL to Utility (Turbine Wheel Conversion Factor = 0.49):
0.49 x 500 = 245 hours T otal Converted Hours = 321 + 245 = 566 hours c Converted cycles = 566/5 = 112 cycles 3 If Non-RHL is selected, sample calculations for hours and cycles for Non-RHL:
a Convert RHL to Non-RHL (Turbine Wheel Conversion Factor = 2.17):
2.17 x 300 = 651 hours T otal converted hours = 651 + 500 = 1,151 hours b Converted cycles = 1,151/2 = 576 cycles
(b) Stage 2 turbine wheel P/N 4002T96P06 with 700 hours Utility and 400 hours RHL:
1 Hours and cycles for RHL:
a Convert Utility to RHL (Turbine Wheel Conversion Factor = 0.64):
0.64 x 700 = 448 hours T otal Converted hours = 448 + 400 = 848 hours b Converted cycles = 848/5 = 170 cycles 2 Hours and cycles for Utility:
a Convert RHL to Utility (Turbine Wheel Conversion Factor = 1.57):
1.57 x 400 = 628 hours b T otal Converted Hours:
628 + 700 = 1,328 hours c Converted cycles = 1,328/5 = 625 cycles 3 Hours and cycles for Non-RHL:
a Convert Utility to Non-RHL (Turbine Wheel Conversion Factor = 1.52):
1.52 x 700 = 1,064 hours July 09, 1979 CT58 S/B 72-A0162 Revision 16, January 07, 2015 PAGE 10 GE PROP RIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Service Life Limits for Rotating Parts b Convert RHL to Non-RHL (Turbine Wheel Conversion Factor = 2.38):
2.38 x 400 = 952 hours c T otal Converted Hours:
1,064 + 952 = 2,016 hours d Converted cycles = 2,016/2 = 1,008 cycles NOTE: Operators are encouraged to direct any questions concerning the need to apply Multiplying Factor for Utility and RHL Operations or use of Turbine Wheel Conversion Factor to:
CT58 Program Manager GE Aviation 1000 Western Avenue Lynn, MA 01910 U.S.A.
C. This Alert Service Bulletin supersedes the following Service Bulletins:
Service Bulletin Number Service Bulletin Title CT58 S/B 72-A0124 (CEB-204) Reduction of Life Limits on St age 2 Compressor Rotor Disk Shaft.
CT58 S/B 72-A0125 (CEB-205) Reduction of Life Limits for Stage 1 and Stage 2 Turbine Wheels and Introduction of New Stage 1 and Stage 2 Turbine Wheels.
CT58 S/B 72-A0132 (CEB-216) Reduction of Life Limits on Stage 1 Disk, Front Disk Shaft, Rear Shaft, and Rear Seal of the Compressor Rotor.
CT58 S/B 72-A0146 (CEB-240) Reduction of Service Life Limits of Compressor Rear Shaft for External Lift Operators Only.
D. Compressor Rotor Components (Figure 2) T able I specifies the life limits for the compressor rotor components that are life limited.
TABLE I - COMPRESSOR ROTOR COMPONENTS - LIFE LIMITS Part Name and Part Number Figure 2 Index No.
Life Limits Hours Cycles Multiplying Factor for Repetitive Heavy-Lift and Utility Operations - Hours to Cycles Stage 1 Disk 1 3920T11P01 4,000 9,900 2.4 July 09, 1979 CT58 S/B 72-A0162 Revision 16, January 07, 2015 PAGE 11 GE PROP RIETARY INFORMATION - Subject to the restrictions on the cover or first page.
ENGINE - Service Life Limits for Rotating Parts
TABLE I - COMPRESSOR ROTOR COMPONENTS - LIFE LIMITS Part Name and Part Number Figure 2 Index No.
Life Limits Hours Cycles Multiplying Factor for Repetitive Heavy-Lift and Utility Operations - Hours to Cycles 3920T11P02 4,000 9,900 2.4 37D400032P101 1,000 2,000 2.4 37D400211P101 1,000 2,000 2.4 37D400218P101 4,000 9,900 2.4 37D400218P102 4,000 9,900 2.4 37D400359P101 4,000 9,900 2.4 37D400359P102 4,000 9,900 2.4 *5001T20P01 4,000 9,900 2.4 5001T20P02 4,000 9,900 2.4 5013T06P01 4,000 9,900 2.4 Front Disk Shaft 2 37E500153P101 2,500 6,000 1.6 37E500213P101 2,500 6,000 1.6 37E500153P101M 2,500 6,000 1.6 **37E500213P103 See S/B 72-0078 (CEB-136) 2,500 6,000 1.6 5005T34P01 6,100 8,500 1.6 *5005T34P03 6,100 8,500 1.6 **5008T79P01 3,000 6,000 1.6 **5008T79P02 6,100 8,500 1.6 595E919P101 1,000 2,700 1.6 Spool 3 102R656P010 4,000 8,000 6.0 102R656P010CEB-147 # 10,000 20,000 6.0 37R600015P105 4,000 8,000 6.0 **37R600108G001 4,000 8,000 6.0 July 09, 1979 CT58 S/B 72-A0162 Revision 16, January 07, 2015 PAGE 12 GE PROP RIETARY INFORMATION - Subject to the restrictions on the cover or first page.