Pw100-098R5 PW127 Fuel Nozzle Flexible Manifold Installation

5/22/2018 Pw100-098R5 PW127 Fuel Nozzle Flexible Manifold Installation

S.I.L NO. PW100-098R5

SERVICE INFORMATION LETTER

This Service Information Letter is valid until superseded or cancelled by revision

EXPORT CONTROL CLASSICATION: P-ECCN / ECCN: 9E991

ISSUED: May 7, 2010 Page 1 of 7REVISED: Nov 27, 2013

PRATT & WHITNEY CANADA CORP.MARIE-VICTORIN, LONGUEUIL

QUEBEC, CANADA J4G 1A1

PRINTED IN CANADA

Subject: Fuel Nozzle Flexible Manifold Installation

Applicability: All PW100 Engines Equipped with Flexible Fuel Nozzle Manifolds

Reason for revision: Introduction of new or modified fuel nozzle adapters and conical

gaskets.

This Service Information Letter (SIL) is revised to advise the release of Service Bulletin (SB) 21841and 21848 to the field. SB21841 introduces new or modified fuel nozzle adapters with a largerinternal diameter while SB21848 introduces a new conical gasket between the metal to metalsealing surfaces.

Background:

Fuel leakage incidents have been reported following the installation of the fuel nozzle flexiblemanifold. In all cases, the fuel nozzles had recently been replaced and the fuel leaks were theresult of improperly torqued B-Nut fittings at the fuel manifold / fuel nozzle adapter connections,leading to fretting wear of the packing. In order to permit detection of an improperly torquedmanifold by maintenance personnel following replacement of fuel nozzles, Pratt & Whitney CanadaCorp. (P&WC) introduced SB21803. This SB removes the preformed packing. With the preformed

METAL CONICAL

GASKET

LARGER INTERNAL

DIAMETER


PRATT & WHITNEY CANADASERVICE INFORMATION LETTER

S.I.L NO. PW100-098R5





QUEBEC, CANADA J4G 1A1PRINTED IN CANADA

packing removed, fuel leaks caused by improper torquing of the B-Nuts will be detected during wetmotoring or ground running of the engine immediately following installation by maintenancepersonnel.

Field experience on post-SB21803 configuration (removal of the o-ring) has shown that it issometimes difficult to achieve a seepage-free assembly at the fuel nozzle/manifold interface andthis will affect fuel nozzle system maintenance time. To compensate for imperfections between thefuel nozzle adapter / fuel manifold interface, P&WC has published SB21848, which introduces newmetal gaskets of a softer material, that will comply with surface variations. The fuel nozzleadapters have been modified per SB21841 to provide a larger inner diameter to accommodate thenew metal gasket.

Because of the serious implication of fuel leaks and seepage, P&WC invites operators to reviewtheir Line Maintenance practices and if not already implemented, to consider the following FuelNozzle Flexible Manifold Installation Best Practices:

1.0 Tooling

1.1 With the introduction of the conical gasket, 2 new tools,PWC45140 and PT454379, are introduced to facilitate theinstallation and removal of the gaskets from the fuel manifoldrespectively.

PWC45140 and PT454379

1.2 Wrench kit number PWC45206 is recommended in the EngineMaintenance Manual (EMM) for post-SB21841 fuel nozzlemanifold removal and installation. Field experience hasdemonstrated this tool kit provides more accessibility andflexibility for component installation and final torqueapplication. With the introduction of the new fuel nozzleadapters and conical gaskets, PWC56601 torque wrench willneed to be re-calibrated to 250-270 lb. in. and re-identified toPWC45200. TSB PW100-744 addresses this conversion.

Wrench Kit PWC45206

1.3 P&WC has also introduced a new tool kit number PWC45215 which includes a complete setof all aforementioned tools for the post-SB21841/SB21848 fuel nozzle configuration. Ofparticular interest for new operators who do not have any of these tools yet, the complete kitor the components of the tool kit can be procured under their respective tool number:



S.I.L NO. PW100-098R5






PWC45206 Wrench kitPWC45200 Pre-set torque wrench (7.5 inches long) for flexible manifold final torque.

This tool calibrated to the EMMs recommended final torque limitfeatures two crowfoot extensions made at different angles to improveaccessibility

PWC56504-1 Wrench (4 inches long) for fuel manifold removalPWC56504-2 Wrench (2.5 inches long) to run down fuel manifold connector fitting

(hex nut).PWC56612 Special crowfoot adapter to be used to avoid No. 5 bearing vent tube

removal.Removal and Installation ToolPWC45150 DriftPT454379 Plastic Pick

1.4 Following the introduction of SB21803, the use of SeatingGauge PWC56962 is no longer required (a revision to theEMM had been made to that effect).

Seating Gauge PWC56962

2.0 Handling, Removal & Installation

2.1 P&WC reminds operators that it is important to ensure that all fuel manifold / fuel nozzleadapter connections are properly engaged and the fuel manifold hose connector fittings aretorqued as per EMM recommendations.

2.2 Installation procedures for the fuel nozzle adapters and flexible manifolds can be found inSB21848. Operators are reminded to refer to the EMM Chapter 72-01-40 for the detailedinstructions.2.2.1 Lubrication requirements for the fuel nozzle adapter and manifold locations have been

added to the instructions. By applying anti-galling compound to the fuel nozzlethreads, the possibility of thread damage is minimized. Furthermore, the lubricationrequirements serve to minimize assembly friction and optimize the amount of torquethat is converted to assembly preload. The following pictures illustrate these changes:

PW

C

4

5

2

1

5



S.I.L NO. PW100-098R5






Fuel Nozzle Adapter Threads

B-Nut Thrust Wire Lock Ring Fingers

2.2.2 Torque wrench PWC45200 must be correctly held to avoid applying insufficient torqueto connections.

Incorrect Hand Grip Correct Hand Grip

2.2.3 A three-step torque, un-torque to zero and final torque procedure is necessary toensure proper seating of the conical gaskets.

2.3 P&WC wishes to stress the importance of compliance with the following maintenance criteriaand cautionary notes as detailed in the EMM:2.3.1 Inspection of the fuel manifold hose for damage (Ref. EMM, Chapter 72-01-40, Fuel

System Inspection).

Application of anti-seizecompound to the threads

only. Avoid applying toconical section.

Application ofengine oil onthrust wire &Moeller fingersprior to applyingtorque.



S.I.L NO. PW100-098R5






2.3.2 Upon Fuel Nozzle replacement, there should be adequate clearance between themanifolds and adjacent tubing (Ref. EMM, Chapter 72-01-40, Fuel SystemInstallation).

2.3.3 Make sure that the preformed packings are NOT installed (Ref. SB21803 and AD CF-2013-29).

2.3.4 Once all Fuel Nozzle Manifold B-Nuts are torqued properly, the locking feature (crownring & lock ring) should be as shown in the illustration below.

3.0 Final Torque Witness Check

3.1 To ensure sealing integrity of the flexible manifold / fuel nozzle adapter connections, P&WCrecommends the implementation of a witness check of the final torque and the visualobservation of the lock ring engagement. Appendix 1 shows a sample sign-off sheet forcompletion by the Line Maintenance mechanic and the witnessing mechanic/inspector.

4.0 Testing of the Fuel Manifold System for Leaks

4.1 With the removal of the preformed packing, a Leak Check is introduced to flow Nitrogen

through the manifolds via the Flow Divider & Dump Valve in order to help locate B-Nuts thatwould not have been torqued properly (Ref. EMM, Chapter 72-01-40, Fuel SystemInstallation). In addition, leak detection fluid is permissible as an aid during the leak test(Refer to SB21848).



S.I.L NO. PW100-098R5






5.0 Commercial coverage

5.1 The introduction of the conical seal is supported commercially by P&WC. Refer to CSPN1007035. Coverage consists of the following:5.1.1 One set of conical seals at no charge, claimable once per engine S/N.5.1.2 Subsequent orders of conical seals at the published list price less 75%.5.1.3 The rework of the fuel nozzle inner diameter to accommodate the conical seal is

provided at no additional cost to the operator. The rework of the fuel nozzle will beincluded in the normal price the operator currently pays for refurbishing nozzles. Noclaims are required to obtain this coverage.

To conclude, substantiation testing has demonstrated that the fuel manifold connector fitting will notbecome loose if properly engaged and the newly introduced metal conical gasket will address anyfuel seepage if the recommended torque is applied and the locking feature properly engaged.

Yours truly,

PRATT & WHITNEY CANADA CORP.

Alfred Lum Alexandre Fortier

Customer Engineer, Customer Engineering Manager, Customer EngineeringPW100/PW150 Engine Programs PW100/PW150 Engine ProgramsCustomer Service Regional Market Customer Service Regional Market



S.I.L NO. PW100-098R5






Pw100-098R5 PW127 Fuel Nozzle Flexible Manifold Installation

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