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ANNEX F Common Solution/Concept List (U)
Air Force Mission Area Plan (MAP)

Engines

 

ENGN002 F100-PW-229 HPT (HIGH PRESSURE TURBINE)

DESCRIPTION: Provides new diffuser case on the F100-PW-229 engine for F-16s which will eliminate a separation in the flow path of the High Pressure Turbine (HPT) module in the area of the 1st stage turbine blades and blade outer airseals (BOAS). This flow separation is caused by a large radial step between the 1st turbine vane outside diameter platform trailing edge and the 1st stage BOAS inside diameter leading edge. Large radial step (.050" to .190") is created by the current configuration of the combustor and HPT.

JUSTIFICATION:

1. Safety. Reduces F-16 Class A rate by 0.78/100k EFH.

2. Reliability and Durability. Package expected to significantly reduce maintainability and extend component life.

3. Configuration Control. This retrofit was initiated in FY97. Failure to complete entire retrofit program would make core module unmanageable and non-supportable in the field and at depot.

4. Cost Savings. $8.667M, through FY14 (TY$)

PROGRAM ELEMENT: 27133F

ISSUES: 1. HPT OD Flowpath (ECP 96QA053) was approved at the 16 Dec 96 ASC Configuration Control Board.

2. Retrofit to be accomplished at depot. This retrofit includes prior year funds.

3. Technically "tied" to mods included in the Falcon P3A.

** P3A includes multiple mods.

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN003 F100-220E IDEEC 5.4.0/EDU 2.5.0

DESCRIPTION: The task supports efforts from the OEM to support the IDEEC5.4.0/EDU 2.5.0 logic incorporation. The OEM will provide engineering and logistics support to ensure Support Equipment compatibility with CEDS, EAU and FRS presently in the field.

JUSTIFICATION: Augmentor combustion instability contributes to 2nd fan disk failure. Software logic changes need to be fine-tuned to eliminate fan disk problems. This logic change revises augmentor fuel/air schedule and transient scheduling addressing 2nd fan disk fracture from coked sprayring, JP-8 fuel, and augmentor instability.

PROGRAM ELEMENT: 27130F/27133F/27134F

ISSUES:

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Schreffler PEM Backup Name:

 

ENGN006 F100-PW-229 ANTI-ICE VALVE FAILED CLOSE

DESCRIPTION: Provide new inlet anti-icing valve featuring improved process carbon rings, increased internal vent areas, new material return spring and revised primary filter retention scheme to reduce potential valve malfunction due to internal leakage. The -229 fleet has experienced numerous occurrences of stuck anti-ice valves caused by air leakage past the carbon rings which exposes the engine to the risk of ice FOD. The carbon rings of some rejected valves were found to be contaminated with aluminum phosphate and other organics which resulted in rings binding on the sleeve and sealing the sleeve to the bore.

JUSTIFICATION:

1. Increased reliability. New valve will reduce unscheduled engine removals due to failed closed valves, reduce maintenance manhours, and reduce scrappage rate for anti-icing valves.

2. Cost Savings. $1.420M, through FY15 (TY$)

ISSUES: 1. New anti-icing valve (ECP 95QA340) approved at the 5 Aug 96 ASC Configuration Control Board.

2. Kit cost $2,820 BY96 dollars.

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN007 F100-PW-229 COMBUSTOR IMPROVEMENTS

DESCRIPTION: Replace existing bill of material (BOM) fuel manifold supply tubes (pigtails) on F100-PW-229 engine cores for F-15s with newly-designed hardware. Pigtails have fractured causing the engine to shutdown and, subsequently, unable to restart. This event has occurred twice since fielding the engine, both involving F-15 aircraft. These fractures have been attributed to High Cycle Fatigue (HCF). [Pigtails on F-16s are planned for retrofit as soon as new hardware is available (projected for Mar 98)]. Driving the need for retrofit is commonality of configuration and reduction of Nonrecoverable Inflight Shutdown (NRIFSD) events.

JUSTIFICATION: 1. Commonality of Configuration. The USAF has taken great strides to maintain a common configuration between F-15 & F-16 modules and takes the position that retrofit modifications must be made to both. Because -229 engine cores are managed as a single configuration item, core management would be exceptionally difficult without the retrofit.

2. Reduction in NRIFSD Events. NRIFSD rate is high (1.58/100k hours) which will lead to nine more projected events over the life of the engine.

3. Cost Savings (for F-15) : $2.392M, through FY12 (TY$)

PROGRAM ELEMENT: 27134F

ISSUES: 1. F100 CIP task 1A-815RO97Z. ECP submittal scheduled for Dec 97.

2. Retrofit at depot and JEIM. No additional support equipment required. Kit cost $12,500 BY 97 dollars.

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN010 F100-PW-229 DEEC LOGIC 2.9.0

DESCRIPTION: Provide software upgrade to Engine Diagnostic Unit (EDU) and Digital Electronic Engine Control (DEEC). New logic will provide: deactivated fan speed avoidance logic for F-15s, activation of aggressive starts for F-15s, EPROM versus UVPROM configuration fault detection, aircraft main fuel valve shutoff closure at high power, inlet ramp failure detection for F-15s, fault detection and accommodation of anti-ice valve malfunction, and expanded envelope for PS2 & PT6 sensors.

JUSTIFICATION:

1. New software provides improved logic which improves maintainability and safety.

2. Cost savings. Approx $9.537M, through FY15 (TY$)

PROGRAM ELEMENT: 27133F / 27134F

ISSUES:

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN014 F110-GE-100 DEC

DESCRIPTION: The Digital Engine Control (DEC) replaces the existing analog fuel temperature control (AFTC) on the F110-GE-100 engine. The DEC includes a variable stator vane fail safe system, eliminates engine caused auto accels, and adds two backup control modes. The DEC retrofit is a prerequisite for the F110-GE-100B model change for the 4000 TAC interval. This retrofit will improve the safety, supportability, reliability and maintainability of the engine.

JUSTIFICATION:

1. Current NRIFSD risk is assessed to be 4.35/MEFH. Implementation of this change will reduce the NRIFSD risk to .367/MEFH (.5/MEFH or lower is acceptable).

2. Redundant variable stator vane control; increases engine safety.

3. Eliminates engine caused auto accels; increases engine safety.

4. Adds two control modes; increases engine safety and supportability.

5. Adds reduced speed excursion (RSE) to allow the F110-GE-100B engines to fly a 4000 TAC interval; increases engine supportability and R&M.

PROGRAM ELEMENT: 27133F

ISSUES: Prior year funding beginning with FY93, including 17.574 FY98 and 21.9 FY99

REFERENCES:

MNS Number & Title: N/A ORD Number & Title: TAF ROC 303-76, F-16 Air Combat Fighter

1067 Number & Title: N/A Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN017 MEC/VSV Improvements

DESCRIPTION:

A unitized VSV spring assembly will replace a separate three piece bearing and spring component assembly (EPD F173M46R2). The spring rate will be increased from 4 to 6 pounds.

This new hardware will be incorporated by a TCTO driven depot level retrofit and new production introduction.

JUSTIFICATION:

Four VSV spring assemblies have been found misassembled during depot level inspections. These missassemblies resulted in a loss of usable thrust due to significant fan core speed mismatches caused by VSV system failure.

PROGRAM ELEMENT: 27133F

ISSUES: Includes $0.4M in FY98 and $0.1M in FY99.

Includes deliveries of 299 ea. in FY97, 564 ea. in FY98 and 170 ea in FY99.

REFERENCES:

MNS Number & Title: N/A ORD Number & Title: N/A

1067 Number & Title: N/A Development Plan Date & Title: N/A

Current CINC IPL:

ACC PEM Name: Capt. Maria Schreffler PEM Backup Name:

 

 

ENGN021 F110-GE -129 TURBINE FRAME COMPOSITE FAIRING

DESCRIPTION: Replace existing composite fairing with titanium fairing similar to the curved ruggedized F110-GE-100 fairing. The turbine frame composite fairing have experienced wear and heat damage. Small burn-through holes have been discovered on several operational engines. On one test engine, a delaminated piece of fairing blocking cooling flow in the exhaust nozzle, resulting in burn through of outer engine case. A burn through occurring in service could result in a catastrophic mishap.

JUSTIFICATION:

1. Eliminate risk of engine case burn through caused by composite fairing delamination.

2. Improve supportability by eliminating 200 EFH recurring inspection burden on maintenance personnel.

PROGRAM ELEMENT: 27133F

ISSUES:

REFERENCES:

MNS Number & Title: N/A ORD Number & Title: N/A

1067 Number & Title: N/A Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN022 F100-PW-100 Engine Upgrade (220E Kits)

DESCRIPTION/JUSTIFICATION:

Upgrade of the F-15C/D F100-PW-100 Engine to the 220E configuration is required to avoid technical obsolescence problems anticipated in supporting the current hydromechanical control system, reduce cost of ownership (operating & support costs), provide logistics commonality and interchangeability with engines in F-16 aircraft, which is beneficial to deployments, composite wing basing, lateral support, etc.

PROGRAM ELEMENT: 27130F

ISSUES: Contract negotiations not complete. Exact kit delivery schedule unknown at this time.

REFERENCES:

MNS Number & Title: ORD Number & Title: CAF (AFLC 002- 89)-III-A F-15 C/D Engine Enhancement Program

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Schreffler PEM Backup Name:

 

ENGN023 F100-PW-229 EAGLE - 229 PROGRAM

DESCRIPTION: Provides a new core and high pressure turbine (HPT) configuration on the F100-PW-229 engine that improves safety, durability, and oxidation/temperature resistance for various components within the core module. Tasks include improved HPT OD flowpath reconfiguration, combustor assembly with brushseals, first HPT vane, first stage HPT blade, super convective shroud/first blade outer airseal (BOAS), second stage HPT vanes, second vane inner air seal, and HPT fasteners.

JUSTIFICATION:

1. Safety. Reduces F-15 Nonrecoverable Inflight Shutdown (NRIFSD) rate by 13/100k EFH.

2. Reliability and Durability. Package expected to significantly reduce maintainability and extend component life.

3. Configuration Control. This retrofit was initiated in FY97. Failure to complete entire retrofit program would make core module unmanageable and non-supportable in the field and at depot.

4. Cost Savings. $78.202M, through FY15 (TY$)

PROGRAM ELEMENT: 27134F

ISSUES: 1. Package (ECP 96QA053) was approved at the 16 Dec 96 ASC Configuration Control Board.

2. Retrofit to be accomplished at depot. Primarily consists of HPT 97 Upgrade package. This retrofit has FY97, 98, & 99 funds.** P3A includes multiple mods

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN024 F100-PW-229 INCREASED PERFORMANCE ENGINES (IPEs) FOR EARLY F-15s

DESCRIPTION: Replace F100-PW-220 engines with F100-PW-229 or F110-GE-129 engines for F-15E model aircraft at Seymour-Johnson AFB, Nellis AFB, and Mountain Home AFB. Displaced -220 engines would flow to USAF and PACAF F-15C that have F100-PW-100 engines.

JUSTIFICATION:

1. The current F100-PW-220 engine used on early F-15E aircraft accumulates too much time at high power in satisfying F-15E mission thrust requirements. Excessive hot section distress occurs. Currently, this is a problem for the 3rd stage of the turbine. Although corrective actions are being planned for these failure modes, the IPEs satisfy mission requirements with greater temperature margin reducing the likelihood of premature hot section distress.

2. Cost savings. $577.963M, through FY20 (TY$)

PROGRAM ELEMENT: 27134F

ISSUES:

1. Includes procurement of new engines, new spare engines to complement the new installs, and modifications required to the airframe.

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN025 T4B Pyrometer Design Improvements

DESCRIPTION:

The T4B pyrometer design improvements result in improved accuracy and reliability. The potting material thermal expansion creates failure of the solder joints. Additionally, accuracy, electronic drift and external contamination contribute to cold shifts.

Change implementation includes rework of field units upon exposure/failure and new production introduction.

JUSTIFICATION:

Incorporation of the proposed redesigned hardware will improve the reliability and safety of the engine. The current design T4B pyrometer is one of the most unreliable LRUs on the F110 engine:

1. Increasing rate of out of range faults

- F110-GE-100 AFTC engines have NRIFSD risk due to speed rollback

2. Numerous cold shifts

- Potential contributor to turbine distress

3. High Maintenance driver

PROGRAM ELEMENT: 27133F

ISSUES: Includes $0.4M in FY98 and $0.4M in FY99.

REFERENCES:

MNS Number & Title: N/A ORD Number & Title: N/A

1067 Number & Title: N/A Development Plan Date & Title: N/A

Current CINC IPL:

ACC PEM Name: Capt. Maria Schreffler PEM Backup Name:

 

ENGN027 Turbine Frame Oil Tube

DESCRIPTION: Incorporate F110-129 style B-nut and anti-rotation bracket (EPD G165D08r2). This design eliminates the resonance to the core excitation from the operating range

JUSTIFICATION: Oil supply tube failures have occurred. These could result in oil loss causing bearing seizure and engine failure.

Change implementation includes retrofit at depot and new production introduction.

PROGRAM ELEMENT: 27133F

ISSUES: Includes $0.6M in FY98 and $0.7M in FY99.

REFERENCES:

MNS Number & Title: N/A ORD Number & Title: N/A

1067 Number & Title: N/A Development Plan Date & Title: N/A

Current CINC IPL:

ACC PEM Name: Capt. Maria Schreffler PEM Backup Name:

 

ENGN028 F110-GE-129 DEC HARDWARE RETROFIT

DESCRIPTION: Change replaces obsolete chip in DEC. This retrofit also improves the reliability and maintainability of the DEC and provides on-wing reprogramming capability for the Block 50 F-16 engines. Currently, the DEC can not be reprogrammed without removing it from the engine. On-wing reprogramming will provide significant O&S savings and allow implementation of operational capability improvements.

JUSTIFICATION:

1. Mandatory change to eliminate an electronic part obsolescence problem.

2. On-wing reprogramming capability; reduces MMH required for reprogramming.

3. Increase supportability by eliminating need to remove DEC for reprogramming.

PROGRAM ELEMENT: 27133F

ISSUES: Includes $.326 M in FY98 and $2.274 M is FY99.

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN 040 F110-GE-129 EXHAUST DUCT LINER BURNTHROUGH

AND SCREECH REDUCTION

DESCRIPTION: The F110-GE-129 has experienced 9 liner burnthroughs since Jan 95. The F110-GE-100 as experienced approximately 30 exhaust duct liner burnthroughs since 1995. Burnthrough for both engines is related to exhaust duct liner aspiration. The exhaust duct liner for both engines will be replaced with a common liner. Additionally, the liner will be redesigned to further reduce screech induced hardware distress experiences on the F110-GE-129.

JUSTIFICATION:

1. Max fuel/air ratio reduced on the F110-GE-129, resulting in lower thrust in the upper left-hand corner of the F-16 flight envelope. Redesign would allow engine to operate at full thrust.

2. Reliability/maintainability improvement

PROGRAM ELEMENT: 27133F

ISSUES: Combines funding for exhaust duct burnthrough and screech reduction.

REFERENCES: (Provide the following information, if relevant.)

MNS Number & Title: N/A ORD Number & Title: N/A

1067 Number & Title: N/A Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN041 F100-PW-229 FALCON -229 UPGRADE

DESCRIPTION: Provides a new core and high pressure turbine (HPT) configuration on the F100-PW-229 engine that improves safety, durability, and oxidation/temperature resistance for various components within the core HPT. Tasks include improved combustor assembly with brushseals, first HPT vane, first stage HPT blade, super convective shroud/first blade outer airseal (BOAS), second stage HPT vanes, second vane inner air seal, unstaged fuel nozzles, and HPT fasteners.

JUSTIFICATION:

1. Safety. Reduces F-16 Class A rate.

2. Reliability and Durability. Package expected to significantly reduce maintainability and extend component life.

3. Configuration Control. This retrofit was initiated in FY94. Failure to complete entire retrofit program would make core module unmanageable and non-supportable in the field and at depot.

4. Cost Savings. $14.613M, through FY14 (TY$)

PROGRAM ELEMENT: 27133F

ISSUES: 1. Package (ECP 96QA053) was approved at the 16 Dec 96 ASC Configuration Control Board.

2. Retrofit to be accomplished at depot. This retrofit package includes prior year funds.

** P3A includes multiple mods.

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN058 F100-PW-229 AIR PARTICLE SEPARATOR

DESCRIPTION: Replace existing air particle separator on the F100-PW-229 engine with redesigned separator. The number four bearing seal air supply manifold assembly is designed to remove debris from the 7th stage bleed air before it enters the compartment buffer chamber. Debris scratches indicate that it is not removing enough of the particulate from the 7th bleed air supply. Disassembly of these compartments frequently find indications of seal debris ingestion.

JUSTIFICATION:

1. Safety. Fractured air particle separators resulted in domestic object damage to sprayrings/liners with a potential of causing secondary nozzle burn-though. To date, three separators on -229 engines have fractured.

2. Cost Savings. $0.519M, through FY15 (TY$)

PROGRAM ELEMENT: 27133F / 27134F

ISSUES: 1. F100 CIP task 1A-129R097C. ECP submittal scheduled for Mar 98.

2. Retrofit proposed at depot or JEIM. Kit cost $500 BY96 dollars

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN062 F100-PW-229 IMPROVED DURABILITY OIL FILTER

DESCRIPTION: Provide new oil filter assembly on F100-PW-229 engine. Existing oil filter assembly head has cracked in the lower mount lug area resulting in oil loss. Four oil filter assemblies have been rejected for oil loss due to cracks in the head casting. Investigation of one assembly found that crack was fatigue initiated from the mount lug fillet.

JUSTIFICATION:

1. Increased reliability. Number of Unscheduled Engine Removals (UERs) due to cracked oil filter assemblies over life of system expected to be 24.

2. Cost savings. $0.053M, through FY15 (TY$)

PROGRAM ELEMENT: 27133F / 27134F

ISSUES:

1. Retrofit proposed at depot or JEIM. No additional support equipment necessary to implement this task.

2. Kit cost $3,000 BY97 dollars.

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN063 F100-PW-229 SCAVENGE ENHANCED 2/3 BEARING COMPARTMENT

DESCRIPTION: Provide baffle for gearbox in F100-PW-229 engines that will aid in oil scavenging. Currently, oil remains in the #2/3 bearing compartment and dumps into the gearbox at engine shutdown in some engines. There is low pressurizing buffer air around the compartment at engine idle conditions. Consequently, there is little air leakage into the compartment to aid oil scavenging.

JUSTIFICATION:

1. Increased maintainability. When oil remains in the bearing compartment, mechanics will add oil to the tank which results in an over-serviced condition that may later cause oil leaks. It may also cause an unscheduled engine removal for suspected excessive oil consumption. During engine operation, excess oil goes to the #2/3 compartment which results in churning, oil aeration, and increased compartment pressure which may manifest itself as high oil pressure and/or compartment coking.

2. Cost Savings. $0.704M, through FY15 (TY$)

PROGRAM ELEMENT: 27133F / 27134F

ISSUES: 1. F100 CIP task 18-863RO96Z. ECP submittal scheduled for Dec 97.

2. Retrofit proposed at depot or JEIM. Kit cost $200 BY96 dollars.

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN064 F100-PW-229 SIXTH STAGE CLIPS

DESCRIPTION: Provide new sixth stage compressor stator vane locks (44 per kit) featuring 3.5 degrees camber increase on the F100-PW-229 engine. This will provide increased rotation for the sixth stage vanes resulting in an increased stall margin. The engine has experienced a stall rate of 0.36 stalls/1000 EFH. Of this, 0.22 have been attributed to malfunctions (e.g., anti-ice valve, bleed strap) with the remaining 0.14 resulting from thermal stalls. To reduce thermal stalls, new stator clips were designed that will reposition the 6th stage vanes 3.5 degrees adding more loading to stator six and reducing the load at rotor seven. The net effect is a 2-3 percent increase in HPC base stall margin. The primary benefit of retrofitting is the reduction of stalls which will improve unscheduled engine removals, readiness, and supportability.

JUSTIFICATION:

1. Reduction of stalls. Together with DEEC 2.8 software logic (See applicable MIP solution summary), new clips will significantly reduce thermal stalls to the expected mature stall rate of 0.25/1000 EFH.

2. Reduction of stall-related field maintenance. Depending on severity, field actions may include tear-down and build-up of engine core.

3. Cost Savings. $0.959M, through FY15 (TY$)

PROGRAM ELEMENT: 27133F / 27134F

ISSUES: 1. New clips (ECP 96QA115) approved at the 17 Mar 97 ASC Configuration Control Board.

2. Retrofit at depot and JEIM. Kit cost $1,400 BY96 dollars.

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN067 F110-GE-129 MODERNIZE EMSC

DESCRIPTION: Produce a commercial parts based interface transparent replacement for the existing EMSC with improved reliability and an ongoing obsolescence management program for the life of the weapon system.

JUSTIFICATION:

1. Mandatory parts obsolescence change.

2. Improves supportability.

3. Download once/week vs once/day

PROGRAM ELEMENT: 27133F

ISSUES:

REFERENCES:

MNS Number & Title: N/A ORD Number & Title: N/A

1067 Number & Title: N/A Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN068 F110-GE-129 # 4 BEARING FAILURE DETECTION CHANGE

DESCRIPTION: The # 4 Bearing Failure Detectability Change improves detectability of bearing failure by alleviating some of the bearing debris (chips) traps in the aft sump. Sump configuration results in centrifugal debris traps reducing flow of # 4 Bearing debris to the detector. The #4 Bearing Failure Detectability change design includes one retrofit kit and 3 rework changes.

  1. Retrofit kit consist of a spacer and nut being unitized into a single assembly
  2. Rework the # 4 bearing carbon seal runner by hand blending out the seal step
  3. Rework the # 5 seal mating ring by hand blending seal step
  4. Rework the LPT shaft by drilling to eliminate step

Change implementation includes retrofit at first exposure in the field and first return to depot. Installation of the unitized spacer/nut assembly (1) and blending of the # 4 bearing carbon seal runner (2) will be accomplished at JEIM first exposure using field TCTOs with kits. Blending of the # 5 seal mating ring (3)and rework of the LPT shaft (4) will be accomplished at first return to depot using depot TCTOs.

JUSTIFICATION: This is a mandatory safety change. The F110 engine family had 18 primary undetected # 4 Bearing failures to date. Eight were IFSD/seizures with one of these failures resulting in a dead stick landing. Currently the Non-recoverable In-flight Shutdown (NRIFSD) risk is assessed to be 2.5/MEFH. Implementation of this change will reduce the NRIFSD risk.

PROGRAM ELEMENT: 27133F

ISSUES: Modification starts in FY99 with $2.0M.

REFERENCES:

MNS Number & Title: N/A ORD Number & Title: N/A

1067 Number & Title: N/A Development Plan Date & Title:

Current CINC IPL: N/A

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN069 F100-100/200/220 Improved Turbine Fasteners (HPT)

DESCRIPTION/JUSTIFICATION:

Nine incidents of HPT pin and collar fracture have occurred which were attributed to stress rupture. A new fastener will alleviate the failure due to stress rupture by incorporating a fastener made from a different material. A retrofit is required at first access to the area to prevent further occurrences.

PROGRAM ELEMENT: 27130F/27133F/27134F

ISSUES:

REFERENCES:

MNS Number & Title: N/A ORD Number & Title: N/A

1067 Number & Title: N/A Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Schreffler PEM Backup Name:

 

ENGN070 F100-PW-229 EJECTOR NOZZLE FOR F-15E AND F-16B52

DESCRIPTION: Provide redesigned nozzle that utilizes cool air available from the engine nacelle to create a boundary layer inside the divergent section of the nozzle. This involves modifying the divergent flaps/seals and engine augmentor duct to provide a pathway for the air source and a sealed plenum between the nozzle static structure and ejector slot which will allow aircraft nacelle air (close to ambient temperature) to be channeled into the divergent section. This process lowers the temperature to down-stream hardware by 500-900 degrees which improves weapon system operational and support (O&S) costs while maintaining or improving system performance.

JUSTIFICATION:

1. Lower O&S costs. Projected savings for F-16 Block 52 aircraft $7.83M [BY 97 dollars] over life of aircraft. Data not currently available for F-15 fleet.

2. Improved survivability. Reduction of infrared radiation (IR) signature reduces threat to aircraft from IR sources.

PROGRAM ELEMENT: 27134F

ISSUES:

1. HQ ACC Director of Logistics and Director of Requirements both support this project and have nominated this development program for DARPA funding.

2. Task to be incorporated into the 1998 CIP. ECP submittal scheduled by mid-FY00.

3. F-16 System Program Office (SPO) fully supports program; F-15 SPO is still evaluating.

4. P&W target price: $64k / engine kit, $27k / aircraft kit.

5. Total Requirement: 129 acft, 253 engines (installs & spares), 49 spare modules

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN071 F100-PW-220/220E EJECTOR NOZZLE FOR F-15C/D/E AND F-16B42

DESCRIPTION: Provide redesigned nozzle that utilizes cool air available from the engine nacelle to create a boundary layer inside the divergent section of the nozzle. This involves modifying the divergent flaps/seals and engine augmentor duct to provide a pathway for the air source and a sealed plenum between the nozzle static structure and ejector slot which will allow aircraft nacelle air (close to ambient temperature) to be channeled into the divergent section. This process lowers the temperature to down-stream hardware by 500-900 degrees which improves weapon system operational and support (O&S) costs while maintaining or improving system performance.

JUSTIFICATION:

1. Lower O&S costs. Projected savings for F-16 Block 42 aircraft $29.34M [BY 97 dollars] over life of aircraft. Data not currently available for F-15 fleet.

2. Improved survivability. Reduction of infrared radiation (IR) signature reduces threat to aircraft from IR sources.

PROGRAM ELEMENT: 27134F

ISSUES:

1. HQ ACC Director of Logistics and Director of Requirements both support this project and nominated this development program for DARPA funding

2. Task to be incorporated into the 1998 CIP. ECP submittal scheduled by mid-FY00.

3. F-16 System Program Office (SPO) fully supports program; F-15 SPO is still evaluating.

4. P&W target price: $64k / engine kit, $27k / aircraft kit.

5. Total Requirement: 878 acft, 1335 engines (installs & spares), 115 spare modules

6. Includes entire -200 family (-200, -220, -220E)

 

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN072 F110-GE-129 ADVANCED EJECTOR NOZZLE KIT FOR F-16B50

DESCRIPTION: Provide redesigned nozzle that utilizes cool air available from the engine nacelle to create a boundary layer inside the divergent section of the nozzle. This involves modifying the divergent flaps/seals and engine augmentor duct to provide a pathway for the air source [two small ram air inlets on the fuselage exterior] and a sealed plenum between the nozzle static structure and ejector slot which will allow aircraft nacelle air (close to ambient temperature) to be channeled into the divergent section. This process lowers the temperature to down-stream hardware by 500-900 degrees which improves weapon system operational and support (O&S) costs while maintaining or improving system performance.

JUSTIFICATION:

1. Lower O&S costs. Projected savings for F-16 Blocks 30, 40, & 50 aircraft (fleet size of 1036 engines) $73.0M [BY 97 dollars] over life of aircraft.

2. Improved survivability. Reduction of infrared radiation (IR) signature reduces threat to aircraft from IR sources.

PROGRAM ELEMENT: 27134F

ISSUES:

1. HQ ACC Director of Logistics and Director of Requirements both support this project and have nominated this development program for DARPA funding.

2. Task to be incorporated into the 1998 CIP. ECP submittal scheduled by mid-FY00.

3. F-16 System Program Office (SPO) fully supports program; F-15 SPO is still evaluating.

4. GE target price: $90k / engine kit, $25k / aircraft kit.

5. Total Requirement: 183 acft, 245 engines (installs & spares)

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:

 

ENGN073 F110-GE-100 ADVANCED EJECTOR NOZZLE KIT

FOR F-16B30 & 40

DESCRIPTION: Provide redesigned nozzle that utilizes cool air available from the engine nacelle to create a boundary layer inside the divergent section of the nozzle. This involves modifying the divergent flaps/seals and engine augmentor duct to provide a pathway for the air source [two small ram air inlets on the fuselage exterior] and a sealed plenum between the nozzle static structure and ejector slot which will allow aircraft nacelle air (close to ambient temperature) to be channeled into the divergent section. This process lowers the temperature to down-stream hardware by 500-900 degrees which improves weapon system operational and support (O&S) costs while maintaining or improving system performance.

JUSTIFICATION:

1. Lower O&S costs. Projected savings for F-16 Blocks 30, 40, & 50 aircraft (fleet size of 1036 engines) $73.0M [BY 97 dollars] over life of aircraft.

2. Improved survivability. Reduction of infrared radiation (IR) signature reduces threat to aircraft from IR sources.

PROGRAM ELEMENT: 27134F

ISSUES:

1. HQ ACC Director of Logistics and Director of Requirements both support this project and have nominated this development program for DARPA funding.

2. Task to be incorporated into the 1998 CIP. ECP submittal scheduled by mid-FY00.

3. F-16 System Program Office (SPO) fully supports program; F-15 SPO is still evaluating.

4. GE target price: $90k / engine kit, $25k / aircraft kit.

5. Total Requirement: 602 acft, 791 engines (installs & spares)

REFERENCES:

MNS Number & Title: ORD Number & Title:

1067 Number & Title: Development Plan Date & Title:

Current CINC IPL:

ACC PEM Name: Capt Maria Schreffler PEM Backup Name:



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ANNEX F Common Solution/Concept List (U)
Air Force Mission Area Plan (MAP)