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Quarterly ReviewQuarterly Review
October, 2008October, 2008
C-17 APU Organic CapabilityC-17 APU Organic Capability
ContractContract
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AgendaAgenda
8:008:00 Welcome and IntroductionsWelcome and Introductions
Contract ReviewContract Review
Progress UpdateProgress Update
Power Section and ElectricalPower Section and ElectricalComponent ModuleComponent Module
UpdateUpdate
Technical Manual UpdateTechnical Manual Update
Drawing UpdateDrawing Update
11:0011:00 Open DiscussionOpen Discussion
12:0012:00 DismissalDismissal
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AttendeesAttendees
Triumph AirTriumph AirRepairRepair
The BoeingThe BoeingCompanyCompany
OO-ALCOO-ALC
WR-ALCWR-ALC
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Contract ReviewContract Review
Deliver Depot Level C-17 APU MaintenanceDeliver Depot Level C-17 APU MaintenanceCapability at OO-ALC by June 2009Capability at OO-ALC by June 2009
Facility ModificationsFacility Modifications SE - Support EquipmentSE - Support Equipment
TD - Technical Data TD - Technical Data
MD&T - Maintenance Demonstration &MD&T - Maintenance Demonstration &
TrainingTraining FA - First Article ( Validation / Verification )FA - First Article ( Validation / Verification )
Drawings and DocumentationDrawings and Documentation
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Contract ReviewContract Review
Facility ModificationsFacility Modifications Fuel-Oil-Pneumatic-APUFuel-Oil-Pneumatic-APU
Routing Utilities (powerRouting Utilities (power& air supply)& air supply)
Floor space allocationFloor space allocation
Test Cell # 4Test Cell # 4
Future Electrical Dept.Future Electrical Dept.
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Contract ReviewContract Review
FacilityFacilityModifications -TestModifications -TestCell # 4Cell # 4 Load BankLoad Bank
Start Power UnitStart Power Unit
Airflow MeasuringAirflow MeasuringSectionSection
Inlet Air Handler &Inlet Air Handler &air deflectorair deflector
Data Acquisition &Data Acquisition &ControlControl
Software SytronicsSoftware Sytronics
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Contract ReviewContract Review
Support EquipmentSupport Equipment Test StandsTest Stands
Test AdaptersTest Adapters Overhaul ToolsOverhaul Tools
Shipping ContainersShipping Containers
COTS itemsCOTS items
OverOver 400400 pieces ofpieces ofSE designed/fabricated toSE designed/fabricated to
datedate+ ~80 more for power+ ~80 more for power
and electrical sectionsand electrical sections
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Contract ReviewContract Review
SupportSupportEquipmentEquipment
Test standsTest stands MaintenanceMaintenanceStandsStands
TransportTransportStandsStands
Oil ComponentsOil Components FuelFuel
ComponentsComponents
PneumaticPneumaticComponentsComponents
Future -Future - 88
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Contract ReviewContract Review
SupportSupportEquipmentEquipment
Test adaptersTest adapters FuelFuelComponentsComponents
Oil ComponentsOil Components PneumaticPneumatic
ComponentsComponentsTest Cell dressTest Cell dress
equipmentequipment
Future -Future -ElectricalElectrical
ComponentsComponents
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Contract ReviewContract Review
SupportSupportEquipmentEquipment
Overhaul toolsOverhaul tools Provided for allProvided for alloil, fuel,oil, fuel,
pneumaticpneumatic
componentscomponents
Provided forProvided forengine test,engine test,gearbox, loadgearbox, load
compressorcompressor
modulesmodules
Designed/mostDesigned/mostready to ship forready to ship for 1010
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Contract ReviewContract Review
SupportSupportEquipmentEquipment
ShippingShippingContainersContainers
Overall APUOverall APU ModulesModules
Gearbox , LoadGearbox , Load
CompressorCompressor Line ReplaceableLine Replaceable
Units ( LRUs )Units ( LRUs )
Power sectionPower sectionmodulemodule
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Contract ReviewContract Review
SupportSupportEquipmentEquipment
COTS itemsCOTS items
Hand ToolsHand Tools Gages - measuringGages - measuring Exceptions perExceptions per
ResponsibilityResponsibilityMatrixMatrix
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Contract ReviewContract Review
Technical OrdersTechnical Orders Derivative of existingDerivative of existing
Component MaintenanceComponent Maintenance
ManualsManuals 23 T.O.s produced and23 T.O.s produced and
accepted including APU,accepted including APU,
gearbox, load compressor,gearbox, load compressor,
and fuel, oil, pneumaticand fuel, oil, pneumatic
LRUsLRUs Validation built in duringValidation built in during
maintenance andmaintenance and
demonstration/1demonstration/1stst ArticleArticle
Development of 14Development of 14
additional T.O.s inadditional T.O.s inro ressro ress
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Contract ReviewContract Review
MaintenanceMaintenanceDemonstrationsDemonstrations
& Training& Training
Hands onHands on
trainingtraining
Onsite at HillOnsite at Hill
AFB w/TriumphAFB w/Triumphlead technicianslead technicians
and engineeringand engineering
Proper use ofProper use of
toolstools
Validation ofValidation of
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Contract ReviewContract Review
Drawings andDrawings andDocumentatiDocumentati
onon
SupportSupport
EquipmentEquipment
drawingsdrawings
andand
documentatidocumentati
on deliveredon delivered
to WR-ALCto WR-ALC
followingfollowing
OO-ALCOO-ALC 1616
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Contract ReviewContract Review
EngineEnginemodulesmodules FuelFuel
ComponentsComponents
Oil ComponentsOil Components
GearboxGearbox
LoadLoad
CompressorCompressor PneumaticPneumatic
ComponentsComponents
Overall APUOverall APU
Power SectionPower Section
ElectricalElectrical 1717
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Contract Review Questions?Contract Review Questions?
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Break
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2020
Progress ReportProgress Report
CompletedCompletedactivitiesactivities
Gearbox Module:Gearbox Module:
SE delivered FebSE delivered Feb20052005
TD delivered JuneTD delivered June
20052005 MD&T completedMD&T completedJune 2005June 2005
FA completed AugFA completed Aug20052005
Additional trainingAdditional training
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Progress ReportProgress Report
CompletedCompletedActivitiesActivities
Fuel ComponentsFuel Components
SE delivered MarchSE delivered March20052005
TD delivered OctTD delivered Oct20052005
MD&T completedMD&T completedNov 2005Nov 2005
FA completed DecFA completed Dec20052005
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Progress ReportProgress Report
Completed ActivitiesCompleted Activities Load CompressorLoad Compressor
SE delivered AprilSE delivered April20062006
TD delivered MarchTD delivered March20062006
MD&T completed MayMD&T completed May20062006 FA completed JuneFA completed June
20062006
Additional trainingAdditional training
provided May 2008provided May 2008
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Progress ReportProgress Report
CompletedCompletedActivitiesActivities
Oil ComponentsOil Components SE delivered JuneSE delivered June
20062006
TD delivered JuneTD delivered June20062006
MD&T completedMD&T completedAug 2006Aug 2006
FA completed SeptFA completed Sept20062006
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Progress ReportProgress Report
Completed ActivitiesCompleted Activities PneumaticPneumatic
ComponentsComponents
SE delivered Oct 2007SE delivered Oct 2007TD delivered Sept 2007TD delivered Sept 2007 MD&T completed DecMD&T completed Dec
20072007
FA completed 01 FebFA completed 01 Feb0808
Delivery of DrawingsDelivery of Drawingsinitial submittalinitial submittal
01 May 0801 May 08
OO-ALC ProcessOO-ALC Process
Engineer reviewed allEngineer reviewed alldrawings 27 June 08drawings 27 June 08
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Progress ReportProgress Report
Completed ActivitiesCompleted Activities Overall APUOverall APU
SE delivered 07 Dec 08SE delivered 07 Dec 08
TD delivered 07 Dec 08TD delivered 07 Dec 08 MD&T completed 14MD&T completed 14
Mar 08Mar 08
FA completed 28 MarFA completed 28 Mar0808
Delivery of manual 30Delivery of manual 30May 08 received 07May 08 received 07July 08July 08
Delivery of DrawingsDelivery of Drawingsinitial submittalinitial submittal 15 July15 July
0808
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Power Section & ElectricalPower Section & Electrical
Components UpdateComponents Update
Power Section ModulePower Section Module SE Nov 2008SE Nov 2008
TD - Nov 2008TD - Nov 2008
MD&T Jan 2009 [12 weeks]MD&T Jan 2009 [12 weeks] FA - April 2009 [12 weeks]FA - April 2009 [12 weeks]
Electrical ComponentsElectrical Components SE - Dec 2008SE - Dec 2008
TD - Dec 2008TD - Dec 2008 MD&T Jan 2009 [4 weeks]MD&T Jan 2009 [4 weeks]
FA Feb 2009 [4 weeks]FA Feb 2009 [4 weeks]
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Power Section Module StatusPower Section Module Status
Special ToolingSpecial Tooling Design 100%Design 100%
completedcompleted
Fabrication 90%Fabrication 90%
completedcompleted
Design/FabDesign/Fab
Verified 75 %Verified 75 %
completedcompleted
Drawings @ 80%Drawings @ 80%
Tech data @ 50%Tech data @ 50%
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Electrical Components StatusElectrical Components Status
ElectricalElectricalComponentsComponents
Starter MotorStarter Motor
Run-In StandRun-In Stand
Starter Dyno TestStarter Dyno Test
StandStand
Wiring HarnessWiring Harness
Test StandTest Stand
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Electrical Components StatusElectrical Components Status
ElectricalElectricalComponentsComponents
StarterStarterMotor Run-InMotor Run-In
StandStand
Starter DynoStarter Dyno
Test StandTest Stand
WiringWiring
Harness TestHarness Test
StandStand
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Electrical Components StatusElectrical Components Status
ElectricalElectricalComponentsComponents
Starter MotorStarter Motor
Run-In StandRun-In Stand
Starter Dyno TestStarter Dyno Test
StandStand
Wiring HarnessWiring Harness
Test StandTest Stand
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Technical Order UpdateTechnical Order Update
Complete engine overhaul requires 37 technicalComplete engine overhaul requires 37 technicalordersorders All are identified and catalogued by WR-ALCAll are identified and catalogued by WR-ALC
23 are compete/in the system/in use23 are compete/in the system/in use Remaining 14 submitted to BoeingRemaining 14 submitted to Boeing
Minimum 50% completeMinimum 50% complete
Major changes completed in Gearbox and LoadMajor changes completed in Gearbox and Load
Compressor manualsCompressor manuals Will be submitted 10/08Will be submitted 10/08
Annual in-house review program established toAnnual in-house review program established toensure currencyensure currency Program shown on next three slidesProgram shown on next three slides
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T.O. Review/Change Log (Page 1 ofT.O. Review/Change Log (Page 1 of
3)3)
Review Month T.O. Number T.O. Title Latest Version Change #
Annual
Review Comments
Jan 2G-GTCP331-3 OVERALL APU 30-May-08 0
Jan 2G-GTCP331-3-12-2
APU TEST CELL FAULT
MATRIX 50% Submitted to Boeing 7/08
Jan 2G-GTCP331-3-12-1 APU RECEIVING PROCESS 50% Submitted to Boeing 7/08
Feb 2G-GTCP331-3-3 FUEL FLOW DIVIDER 16-Dec-05 0
Feb 2G-GTCP331-3-2 FUEL CONTROL UNIT 22-Dec-05
Chg 1 IN
WO RK C/W Apr 08 Finalizing Change 1
Feb 2G-GTCP331-3-4 IGV ACTUATOR ASSEMBLIES 16-Dec-05 0
Mar 2G-GTCP331-3-5 FUEL MANIFOLD ASSEMBLY 22-Dec-05 0
Mar 34Y26-6-1-3 FUEL COLLECTION STAND 22-Dec-05 0
Mar 34Y26-6-1-4 HYDRAULIC SUPPLY CART 22-Dec-05 0
Mar LDP-OO/ALC-15
CALIBRATION for HYDRAULIC
SUPPLY CART 28-Feb-05 0
Apr 2G-GTCP331-3-1
GEARBOX MODULE
ASSEMBLY 25-Aug-05
Chg 1 IN
WORK C/W Apr 08 Change 1 ready to submit
May 2G-GTCP331-3-11 LOAD COMPRESSOR MODULE 28-Jul-06
Chg 1 IN
WORK C/W Apr 08 Change 1 ready to submit
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T.O. Review/Change Log (Page 2 ofT.O. Review/Change Log (Page 2 of
3)3)
Review Month T.O. Number T.O. Title Latest Version Change #
Annual
Review Comments
Jun 2G-GTCP331-3-12 POWER SECTION MODULE 50% Submitted to Boeing 7/08
Jun 2G-GTCP331-3-12-3 PRESSURE RELIEF VALVE 50% Submitted to Boeing 9/08
Jun 34Y26-7-1-2 THERMOCOUPLE TESTER 50% Submitted to Boeing 9/08
Jul 33D2-9-10-3 PNEUMATIC TEST STAND 29-Feb-08 0 C/W Sep 08
Jul 7J14-9-3 FLOW SENSOR ASSEMBLY 29-Feb-08 0
Jul 7J6-21-3 SURGE CONTROL VALVE 29-Feb-08 0
Aug 7J6-6-17-3 LOAD CONTROL VALVE 29-Feb-08 0
Aug 7J15-9-3
COOLING FAN ASSEMBLY
3616959-6 29-Feb-08 0
Aug 7J15-10-3
COOLING FAN ASSEMBLY
3614416-1/-2 29-Feb-08 0
Sep 2G-GTCP331-3-13 STARTER MOTOR (-6) 50% Submitted to Boeing 7/08
Sep 2G-GTCP331-3-14 STARTER MOTOR (-7/-8) 50% Submitted to Boeing 7/08
Sep 34Y26-7-1-5 STARTER DYNO TEST STAND 50% Submitted to Boeing 9/08
Sep 34Y26-7-1-4 STARTER BREAK-IN STAND 50% Submitted to Boeing 9/08
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T.O. Review/Change Log (Page 3 ofT.O. Review/Change Log (Page 3 of
3)3)
Review Month T.O. Number T.O. Title Latest Version Change # Annual Review Comments
Oct 2G-GTCP331-3-15 IGNITION EXCITER 50% Submitted to Boeing 7/08
Oct 2G-GTCP331-3-17 IGNITER PLUG 50% Submitted to Boeing 7/08
Oct 2G-GTCP331-3-18 IGNITER PLUG LEAD 50% Submitted to Boeing 7/08
Oct 2G-GTCP331-3-16 WIRING HARNESS ASSEMBLY 50% Submitted to Boeing 9/08
Oct 34Y26-7-1-3 WIRE HARNESS TEST STAND 50% Submitted to Boeing 9/08
Nov 2G-GTCP331-3-6 LUBE PUMP ASSEMBLY 3-Nov-06 0
Nov 34Y26-2-3 OIL TEST STAND 3-Nov-06 0
Nov 2G-GTCP331-3-7
GENERATOR FILTER
ASSEMBLY 3-Nov-06 0
Nov 2G-GTCP331-3-8
GENERATOR SCAVENGE
PUMP ASSEMBLY 3-Nov-06 0
Dec 2G-GTCP331-3-9 OIL COOLER 3-Nov-06 0
Dec 34Y26-1-3 FLUSHING STAND 3-Nov-06 0
Dec 2G-GTCP331-3-10 OIL TEMP. CONTROL VALVE 3-Nov-06 0
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Drawing UpdateDrawing Update
I need your helpI need your help And some more helpAnd some more help
And some more.And some more.
Remembertheyll make an issue of lateness, so itRemembertheyll make an issue of lateness, so it Would be best to show the step-by-step progressionWould be best to show the step-by-step progression
(and headaches) to show this has been(and headaches) to show this has been
a full time tasking times 3 peoplea full time tasking times 3 people
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Drawing UpdateDrawing Update
I need your helpI need your help And some more helpAnd some more help
And some more.And some more.
Remembertheyll make an issue of lateness, so itRemembertheyll make an issue of lateness, so it Would be best to show the step-by-step progressionWould be best to show the step-by-step progression
(and headaches) to show this has been(and headaches) to show this has been
a full time tasking times 3 peoplea full time tasking times 3 people
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FY08 Triumph Training @ HAFBFY08 Triumph Training @ HAFB
Training breakdown is as follows:Training breakdown is as follows: Feb 08120 hours (2 technicians x 60 hours each): CoolingFeb 08120 hours (2 technicians x 60 hours each): Cooling
Fan (both part numbers)Fan (both part numbers) Feb 08240 hours (2 technicians, 1 at 150 hours, 1 at 90Feb 08240 hours (2 technicians, 1 at 150 hours, 1 at 90
hours): Load Control Valve, Surge Control Valve, Flowhours): Load Control Valve, Surge Control Valve, FlowPalletPallet
Feb 08120 hours (1 technician): Pneumatic Test StandFeb 08120 hours (1 technician): Pneumatic Test Standintroduction and testing of Load Control Valve, Surgeintroduction and testing of Load Control Valve, SurgeControl Valve, Flow PalletControl Valve, Flow Pallet
Mar 08160 hours (2 technicians x 80 hours each): TestMar 08160 hours (2 technicians x 80 hours each): TestCell operationCell operation
Mar 08180 hours (3 technicians x 60 hours each): OverallMar 08180 hours (3 technicians x 60 hours each): OverallAPU (everything except Power Section)APU (everything except Power Section)
May 08240 hours (3 technicians x 80 hours each):May 08240 hours (3 technicians x 80 hours each):Gearbox and Load Compressor requalification trainingGearbox and Load Compressor requalification training
Total hands-on training hours from above:Total hands-on training hours from above: 10601060 hourshours Note that this does not include the time spent correlating the test cellNote that this does not include the time spent correlating the test cell
in Nov and Dec 07. This was approximately three weeks of engine runin Nov and Dec 07. This was approximately three weeks of engine runtime to solve the problems we encountered, and that entire time theretime to solve the problems we encountered, and that entire time therewas a Hill AFB en ineer and technician hel in and learnin .was a Hill AFB en ineer and technician hel in and learnin .
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Next meeting discussionNext meeting discussion
Location:Location: ??
Date:Date: ??
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Open DiscussionOpen Discussion
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