PRATT & WHITNEY CANADA

SERVICE BULLETIN
P&WC S.B. No. 1003R28

BULLETIN INDEX LOCATOR

TURBOPROP ENGINE OPERATING TIME BETWEEN OVERHAULS AND HOT SECTION INSPECTION FREQUENCY MODEL APPLICATION PT6A-6,PT6A-6A,PT6A-6B,PT6A-25,PT6A-25A,PT6A-25C,PT6A-34B Model(s) deleted this revision: PT6A-6/C20,PT6A-20,PT6A-20A,PT6A-20B,PT6A-21,PT6A27,PT6A-28,PT6A-114,PT6A-114A,PT6A-135,PT6A-135A Compliance: Summary: Refer to Para. 1.E. in the Service Bulletin

This service bulletin provides a recommended basic operating time between overhauls and species a recommended initial hot section inspection frequency. P&WC turbine engines are required to undergo periodic inspection in accordance with a pre-established schedule in order to ensure serviceability. The Time Between Overhaul (TBO) and hot section inspections (HSI) intervals represent the two major scheduled periodic inspections, and are dened in this SB.

Dec 01/1973 Revision No. 28: Nov 13/2001

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PT6A-72-1003 Cover Sheet

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Pratt & Whitney Canada Corp. 1000, Marie-Victorin Longueuil, Qubec, Canada J4G 1A1 Tl. 450-677-9411

13 November 2001 P&WC S.B. No. 1003R28 REVISION TRANSMITTAL SHEET TURBOPROP ENGINE MODEL PT6A

SUBJECT:

Pratt & Whitney Canada Service Bulletin No. PT6A-72-1003, Rev. No. 28, dated Nov 13/2001 (P&WC S.B. No. 1003R28) OPERATING TIME BETWEEN OVERHAULS AND HOT SECTION INSPECTION FREQUENCY

Replace your existing copy of this service bulletin with the attached revised bulletin. Destroy the superseded copy. Please retain this Revision Transmittal Sheet with the revised bulletin. SUMMARY: This service bulletin is revised to: v Delete engine models that are no longer applicable to this service bulletin; v Add a note to the Para. 1.A. Effectivity to reference SBs 1703 and 1803; v Remove references to the deleted engine models in Para. 3. Accomplishment Instructions; v Revise an example in the Para. 3. Accomplishment Instructions to use applicable engine models; v Delete a redundant reference to inspect Post-SB1404 rst stage reduction planet gear bearings from the Para. 3. Accomplishment Instructions; v Add a reference to SIL PT6A-107 in the Para. 1. J. References and Para. 3. Accomplishment Instructions: v Add a note to explain the accessory TBO; v Revise a step in the Para. 3. Accomplishment Instructions to state that P&WC will no longer endorse requests for on-condition programs; v Delete the reference to compressor turbine blades P/N 3120011-01 from Para 3.A. (13); v Give information for contacting the FSR; v Change the reference for engine trend monitoring from the Engine Trend Monitoring Analytical Guide to SIL GEN-055.

Pratt & Whitney Canada Corp.

EFFECT OF REVISION ON PRIOR ACCOMPLISHMENT: The TBO and HSI information are transferred from this service to the service bulletins that follow: For PT6A-6/C20, PT6A-20, PT6A-20A, PT6A-20B PT6A-21, PT6A-27, PT6A-28, PT6A-135 and PT6A-135A Engines, v P&WC S.B. No. 1803; For PT6A-114 and PT6A-114A Engines, v P&WC S.B. No. 1703. NOTE: TBO extensions that were approved using this service bulletin are still valid. All new or pending recommendations will be subject to the conditions of P&WC S.B. No. 1703 or P&WC S.B. No. 1803, as applicable. A black bar in the left margin indicates a change in that line of text or gure.

NOTE:

REVISION HISTORY: Original Issue: Dec 01/1973 Revision No. 1: May 01/1974 Revision No. 2: Jun 28/1974 Revision No. 3: Jul 17/1975 Revision No. 4: Oct 22/1975 Revision No. 5: Jun 22/1976 Revision No. 6: Oct 26/1977 Revision No. 7: May 07/1979 Revision No. 8: Aug 16/1979 Revision No. 9: Oct 06/1980 Revision No. 10: Jan 27/1981 Revision No. 11: Mar 10/1981 Revision No. 12: Jun 05/1981 Revision No. 13: Aug 25/1982 Revision No. 14: Apr 27/1983 Revision No. 15: Jul 12/1984 Revision No. 16: Jan 29/1985 Revision No. 17: May 11/1989 Revision No. 18: Jul 13/1990 Revision No. 19: Sep 14/1994 Revision No. 20: Nov 06/1995 Revision No. 21: May 07/1996 Revision No. 22: Dec 11/1997 Revision No. 23: Apr 06/1998 Revision No. 24: Nov 24/1998 Revision No. 25: Feb 04/1999 Revision No. 26: Oct 03/2000 Revision No. 27: May 02/2001 Revision No. 28: Nov 13/2001

PRATT & WHITNEY CANADA

SERVICE BULLETIN
P&WC S.B. No. 1003R28 TURBOPROP ENGINE OPERATING TIME BETWEEN OVERHAULS AND HOT SECTION INSPECTION FREQUENCY 1. Planning Information A. Effectivity PT6A-6, PT6A-6A, PT6A-6B, PT6A-25, PT6A-25A, PT6A-25C, PT6A-34B NOTE: For other small PT6A models no longer listed, TBO extensions that were approved using this service bulletin are still valid. All new or pending recommendations for the models deleted from this service bulletin will be subject to the conditions of P&WC S.B. No. 1703 or P&WC S.B. No. 1803, as applicable.

B.

Concurrent Requirements None.

C.

Reason To provide a recommended basic operating time between overhaul (TBO); to specify a recommended initial hot section inspection (HSI) frequency; and to describe the TBO escalation/evaluation process.

D.

Description (1) Time Between Overhaul (TBO) recommendations take into consideration the average effect of the many variables affecting overhaul life, such as average ight duration, percentage of time at any given power level, climatic conditions and environment, maintenance practices, utilization and engine modication standards. Under extreme conditions of very low utilization, coupled with continuous operation in salt water atmosphere or heavy sand or dust environment, periodic inspections in accordance with the applicable maintenance instructions may indicate maintenance action prior to the recommended overhaul life. The operator eet TBO interval may be escalated in increments of 500 Engine Flight Hours (EFH), subject to the approval of the local Airworthiness Authority. The TBO escalation process requires a minimum of one (1) satisfactory engine sample at each subsequent TBO level. The minimum requirements for a satisfactory engine sample are described below (Ref. Para. 3.A.5 and Para. 3.B.).

(2)

(3)

E.

Compliance The inspection intervals and overhaul periods provided in this bulletin are the manufacturers recommendations. Airworthiness authorities normally require operators to follow these recommendations unless alternative arrangements have been made between the operator and the manufacturer, and approved by the operators airworthiness authority.

P&WC No. N/A Dec 01/1973 Revision No. 28: Nov 13/2001
1973 Pratt & Whitney Canada Corp. PRINTED IN CANADA

PT6A-72-1003 Page 1 of 10

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SERVICE BULLETIN
P&WC S.B. No. 1003R28 TURBOPROP ENGINE OPERATING TIME BETWEEN OVERHAULS AND HOT SECTION INSPECTION FREQUENCY

1.

Planning Information (Contd) F. Approval Transport Canada has reviewed and approved the technical contents of this Service Bulletin. NOTE: The service life values quoted herein are determined by the limiting values stated on the Pratt & Whitney Canada drawings which form part of the Department of Transport Aircraft Engine Type Approval for the applicable engine model. These limiting values are based on the use of P&WC parts installed on/in the engine. Use of other than P&WC supplied components may reduce the life limits.

G. Weight and Balance None. H. Electrical Load Data Not changed. I. Software Accomplishment Summary Not applicable. J. References Applicable PT6A Technical Manuals Engine Condition Trend Monitoring Analytical Guide Manual 3043607 P&WC S.B. No. 1002, 1303, 1403, 1404, 1505 and 1510 Service Information Letter No. PT6A-107 K. Publications Affected None. L. Interchangeability and Intermixability of Parts Interchangeability - Refer to Para. 2.D. Intermixability - Not changed.

Dec 01/1973 Revision No. 28: Nov 13/2001

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SERVICE BULLETIN
P&WC S.B. No. 1003R28 TURBOPROP ENGINE OPERATING TIME BETWEEN OVERHAULS AND HOT SECTION INSPECTION FREQUENCY

1. 2.

Planning Information (Contd) Material Information A. Industry Support Information Not applicable. B. Material - Cost and Availability Not applicable. C. Manpower Not applicable. D. Material Necessary for Each Engine Not applicable. E. Reidentied Parts None. F. Tooling - Price and Availability Not applicable.

3.

Accomplishment Instructions A. Time Between Overhaul (TBO) Recommendations: (1) Rotor component life limitations outlined in the latest revision of P&WC S.B. No.1002 override TBO considerations. The basic industry TBO is published in this SB. All PT6A-6, PT6A-6A, PT6A-6B, and PT6A-34B engines may be operated to a TBO of 3,600 hours. All PT6A-25, PT6A-25A, and PT6A-25C engines may be operated to a TBO of 3,000 hours. The basic TBO may be escalated, on a sampling basis, for the operators eet in increments not exceeding 500 EFH, subject to the approval of the local Airworthiness Authority, following a minimum of one (1) satisfactory engine sample at each new TBO interval.

(2)

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SERVICE BULLETIN
P&WC S.B. No. 1003R28 TURBOPROP ENGINE OPERATING TIME BETWEEN OVERHAULS AND HOT SECTION INSPECTION FREQUENCY

3.

Accomplishment Instructions (Contd) Example: An operator having a basic 3,600 hour TBO will have one engine time expired, inspected and overhauled at that level, at the same time requesting a TBO evaluation report from a P&WC Distributor and Designated Overhaul Facility (DDOF). If the engine proves to be in a satisfactory condition, P&WC will consider recommending a eet extension to 4,100 hours.

NOTE:

The TBO established by individual operators is independent of the TBO published for the industry.

(3)

Pre-SB1404: First-stage reduction planet gear bearings must be replaced at each and every overhaul, or 8,000 hours, whichever occurs rst. Deleted. Escalation of an operators eet TBO requires a minimum of one (1) sample engine meeting the following minimum requirements: (a) The sample engine was operated by the operator for a majority of the TBO interval (i.e. more than 50% of the current TBO interval). (b) The sample engine has not had a major shop visit repair since the last overhaul (where components normally replaced at scheduled overhaul were replaced, i.e. M/M level repairs only). (c) The sample engine is within 250 EFH of the operators current TBO interval. (d) The operator requested a TBO evaluation and submitted a completed TBO Evaluation Sample Request Form (copy attached). (e) The sample engine was disassembled to a detail level and a hardware evaluation was performed, prior to cleaning the hardware. (f) The sample engine was evaluated by a P&WC DDOF.

(4) (5)

(g) The TBO escalation is subject to the approval of the local Airworthiness Authority.

Dec 01/1973 Revision No. 28: Nov 13/2001

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SERVICE BULLETIN
P&WC S.B. No. 1003R28 TURBOPROP ENGINE OPERATING TIME BETWEEN OVERHAULS AND HOT SECTION INSPECTION FREQUENCY

3.

Accomplishment Instructions (Contd) (h) P&WC reserves the right to request additional information on the sample condition, or further TBO escalation samples, and does not guarantee that the operator will be granted a TBO escalation. NOTE: 1. When shipping an engine to a P&WC DDOF as a sample, operators should state that it is a sample and request a TBO extension evaluation report. NOTE: 2. When desiring a TBO extension, operators should submit a formal request in writing together with sample engine number and evaluation report to: Pratt & Whitney Canada Corp. 1,000 Marie-Victorin Longueuil Quebec Canada J4G 1A1 Attention: Manager PT6A Technical Support NOTE: (6) All TBO extension recommendations are subject to approval of the local regulatory authority.

Operators who have obtained TBO extension on one engine model covered by this service bulletin and who later acquire other engine models also covered by this service bulletin, with the exception of PT6A-25, PT6A-25A and PT6A-25C may apply this extension to the newly acquired models. Example: An operator having PT6A-6 engines obtains a TBO of 4,500 hours by adherence to this bulletin purchases aircraft equipped with PT6A-6A engines. The PT6A-6A engines may now be operated to a TBO of 4,500 hours.

(7)

Basic engine accessories as dened in the applicable Illustrated Parts Catalogs may be operated to the engine/module TBO plus 500 hours. NOTE: Where accessories are removed for shop repair and subsequently reinstalled, operating time since new or overhaul must be recorded on the repair tag. The operator, and/or the maintenance organization selected by the operator, must have a system to log the accumulated time.

(8) (9)

For engines engaged in crop dusting and other chemical applications, refer to P&WC S.B. No.1303 as applicable to the appropriate AG model. Compressor turbine disk and compressor turbine blade set must each be submitted to an overhaul type inspection. Such inspection must include Non Destructive Testing (NDT) inspection and stretch measurement in accordance with overhaul manual instructions at the following intervals:

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SERVICE BULLETIN
P&WC S.B. No. 1003R28 TURBOPROP ENGINE OPERATING TIME BETWEEN OVERHAULS AND HOT SECTION INSPECTION FREQUENCY

3.

Accomplishment Instructions (Contd) (a) Compressor turbine disk with full set of zero time blades installed at last shop visit, inspect within 5,000 hours. (b) Compressor turbine disk with full or partial set of previously run compressor turbine blades installed, inspect within 3,000 hours since last compressor turbine blade inspection. (10) (11) For the PT6A-25C engines installed on the Pilatus PC-7MKII: Replace the propeller shaft at every overhaul with a new propeller shaft. For the PT6A-25C engines installed on the Embraer EMB-312: Pre-SB1426: Replace the propeller shaft at overhaul with a new propeller shaft. Post-SB1426: Replace the propeller shaft with a new propeller shaft at every third overhaul or 9,000 hours whichever is less. For the PT6A-25C engines installed on the Pilatus PC-7MKII: Pre-SB1510: Incorporate the third-stage compressor-stator assembly in accordance with SB No. 1510 at overhaul. Deleted. TBO extension recommendations from P&WC are subject to fees per Service Information Letter (SIL) PT6A-107. P&WC will no longer endorse requests for on-condition programs on the PT6A models.

(12)

(13) (14) (15)

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SERVICE BULLETIN
P&WC S.B. No. 1003R28 TURBOPROP ENGINE OPERATING TIME BETWEEN OVERHAULS AND HOT SECTION INSPECTION FREQUENCY

3.

Accomplishment Instructions (Contd) B. Sampling Process (Ref. Fig. 1): (1) The aircraft/engine owner/operator must initiate the TBO escalation sampling process, when one or more of their engines reach the applicable published TBO limits. The owner/operator will ll out and submit the attached TBO Sample Request Form to a P&WC DDOF. The owner/operator may request a TBO contingency of up to 200 EFH, subject to the approval of the local Airworthiness Authority, for the remaining engines in the eet. This will permit continued operation beyond the current TBO interval, while the sample engine is evaluated and overhauled, provided that engine performance remains satisfactory, in accordance with the applicable P&WC M/M. This TBO contingency may be requested from the local P&WC Field Service Representative (FSR). NOTE: 1. P&WC FSRs are listed on the internet at www.pwc.ca. NOTE: 2. The P&WC Customer Help Desk may also be contacted to get the name of the local FSR: v 1-800-268-8000 (Toll free in Canada or continental US only); v 8000-268-8000 (International toll free, where available); v 1-450-647-8000. (2) The sample engine must be sent to a P&WC DDOF for the TBO evaluation. The evaluation requires the engine to be disassembled and reviewed, prior to cleaning the hardware, to determine if the condition of the parts is such that they could have stayed in service for another 500 EFH. The P&WC DDOF will forward the evaluation report to P&WC for review and request a TBO escalation. A successful sample will result in a letter from P&WC to the operator stating that a TBO escalation of 500 EFH is recommended, subject to the approval of the local Airworthiness Authority. The escalated TBO will apply to all other engines in the operators eet covered by the same TBO SB. The TBO escalation process may be repeated when the next engine reaches the new escalated TBO interval. The following example is for two engines installed in one twin-engine aircraft. The same TBO escalation process is applicable, for two engines installed in two different twin-engine aircraft, as well as two engines installed in two single-engine aircraft, in the operators eet. A similar process is applicable for single-engine, single aircraft operators. (a) An operators engines have a TBO of 3,000 EFH. Both engines on an aircraft have a time since new (TSN) of 2,990 EFH. The left engine is removed, sent to a P&WC DDOF and a rental engine is installed. The sampling is successful and the operator now has a TBO of 3,500 EFH thereby allowing the right engine to continue to 3,500 EFH.

(3)

(4)

(5)

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SERVICE BULLETIN
P&WC S.B. No. 1003R28 TURBOPROP ENGINE OPERATING TIME BETWEEN OVERHAULS AND HOT SECTION INSPECTION FREQUENCY

3.

Accomplishment Instructions (Contd) (b) The operator will then have overhauled one engine instead of two. The operator will also have deferred the second overhaul by 500 EFH, should they continue to operate the same aircraft or other aircraft with the same family of engines, to the extended TBO interval (covered by the same TBO SB). (c) If the operator continues to operate the aircraft, the right engine will be removed for overhaul and sampling at TSN of 3,500 EFH. Successful sampling will extend the operators eet TBO to 4,000 EFH. As a result the operator has now escalated his eet TBO by 1,000 EFH (3,000 to 4,000 EFH) by staggering the overhauls. If both engines had been overhauled at the same time, the eet TBO would have only been escalated to 3,500 EFH. Therefore, the benets of using this approach for the operator are two-fold: 1 2 (6) Deferral of one overhaul by 500 EFH. Escalation of operators TBO interval by 1,000 EFH.

Contact the local FSR for additional information. NOTE: 1. P&WC FSRs are listed on the internet at www.pwc.ca. NOTE: 2. The P&WC Customer Help Desk may also be contacted to get the name of the local FSR: v 1-800-268-8000 (Toll free in Canada or continental US only); v 8000-268-8000 (International toll free, where available); v 1-450-647-8000.

C.

Hot Section Inspection (HSI) Frequency (1) (2) (3) P&WC recommends to perform the HSI within 50 EFH of the scheduled HSI interval. The HSI interval does not increase, as the TBO is escalated. All PT6A engines may be operated to a scheduled HSI interval. Alternatively, the HSI frequency may be based on Engine Condition Trend Monitoring in accordance with the Service Information Letter (SIL) Gen-055 Guidelines and Standards for Utilizing the Engine Condition Trend Monitoring (ECTMT) software for the model concerned. If trend monitoring is introduced part way through engine life, a compressor wash and HSI must be accomplished to establish a performance base line. Scheduled HSI intervals, if selected are:

(4) (5)

Dec 01/1973 Revision No. 28: Nov 13/2001

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SERVICE BULLETIN
P&WC S.B. No. 1003R28 TURBOPROP ENGINE OPERATING TIME BETWEEN OVERHAULS AND HOT SECTION INSPECTION FREQUENCY

3.

Accomplishment Instructions (Contd) (a) PT6A-6, PT6A-6A, PT6A-6B, and PT6A-34B = 1,800 hours (b) PT6A-25, PT6A-25A and PT6A-25C = 1,500 hours

4.

Appendix Not applicable.

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SERVICE BULLETIN
P&WC S.B. No. 1003R28 TURBOPROP ENGINE OPERATING TIME BETWEEN OVERHAULS AND HOT SECTION INSPECTION FREQUENCY

C72341 TBO Evaluation Sample Request Form Figure 1

Dec 01/1973 Revision No. 28: Nov 13/2001

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