Re: Excess Operational Temperature and Related Failures

QUI TAM RELATOR'S (Ballew's) DISCLOSURE - MICROFICHE SET

(Random Samples From Microfiche Set Created On 06/24/88 And Delivered To Vogel/DOJ)

(Microfiche Key: 65.60 = Sheet 65 of 65, frame #60.)
(Theoretical "total number of documents" in the microfiche set = 3900)

Click Here! 08/21/87 - Plaintiff rejected or "Red-tagged" all LTS101 hardware, software, and services at AHC (due to "overheat" and "snow").

Click Here! 05/12/89 - DOJ's Vogel calls and asks RCB to explain more about the coking, excess heat, blades and rotors ("overheat" and "snow") and to send more documents for DOJ's use. This is the first occassion that Vogel/DOJ claims that the majority of the recovery under my lawsuit will be "contractual damages" and "not qui tam proceeds". A violent argument took place over the phone with Vogel, Morgan, and Ballew.

From - To Description
01.44 thru 01.48 Document, Finmark/MIS/AHC to McKinnon/Pres/AHC, 09/28/81 - "...(1) No configuration control at ADH (AHC's parent company), (2) No "spare parts" configuration tracking..."
16.09 16.11 16.14 Memo, 08/08/87, AHC's parent company delivered unapproved alternate parts to AHC and AHC to USCG without USCG review or approval. USCG will not accept anymore.
16.12 - - FAX: AHC to ADH, "Do not ship any more unapproved alternate part numbers."
16.27 - - CRITICAL FACTORS - PT wheel failures, GP nozzle failures, PT Governor shortages.
16.43 - - PT Rotor, Coking (overheat), and GP Blade "improvement program" explained and identified. CRITICAL NOTE: "...Overheat is causing oil viscosity breakdown, metal fatigue and failure!..."
16.43 - - Telecom notes, 07/27/87, Childs/AHC to Bolivar/AHC - approval (for relator) to reject "non-compliant" engines.
16.46 thru 16.47 SHREDDED MEMO - Childs to Carbone, 07/17/87, AHC/MA87M-031, "...engines are non-compliant, must be corrected and disclosed to government..." Management meeting held, problem discussed, decision made, memo copies recovered by AHC management and shredded!
16.50 - - Avco's Hemingway threatens to "...just shut down the production line and walk away..."
16.51 - - Major change for AHC without approval, "PT retention system", 15 second, retain PT shaft and wheel when #3 bearing fails.
16.52 - - Mobile Oil #254 - recommended by Avco's Customer Sertvice Letter #013, dated 06/30/84, but technical meeting says "Don't use!"
- Paragraph 9 - "Blade Unwrap" theory.
- Paragraph 10 - "...temperature spread is more than they (Avco) want to publicize..."
- Paragraph 10C - !!!!! #2 & #3 bearing problem discussed. Avco stops meeting and refuses to discuss any more. Alert = cover-up! Major "time-out" by Avco during meeting.
16.54 - - Technical Report, 07/17/87, AHC/87M-E-385, by John Murphy, "My impression of this whole thing is that Lycoming will make available design changes which will be an acceptable alternative to this AD's inspections but that these changes will be profitably priced resulting in a prohibitive cost of implementation."
17.01 + + ...-39 power turbine rotor "blade cracking" (AD 87-10-09)
17.02 - - ...#4 bearing "power turbine burst" (AD 87-12-11)
17.06 - - ...maintain adequate oil flow...two related burst
17.18 thru 17.24 #2 & 3 bearing coking - "Problem identified as (1) high vent strut temperatures (2) #2 & 3 seal leakage, heat soak back into bearing package.
17.24 - - "...modify (PT) wheel heat treat..."
17.47 thru 17.57 Relator's Daily Log/Notes/Trip Report, 07/06/87 thru 06/10/87, to Avco for "Engine Technical Meeting", "... engine is too hot ... thermocouple leads melted ... thermocouple that fails is p/n 4-301-254-01 and Avco has changed it to p/n 4-301-329-01 without anyone's approval ... Called J. Murphy/AHC Eng. ... this configuration change has not been approved ... Called R. Childs/AHC MA - "Avco is out of control and engines are non-compliant to prime contract and sub-contract!" (See fiche sheet 16.52, note #6)
17.51 - - USCG says to use Mobile oil #254 (detergent)(bad idea - this would eliminate mil-spec competition). Absolutely unacceptable - #254 will break coking loose inside the engine and plug oil jets and cause catastrophic oil starvation if entire engine (internal) is not thoroughly cleaned in autoclave. Absolute "safety-of-flight" problem.
17.52 - - Avco's Program Manager (Hemmingway) denies that "Configuration Management Plan" exist or that AHC has a right to have a representative on the CM Board and is corrected by Avco attorney (L. Remsen).
17.55 - - "...high failure rate of actuaters (85%) - temperature sensative..."
17.56 - - combustor (failure) development program (fuel manifold problem, coking / carbon problem). Hemingway says, "...send rejections back to Avco..."
17.57 - - Physical audit of engines at Avco (one engine lost by Avco!)
18.52 thru 18.54 FAX, A. Wilcox/AL-T to J. Murphy/AHC, 07/01/87 - Avco tries to change engines' "Effective Parts List" and hide "power turbine rotor" problem and unapproved change. (Note: The title "effective" as opposed to "approved" says it all.)
18.39 - - ...oil temperature accuracy - engine
19.48 - - USCG Memo #4200-231 dated 05/22/87 from Frost to AHC's McNiell - AHC delivered "used" engine as "new", got caught by the USCG and the engines were "rejected".
20.06 - - Unapproved changes identified! - Wilcox/Avco to Murphy/AHC - unapproved ENPL #T37.
20.08 - - PT Rotor changed "unapproved". (P/N 4-111-040-49 and -39) (-11 added as alternate without approval) Plan announced by Hemingway - thermocouples to be moved. Being moved away from heat to give lower reading because engine runs much hotter than advertised. This hid the problem.
20.52 - - Main (transmission) gearbox from Aircraft Gear Corporation are contract non-compliant and can't be shipped. (Memo - Ballew & Bolivar to Sauerman/AHC/QA.)
20.53 - - Letter, Frost/USCG to McNiell/AHC, 4200/253, dated 05/17/88. USCG is waiting for (1) the "commodity ECP" that list all unapproved changes and "from" and "to" part numbers that relator has demanded from Avco and (2) "polished" Engineering Change Proposals. "...AHC can anticipate approval afterwards..."
20.55 - - Letter, Frost/USCG to McNiell/AHC, #4200/199 dated 04/27/88, titled Engine Model Specification:
- Paragraph 3.3.8.3 - ...PT Rotor - failed at 8% of contract required life...
- Paragraph 3.3.8.8 - ...GP Turbine Blades - 50% failed by 300 hours (instead of 2400), (90% failed by 500 hours). = 7% of contract guaranteed life.
- Paragraph 3.7.7.3.4 - ...coking is a recurring problem (overheat).
20.56 - - Letter 4200-199, dated 04/27/88, Frost/USCG to McNiell/AHC, "...Failures are the results of defects latent in nature or by such gross mistakes as amount to fraud."


QUICK REFERENCES:

  • Sheet 16, frame 27 - "...critical factors...(cast) power turbine wheels, gas producer nozzles, power turbine governors..."
  • Sheet 16, frame 53, Paragraph 6 - "...#3 bearing failure, Avco considers these failures to be due to (overheat) coking. Their (proposed) solutions include:...(more P/N's)"
  • Sheet 16, frame 53, Paragraph 10.b. - "...AHC's engineer's opinion "...temperature spread is more than they want to publicize and in fact may be the real reason for the MGT altitude shift..."
  • Sheet 16, frame 54, Paragraph 10.j. - "...All GP turbines in which (blade) dampers were installed on used blades have been recalled. (This contradicts AVCO's previous contention that the 750A-1/B-2 is spec compliant without (blade) dampers)..."
  • Sheet 16, frame 59 - "...# 3 Bearing - Cause of (bearing) brg failure - insufficient lubrication of bearing caused by (overheat coking) obstruction of oil jets..."
  • Sheet 17, frame 1+ - "...xxx-39 (cast) power turbine rotor blade cracking..."
  • Sheet 17, frames 18 - 24 - "...#2 & 3 bearing coking and failure...problem has been identified as high vent strut temperature, #2 & 3 seal leakage and heat soak back into into bearing package..."
  • Sheet 17, frames 51+ - "...hot-end section thermocouple (temperature sensitive) potting is melting and leads are separating. Avco recommends different potting and physically moving thermocouple away from heat source (Avco proposed change from P/N 4-301-254-01 to P/N 4-301-329-01). In Technical Meeting at Avco Ballew's verbal position is "...this is unacceptable. Fix overheat problem, not component failure that is a result of it..."
  • Sheet 18, frame 39 - "...engine oil temperature accuracy?"
  • Sheet 20, frame 43 - "...failure causes identified...(cast) PT rotor...coking...carbon build-up...gas producer blade failures...excessive heat is causing (oil) viscosity breakdown, fatigue and failure..."

END


2000 © Bob Ballew & Associates, L.L.C. All rights reserved.