Skip to comments.Defect found in Boeing GE engine not isolated
Posted on 09/15/2012 7:55:47 PM PDT by smokingfrog
The engine installed on every Boeing 787 built in South Carolina so far has a problem.
The first sign something was wrong came on a Saturday afternoon in July when the second locally made Dreamliner experienced a pre-flight engine failure as it accelerated down the runway at Charleston International Airport.
A month and a half later, the extent of the defect has become clearer and bigger.
The North Charleston incident was not isolated, as had been the original hope. Instead, two other General Electric-made GEnx engines have been found to suffer from a similar defect in the drive shaft.
And the concern is that the problem could be even more widespread, inherent to the make-up of the engine itself.
That news came Friday afternoon as the National Transportation Safety Board, which has been investigating the July 28 incident, issued a pair of urgent safety recommendations regarding the fan midshafts of GEnx engines.
The NTSB called on the Federal Aviation Administration to require ultrasound inspections of all GEnx-powered 787s and 747s not already inspected before any further flight.
The NTSB also recommended that the FAA require repetitive inspections of the fan midshafts of all GEnx engines at a sufficiently short interval that would permit multiple inspections and the detection of a crack before it could reach critical length and the FMS fractures.
Thats what happened in Charleston in July and on Tuesday as a Boeing 747-8F cargo jet was preparing to take off from Shanghai.
(Excerpt) Read more at aikenstandard.com ...
Dollar to donuts an engineer somewhere sounded the alarm months ago only to be told to shut up by “management”.
Out of curiosity, were the GE engines manufactured in a union shop in Ohio, before being sent to the Boeing facility in right-to-work South Caroina?
The unions are very unhappy about the South Carolina plant. Just saying....
Just like the O rings on the Challenger. May they R.I.P.
I see it was tested in Ohio.
Everything that is GE is a piece of crap. Like my stove, and refrigerator etc;
I remembered from 50 years ago that GE manufactured engines in a suburb of Cincinnati.. I went looking to see it it had all been outsourced to Red China. Nope. But I could not verify where the failed parts were made.
Looks like quite a bit of interesting stuff at that site.
My GE dishwasher is also a piece of crap. Never again.
My GE dishwasher is also a piece of crap. Never again.
Evendale OH if they are GE engines, used to help them with their Calma systems back in the day. We would not outsource
these to China of whatever color.
Yes you are. And you'd better believe there was one hell of a stink at the time. Look at these Google links.
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This is going to be a huge problem when Dreamliner production is behind schedule. I was down at Paine field on Wednesday and there is a big long taxiway filled with airplanes that don’t have engines.
I have heard it said that the only thing GE makes that doesn’t suck is a vacuum cleaner.
I could have told them that O rings wouldn’t hold. I had faucets in my house in Houston that were fitted with O rings that leaked and fell apart because of the hard water. As I remember, the Challenger launch was postponed a couple of times because of the unseasonably cold weather. There was at least one engineer who came forward and related that he’d warned them, but...we all know the rest.
That was Thiokol that made the boosters, wasn’t it?
My last GE refrigerator lasted 21 years. I was more then happy.
Things that make you go “Hmmmm.”
The Part that Broke in Charleston is a Turbine shaft made by IHI of Japan. They are thinking the 747-8 that had an engine let go in Shanghia has the same problem.
When the LPT Turbine shaft breaks, the LPT turbine wheels overspeed and it’s only a matter of time before all of the blades fly off and if it continues to spin, catastophic, uncontained disk failures can result.
My GE fridge is a piece of crap also.
“The Part that Broke in Charleston is a Turbine shaft made by IHI of Japan. “
The same company that made the turbocharger for my MX5.
I’m told that everything the GE makes sucks except for their vacuums.
Boeing doesn’t work on the engines.
Im told that everything the GE makes sucks except for their vacuums.
I have a GE vacuum:It blows.
Someone is definitely going to get shafted over this mess.
Is it too late to put in some Rolls Royce engines?
Wish there was more info here. Does this mean that all GEnx powered aircraft are grounded, wherever they are? How many aircraft are affected? Where? How many passengers will be stranded in airports worldwide?
My first GE washer lasted 30 years. The next one lasted four. Changed brands.
Indeeed. Who the heck is "Boeing GE"?
and I thought spending 3 hours pulling/replacing wiring because a new GE ground fault kept tripping was a pain in the rear. In the end, a new GFCI from a different company fixed the original problem. (original GFCI would not reset, GE one would trip randomly)
Turns out the GFCI outlet is not much better than their plane engine.
at least no one would die if the GFCI tripped when it should not have.
GE paying their fair share yet?
Sounds like it's really going to affect the delivery of new planes until they figure out what the problem is.
GE used to make pretty good electrical equipment.
(Better than Federal Pacific, Zinsco, and some others, anyway.)
You are an idiot. GE makes the best aircraft engines in the world. They are used to power 737’s, 767’s, 777’s, and many small regional jets in addition to military aircraft. The GE engine on a Boeing 777-200LR is the reason this aircraft can fly nonstop between any two cities in the world. It is incredibly reliable. GE will fix the problem with the new engine and they will stand behind it. GE owns more commercial aircraft, thru their leasing division, than any airline in the world. No I don’t work for GE, but I do work on them, along with Pratt & Whitney and Rolls Royce.
GE — Government Electric.
Pratt makes a better engine. If a GE barks, off the wing it comes.
The fan shaft forms the low-pressure spool of the GEnx-1B engine and connects the fan stage with the low-pressure (LP) turbine. The shaft is made up of two main sections, and the failure is thought to have emanated in the torque-retaining nut connecting the two. The NTSB says the GEnx engine fractured at the forward end of the shaft, rear of the threads where the retaining nut is installed. It adds that the fan mid-shaft is undergoing several detailed examinations, including dimensional and metallurgical inspections.
Investigators and a team of experts from the NTSB, FAA, Boeing and GE specializing in engine systems and metallurgy found the small fracture leading to the aft part of the shaft, which is made by Ishikawajima Heavy Industries of Japan.
The fracture in the shaft assembly allowed the rotating LP turbine to move aft, clashing with the LP stators. The impact caused significant damage to the LP turbine section, pieces of which were jettisoned from the engine exhaust. The hot parts exited the engine and sparked a grass fire by the runway which caused the airport at Charleston, S.C., to be briefly shut down. The engine was powering a 787 on a pre-first flight high speed taxi run. The aircraft was the second to be completed at Boeings Charleston site and is destined for delivery to Air India.
The fan shaft is designed to separate in extreme stress events to avoid over-speeding the LP turbine and risking an uncontained failure.
And who is the Idiot that put those Red Letters right on top of the Compressor Blades? Those sharp corners will tear them up, especially the “q” that's sticking down into the mechanism.
Are those guys Color Blind or something? I can clearly see the problem and I used to be a Corporate Manager, not a Jet Engine Mechanic.
My brother says Rolls Royce engines are better than GE and P&W.
I’m sure he’s not prejudiced, even though he works for Rolls Royce.
Now that’s funny.
I regret I didn’t think of it first.
It sure was.
So to avoid overspeeding the Turbine, they intentially allow the LPT Rotors to crash into the LPT stators, because that is safer than the alternative (a grenade).
That would mean there is no reverse thrust loaded Bearing aft of this part that breaks... hmmmmmmmm....
I wonder if normal takeoff run ups are considered "extreme stress events".
GE is going to have to walk a fine line if they want to make a part that doesn't break, yet breaks when they want it to and not have the airline inspect it every 10 flights to see if its breaking yet. They are asking a lot out of IHI.
Presumably the engine control shuts the fuel down immediately upon sensing the turbine overspeed. However, I wonder if it continues to windmill during flight; I suppose this could be a problem.
I wear my hat proudly.
A similar incident occured in Japan recently.