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					AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                                Page 1 of 21
                                                         Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc

The Problem
The current compressor acceleration valves fitted to the AE3007A engine are costly and susceptible to
contamination. A single production standard compressor acceleration bleed valve is required in a short
time-scale and in volume to support the new standard of engine.
The Objective of the IPT
Project Manage the design, development, certification and manufacturing programme of a compressor
acceleration bleed valve for the Rolls-Royce Corp. AE3007A engine. The project timescales are to be
commensurate with Dunlop Equipment’s commitments to Rolls-Royce Corp.
The Team
Alan Benn            Project Team Leader & Design +44 (0)24 76294285          alan.benn@dunlop-equip.co.uk
Dave Welch           Design & Deputy                  +44 (0)24 76294260      david.welch@dunlop-equip.co.uk
Andrew Horrocks-Taylor         Programmes             +44 (0)24 76294223      andrew.H-T@dunlop-equip.co.uk
Paul Neal                      Design                 +44 (0)24 76294260      paul.neal@dunlop-equip.co.uk
Robert Bouwens Transmissions design Engineer          (001) 317 230 5041      robert.j.bouwens@rolls-royce.com
Craig Weeks       Transmissions, Structures IPT Lead (001) 317 230 8167       craig.a.weeks@rolls-royce.com
Dan Clark         Commodity Owner – controls          (001) 317 230 4588      dan.j.clark@rolls-royce.com
Lisa Pleasant       Buyer controls                    (001) 317 230 8843      lisa.a.pleasant@rolls-royce.com
Richard Parkes / Kev Yeomans Stress                                           232
Martin Griffiths               Production Engineering                         245
Simon Timothy                  Production Engineering                         258
Bill Davies                    Manufacturing                                  216
Jeremy Tiff                    Supplier Chain                                 268
Tony Ryan                      Customer Interface Module                      262
Tim Ratcliffe                  Reliability Engineer                           244

The IPT Close-Out Criteria
Production Valves Delivered with satisfactorily FAIRs
Component Maintenance Manuals Issued
Modus Operandii – We will
Communicate openly
Be helpful & courteous
Meet our commitments
Listen
Utilise IT systems (e-mail, attachments etc)
Record all decisions/actions
Meet regularly
Maintain at least 1 month horizon for meetings
Develop and maintain an agreed protocol for programme management IT tools
Embrace CVP, SCRIA, IPM, EFACS, MRP principles and operating procedures
Avoid excessive use of abbreviations, acronyms, jargon and
Maintain a sense of humour!

Green  =On Schedule per plan      Yellow    = Not on schedule per plan    Red  = No plan in place to recover

Bulls eye - Item completed    Improving     deteriorating    Item cancelled      Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                                Page 2 of 21
                                                         Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc

IPT Meetings             = teleconference                   = Face to Face
     Date          Type            Time               Venue                       Comments
 Every                           1:00pm              Dunlop         Updated for British Summer Time W/C
 Tuesday                          2.00pm                             26/03/01
 Every                           8:00am           Rolls Royce
 Tuesday




Green  =On Schedule per plan      Yellow    = Not on schedule per plan   Red  = No plan in place to recover

Bulls eye - Item completed    Improving     deteriorating    Item cancelled     Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                                Page 3 of 21
                                                         Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc

Programme Milestones
      Milestone item                             Programme Constraint                    Status
                                                                                         date
DDP to be submitted to RR         10th July 2001                                         17 Jan 01
                                  25th July 2001                                         23 Apr 01
                                  13th Aug 2001                                          17 Jul 01
1st Production Valves Despatched  10th July 2001                                         17 Jan 01
                                  30th July 2001                                         23 Apr 01
                                  15th Aug 2001                                          17 Jul 01
Qualification Test Hardware       13th April 2001 (to be confirmed)                      15 Jan 01
                                  Qualification Test Hardware dates dependant            20 Feb 01
                                  on outcome of Bullet/Poppet Trade Study
                                  TBA                                                    12 Mar 01
                                  5th June 2001                                          23rd Apr 01
                                  Item Captured on Page 4                                22 May 01
Customer Test Hardware            End of March 2 off (dev standard units) to             02 Feb 01
                                  support engine test Mid-April.
                                  Engine Test scheduled to begin April (19th)            20 Feb 01
                                  Confirmed via E-Mail (15th Feb 01)
                                  Dunlop to inform RR on earliest possible               12 Mar 01
                                  hardware availability
                                  Endurance test no longer an option: 150hr              13 Mar 01
                                  engine test commencing May 1st
                                  RR to confirm Endurance test start date                20 Mar 01
                                  (due date 26th March 01)
                                  1st Engine Test Unit 8th June 2001                     23rd Apr 01
                                  2nd Engine Test Unit 20th June 2001
                                  Flight Test Units 25th July 2001- B standard           15th May 01
                                  units (connector at 0)
                                  Engine Test Units 8th June 2001-A1 standard
                                  units (connector at 15)
Requirements confirmed via E-Mail Item Captured on Page 4                                22 May 01
(22 May 01)
CDR                               W/C 12th March                                         02 Feb 01
                                  W/C 20th March                                         20 Feb 01
                                  W/C 2nd April (Tue – Wed 3rd/4th April)                12 Mar 01
                                  Wed 11th/Thur 12th April                               13 Mar 01
                                  Thur 5th/Fri 6th April                                 20 Mar 01
                                  CDR Completed



Green  =On Schedule per plan      Yellow    = Not on schedule per plan   Red  = No plan in place to recover

Bulls eye - Item completed    Improving     deteriorating    Item cancelled     Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                                  Page 4 of 21
                                                           Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc

Customer Test Hardware/Deliveries
 Unit                                           RR Part No               Dunlop Part No            Conn           Op
             Purpose            Date
  No                                         Valve       Kit            Valve         Kit           Pos          Press
                                20th
 1–3       Qualification                  23074930       N/A        EB101491A1         N/A           15        2.0 – 3.5
                                June
        AE3007C Engine
   4                           4th June   23074930       N/A        EB101491A1         N/A           15        2.0 – 3.5
              Test
           AE3007A             w/c 23
   5                                      23074930       N/A        EB101491A1         N/A           15        2.0 – 3.5
        Development Unit        Jul
         AE3007A Flight                                                                                          TBD
   6                           30 Jul     EX178771       TBD        EB101586A1       EC101587        0
           Test Unit                                                                                           (4.3 – 5.2)
         AE3007C Flight
   7                           30 Jul     23074986       TBD         EB101491B       EC101568        0         2.0 – 3.5
           Test Unit
        AE3007A Service         15th                                                                             TBD
 8-11                                     23075190     23074443      EB101586B       EC101587        0
        Evaluation Units        Aug                                                                            (4.3 – 5.2)




        Requirement for two Valve variants & individual Part No’s to be reviewed – 18th June 2001
                           Part No’s updated following E-Mail 28th June 2001


                                Dates – Updated to reflect programme Issue 7




Green  =On Schedule per plan      Yellow      = Not on schedule per plan   Red  = No plan in place to recover

Bulls eye - Item completed    Improving       deteriorating    Item cancelled      Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                                  Page 5 of 21
                                                           Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc

Formal Documentation
    Document Ref                            Title                  Issued/                      Comments
                                                                   Updated
IPT-EDU154               Team Charter                              See Header        Will be up issued after every
                                                                                     meeting, previous issues may be
                                                                                     deleted.

EDS3519                  Rolls-Royce Corp. Specification
(Draft)
EDS3519                  Re-Issued following IPT Meeting
2nd March 01             RR Indianapolis 27th Feb to 2nd
                         March 01
EDS3519 Issue 5          Communicated via E-Mail 19th
‘Draft’                  June 2001

EC101367A1               Unit number (mod to be
                         announced)
EB101491A1 Mod A         Dunlop Part No (Bleed Valve)
63005-23074930 Rev       RR Part No (Bleed Valve)
23074930 Rev             RR Part No (Bleed Valve)
23074443                 RR Part No (Kit of Parts)
23074929                 RR Part No (Gasket)
                         Part No’s captured on Page 4

EDU154/13 – Issue 1      Pollution Test Report
                         Pressure Distribution & Force
EDU154/15 – Issue 1
                         Balance Report
EDU154/08 – Issue 1      Qualification Test Report
                         (Awaiting Signed Hard Copy)




Green  =On Schedule per plan      Yellow      = Not on schedule per plan   Red  = No plan in place to recover

Bulls eye - Item completed    Improving       deteriorating    Item cancelled        Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                                Page 6 of 21
                                                         Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc

Action Items
    #    ACTION ITEM           OWNER         STOP-       OUTSTANDING ACTION /                 Action date       Status
                                             LIGHT      COMMENTS / RESOLUTION                                    date
                                                                PLAN
   01    Valve profile     Dunlop                    Design new valve profile to meet        05 Feb 01     02 Feb 01
                                                      envelope.                               07 Feb 01     06 Feb 01
                                                      Cylindrical valve sized; failed to                    20 Feb 01
                                                      meet envelope requirements
   02    Aluminium         Dunlop                    Study possibility of using              05 Feb 01     02 Feb 01
         study                                        Aluminium as alternative                TBA           06 Feb 01
                                                      material.
                                                      Awaiting Temp Data
                                                      Temperature Data indicates
                                                      Aluminium is no longer suitable                       02 Mar 01
   03    Mounting flange   Dunlop                    Alternative mounting flange if two      TBA           02 Feb 01
                                                      valve option chosen (retrofit fleet)
                                                      Mounting Flange now not an                            20 Feb 01
                                                      option on Bullet design, due to
                                                      envelope height restrictions
   04    System Test       Dunlop                    Check viability of using entire         TBA           02 Feb 01
                                                      manifold on a Dunlop test rig.
                                                                                              Ongoing       20 Feb 01
                                                      No relevant information will be
                                                      gained from Dunlop test Rig prior
                                                      to engine testing                                     02 Mar 01
   05    Engine test       Rolls Royce               RR to conduct test on current           08 Feb 01     02 Feb 01
                                                      design
                                                      Engine test on current system           21 Feb 01     20 Feb 01
                                                      scheduled to start 21st Feb 01
                                                      Engine test completed & Results                       02 Mar 01
                                                      presented 2nd March 01
   06    Temperature       Rolls Royce               RR to supply engine temperature         02 Feb 01     02 Feb 01
         Data                                         data of flight envelope.
                                                      Max temp approx 390F (200C)           12 Feb 01     06 Feb 01
                                                      Awaiting engine test                    23 Feb 01     20 Feb 01
                                                      Max temp confirmed as 530F
                                                      (277C) Mounting & 670F                              02 Mar 01
                                                      (354C) Air Temp
   07    Supply of Test    Rolls Royce               RR to supply Dunlop with the            12 Feb 01     02 Feb 01
         Components                                   current components for test.            TBA           06 Feb 01
                                                      IPT to discuss testing to validate
                                                      design                                                12 Mar 01
                                                      Testing to be discussed @ CDR                         13 mar 01
   08    Unigraphics       Rolls Royce               RR to e mail unigraphics files to       02 Feb 01     02 Feb 01
         Files                                        Dunlop
   09    Photographs       Rolls Royce               RR to supply Dunlop with                02 Feb 01     02 Feb 01
                                                      photograph’s of current set up


Green  =On Schedule per plan       Yellow   = Not on schedule per plan     Red  = No plan in place to recover

Bulls eye - Item completed    Improving     deteriorating    Item cancelled         Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                                Page 7 of 21
                                                         Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc
   10    Flow Reduction    Rolls Royce               Investigate allowable flow            TBA           02 Feb 01
                                                      reduction for system                  12 Feb 01     06 Feb 01
                                                      Defined figure for 100% & 95%         20 Feb 01     20 Feb 01
                                                      flow to be confirmed
                                                      Flow Reduction not necessary for
                                                      Poppet design                                       02 Mar 01
   11    Operating         Rolls Royce               Confirm opening and closing           05 Feb 01     02 Feb 01
         Characteristics                              pressures.                            12 Feb 01     06 Feb 01
                                                      Information needed before
                                                      12 Feb 01
                                                      Information delayed due to engine     23 Feb 01     20 Feb 01
                                                      test
                                                      Operating Pressures confrimed                       02 Mar 01
                                                      2nd March 01. Requirement for
                                                      specific margin to re-open
                                                      removed
   12    2-Valve Option    Rolls Royce               Investigate space envelope for 2nd    02 Feb 01     02 Feb 01
                                                      Valve                                 06 Feb 01     06 Feb 01
                                                      UG Model reviewed by Dunlop.                        20 Feb 01
                                                      Envelope found to be more
                                                      restrictive for second valve
                                                      2 Valve option dismissed                            02 Mar 01
   13    CFD Analysis      Rolls Royce               Conduct CFD analysis on               TBA           02 Feb 01
                                                      manifold (risk mitigation)                          06 Feb 01
                                                      RR confirmed CFD would not be                       02 Mar 01
                                                      completed prior to engine test
                                                     CFD still to be considered in         TBA           13 Mar 01
                                                      parallel with engine testing, as
                                                      possible mitigation                                 24 Apr 01
                                                      CFD will only be considered if
                                                      engine test proves unsuccessful
   14    Meeting minutes   Rolls Royce               Send out meeting minutes from         05 Feb 01     02 Feb 01
                                                      previous meeting                      06 Feb 01     06 Feb 01
   15    Risk table        Rolls Royce               Supply risk table                     05 Feb 01     02 Feb 01


   16    Program update    Andrew                    Program to be updated following       12 Feb 01     06 Feb 01
         required                                     information forwarded from RR




Green  =On Schedule per plan       Yellow   = Not on schedule per plan    Red  = No plan in place to recover

Bulls eye - Item completed    Improving     deteriorating    Item cancelled       Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                                Page 8 of 21
                                                         Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc
   17    Program           Andrew                    Initial program received by RR.         TBA           20 Feb 01
                                                      Dates now dependant on results of
                                                      Bullet/Poppet Trade Study
                                                      Program to be updated to reflect        13 Mar 01     02 Mar 01
                                                      Poppet Valve decision
                                                      Updated program to be                   15 Mar 01     13 Mar 01
                                                      forwarded & discussed 15/03/01
                                                      8.00am/1.00pm
                                                      Dunlop informed RR that they                          20 Mar 01
                                                      will make every attempt to
                                                      accelerate the milestones in Issue 4
                                                      of the program, but further
                                                      information on engine test dates is
                                                      required before an updated
                                                      program can be considered
                                                      (Action 28)                                           23 Apr 01
                                                      Issue 6 to be issued reflecting CDR
                                                      discussion: schedule allowed to
                                                      slip by 1 week for valve
                                                      optimisation & 2 weeks for
                                                      production delivery due to
                                                      exchange of documents
                                                      Issue 6 was accepted by RR with                       24 Apr 01
                                                      the following change: Engine test
                                                      units (Items 38 & 39) to be
                                                      delivered on the same date 8th Jun      08 May 01     01 May 01
                                                      Issue 7 to include P/O                  22 May 01     08 May 01
                                                      requirements (Action 48) and
                                                      change to valve requirements.
                                                      FAA requirements to be added
                                                      Issue 7 to identify the delay in        13 Jun 01     12 Jun 01
                                                      Qualification Testing on the
                                                      understanding that RR will
                                                      communicate a decision on the
                                                      operating requirements 18th June
                                                      2001.
                                                      RR requested a breakdown of the
                                                      Qualification Testing Plan.             14 Jun 01
                                                      Issue 7 or programme received.                        26 Jun 01
                                                      Issue 5 of Qual Test programme
                                                      received.
                                                      RR to review and comment                              17 Jul 01
                                                      RR stated that it was unlikely that
                                                      the current valve variant
                                                      (EB101586B) would be acceptable
                                                      for the AE3007A. Dunlop stated
                                                      that any requirement for re-design
                                                      would impact the programme by 6
                                                      weeks. Dunlop to continue to
                                                                                              w/c 23 Jul
                                                      Issue 7 awaiting engine test results    01

Green  =On Schedule per plan       Yellow   = Not on schedule per plan     Red  = No plan in place to recover

Bulls eye - Item completed    Improving     deteriorating    Item cancelled         Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                                  Page 9 of 21
                                                           Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc
   18    Casting Study       Dunlop                    Dunlop to investigate implications      TBA           20 Feb 01
                                                        of casting (-3 requirement)
                                                        Casting not an immediate option
                                                        due to timescales, but may be                         02 Mar 01
                                                        considered as a future option
   19    -3 casting         Rolls Royce               Rolls Royce to forward                  23 Feb 01     20 Feb 01
         requirement                                    information regarding -3 casting
                                                        requirement                             TBA           02 Mar 01
                                                        No longer as significant, as
                                                        Aluminium is no longer an option                      13 Mar 01
   20    Oval Valve          Dunlop                    Oval Valve envelope to be sized         21 Feb 01     20 Feb 01
         Design                                         and sent to RR
                                                        No longer an option                                   02 Mar 01
   21    Pollution Testing   Dunlop                    RR & Dunlop to design a suitable        02 Apr 01     02 Mar 01
                                                        pollution test for ‘Retimet’
                                                        Dunlop to inform RR of proposed
                                                        pollution test setup & pollutants to    15 Mar 01     13 Mar 01
                                                        be used
                                                        RR request that Dunlop test to a                      20 Mar 01
                                                        higher level of pollution
                                                        (300g/m3). Dunlop stated that the
                                                        level of pollution required would
                                                        be clearer during testing.
                                                        Dunlop expressed concern
                                                        regarding scheduling of the
                                                        pollution testing prior to CDR,
                                                                                                TBD
                                                        citing a possible conflict with RR
                                                        Anti-Ice Valve testing. RR to
                                                        advise on testing priorities
                                                        Pollution testing discussed &                         23 Apr 01
                                                        agreed at CDR. Testing delayed,
                                                        awaiting test components
                                                        RR to be updated on pollution test
                                                        schedule when components are                          24 Apr 01
                                                        received by Dunlop.
                                                        Dunlop expecting components w/e
                                                        4th May. Pollution test to be                         01 May 01
                                                        scheduled around anti-ice valve
                                                        certification.
                                                        All components received 8th May
                                                        01                                      18 May 01     08 May 01
                                                        Pollution Testing underway. RR          29 May 01     22 May 01
                                                        communicated requirements via
                                                        E-Mail. Dunlop to include exact
                                                        details of test & results in formal
                                                        report w/c 28th May 2001
                                                        Report Issued 8th June 2001. RR                       12 Jun 01
                                                        to review & comment.
                                                        RR comment required.                    03 July 01    26 Jun 01


Green  =On Schedule per plan         Yellow   = Not on schedule per plan     Red  = No plan in place to recover

Bulls eye - Item completed     Improving      deteriorating    Item cancelled         Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                               Page 10 of 21
                                                         Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc
   22    Poppet Valve      Dunlop                    Dunlop to inform RR of Poppet          12 Mar 01     02 Mar 01
                                                      Valve envelope and Mounting Feet
                                                      requirements
                                                      See Decision No 6                                    13 Mar 01

   23    8th Stage         Rolls Royce               RR to investigate impact of 8th        16 Mar 01     02 Mar 01
         Pressures                                    Stage pressures on Valve
                                                      operating characteristics
                                                      2.0 to 3.5 psia opening closing        16 Mar 01     13 Mar 01
                                                      requirement could reduce to 2.4 to
                                                      3.5 psia. Further investigation is
                                                      required
                                                      RR confirmed that the spec was to                    20 Mar 01
                                                      remain at the current operating
                                                      characteristics (2.0 to 3.5 psia
                                                      closing & < 2.0 psia re-open)
                                                      RR stated that there would be a
                                                      risk involved by remaining with
                                                      these pressures and not decreasing
                                                      the closing requirement (2.4 to 3.5
                                                      psia). This risk is to be mitigated
                                                      by engine testing
   24    Flow Mockup       Dunlop                    RR require Flow Mock up to             02 Apr 01     02 Mar 01
                                                      validate engine start                  11 Apr 01
                                                      Flow piece sent 18th April 2001                      23 Apr 01
                                                     RR requested shipping info to
                                                                                                           24 Apr 01
                                                      track test piece & thread info for
                                                      ‘blanking’ plugs                       03 May 01     01 May 01
                                                      Engine test due 03 May 01
                                                      Engine test delayed to 8th May 01
                                                      RR to provide feedback 10th May        10 May 01     08 May 01
                                                      01. Telecon to be held 3.30pm
                                                      (9.30am), Sir Arthur Du Cross
                                                      +44 2476 294 214
   25    Material          Dunlop                    Dunlop to provide details of Valve     15 Mar 01     13 Mar 01
                                                      materials
                                                                                             21 Mar 01     20 Mar 01
                                                      Material details supplied at CDR
                                                                                                           23 Apr 01
                                                      Specific details for BS S143
                                                      communicated 23rd April 2001
   26    Weight & C of G   Dunlop                    Dunlop to provide Weight &             16 Mar 01     13 Mar 01
                                                      C of G of Poppet Valve
                                                      RR to design Manifold for
                                                      maximum valve weight of 2.9 Lbs                      20 Mar 01
                                                      Valve optimised following CDR.                       23 Apr 01
                                                      Guaranteed weight currently 2.60
                                                      Lbs.
                                                      Revised weight of valve accepted                     24 Apr 01
                                                      by RR, Dunlop to forward C of G
                                                      (Action 38)
                                                      C of G supplied 01 May 01                            01 May 01

Green  =On Schedule per plan       Yellow   = Not on schedule per plan    Red  = No plan in place to recover

Bulls eye - Item completed    Improving     deteriorating    Item cancelled        Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                               Page 11 of 21
                                                         Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc
   27    Life              Dunlop                    Dunlop to investigate performance      11 Apr 01     13 Mar 01
         Performance                                  of similar valves during service,
         Characteristics                              including operating & leakage
                                                      characteristics                        27 Apr 01     24 Apr 01
                                                      PAT (conformity) details for 3                       01 May 01
                                                      random valves (HP & IP) given
                                                      to RR, as supplied and service
                                                      condition
   28    Testing           Rolls Royce               RR to inform Dunlop of testing         27 Mar 01     20 Mar 01
         Priorities                                   priorities between CABV and Anti
                                                      Icing Valve
   29    Updated           Dunlop                    Updated sectional to be supplied       22 Mar 01     20 Mar 01
         Sectional                                    to RR for further discussion
   30    Engine Testing    Rolls Royce               RR to inform Dunlop of updated         11 Apr 01     20 Mar 01
                                                      engine test dates
   31    CDR               RR/Dunlop                 CDR Minutes to be agreed by            27 Apr 01     23 Apr 01
                                                      both parties and issued by Dunlop
                                                      CDR Minutes to be issued               24 Apr 01     24 Apr 01
                                                      RR received CDR minutes.
                                                                                             08 May 01     01 May 01
                                                      RR to print, sign & return 2
                                                      copies to Dunlop. Dunlop to attach
                                                      presented documents, including
                                                      the following appendices, Stress
                                                      report issue 2 & updated tolerance
                                                      summary, and return 1 copy to
                                                      RR
                                                      Copies sent to Dunlop                                08 May 01
                                                      Dunlop to officially issue CDR
                                                                                                           22 May 01
                                                      Minutes w/c 28th May 2001
                                                      CDR Minutes Issued 6th June 2001                     12 Jun 01




Green  =On Schedule per plan       Yellow   = Not on schedule per plan   Red  = No plan in place to recover

Bulls eye - Item completed    Improving     deteriorating    Item cancelled        Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                               Page 12 of 21
                                                         Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc
   32    Specification     Rolls Royce                RR to re-issue specification             20 Apr 01     23 Apr 01
                                                      EDS3519 incorporating items
                                                      discussed at CDR & recorded in
                                                      the minutes
                                                      RR to issue EDS3519 Draft Issue 3        30 Apr 01     24 Apr 01
                                                      Prior to signed copy following           08 May 01     01 May 01
                                                      item 33
                                                      EDS3519 Draft Issue 3 which will         09 May 01     08 May 01
                                                      reflect official issue to be released
                                                      09 May 01
                                                      EDS3519 Draft Issue 4 which will                       15 May 01
                                                      reflect change of connector angle
                                                      and amendment to test
                                                      requirement
                                                      RR to send by 25th May 2001              25 May 01     22 May 01
                                                      EDS3519 Draft Issue 5 to be              19 Jun 01     12 Jun 01
                                                      issued Tue 19th June 2001,
                                                      detailing RR decision on operating
                                                      requirements
                                                      Current ‘Draft’ issue 5 of               10 Jul 01     26 Jun 01
                                                      EDS3519 deemed fit for TTS to
                                                      commence. RR to communicate
                                                      signed spec prior to 10th July 2001.
                                                      Specification held until engine test                   17 Jul 01
                                                      results are available to clarify the
                                                      operating characteristics for
                                                      AE3007A




Green  =On Schedule per plan      Yellow    = Not on schedule per plan     Red  = No plan in place to recover

Bulls eye - Item completed    Improving     deteriorating    Item cancelled          Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                               Page 13 of 21
                                                         Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc
   33    Certification     Dunlop                    Dunlop to advise RR on amended           27 Apr 01     23 Apr 01
         (Type Test                                   test procedures as discussed at
         Schedule)                                    CDR
                                                      RR to review updated TTS &               02 May 01
                                                                                                             01 May 01
                                                      meeting to be arranged 02 May 01         15 May 01
                                                      TTS re-issued following meeting                        08 May 01
                                                      02 May 01. RR to review and
                                                      comment. TTS to be
                                                      communicated to FAA

                                                      RR to review supplied analogy            22 May 01
                                                      summary and feedback concerns                          15- May 01

                                                                                               22 May 01
                                                      RR to supply pipe model for                            15 May 01
                                                      compressor wash connector up to
                                                      first point of attachment.
                                                      Received 22nd May 2001                   23 May 01     22 May 01

                                                      Dunlop requested formal reply to         25 May 01
                                                      TTS questions to allow updated
                                                      TTS to be issued.
                                                      Dunlop stated that outstanding
                                                      issues on the TTS should be
                                                      resolved ‘sooner rather than later’
                                                      to prevent delays in testing
                                                      Only outstanding issue on TTS is         13 Jun 01     12 Jun 01
                                                      the level of contamination called
                                                      for in EDS3519 Draft issue 4. RR
                                                      to review requirement and
                                                      comment ASAP.
                                                      Contamination levels discussed           27 Jun 01     26 Jun 01
                                                      and agreed via E-Mail 15th June
                                                      2001. TTS signed front sheet
                                                      required ASAP .                                        16 Jul 01
                                                      TTS Front sheet received 28th
                                                      June 2001. Awaiting hard copy.
                                                      Vibration, Flow & Proof complete,
                                                      awaiting provisional PAT Limits
                                                      to allow pass fail criteria to be
                                                      determined.
                                                                                                             17 Jul 01
                                                      PAT following vibration indicated
                                                      that the closing pressure had been
                                                      reduced from 2.8 to 2.3psig. RR
                                                      stated that coupled with the
                                                      ‘bottom’ limit initial closing
                                                      pressure of 2.7psig, this is unlikely
                                                      to be acceptable for engine
                                                      AE3007A. Dunlop to continue
                                                      testing to meet current
                                                      programme targets

Green  =On Schedule per plan       Yellow   = Not on schedule per plan     Red  = No plan in place to recover

Bulls eye - Item completed    Improving     deteriorating    Item cancelled          Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                                 Page 14 of 21
                                                           Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc
   34    Flow               Dunlop                     Dunlop to forward full copy of         27 Apr 01     23 Apr 01
         Requirement                                    flow test results to RR
   35    Tolerance effect   Dunlop                     Dunlop to expand on tolerance          27 Apr 01     23 Apr 01
                                                        summary presented at CDR
   36    Valve              Dunlop                     RR requested Dunlop to further         TBD           23 Apr 01
         frequencies                                    investigate theoretical valve
                                                        frequencies
   37    Pedigree           Dunlop                     RR requested a summary of              04 May 01     23 Apr 01
                                                        Dunlop pedigree relating to the
                                                        critical design features used
   38    Valve Envelope     Dunlop                     RR require CAD model of                23 Apr 01     23 Apr 01
                                                        external envelope for engine           26 Apr 01     24 Apr 01
                                                        assembly
   39    OE Kit             RR/Dunlop                  Both parties to discuss supply of      TBD           23 Apr 01
                                                        OE kit (Corruseal Gasket & Bolts)
                                                        RR to update Dunlop on OE Kit          24 Apr 01     24 Apr 01
                                                        situation ASAP
                                                        RR confirmed Dunlop to supply
                                                        Kit of Parts (Valve, Gasket &
                                                        Bolts) via E-Mail 25 Apr 2001
   40    Stress Analysis    Dunlop                     Stress report to be re-issued          20 Apr 01     23 Apr 01
                                                        incorporating actions discussed at
                                                        CDR                                    27 Apr 01     24 Apr 01
                                                        Stress Analysis completed. Report
                                                        delayed due to the priority for        11 May 01     01 May 01
                                                        Bolt selection (Action 46)

                                                        RR to review supplied report and       22 May 01     15 May 01
                                                        feedback concerns

                                                        RR stated that Bolt Calculations       25 May 01     22 May 01
                                                        should be re-calculated
                                                        considering ‘wasted shank’
                                                        diameter. Stress report issue 2 was
                                                        accepted                                             12 Jun 01
                                                        Stress report Issue 3 accepted by
                                                        RR & communicated as an
                                                        appendix to the CDR Minutes 6th
                                                        June 2001
   41    Stress Analysis    RR                         RR to investigate Stress issues        18 Apr 01     23 Apr 01
                                                        concerning the Union & Bolts
                                                        RR to communicate results of
                                                        stress analysis; Dunlop to             24 Apr 01     24 Apr 01
                                                        comment
                                                        Dunlop reviewed RR stress                            01 May 01
                                                        calculations. As Dunlop are now
                                                        taking responsibility for supply of
                                                        bolts, calculations to be revised
                                                        accordingly (Action 46)
Green  =On Schedule per plan        Yellow    = Not on schedule per plan    Red  = No plan in place to recover

Bulls eye - Item completed      Improving     deteriorating    Item cancelled        Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                               Page 15 of 21
                                                         Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc
   42    Valve             Dunlop                    Valve to be optimised for weight         13 Apr 01     23 Apr 01
         optimisation
   43    Drawings          Dunlop                    Dunlop to supply                         27 Apr 01     23 Apr 01
                                                      Outline/Sectional drawings to RR
                                                      following optimisation
                                                      Drawings supplied as JPEG’s. RR
                                                                                               02 May 01     01 May 01
                                                      requested IGES translation
                                                      instead
                                                      RR to review part marking on
                                                      Outline & communicate changes
                                                      required ASAP                            11 May 01     08 may 01
   44    Risk Analysis     RR/Dunlop                 Joint Risk Review required               TBD           23 Apr 01
                                                      Provisional date 21st May 01             21 May 01     08 May 01
                                                      RR stated that system Risk               29 May 01     22 May 01
                                                      Analysis had been completed.
                                                      Necessity for Valve Risk Analysis
                                                      had now diminished. Results to be
                                                      communicated.
                                                      RR stated that relevance of Risk                       26 Jun 01
                                                      Analysis to Dunlop had now
                                                      diminished
   45    Maintainability   Dunlop                    Dunlop to clarify maintenance            24 Apr 01     23 Apr 01
                                                      philosophy

                                                     Dunlop to supply draft
                                                                                               02 Jun 01     23 Apr 01
                                                      maintenance manual for review
                                                      Dunlop stated that the Customer          Mid-July      26 Jun 01
                                                      Maintenance Manual (75-31-05)
                                                      will be available in ‘Draft’ format
                                                      around Mid-July. Communication
                                                      has taken place between Frank
                                                      Bull (Dunlop) & Stanley Krska
                                                      (RRC Tech Pubs CMM Co-
                                                      ordinator) regarding CMM
                                                      Format & Part No configuration,
                                                      via E-Mail 27th June 2001.
                                                      Draft maintenance manual sent to                       17 Jul 01
                                                      Stanley Krska w/c 23rd July 2001




Green  =On Schedule per plan       Yellow   = Not on schedule per plan    Red  = No plan in place to recover

Bulls eye - Item completed    Improving     deteriorating    Item cancelled          Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                               Page 16 of 21
                                                         Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc
   46    Bolt              Dunlop/RR                 As Dunlop are now responsible for                       01 May 01
         procurement                                  bolt procurement, additional
                                                      stress analysis is required.
                                                      Dunlop to analyse the following
                                                      bolt options: MS9557-26, MS9697-
                                                      24 & Jethete using dimensional            08 May 01
                                                      information provided by RR.
                                                      RR to investigate thermal
                                                      expansion of MS9697-24 &
                                                      provide further details of Bracket
                                                      & Manifold dimensions.                    08 May 01
                                                      Further details of Bracket &
                                                      Manifold provided
                                                                                                08 May 01
                                                      RR to investigate Nut
                                                      configuration (similar material to
                                                      bolt)
                                                      RR to clarify temperature                 08 May 01
                                                      requirements for the Mounting
                                                      Flange
                                                      Dunlop stated that CDR Minutes
                                                      would include the Bolt analysis as
                                                      an appendix, which would serve to
                                                      control the details of the system
                                                      configuration to which it had been
                                                      analysed.
                                                      Analysis shows that at specified                        08 May 01
                                                      temperature, Jethete is the only
                                                      viable option from those listed
                                                      above.
                                                      RR stated that reducing the
                                                      temperature would only be
                                                      considered as a last resort
                                                      RR suggested Inconel 718 Bolts,
                                                      AS3237-26
                                                      RR stated that Nut would be
                                                      standard, regardless of bolt used
                                                      AS1789/C4 (Silver Plated)                 15 May 01
                                                      Dunlop to further investigate bolt
                                                      selection, Jethete Vs Inconel, Cost
                                                      implications etc…

                                                      Dunlop to revisit to investigate          22 May 01     15 May 01
                                                      fitting Inconnel Bolts by mistake

                                                      Dunlop proposed use of bolt               22 May 01     15 May 01
                                                      AS24028. RRC to confirm
                                                      acceptability after discussion with
                                                      their service area.

                                                       Dunlop to supply usage from their   22 May 01     15 May 01
                                                       current stockist
Green  =On Schedule per plan      Yellow    = Not on schedule per plan    Red  = No plan in place to recover

Bulls eye - Item completed    Improving     deteriorating    Item cancelled           Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                               Page 17 of 21
                                                         Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc
    46    Bolt              Dunlop/RR                RR accepted Jethete Bolts                            22 May 01
   Cont   procurement                                 (AS24028) in principle – awaiting
                                                      Stress Report issue 3
                                                      Stress report issue 3 accepted. RR                   12 Jun 01
                                                      re-iterated AS24028 Bolts to be
                                                      used for Proof & Vibration tests.
                                                      RR requested that Dunlop
                                                      investigate wasted bolts MS9557
                                                      Vs AS24028 in regards to shank
                                                      diameter. Dunlop to communicate
                                                      clearance hole diameter in Body        9 Jun 01
                                                      RR require 8 off AS24028 for           26 Jun 01     26 Jun 01
                                                      Endurance engine test 29th June
                                                      2001. Dunlop to dispatch against
                                                      RR purchase order, required 26th
                                                      June 2001.                                           16 Jul 01
                                                      Bolts received by RRC.
   47     FAA Conformity    Dunlop/RR                RR to confirm FAA requirements.        08 May 01     01 May 01
                                                      Dunlop to illustrate proposed flow
                                                      of documents to cover certification
   48     Purchase Orders   Dunlop/RR                Info                                                 01 May 01
                                                      Initial PO’s required 3 days prior
                                                      to shipping ie 5th June 01
                                                      PO’s required to cover the
                                                      following units:
                                                      2 off dev Std EB101491A1 FOC
                                                      6 off Kits (Prodn Std) Part No
                                                      23074443 FOC
                                                      16 off Kits (Prodn Std) Part No
                                                      23074443
                                                      Dunlop to confirm if entire kits       08 May 01
                                                      are FOC                                15 May 01     08 May 01
                                                      PO’s to reflect delivery
                                                                                                           22 May 01
                                                      requirements Page 4                                  17 Jul 01
                                                     Dunlop communicated Concerns
                                                      over PO’s in E-Mail 20th July
                                                      2001. RR replied recognising
                                                      concerns: PO’s to be sent w/e 27th
                                                      July 2001




Green  =On Schedule per plan      Yellow    = Not on schedule per plan    Red  = No plan in place to recover

Bulls eye - Item completed    Improving     deteriorating    Item cancelled        Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                                Page 18 of 21
                                                          Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc
   49    Valve Variants    Dunlop/RR                  RR stated that two valve variants                   22 May 01
                                                       would be required to cover the
                                                       range of operating pressures on
                                                       the AE3007 A & C Engines.
                                                       Dunlop agreed to supply a
                                                       development valve ASAP for
                                                       engine testing (EB101491A1)
                                                       Dunlop to prepare calculations for
                                                       a higher operating pressure
                                                       variant (TBD 4.3 – 5.2 psig)
                                                       Engine Testing (AE3007A1)             18 Jun 01     12 Jun 01
                                                       completed 9th June 2001, using
                                                       EB101491A1 with spring variant
                                                       ED101592. RR communicated
                                                       results via E-Mail Mon 11th June
                                                       2001. Second engine test 14th June
                                                       (AE3007C). RR to define
                                                       operating requirements based on 2
                                                       engine tests and communicate 18th
                                                       June 2001. Impact to Dunlop
                                                       schedule based on results 18th
                                                       June 2001.
         Engine Testing    RR                          Endurance Engine Testing to           W/C           26 Jun 01
                                                       commence 29th June 2001. Results      02 Jul 01
                                                       expected w/c 2nd July 2001                          17 Jul 01
                                                       RR stated that engine test had
                                                       been delayed (E-Mail 24th July
                                                       2001). Both parties had hoped
                                                       engine testing would indicate
                                                       operating characteristics for
                                                       AE3007A variant. RR stated that
                                                       theoretical values suggested that
                                                       the current variant EB101586B
                                                       would be unacceptable. Impact on
                                                       schedule (Action 17). Impact on
                                                       Type Test (Action 33)




Green  =On Schedule per plan       Yellow    = Not on schedule per plan   Red  = No plan in place to recover

Bulls eye - Item completed     Improving     deteriorating    Item cancelled       Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                               Page 19 of 21
                                                         Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc
   50    PAT               Dunlop/RR                  Dunlop stated that PAT limits         TBD           12 Jun 01
         Instructions                                 would need to be set using a
                                                      combination of engine test results
                                                      & Dunlop Flow Rig results. Both
                                                      parties agreed that qualification
                                                      could commence without a
                                                      ‘signed’ copy of the PAT.
                                                      Provisional PAT limits are now                      16 Jul 01
                                                      essential. Delay in Engine Testing
                                                      has resulted in qualification
                                                      testing becoming the primary
                                                      driver. Dunlop communicated
                                                      concerns in E-Mail 16 July 2001.
                                                                                                          17 Jul 01
                                                      PAT limits required to allow
                                                      current variant (EB101586B) to be
                                                      acceptable for type testing &
                                                      production, are not acceptable for
                                                      engine.




Green  =On Schedule per plan      Yellow    = Not on schedule per plan   Red  = No plan in place to recover

Bulls eye - Item completed    Improving     deteriorating    Item cancelled       Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                                       Page 20 of 21
                                                                 Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc

Decisions
    #                       Decision                     Date made                 Justification/thoughts/comments
  001    RR stated certain testing will be required      06 Feb 01      Dunlop and RR to investigate air worthiness
         prior to full certification                                    requirements for engine test valve’s
  002    Dunlop introduced RR to second design           15 Feb 01      Dunlop introduced second concept to alleviate timescale
         concept                                                        concerns associated with Bullet Valve design
  003    RR request overview of Dunlop decision          20 Feb 01      RR requested to become more involved with Dunlop’s
         making criteria Ref: Bullet/Poppet design                      decision to introduce a second design concept, to allow a
                                                                        joint decision on project ‘direction’ to be made.
  004    Valve to be of a ‘Poppet’ design                02 Mar 01      All iterations of the Bullet Valve design have been looked
                                                                        at and dismissed, due to Flow, Operating Constraints and
                                                                        Cost/Weight issues
  005    1 Single Valve to be designed                   02 Mar 01      1 Single Valve was chosen Vs 2 smaller Valves on the
                                                                        basis of Design Considerations, Cost & Weight
  006    Valve Envelope confirmed                        13 Mar 01      Valve envelope was confirmed and proposed valve
                                                                        mounting was accepted via E-Mail 13 Mar 01
  007    CDR                                             24 Apr 01      CDR Minutes accepted by both parties and released for
                                                                        signing
  008    Kit of Parts                                    25 Apr 01      RR stated that Dunlop are to supply a Kit of Parts for OE
                                                                        requirement (Valve, Gasket & Bolts)
  009    Mounting Bolts                                  01 May 01      Responsibility for design and procurement of Mounting
                                                                        Bolts has been assigned to Dunlop
  010    Mounting Bolts                                  22 May 01      RR accepted Jethete Bolt AS24028 for use on the CABV
  011    Valve Variants                                  22 May 01      RR stated that two valve variants were required to cover
                                                                        the operating pressures on the AE3007 A & C Engines
  012    PAT Instructions                                12 Jun 01      PAT Limits will be set using direct correlation to engine
                                                                        test results & Dunlop Flow Rig results. PAT limits may
                                                                        not be identical to Spec limits due to rig limitations
  013    Gasket                                          16 July 01     Confirmed via E-Mail 15th July 2001, RRC stated that
                                                                        Dunlop were no longer responsible for Gasket
                                                                        procurement. The original gasket is now to be removed
                                                                        form the Kit of Parts & all certification/PAT to be carried
                                                                        out using a metal to metal seal.
  014    Variant EB101586B                               17 July 01     Having communicated Operating Limits for variant
                                                                        EB101586B, coupled with the delay in engine testing &
                                                                        therefore verification, RR stated that this variant is
                                                                        unlikely to be acceptable for engine AE3007A. Dunlop
                                                                        stated that they will continue with Type Testing to meet
                                                                        current programme targets.



Programme Management Protocol
  Plan Description                                              Owner             Configuration
  Overall Dunlop Equipment Programme for:               Alan Benn        BDPP088 issue 1
  Design, Manufacture of Development
  hardware, Qualification, Production Readiness
  & 1st off manufacture
Green  =On Schedule per plan       Yellow    = Not on schedule per plan   Red  = No plan in place to recover

Bulls eye - Item completed       Improving          deteriorating    Item cancelled          Bring in the Coffin 
AE3007A Compressor Acceleration Bleed Valve
Integrated Programme Team (IPT) Charter
Issued ex meeting: See filename below
                                                                                               Page 21 of 21
                                                         Filename: 1efa8aa3-c47b-4bc8-bccd-ea28e7e4a3c5.doc




Green  =On Schedule per plan      Yellow    = Not on schedule per plan   Red  = No plan in place to recover

Bulls eye - Item completed    Improving     deteriorating    Item cancelled     Bring in the Coffin 

				
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