Pratt & Whitney PW4000

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PW4000
PW4000-112 (cropped).jpg
The 112-inch (2.8 m) fan diameter PW4098 used on the Boeing 777
Type Turbofan
National originUnited States
Manufacturer Pratt & Whitney
First runApril 1984 [1]
Major applications Airbus A300-600/Airbus A310
Airbus A330
Boeing 747-400
Boeing 767/KC-46
Boeing 777
McDonnell Douglas MD-11
Scaled Composites Stratolaunch
Produced1984–present
Number built2,500 (June 2017) [2] [ needs update ]
Developed from Pratt & Whitney JT9D
Developed into Engine Alliance GP7000

The Pratt & Whitney PW4000 is a family of dual-spool, axial-flow, high-bypass turbofan aircraft engines produced by Pratt & Whitney as the successor to the JT9D. It was first run in April 1984, was FAA certified in July 1986, and was introduced in June 1987. With thrust ranging from 50,000 to 99,040 lbf (222 to 441 kN), it is used on many wide-body aircraft.

Contents

Development

The 52,000–62,000 lbf (230–275 kN), 94 in (2.4 m) -fan PW4000 made its first run in April 1984, was FAA certified in July 1986, and was introduced in June 1987. It powers the Airbus A300-600 and Airbus A310-300, Boeing 747-400 and 767-200/300, and McDonnell Douglas MD-11 widebodies. [1]

Development of the 64,000–68,000 lbf (280–300 kN), 100 in (2.5 m)-fan version began in December 1991 for the Airbus A330, was FAA certified in August 1993, and made its first flight two months later. It received 90min Extended-range Twin-engine Operations (ETOPS) approval at introduction in December 1994, and 180min ETOPS approval in July 1995. In January 2000, it was the A330 market leader with more than half of the installed base and one million hours, more than twice that of each competitor. [1] The Advantage 70 upgrade package for the PW4168A, which powered around one-third of the active Airbus A330 fleet, was launched at the 2006 Farnborough Airshow, increasing thrust to 70,000 lbf (311 kN), and reducing fuel burn by about 1.2% as well as overall operating costs by as much as 20%. [3]

A PW4074 on an ANA 777-200 under maintenance with the fan doors open, showing the fan disk inside the inlet cowling at the front of the engine Pratt & Whitney PW4074 crop.jpg
A PW4074 on an ANA 777-200 under maintenance with the fan doors open, showing the fan disk inside the inlet cowling at the front of the engine

For the Boeing 777, the 84,000–98,000 lbf (370–440 kN), 112 in (2.8 m)-fan version development began in October 1990, achieved 100,000 lbf (440 kN) in May 1993, and was approved for 180min ETOPS at service entry in June 1995.The 777 launch engine, it entered service on 7 June 1995, with United Airlines. The 90,000 lbf (400 kN) PW4090 entered service in March 1997. The 98,000 lbf (440 kN) PW4098 received FAA certification in July 1998 and was introduced on the Boeing 777-300 in September 1999. [1]

In 2000, over 2,000 PW4000 engines had accumulated over 40 million hours of service with 75 operators. [1] In 30 years between June 1987 and 2017, more than 2,500 engines have been delivered, logging more than 135 million flight hours. [2]

Design

PW4077 titanium-bladed fan section with containment ring in the United Airlines maintenance facility at SFO PW4077 Fan.jpg
PW4077 titanium-bladed fan section with containment ring in the United Airlines maintenance facility at SFO

The PW4000 has a dispatch reliability rate of 99.96% and is approved for ETOPS 180. The average engine stays on wing 13,500 flight hours before a shop visit (a Shop Visit Rate of 0.073 per thousand hours). It is claimed to be cumulatively 3.4 dB quieter than other engines in its class. [1]

Like other modern aircraft power plants, it has a Full Authority Digital Engine Control (FADEC), for better fuel economy and reliability. [4] Furthermore, single-crystal alloys allows higher temperature capability and PW's Floatwall combustor liners improve durability and maintainability. [1] Also, the Talon ("Technology for Affordable Low NOx") single-row combustor improves fuel-air mixing, for over 10% better NOx, CO, and HC emissions. [1]

Variants and applications

Boeing 767-2B1(ER), Aeromexico JP6079092.jpg
A -94 powering the Boeing 767 with 38 fan blades
Airbus A330-223, Kingfisher Airlines JP6833765.jpg
A -100 powering the Airbus A330 with 34 fan blades
Pratt & Whitney PW4000 (4836578201).jpg
A -112 powering the Boeing 777 with 22 fan blades

The PW 4000 series engine family uses a numbering systematic with the last three digits (PW 4XYZ) as identification of the application and thrust power:

Example: A PW4077 identifies a PW4000 series engine certified for Boeing (777-200) and has a certified thrust of 77,000 lbf.

PW4000-94

Variants: PW4052, PW4056, PW4060, PW4062, PW4062A, PW4152, PW4156A, PW4156, PW4158, PW4460 and PW4462.
Thrust range: 231–276 kN (52,000 lbf – 62,000 lbf) [5]
Applications:

PW4000-100

Variants: PW4164, PW4168, PW4168A and PW4170.
Thrust range: 287–311 kN (64,500 lbf – 70,000 lbf) [6]
Applications: the engine variants are designed exclusively for Airbus A330-200 and -300 (Note that this does not include the A330neo: -800 or -900 nor the BelugaXL (A330-700)).

PW4000-112

Variants: PW4074/74D, PW4077/77D, PW4084/84D, PW4090 and PW4098.
Thrust range: 329–436 kN (74,000 lbf – 98,000 lbf) [7]
Applications: the engine variants are designed exclusively for Boeing 777-200, -200ER, -300. (Note that this does not include the -200LR, -300ER or F).

Accidents and incidents

UAL1175 PW4077 fan blade root section fracture surface showing metal fatigue UAL1175 PW4077 fan blade 11 fracture.png
UAL1175 PW4077 fan blade root section fracture surface showing metal fatigue
Damage to hollow fan blades from UA328, fracture surface near hub at top of photo United Airlines Flight 328 damage 2.jpg
Damage to hollow fan blades from UA328, fracture surface near hub at top of photo

Involving PW4000-112 series

17 March 2003, United Airlines Flight 842
A PW4090 failed bearing caused the engine loss and the diversion to Kona, Hawaii, of a Boeing 777-200ER bound from Auckland, New Zealand, to Los Angeles. At 190 minutes this was the longest single-engine diversion on record at the time. [8] [9] [10]
27 May 2016, Korean Air Flight 2708
A PW4098 uncontained turbine failure caused an aborted take-off, [11] [12] on a Boeing 777-300 at Tokyo-Haneda Airport. [13]
13 February 2018, United Airlines Flight 1175
A PW4077 fan blade failure caused significant engine damage to a Boeing 777-200 on descent into Honolulu from San Francisco. [14] Routine fan blade inspection in 2005 and 2010 had shown a crack in the blade's metal structure but insufficiently trained inspectors had confused it for a defect in the paint. [15] [16] In 2019, an airworthiness directive mandated recurring engine inspections based on usage cycles. [17]
4 December 2020, Japan Airlines Flight 904
A PW4074 engine had a fan blade failure and associated engine cowl damage as the Boeing 777-200 was climbing out of Okinawa. [18] As of March 2021 the investigation is ongoing.
20 February 2021, United Airlines Flight 328
Boeing 777-200's right hand PW4077-112 had a blade failure shortly after taking off from Denver, causing significant engine damage. [19] Two fan blades had broken off: one had suffered metal fatigue and possibly chipped another blade which also broke off. [20] The failed blade was compliant with the inspection interval set by the FAA following the 2018 incident. The FAA grounded the affected 777s and issued an emergency Airworthiness Directive on 23 February, requiring a Thermal Acoustic Inspection (TAI) of the -112 fan blades before next flight. [21] [22] Japanese authorities and the UK's CAA followed suit, [23] grounding 69 in-service and 59 in-storage Boeing 777s. [24] [25] Most carriers had voluntarily grounded the aircraft before, except South Korea's Jin Air's four aircraft. [26] As of March 2021 the investigation is ongoing.

Involving PW4000-100 series

6 May 2014, Vietnam Airlines VN-A371
Uncontained failure of a PW4168A low-pressure turbine's stage four causing an Airbus A330 rejected take-off at Melbourne Airport in Australia. [27]
13 February 2018, Delta Air Lines Flight 55
PW4168 fire in an Airbus A330-200 climbing from Lagos (Nigeria) at 2000 feet. [28]
18 April 2018, Delta Air Lines Flight 30
Airbus A330-323's PW4168A fire after takeoff from Atlanta, [29] [30] investigated by the NTSB and the French BEA. [31]

Involving PW4000-94 series

7 June 2017, Delta Airlines flight 276
Metallic debris in a PW4056 tailpipe and a 360 degrees crack in the LP turbine case just forward or the rear flange caused a Boeing 747-400 cruising at FL320 to return to Tokyo Narita. [32] All of the HPC airfoils from the 5th to the 15th stage were damaged with nicks, dents, and tears to the leading and trailing edges and/or were broken off at various lengths above the blade root platforms. The HPT and LPT also had extensive damage, and the LPT case had a 360° split in line with the 6th stage turbine rotor. [32] The NTSB reports 38 airfoil fractures of the 5th stage compressor blade before the part was updated. [32]
20 February 2021, Longtail Aviation Flight 5504
Boeing 747-412BCF PW4056 failure shortly after taking off from Maastricht Aachen Airport  : falling turbine blades slightly injured two persons on the ground, the airplane was able to land safely at Liège Airport. [33] [34] [35] [36]
28 March 2022, United Airlines Flight 134
Boeing 767 powered by Pratt & Whitney PW4060 engines experienced fan blade separation on the right-side (number 2) engine during a flight from New York to Zürich. The incident occurred over the Atlantic Ocean. The aircraft diverted to Shannon, Ireland, and landed safely with 123 persons on board. [37]

Specifications

The PW4000 is produced in three distinct models, with differing LP systems to address different thrust needs.

Variant-94 [38] -100 [39] -112 [40]
TypeTwo spool high bypass ratio Turbofan
Length153.6 in (390 cm)167.2 in (425 cm)190.4 in (484 cm)
Weight9,420 lb
4,273 kg
12,900 lb
5,851 kg
15,095–15,741 lb
6,847–7,140 kg
16,260 lb
7,375 kg
Compressor 1 fan, 4 LP, 11 HP1 fan, 5 LP, 11 HP1 fan, 6 LP, 11 HP1 fan, 7 LP, 11 HP
Combustor Annular
Turbine 2 HP, 4 LP2 HP, 5 LP2 HP, 7 LP
Thrust 50,000–62,000 lbf
222–276 kN
64,500–70,000 lbf
287–311 kN
77,440–91,790 lbf
344–408 kN
91,790–99,040 lbf
408–441 kN
Variant-94 [41] -100 [42] -112 [43]
Fan94 in (239 cm)100 in (254 cm)112 in (284 cm)
Bypass ratio 4.8–5:14.9:15.8–6.4:1
Overall pressure ratio 27.5–32.332.0–34.134.2–42.8
Fan pressure ratio1.65–1.801.75–1.761.70–1.80
Applications B747-400, B767, MD-11
A300-600, A310
A330 B777

See also

Related development

Comparable engines

Related lists

Related Research Articles

<span class="mw-page-title-main">Boeing 767</span> Wide-body twin-engine jet airliner family

The Boeing 767 is an American wide-body aircraft developed and manufactured by Boeing Commercial Airplanes. The aircraft was launched as the 7X7 program on July 14, 1978, the prototype first flew on September 26, 1981, and it was certified on July 30, 1982. The initial 767-200 variant entered service on September 8, 1982, with United Airlines, and the extended-range 767-200ER in 1984. It was stretched into the 767-300 in October 1986, followed by the extended-range 767-300ER in 1988, the most popular variant. The 767-300F, a production freighter version, debuted in October 1995. It was stretched again into the 767-400ER from September 2000.

<span class="mw-page-title-main">Boeing 777</span> Wide-body, long-range, twin-engine jet airliner family

The Boeing 777, commonly referred to as the Triple Seven, is an American long-range wide-body airliner developed and manufactured by Boeing Commercial Airplanes. The 777 is the world's largest twinjet and the most-built wide-body airliner. The jetliner was designed to bridge the gap between Boeing's other wide body airplanes, the twin-engined 767 and quad-engined 747, and to replace aging DC-10 and L-1011 trijets. Developed in consultation with eight major airlines, the 777 program was launched in October 1990, with an order from United Airlines. The prototype was rolled out in April 1994, and first flew in June. The 777 entered service with the launch operator United Airlines in June 1995. Longer-range variants were launched in 2000, and first delivered in 2004.

<span class="mw-page-title-main">Airbus A340</span> Type of aircraft

The Airbus A340 is a long-range, wide-body passenger airliner that was developed and produced by Airbus. In the mid-1970s, Airbus conceived several derivatives of the A300, its first airliner, and developed the A340 quadjet in parallel with the A330 twinjet. In June 1987, Airbus launched both designs with their first orders and the A340-300 took its maiden flight on 25 October 1991. It was certified along with the A340-200 on 22 December 1992 and both versions entered service in March 1993 with launch customers Lufthansa and Air France. The larger A340-500/600 were launched on 8 December 1997; the A340-600 flew for the first time on 23 April 2001 and entered service on 1 August 2002.

<span class="mw-page-title-main">Airbus A330</span> Wide-body twin-engine jet airliner

The Airbus A330 is a wide-body aircraft developed and produced by Airbus. Airbus conceived several derivatives of the A300, its first airliner from the mid-1970s. Then the company began development on the A330 twinjet in parallel with the A340 quadjet and launched both designs with their first orders in June 1987. The A330-300, the first variant, took its maiden flight in November 1992 and entered service with Air Inter in January 1994. The slightly shorter A330-200 variant followed in 1998.

<span class="mw-page-title-main">ETOPS</span> Rules for aircraft with a failed engine

ETOPS is an acronym for Extended-range Twin-engine Operations Performance Standards—a special part of flight rules for one-engine-inoperative flight conditions. The International Civil Aviation Organization (ICAO) coined the acronym for twin-engine aircraft operation in airspace further than one hour from a diversion airport at the one-engine-inoperative cruise speed, over water or remote lands, or on routes previously restricted to three- and four-engine aircraft.

<span class="mw-page-title-main">Pratt & Whitney JT9D</span> Turbofan aircraft engine first flown in 1968

The Pratt & Whitney JT9D engine was the first high bypass ratio jet engine to power a wide-body airliner. Its initial application was the Boeing 747-100, the original "Jumbo Jet". It was Pratt & Whitney's first high-bypass-ratio turbofan.

<span class="mw-page-title-main">General Electric GE90</span> High-bypass turbofan aircraft engine

The General Electric GE90 is a family of high-bypass turbofan aircraft engines built by GE Aviation for the Boeing 777, with thrust ratings from 81,000 to 115,000 pounds-force. It entered service with British Airways in November 1995. It is one of three options for the 777-200, -200ER, and -300 versions, and the exclusive engine of the -200LR, -300ER, and 777F. It was the largest jet engine, until being surpassed in January 2020 by its successor, the 110,000 lbf (490 kN) GE9X, which has a 6-inch (15 cm) larger diameter fan. However, the GE90-115B, the most recent variant, is rated for a higher thrust than the GE9X.

<span class="mw-page-title-main">Rolls-Royce Trent</span> Family of turbofan aircraft engines

The Rolls-Royce Trent is a family of high-bypass turbofans produced by Rolls-Royce. It continues the three spool architecture of the RB211 with a maximum thrust ranging from 61,900 to 97,000 lbf . Launched as the RB-211-524L in June 1988, the prototype first ran in August 1990. Its first variant is the Trent 700 introduced on the Airbus A330 in March 1995, then the Trent 800 for the Boeing 777 (1996), the Trent 500 for the A340 (2002), the Trent 900 for the A380 (2007), the Trent 1000 for the Boeing 787 (2011), the Trent XWB for the A350 (2015), and the Trent 7000 for the A330neo (2018). It has also marine and industrial variants like the RR MT30.

<span class="mw-page-title-main">Pratt & Whitney PW2000</span> Series of high-bypass turbofan aero engines

The Pratt & Whitney PW2000, also known by the military designation F117 and initially referred to as the JT10D, is a series of high-bypass turbofan aircraft engines with a thrust range from 37,000 to 43,000 lbf. Built by Pratt & Whitney, they were designed for the Boeing 757. As a 757 powerplant, these engines compete with the Rolls-Royce RB211.

<span class="mw-page-title-main">Engine Alliance GP7000</span> Turbofan engine manufactured by Engine Alliance

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<span class="mw-page-title-main">General Electric CF6</span> Turbofan aircraft engine family

The General Electric CF6, US military designations F103 and F138, is a family of high-bypass turbofan engines produced by GE Aviation. Based on the TF39, the first high-power high-bypass jet engine, the CF6 powers a wide variety of civilian airliners. The basic engine core also powers the LM2500 and LM6000 marine and power generation turboshafts. It is gradually being replaced by the newer GEnx family.

<span class="mw-page-title-main">Rolls-Royce Trent 700</span> 1990s British turbofan aircraft engine

The Rolls-Royce Trent 700 is a high-bypass turbofan aircraft engine produced by Rolls-Royce plc to power the Airbus A330. Rolls-Royce was studying a RB211 development for the A330 at its launch in June 1987. It was first selected by Cathay Pacific in April 1989, first ran in summer 1992, was certified in January 1994 and was put into service on 24 March 1995. Keeping the characteristic three-shaft architecture of the RB211, it is the first variant of the Trent family. With its 97.4 in (247 cm) fan for a 5:1 bypass ratio, it produces 300.3 to 316.3 kN of thrust and reaches an overall pressure ratio of 36:1. It competes with the General Electric CF6-80E1 and the PW4000 to power the A330.

<span class="mw-page-title-main">Rolls-Royce Trent 800</span> Turbofan engine produced by Rolls-Royce beginning 1993

The Rolls-Royce Trent 800 is a high-bypass turbofan produced by Rolls-Royce plc, one of the engine options for the early Boeing 777 variants. Launched in September 1991, it first ran in September 1993, was granted EASA certification on 27 January 1995, and entered service in 1996. It reached a 40% market share, ahead of the competing PW4000 and GE90, and the last Trent 800-powered 777 was delivered in 2010. The Trent 800 has the Trent family three shaft architecture, with a 280 cm (110 in) fan. With a 6.4:1 bypass ratio and an overall pressure ratio reaching 40.7:1, it generates up to 413.4 kN of thrust.

<span class="mw-page-title-main">Rolls-Royce Trent 900</span> 2000s British turbofan aircraft engine

The Rolls-Royce Trent 900 is a high-bypass turbofan produced by Rolls-Royce plc to power the Airbus A380, competing with the Engine Alliance GP7000. Initially proposed for the Boeing 747-500/600X in July 1996, this first application was later abandoned but it was offered for the A3XX, launched as the A380 in December 2000. It first ran on 18 March 2003, made its maiden flight on 17 May 2004 on an A340 testbed, and was certified by the EASA on 29 October 2004. Producing up to 374 kN (84,000 lbf), the Trent 900 has the three shaft architecture of the Rolls-Royce Trent family with a 2.95 m (116 in) fan. It has a 8.5–8.7:1 bypass ratio and a 37–39:1 overall pressure ratio.

<span class="mw-page-title-main">Twinjet</span> Jet aircraft powered by two engines

A twinjet or twin-engine jet is a jet aircraft powered by two engines. A twinjet is able to fly well enough to land with a single working engine, making it safer than a single-engine aircraft in the event of failure of an engine. Fuel efficiency of a twinjet is better than that of aircraft with more engines. These considerations have led to the widespread use of aircraft of all types with twin engines, including airliners, fixed-wing military aircraft, and others.

<span class="mw-page-title-main">Pratt & Whitney PW1000G</span> Geared turbofan engine produced beginning 2007

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<span class="mw-page-title-main">Four-engined jet aircraft</span>

A four-engined jet, sometimes called a quadjet, is a jet aircraft powered by four engines. The presence of four engines offers increased power, allowing such aircraft to be used as airliners, freighters, and military aircraft. Many of the first purpose-built jet airliners had four engines, among which stands the De Havilland Comet, the world's first commercial jetliner. In the decades following their introduction, their use has gradually declined due to a variety of factors, including the approval of twin-engine jets to fly farther from diversion airports as reliability increased, and an increased emphasis on fuel efficiency.

<span class="mw-page-title-main">United Airlines Flight 1175</span> A flight that experienced an engine failure in 2018

On February 13, 2018, around noon local time, a Boeing 777-222 airplane, operating as United Airlines Flight 1175 (UA1175), experienced an in-flight separation of a fan blade in the No. 2 (right) engine while over the Pacific Ocean en route from San Francisco International Airport (SFO) to the Daniel K. Inouye International Airport (HNL), Honolulu, Hawaii. During level cruise flight shortly before beginning a descent from flight level 360, and about 120 miles from HNL, the flight crew heard a loud bang, followed by a violent shaking of the airplane, followed by warnings of a compressor stall. The flight crew shut down the failed engine, declared an emergency, and began a drift-down descent, proceeding direct to HNL where they made a single-engine landing without further incident at 12:37 local time. There were no reported injuries to the 374 passengers and crew on board and the airplane damage was classified as minor under National Transportation Safety Board (NTSB) criteria.

<span class="mw-page-title-main">United Airlines Flight 328</span> February 2021 Boeing 777 engine failure over Broomfield, Colorado

On February 20, 2021, United Airlines Flight 328 (UA328/UAL328), a scheduled U.S. domestic passenger flight from Denver to Honolulu, suffered what was technically ruled a contained engine failure despite shedding large pieces of debris, approximately four minutes after takeoff from Denver International Airport (DEN). Parts departing from the engine cowling of the Boeing 777-222 aircraft resulted in a debris field at least 1 mile (1.6 km) long over suburban residential areas of Broomfield, Colorado. Falling debris was recorded by eyewitnesses using smartphone cameras and a dash cam. Debris fell through the roof of a private home and significantly damaged a parked vehicle.

References

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Further reading