Engine Workscope Management CFM56-5B/P Eric Martin Table of Contents • Shop Visit Causes • Shop Visit Outlook • Workscope Establishment Content • Workscope Planning Guide • Workscope Recommendations • On-wing Waterwash - Focus Team Results CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 3 Shop Visit Causes by Thrust Category CFM56-5B1 CFM56-5B2 CFM56-5B3 CFM56-5B4 CFM56-5B5 CFM56-5B6 PSECause / Thrust 30,000 31,000 32,000 27,000 22,000 23,500 Total LPT Frame - SB. Compliance (DAC) 26 53 17 96 /PConversion 17 23 3 43 HPT Blade Distress 4 21 5 10 1 41 NOEC- F.O.D. 2 3 2 6 6 19 HPT Blade - SB Compliance 2 5 11 18 HPT C-Clips Program 1 9 5 1 2 18 Combustion Chamber Distress 9 7 16 HPCR-S.1-2 Contact A/O Seal 4 11 15 LPT Blade Stg 1 Failure (DAC) 2 2 4 7 15 TRF Cracking (DAC) 10 2 2 14 Combution Chamber - SB Comp. 4 3 6 13 NOEC - Maintenance 1 3 1 4 2 11 HPT - LLP 7 3 10 LPT Blade Stage 1 - SB Comp (DAC) 1 3 6 10 N4 Bearing - SB Compliance 2 2 6 10 NR3 BRG FAILURE 2 3 3 8 RDS Failure 1 1 4 2 8 Booster Blade Stage 5 5 2 7 Data as of March 25, 2002 CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 4 SAC only - last 12 months (3/01 to 3/02) PSE Cause / Rating 5B1 5B1/P 5B2 5B2/P 5B3/P 5B4 5B4/P 5B5/P 5B6/P Total HPT Rotor Blade Distress 4 6 7 17 HPT Rotor Blade-S/B Compliance 4 5 9 NR4 Roller Bearing-S/B Compliance 2 2 5 9 Booster Blade STG5 5 5 HPT Rotor Disk - LLP 4 4 NR3 Roller Bearing 1 2 1 4 Oil Leak 2 2 4 HPCR Blades 1 2 3 HPT C-Clip 1 1 1 3 Perf. Deterioration 1 1 2 R.D.S. Bearing 1 1 2 Eng. Oil System 1 1 NR3 BRG AFT S. A/O SSuspected 1 1 NR4 Roller Bearing 1 1 TGB Housing Assembly 1 1 Vibration 1 1 Total 4 1 2 4 22 3 23 1 10 70 Shop Visit Causes by Thrust Category CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 5 Shop Visit Outlook Special programs driving Shop Visits over the next 1-2 years • HPT Blade Programs - Replace P04/P05 Blades with latest configuration (S/B 72-370) • Stage 5 Booster Blade and Vane Abradable Clearance - Potential heavy rubbing and blade damage from over-length blades (S/B 72-391) - Repair stage 5 abradable to avoid heavy blade rubs (S/B 72-418) • Radial Drive Shaft Failures - Inspect inner RDS housing for bearing outer race ovalization (S/B 72-409) - Engines with less than 5000 hours affected • HPT Phase II C-Clip Program - - Rework HPT shrouds & hangers for improved cooling (S/B 72-217) - Incorporate low stress c-clip (S/B 72-196) CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 6 Shop Visit Outlook • Engine shop visits driven by special programs - Trend will continue for next 1-2 years - Engine performance / LLP currently not a factor - Workscoping should be focused on upgrades /retrofits - Anticipate long time on-wing - Performance restoration recommended at shop visit • Engine performance retention similar to other CFM56 engines Workscope Establishment & Content Workscope Planning Guide Update CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 8 Workscope Establishment WORKSCOPE DEFINITION ENGINE HEALTH STATUS TSN/CSN TSSV/CSSV REMOVAL CAUSE IN SERVICE EVENTS SERVICE BULLETIN COMPLIANCE HARDWARE CONFIGURATION WPG PLANNING GUIDE AD ENGINE SHOP MANUAL AIRCRAFT MAINTENANCE MANUAL CUSTOMER REQUIREMENTS SHOP VISIT COST SHOP VISIT TAT CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 9 WORKSCOPE DEFINITION DISASSEMBLY REQUESTS Workscope Content REPAIR PARTS REPLACE PARTS INTRODUCE NEW P/N CLEAN / RESTORE SURFACEs REFURBISH CLEARANCES REPLACE LLP PERFORM TESTS INSPECTIONS CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 10 Guidelines for Optimizing Engine Mean Time Between Visits • Major Goals: - Performance (best practices) - Durability (service bulletins issued) - Reliability (service bulletins issued) • Engines re-built for a MTBSV close to customers’ expectations, and removed for performance and LLP • Updated based on Overhaul Shop feedback and on PSE hardware owners recommendations. - Shop Findings Reports analyzed by CFM PSE Workscope Planning Guide CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 11 Workscope Planning Guide • WPG structure: - For each major engine module : - Priority list of Service Bulletins - Minimum workscope - Performance workscope - Full workscope - Control and Accessories Workscope - Special Investigation Workscopes - High EGT - Oil Smell in Cabin - High Oil Consumption - High N2 Vibration cwcs.customer.cfm56.com WPG can be viewed and downloaded from the CFM Customer Web Center CFM56-5B/P Workscope Planning Guide 2002 CFMI Proprietary Information The information contained in this document is CFMI Proprietary Information and is disclosed in confidence. It is the property of CFMI and shall not be used, disclosed to others, or reproduced without the express written of CFMI. If consent is given for reproduction in whole or in part, this notice set forth on each page of this document shall appear in any such reproduction in whole or in part. The information contained in this document may also be controlled by the U.S. export control laws. Unauthorized export or re-export is prohibited. Workscope Recommendations CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 13 Fan and Booster Module Inspect Fan disk dovetail pressure face for wear. ECI of bore & dovetail slot Inspect and refurbish Booster blades and abradable as required Perform N1 speed sensor guide tube BSI per S/B 72-049 If last relube is between 1500- 3000 cycles, inspect Fan blade dovetail coating (Cu-Ni-In). Relubricate per CESM 010 Assure proper Blade L/E contour Inspect acoustical panels for surface erosion and repair per ESM. Check bolts for looseness per S/B 72-213 CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 14 Fan and Booster Module If engine is affected by SB 72-391 for over length stage 5 booster blades, disassemble and replace blades If engine is not affected by SB 72-391: Steel stator : Open clearance per SB 72-418 Titanium stator : BSI per SB 72-420 : • If Wave rubbing observed, perform SB 72-418 • Otherwise, perform SB 72-418 at area exposure Typical Wave rubbing CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 15 Fan and Booster Module •Check VBV system for damage or looseness •Re-lube with Mobil 28 grease, change boots for deterioration • Inspect flexible shafts, bearings and replace as required Visual and dimensional inspect N°1 bearing air/oil seal if oil is found in booster spool •Restore paint OGVs per for erosion • Inspect OGV for outer platform cracks CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 16 Accessory Drive Module Replace O-ring sealol seal on AGB Starter pad, per S/B 72-105 Inspect TGB centering ring for damage or overheating condition and TGB housing for heat discoloration Inspect RDS per ESM including upper and lower splines Inspect the inner Radial drive shaft housing per SB 72-409 Improve the reliability of TGB brackets with introduction of new bolts per SB 72-178 (-5B) CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 17 HPC Rotor Module HPC Front Shaft - • Inspect threads for distortion • Inspect FWD end slots for wear and repair per ESM Inspect CDP Seal AFT rabbet diameter to assure proper fit Restore blade tips and L/E profiles with HPT FWD Shaft – SWECO clean to restore surface finish Stages 1-3 only: - Introduce improved Al-Br dovetail coating - Reprofile L/E per enhanced Repair 7 - Replace RTV on dovetails per Repair 5 CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 18 HPC Rotor Module • Measure/grind new or tip repaired blades to ESM targets using high speed grinder • Perform HPC linipot in vertical position during Core assembly • During assembly, pay attention to stacked rotor cavities for oil/ dust accumulation to prevent vibration problem • Perform dynamic balance if HPC blades are removed for inspection/repair or replaced CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 19 HPC FWD and AFT Stators • Inspect casing rub lands for scabbing – Remove any positive material – Ensure smooth & flush with flowpath • For increased performance – Vibratory (SWECO) clean IGV & VSVs – Alkaline or abrasive blast vane segments • Visually inspect cases with white light – FPI any suspected areas – Check FWD stator horizontal split line for cracking CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 20 VSV Systems Check • Check VSV System condition –- check lever arms for wear, cracks or distortion • Incorporate ruggedized lever arms on IGV and Stg 3 VSV per S/B 72-157 • Replace all VSV inner/outer bushings and outer washers • Introduce inner bushings with new ST2010 (stg 1) and DG20 (stgs 2,3) material per S/B 72-395 • Replace outer washers with new DG20 material Contact between shroud and blade platform T/E fillet Contact between seal hook and spool tangs CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 21 Honeycomb Seal Refurbishment FOS (3T) Seal CDP Seal FWD Stator AFT • Replace or refurbish honeycomb seals - grind Stator to min shop manual reference limit • Inspect corresponding rotating seals to ensure within shop manual limits Ensure proper cell clean up.... closed cells can lead to core seizures at test and less effective sealing CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 22 Combustion Case • Clean, inspect and rig check fuel nozzles per CMM 73-11-42 – Fuel nozzle exit profile can be improved by minimizing flow variation within a set • Rework fuel manifolds per S/B 73- 052 to prevent blockage from coke accumulation Fuel Nozzle Coking Inspect CDP and fuel nozzle pad areas, fuel lines, manifolds and nozzles for evidence of leakage CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 23 Inspect Inner and Outer Liners for cracks, burning and sulfidation and repair as required per ESM Eliminate dome swirler supports during combustor re-assembly per S/B 72-273 Combustion Chamber Inner liner window area - circumferential and axial cracking Common findings on other CFM models that may be seen include (all repairable): • Swirler ovalization • Liner cracking/burn through • Deflector/sleeve missing material CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 24 Combustion Chamber CFM56-3 / F110 Outer Liner Fuel Nozzle Tip Sleeve Deflector • Perform full combustion chamber inspection and repair as required including: – Resize combustor dome (Repair 13) to correct dome angle and venturi positioning – Replace Thermal Barrier Coating (TBC) on inner and outer liners • Replace outer cowl with HS188 material per S/B 72-327 Primary Swirler Secondary Swirler Venturi Inner Liner Outer Cowl Inner Cowl CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 25 HPT Nozzle Assembly Replace Internal ‘ W ’ pressure seal with latest part number Replace HPT Outer Stationary Seal (3T) with new or refurbished seal per S/B 72-231 HPT Nozzle Leaf Seals - inspect and replace damaged seals Inspect HPT nozzle segments for cracking, burning, cooling hole blockage and TBC spalling CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 26 HPT Nozzle Assembly NGV trailing edge cracking NGV outer platform burning NGV concave leading edge cracking and burning Typical condition of HPT nozzle guide vanes will require full restoration CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 27 HPT Rotor Module Damper Sleeve Cracking - Replace sleeve if found cracked HPT Front Shaft Rabbet Diameter Shrinkage - Check at module level to assure proper interference fit with CDP Seal Check for the presence of the blade seals between the platforms HPT Rear Shaft - ECI outer seal teeth at module level per ESM HPT Disk/Front Rotating Air Seal - FPI and ECI at piece part per FAA enhanced inspection CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 28 HPT Rotor Module Grind the HPT rotor assembly blade tip diameter to achieve a J05 clearance of 0.056 inch (1,42mm) If 2002M52P04/P05 blades installed, replace with latest configuration per S/B 72- 370. Inspect all other configurations per ESM. During Core module assembly, pay particular attention to the CDP seal bore runout to prevent vibration problem Perform HPT linipot inspections in both vertical and horizontal positions CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 29 HPT Shroud/LPT S1 Nozzle To improve C-clip reliability, rework HPT shrouds and hangers per S/B 72-217 Remove and discard ALL Cclips at each shop visit. Re-assemble with new low stress clips per S/B 72-196 Reworked stage 1 LPT nozzles per S/B 72-229 for improved LPT case hook #1 cooling Cracked C-clip CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 30 HPT Shroud/LPT S1 Nozzle Rework FWD flange per S/B 72-270 (T800 coating) for improved wear resistance Inspect LPT stage 1 nozzle for FOD, cracking, burning and erosion Measure shroud diameters (post S/B 72-217) to determine if should be skim-cut or replaced with new or repaired For performance, match grind shroud with HPT rotor to achieve optimum J05 clearance of .056” NGV mid span L/E crack CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 31 LPT Module - Case Inspect and restore the LPT case forward and aft rabbet diameters and the LPT frame forward diameter to prevent HPT horizontal Linipot problem Visual inspect LPT case for crack damage, wear, and distress. Spot FPI suspect areas of the front and rear flanges, case bosses and anti-rotation slots CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 32 LPT Module - Rotor/Stator If HPT shrouds and hangers are modified during SV, install new stage 1 outer air seals per SB 72 -229 Rework LPT stage 2 and 3 nozzles per SB 72-328 Inspect LPT blades for evidence of cracking and damage. Check shroud interlocks for evidence of unlatching, shingling, or excessive looseness Restore LPT inner & outer air seals for rub or erosion per ESM CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 33 LPT shaft paint may require touch-up at shop visit Inspect LPT shaft inner diameter for corrosion, paying close attention to journal beneath No. 2 Bearing Inspect #4 bearing bearing per ESM Install new center vent tube supports per S/B 72-316 when scrapped for not meeting torque requirements LPT Module - Shaft CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 34 Bearing #4 rollers with surface pitting Bearing #4 outer race pitted running surface LPT Module - #4 Bearing • As of today, #4 Bearing experience in -5B is very good. • CFM recommends that shops review and follow Best Practices per CESM 008 CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 35 LPT Module - TRF Check N°5 bearing Sleeve runout if vibrations have been reported Inspect centerbody studs for looseness and repair per ESM Visually inspect LPT frame assy to detect any oil leakage Inspect forward rabbet diameter with LPT case for fretting or pitting and repair the flange per ESM Inspect LPT frame outer case, engine clevis mount and leading edge of No. 1, 3, 14 mount struts for cracks Inspect oil supply and scavenge tubes Inspect overboard drain tube for failure. CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 36 Oil Consumption Improvements FWD SUMP AFT SUMP Improve engine oil consumption by reducing air flow through FWD and AFT oil sumps (S/B 72-332) All changes must be introduced simultaneously and cannot be mixed with old configurations Reduced orifice diameters Decreased gap in #2 bearing nut Reduced air/oil seal clearance Reduced section in LPT shaft plug Reduced airflow in AFT center vent tube Focus Team Status: Water Wash CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 38 Water Wash - Focus Team Summary Sub-Team Objective: • To assess the effectiveness of on-wing Water Wash and to share Best Practices and results from experience in the field • Surveys were distributed to Focus Team members currently performing Water Wash. Items addressed include: - Equipment Type - Results - Procedures - Timing/intervals - Policies - Criteria CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 39 Water Wash - Focus Team Summary Survey Results: Operation A B C D E F G Agree? 1 What model engines do you operate? 5A3 5A1, A5 5B4 5B2, B2/P 5A 5B6/2P 5A1/A3/A4 2 Do you perform waterwash on wing? Yes Yes Yes Yes Yes Yes Yes Yes 3 Do you perform a waterwash on outbound test? Yes No No Yes No No Yes No 4 What criteria is used to determine wash interval/frequency Every 4000 hrs or when below 10 deg C When EGTM nears zero Every 1000 hours When EGTM drops below 5 deg C After 1st 10 deg C drop & every 1100 cycles Every 1000 hours Every 2500 hrs above 10 deg/every 600 hrs below 10 No 5 What type of equipment is used? Juniper Hand Spray Hand Spray Hand Spray (OW), Juniper type (tc) Hand Spray --- Juniper No 6 What is the average EGTM gain typically seen? 8 deg C No Stat 7 deg C 12 deg C 12 deg C 11 deg C 7 (water) 10 (det) Similar Results 7 What is the maximum EGTM gain typically seen? 15 deg C 15 deg C 15 deg C 18 deg C 22 deg C 12 deg C 8 (water) 13 (det) Similar Results 8 Do you use pure water or detergent? Detergent Pure Water Pure Water Water (ow ), Det (tc) Both Pure Water Water > 10 deg, Det < 10 deg No 9 Is wash unit heated? No No Yes No No Yes Yes No 10 Do you perform single or double washes? Double Triple Single Single (ow) Double (tc) Single & Double Single Double No 11 How many rinse cycles do you perform? 3 3 1 3 3 --- 1 No 12 Do you inject through Fan or directly into booster? Booster Booster Fan Fan (ow) Booster (tc) Fan --- Fan No 13 How long is the approximate retention period 4-5 months No Stats No Stats 400 cycles 600 cycles No Stats 5 deg/ 1000 cyc No CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 40 Observations: • EGTM gains range from 0 to 20 °C with an average of 10 °C –Most benefit seen in first wash since new or overhaul –Differing results from low time vs. high time engines • Most customers surveyed use plain water for washes –Double detergent cleaning may yield improved results –Environmental issues / cabin fume risks must be considered for detergent washes • Hot or warm water is preferred by some operators over cold Water Wash - Focus Team Summary CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 41 Observations: Water Wash - Focus Team Summary •Improved results experienced from injecting directly into booster versus fan •ost wash runs with “Packs ON” helps clear detergent residue (AMM requirement) •Double (sometimes triple) washes performed on excessively dirty engines •Cleaning intervals/policies vary widely among operators –Drop in EGTM and/or limit above zero margin –Fixed number of flight hours or cycles CFM56-5C China All Operators Meeting 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 42 Conclusions: • Water wash has proven benefits for restoring EGTM and open beta stall margin and can extend time on wing • Processes, procedures and equipment types vary widely among operators surveyed but yield similar results • Cleaning interval will depend on individual airline’s operating environment • Refer to AMM Section 72-00-00 for complete instructions for performing on-wing water wash Water Wash - Focus Team Summary作者: kinran 时间: 2011-6-4 23:05:29
ost wash runs with “Packs ON” helps clear detergent residue