CFM56 Upgrade Programs

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CFM56
Upgrade
Programs
Overview
• CFM56 Technology Philosophy
• CFM56 Upgrade Approach
• Upgrade Program Status
CFM56
Technology
Philosophy
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 4
Airline Requirements
• Longer time on wing
• Higher engine reliability
• Lower scrap rates
• Lower fuel consumption
• Lower noise/emissions
• Lower costs
CFM Addresses
These
Requirements with a
Constant Flow of
Technology
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 5
Incorporating Advanced, Proven Technology
CFM56 Engine Family:
Continuous Improvement
CFM56-7
1997
CFM56-5B/P
1996
Generation
4
• Wide chord fan blades
• Low emissions
• 3-D aero
2000
Thrust (1000 pounds)
1970
•High bypass
•Hydromechanical
controls
Generation
1
• Static composites
• Containment tech
• Noise reduction
Generation
2
CFM56-2
CFM56-3
1984
25
30
35
CFM56-5C
1993
CFM56-5A
1988
•FADEC
•Active clearance
•Advanced turbine materials
and coatings
Generation
3
CFM56-5C/P
2003
B737-300
B737-400
B737-500
A319
A320
A340 A318
A319
A320
A321
B737-600
B737-700
B737-800
B737-900
DC-8
Military
A340 Enhanced
CFM56
Upgrades
Approach
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 7
CFM56: Product Upgrade Packages
• Objectives:
- Reduced cost of ownership
- Longer on-wing life
- Leverage proven CFM56 technology
Real Solutions to Real Customer Issues
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 8
Increasing New Engine TOW …
Driven by Product Design
Improvements
0
4000
8000
12000
16000
Average Hours to Shop Visit
1986
1988
1990
1992
1994
1996
Decreasing TOW with
Subsequent SV’s …
Opportunity to restore
performance
0%
20%
40%
60%
80%
100%
Percent of First Visit Capability
SV #1 SV #2 SV #3 SV #4 SV #5
Identify Opportunities to Improve
Time-on-wing for Mature Fleet
Date-Driven Analysis
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 9
Average Time-On-Wing Increased*
• 1400 Cycles for Low Thrust Engines
• 1600 Cycles for Medium Thrust Engines
• 2000 Cycles for High Thrust Engines
1.1% Fuel Burn improvement
50% reduction in material and
repair costs of HP turbine
nozzles, blades, shrouds
15°C increase in EGT margin
Upgrade Benefit Equation
*Assumes compatible LLP stub lives
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 10
Financial Benefits
At time of kit installation
• Upgrade kit will be value priced
• Normal repair and new material costs would be avoided because of
replacement with new upgraded parts
- The investment required is the incremental cost
• No impact on TAT
Ongoing
• Reduced number of shop visits per year due to time on wing benefit
• Fuel burn savings
• Reduced HP turbine material costs
• One time all new hardware impact
• Upgraded engines will have higher residual value
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 11
Incremental Material Cost Impact at Shop Visit
New
Hardware
Component
repair
Upgrade
Kit
Labor Labor
New
Hardware % reduction
C/R % reduction
Overhaul
w/o upgrade
Overhaul
w/ upgrade
S/V cost
$
Incremental
cost
Upgrade Shop Visit Cost
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 12
Current CFM56 Upgrades
CFM56 Upgrades
Program Status
• CFM56-3 Core Upgrade
• CFM56-5B Acoustic Upgrade
• CFM56-5C/P Upgrade
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 14
3-D Aero Technology
Insert 3-D Aero Video
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 15
New material
Improves:
• sealing and cooling
• durability
Improves:
• Compressor
Efficiency
Hardware Change - Upgrade
New Material Plus
coating improvement
Improves:
• durability
HPT Blades
Enhanced design
Improves:
• Cooling
• EGT
Deterioration
• Durability
HPT Nozzles HPT Shrouds
HPC
3D Aero Stators
HPC Blades
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 16
Entry Into Service - July 2002
CFM56-3 Core Upgrade Program
• 3D aero in compressor and new HPT hardware
• Potential market of ~1,000 engines
• Benefits:
- Longer on-wing life
- ~2,000 more cycles on wing
- Lower operating cost
- 1% SFC improvement
- Lower maintenance costs
- 50% lower HPT nozzles, blade
and shroud repair
- Lower scrap rates
- Enhanced durability
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 17
Animation
• 400+ hours of certification testing completed
- Aeromechanical - Performance
- Operability - Water ingestion
- Endurance - Icing
• Block test: 150 hours
- High stress, high temperature
- Hardware disassembled and inspected
- In “Like New” condition.
• Flight testing on 737 complete
- Boeing completed 50 hour flight test
program
- Performance and operability evaluated
through out the flight envelope
• Certification - 2Q 2002
• EIS - July 2002
CFM56-3 Core Upgrade Program (Continued)
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 18
• CAEP Recommandations: Capter 4
- 10 EPNdB cumulative margin vs Chapter 3 limits
- No exceedance allowed at any point, cumulative
margin greater than 2 EPNdB at any two points
- Applicable by January 1, 2006 for new and derivative
aircraft
• Goal:
- Bring all engines to Stage III -10 EPNdB
• Full engine tests underway
• Certification 4th Q 2003
CFM56-5B Acoustic Program
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 19
Core chevron exhaust nozzle
Improved
inlet liner
Swept and leaned OGV’s
Increased acoustic liner area
CFM56-5B Acoustic Technology
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 20
• 3-D aero HPC compressor
- Developed for CFM56-5B/P
• Latest HPT blade design
- Integrate with current LPT
• New LPT stage 1 nozzle
• Benefits:
- Completely interchangeable with
current -5C
- 1% SFC improvement
- 13°C lower EGT
- 10% lower maintenance costs
- Maintains current CFM56-5C noise (26
EPNdB margin)
- Uses the existing nacelle
CFM56-5C/P Technology
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 21
CFM56-5C/P Certification Schedule
• FETT November 2001
• 400+ hours of ground testing
- Performance - Operability
- Mechanical response - Control systems
- Icing - Acoustics
• 100+ hours flight testing on A340
- Begins early 2003
- Performance and operability
• Cyclic endurance testing
- Demonstrate durability
- Beyond normal certification requirements
- 3,000+ cycles
• EIS on A340: 2003
Upgrade Kits Available Late 2003
CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 22
Summary
• CFM56 product line has continued to improve
- CFM56-3: from 6,000 hours to 17,000 hours first run
- CFM56-5A: from 4,000 to 18,000 hours first run
• CFM56-5B & -7 are the current state of the art
- Continuing to improve durability based on operating experience
• CFM56 products meet all current environmental regulations
- All engines meet ICAO emissions standards
- Only one CFM56 engine does not meet Stage 4 noise
- Aggressive program in place to resolve this issue
• Major upgrade packages are being introduced into the CFM56-3 and
CFM56-5C to bring even greater value
CFM Committed to Enhance Value to Support 13,000 Engines
Logging 23 Million Flight Hours a Year

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CFM56 Upgrade Programs