Engine Workscope Management CFM56-5B/P

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Engine Workscope Management CFM56-5B/P

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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
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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