CFM56-5B/-7B

HPC Module

CFM56 Symposium
June 2017 – Milan
Overview

IGV Actuation Ring

• PN 1318M20G03

Metallic/Hybrid VSV
• Review

CFM56-5B Performance Analytic

• 2018 Planned release to CFM56-5B Fleet

HPC Reference Materials

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 IGV Actuation Ring

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IGV Actuation Ring Background (PN 1318M20G03)
Experience
• Distress located at either 2 or 8 o’clock (ALF) position
- Corresponds with end of internal stiffener and first rub button

• Potential Significant Event / High Cost Shop Visit

- Comply with ESM TASK 72-00-00-200-001 Off-Schedule Vane if any
lever arm found broken, disengaged, or bent >4 degrees

Model Crack Fracture Total

3 3 3
5A 1 6 7
5B 4 10 14
7B 69 65 134
Total 74 84 158

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-7B IGV Actuation Ring Field Management

Inspection
SB 72-0825 (Cat 2, April 2011) for inspection of IGV rings (PN 1318M20G03 )
• Inspect with flex borescope: 15K cycles or 25K hours - 1600 cycle repeat
Training video package (GEK 117617) available via myCFM Portal / CTEC University

Remote Diagnostics
Potential ring fractures identified with performance parameter shifts
• Algorithm updated to improve catch rate – Aug, 2016
• Not intended to replace on-wing inspection
IGV ring inspection added to bleed leak CNR (Oct 2012)

Replacement
SB 72-0811 (Category 3, January 2011)
• Terminating action for SB 72-0825 inspection

IGV Ring field plan continues to be successful

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-5B IGV Actuation Ring Field Management

Inspection
On-wing inspection procedure added to Airbus AMM for proactive inspection
• Task 72-32-00-210-802
Training video package (GEK 117617) available via myCFM Portal / CTEC University

Remote Diagnostics
Additional data required to construct -5B remote diagnostic

Replacement
SB 72-0792 (Revision 01, Category 3, May 2016)

Management Plan Optimized for -5B Experience

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 Metallic/Hybrid
VSV System

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Metallic/Hybrid Background

Improved VSV shroud system

• Terminating action for on-wing rotor/stator contact BSI:
- SB 72-0515 (7B)
- SB 72-0553 (5B) Waspalloy Notched vane
wear sleeve (no wear sleeve)

Full metallic bushing system

• Introduced Apr 2006: L605 metallic bushing
- SB 72-0581 (7B)
- SB 72-0612 (5B)

Hybrid bushing system

• Introduced Apr 2007:
- SB 72-0665 (7B) SC610 composite bushing
- SB 72-0672 (5B)
• Composite bushings at pin notch locations Hybrid Bushing System
• More economical upgrade

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Metallic/Hybrid Field Experience

Honeycomb Seal Rotation

• Seals can rotate by cutting through anti-rotation pin head and
overlapping adjacent seal
• Exposed metallic bushing can liberate and damage rotor
• Radial retention pin liberation possible

Field Experience
• 3 known Stage 2 metallic bushing liberations
• (1) -5B, (2) -7B
• Incidental findings - no associated operational events
• No known radial retention pin liberations due to seal rotation

All metallic/hybrid engines effected equally

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Metallic/Hybrid Field Experience

Stage 3 Slab Head Anti-Rotation Pin Experience Pin Head

• 104 Total (All CFM56 models):
• 72 UER: 55 Routine BSI, 17 for cause
• 32 Incidental Finding (SV)
• All Wide Slot Shrouds – see November 2014 CFM Fleet Highlites Slot Width
• Liberated pin can damage HPC blades and LLP

Pin Missing Blade and Rotor damage

All metallic/hybrid pin liberations from wide slot shrouds

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Metallic/Hybrid Recommendations

Inspection Gap between seals

• SB 72-0986 (7B) and SB 72-0921 (5B)

• Inspection for seal rotation and slab head pin rotation
• First Inspection 10,000 +/- 1,000 cycles
• Repeat Inspection 5,000, +/- 800 cycles
• Flexible BSI of S2 & S3 VSV inner shrouds at 3:00 & 9:00 position
• No recommendation to inspect for rotor-to-stator contact
• Digital Training Aid (GEK 133765) available via myCFM
Portal / CTEC University
 Reference August 2015 Fleet Highlites article Rotated Pin

Shop Recommendation
• Incorporate current VSV brazed end block design
• SB 72-0958 (7B) / SB 72-0906 (5B)
• If system not replaced, overhaul HPC front stator assembly
per ESM piece part inspection

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 CFM56 -5B HPC
Performance
Analytic

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HPC Performance Analytic

Background Gradual Deterioration

• Overall compression efficiency calculation
• Based on cruise snapshot parameters
• Monitors engine condition
• Threshold established for recommended actions Threshold

Status Time (years)

• Phase 1: Pilot (3 customers), complete
• Phase 2: 10 additional customers, initiated Sudden Shift (FOD/DOD)
• 2018 planned release to -5B fleet pin liberation

Threshold

Time (months)

Analytic Improves Fleet Management

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 HPC Reference
Materials

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HPC Reference Material

HPC Blade Borescope Guide

• Applicable to CFM56 -3, -5A/B/C, -7B models
• Addresses common blade BSI questions
• Location
• Types of damage
• Measurement
• Available via download on MyCFM Portal
• Search “GEK 119347”

Digital Training Aids

• Available via MyCFM Portal / CTEC University
 IGV Actuation Ring Inspection - GEK 117617
 Composite VSV System Rotor/Stator Contact – GEK 115545
 Metallic/Hybrid VSV System Seal/Pin Rotation – GEK 133765

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HPC Reference Material

VSV Design Summary

CONFIGURATION INTRODUCED BY INSPECTION

72-0515 (7B)
Composite EIS 72-0553 (5B)
(rotor/stator contact)
72-0581 (7B)
Metallic 72-0986 (7B)
72-0612 (5B)
72-0921 (5B)
72-0665 (7B) (Seal & Pin Rotation)
Hybrid
72-0672 (5B)
72-0958 (7B)
Brazed End Block NONE
72-0906 (5B)

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Summary

IGV Actuation Ring

• Replace PN 1318M20G03 at exposure
• Maintain on-wing inspections until replaced (7B)

Metallic/Hybrid VSV
• Maintain on-wing inspections
• Consider incorporation of Brazed End Block design at shop

CFM56-5B Performance Analytic

• 2018 planned release to CFM56-5B Fleet

HPC Reference Materials

• Available via MyCFM portal

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 Thank you

Grazie

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 Additional Information

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VSV Configurations

Inner Shroud Designs

• Composite Design
- Initial production configuration
- composite bushings

• Metallic/Hybrid Design Stg1

Vane
Stg2 Stg2 Stg3 Stg3
Blade Vane Blade Vane

- 2006/2007 introduction
- metallic bushings, (stage 2 & 3)

• Brazed End Block Design

- 2014 introduction
- anti-rotation pin eliminated

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 Composite VSV
System

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Composite System Background & Experience

Rotor-to-Stator axial contact

• Root cause is VSV bushing & shroud wear
• Inner bushings wear due to motion of vane stems
• Shroud bores wear due to contact with vane stems
• Outer bushing and thrust washer wear contribute to gap closure
Outer Bushing
Outer Washer
Rotor/Stator contact can result in:
• honeycomb seal liberation
• radial retention pin liberation
• wear on rotor structure Sg3
Vane

Inner Bushing

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Composite System Recommendations

On-wing Recommendation
• BSI per Category 2 SB 72-0515 (7B) or SB 72-0553 (5B)
• Initial inspection: 24K hours since new / overhaul
• Re-inspection interval: 1800 hr/1200 hr/ 800 hr/ 10 cycle, based on findings

Shop Recommendation
• Incorporate current VSV brazed end block design
• SB 72-0958 (7B), SB 72-0906 (5B)
• If not replaced, overhaul HPC front stator assembly per ESM piece part
inspection

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 Brazed End Block VSV System

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VSV System Design Improvements
2. Hard Anodizing
Brazed End Block VSV system – released 2014
• SB 72-0958 (7B) / SB 72-0906 (5B)
• Terminating action for on-wing inspections
- SB 72-0515/ SB 72-0986 (7B)
- SB 72-0553/ SB 72-0921 (5B)

Improvements
1. Brazed End Blocks 1. Seal End Blocks
• Anti-rotation pins eliminated
• Reduced seal sliding and wear 4. Increased Fwd Shroud Clearance
2. Shroud Hard Anodizing
• Reduced wear on all surfaces
3. Increased Aft Shroud Clearance .030”

• 0.070” additional clearance

• Increased time to 4-9 spool contact
4. Increased Forward Shroud Clearance .070”
• 0.030” additional clearance
• Increased time to shroud to blade platform contact 3. Increased Aft Shroud Clearance

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