Cfmoildebris.pdf

SAA DIR:-10164377

Field Guide for Lubrication System Debris Airbus Programs

CFM56-5A CFM56-5B CFM56-5C

Tool Number: GEK 119194 November 2012 Basic

About this guide

This guide is to aid Operator Line Maintenance Personnel with the identification of lubrication system debris on CFM56 Engines. Engine specific limitations and acceptance or non-acceptance criteria are only found in the Engine Manuals and/or Aircraft Maintenance Manuals.

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CFM56 Proprietary Information CFM, CFM56, LEAP and the CFM logo are trademarks of CFM International, a 50/50 joint company between Snecma (Safran group) and GE. The information in this document is CFM Proprietary Information and is disclosed in confidence. It is the property of CFM International and its parent companies, and shall not be used, disclosed to others or reproduced without the express written consent of CFM. If consent is given for reproduction in whole or in part, this notice 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. and French export control laws. Unauthorized export or re-export is prohibited.

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Table of contents 6

Introduction

8

Contact information

10

Handling, collection and inspection

15

Magnetic sensor quantification

17

Scavenge screen quantification

20

CFM MCD inspection guidelines

25

Debris identification

60

Definitions

66

Appendix Bearing cross-sections Turbine jet engine oil identification Scale

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Introduction This guide is intended exclusively for the owners and operators of CFM56 aero turbo machinery. It has been prepared as a guide for use in the analysis of debris collected from or generated by the lubrication system of these engines. The purpose of this guide is to enable quick and accurate identification of contaminates and debris material. The visual identification of debris is a valuable skill, but can not substitute for laboratory analysis to confirm material identification. The data presented here does not supersede or replace any FAA approved documents. This document and the material within it are subordinate to Aircraft and Engine Maintenance Manuals.

Hardware location Hardware location is not included for all debris noted. This guide is produced for multiple CFM engine lines and material from one engine location may not correspond to a different engine. Additionally, in the future hardware may be redesigned with different materials.

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Introduction (cont.) Debris acceptability/serviceability Some debris may be acceptable to one engine model, but not to another. Additionally, Engine and Aircraft Maintenance Manual limits are subject to change. Refer to applicable AMM

Failure mode determination Determination of failure mode (or root cause) can be difficult. While certain failures leave clear evidence, many others are difficult to identify. This guide has included some failure mode data, but determining root cause often requires information from many sources – not just debris.

Updates to this guide This guide will be updated and new versions will be published periodically. Suggestions and recommendations are welcome. If you have suggestions or interesting debris photos, please contact the CFM Customer Support Center with your comments. The CSC will help collect this information for inclusion in the next updated guide.

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Contact information

If assistance is needed with this guide or with material identification, please contact:

Customer Support Center (CSC) CFM56 Infrastructure – CFM56 Aviation USA telephone: 1 (877) GEAE-CSC or 1 (877) 432-3272 International telephone: 1 (513) 552-3272 Email: [email protected] This guide is produced by CFM Product Support Engineering

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Debris collection Collection of debris is primarily accomplished via magnetic detectors and/or scavenge screens. See AMM for proper assembly and disassembly techniques. If debris is found, proper tracking and collection is critical to determining which hardware needs to be inspected or replaced.

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Handling, collection and inspection Debris can be difficult to locate and easy to misplace. In some cases, oil may be toxic or dangerous. For these reasons, CFM56 recommends the use of specific tools to aid in the safe and proper handling of debris. Included on the next few pages are some examples of the tools and tips used by CFM56 professionals to handle, collect and inspect debris. Note: Visually inspecting debris while it is in the filter is not recommended. Back-flushing of filter or cutting open per approved procedures to aid visual identification is preferred.

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Oil sampling guidelines • Use a clean glass or plastic container for oil samples.

• Label the container with the name of the operator, engine mode, engine serial number, the sample date and the name of the oil in use. • If possible, take the sample within 30 minutes of shutdown. • Clean dirt from the outside of the sampling port prior to taking sample. • Do not sample the initial 20 ml of oil. If possible, take the sample from the middle, center of the tank.

• Preferable minimum sample quantity is 120 ml (which equals 4 oz or ½ cup). • Do not use a funnel that is contaminated, unless it was thoroughly cleaned with alcohol (or other solvent). • Leave some air in the container for expansion of the sample during shipping. • Put strong tape over the gap between the container and its lid to prevent spillage. CFM International / 11 CFM Proprietary Information is subject to restrictions

Debris collection tools Collection tools may include tweezers, petri dishes, dowels and special one-sided tape. Utilization of sterile tools reduces the likelihood of contamination and improves the accuracy of laboratory analysis. Note: Utilizing office, transparency or other tapes is not recommended because laboratory analysis requires dissolving the tape – which takes time and requires the use of stronger chemicals. Specially designed carbon tabs are recommended.

Carbon tabs with backing removed CFM International / 12 CFM Proprietary Information is subject to restrictions

Debris inspection tools 10X (or higher) magnification is recommended, but not always needed. This photograph shows three suitable examples of magnifying devices that may be valuable to line maintenance personnel. A magnet may also be valuable for identifying the magnetic properties of debris.

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Field magnetic sensor collection

CFM56 strongly recommends sending debris to certified laboratories for identification; however, the following steps may be followed if field data is needed and/or if laboratory analysis is not possible. • Note date, aircraft, engine number/position and chip detector prior to removing debris.

• Lightly press carbon tabs to debris on sensor. • Under controlled conditions, remove debris from carbon tabs and degrease debris. • Use sieves to determine debris size. If sieves are not available, place debris on grid and take high-resolution photographs

• Note quantity and size of debris. • Refer to Engine and Aircraft Maintenance Manuals for disposition. CFM International / 14 CFM Proprietary Information is subject to restrictions

Magnetic sensor quantification Shoulder wear This relative scale can be utilized when communicating magnetic sensor debris levels. Note: These photographs depict one type of sensor. Different engine models may have differently shaped sensors.

0

1

2

3

4

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Magnetic sensor quantification Spall wear This relative scale can be utilized when communicating magnetic sensor debris levels. Note: These photographs depict one type of sensor. Different engine models may have differently shaped sensors.

0

1

2

3

4

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Scavenge screen quantification This relative scale can be utilized when communicating screen debris levels. Note: Different engine models will have screens of different sizes and shapes.

0

1

2

3

4

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General characteristics and appearance Debris identification The following pages show a range of debris; some of which is rarely found, but is included for comprehensiveness. The first two pages of photos (which show debris from events) are included to help illustrate differences between what may be seen on the flight line versus what is extracted in a laboratory. This is followed by photos of magnetic and then non-magnetic debris. Appearance descriptions are also provided. Each material is described as metallic or non-metallic followed by the descriptors that most readily identify the debris.

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Bearing information The primary objective of debris identification is for the detection of bearing distress prior to failure. Any bearing debris identification, either visually or by laboratory analysis, is cause for immediate concern. The following visual characteristics can be helpful in distinguishing bearing material.

• Many chips of similar size and shape • Magnetic material • Smooth, reflective (silvery) surface on one or both sides • Roughly circular or elliptical flakes, thinner around edges • Material that is hard and brittle

• Metal chunks as small dark irregular particles • Pieces of bearing cage material • Chunks of silver plated steel

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CFM MCD inspection guidelines The decision for action must be driven by key factors:

Debris Examination • Visual aspect (shape, color, plated or not, laminated … ) • Nature (magnetic or non-magnetic) • Size, quantity • Oil sump source

Engine history • Low time/cycle engine since new or overhaul • Recent engine squawks • Maintenance report (past MCD findings, oil circuit contamination … ) • Engine trend shift (vibes, oil consumption … )

References • Applicable Aircraft Maintenance Manual • CFM56 Non-Destructive Test Manual • Part 10 Chip Analysis (CFMI-TP-NT.11)

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CFM MCD guidelines for magnetic particles When particles are just collected, visual inspect per 10x magnifying lens to identify the category

Satisfactory - Serviceable Marginal - Means continue in services while debris are sent to Lab Unsatisfactory - Immediate action is required CFM International / 21 CFM Proprietary Information is subject to restrictions

CFM MCD guidelines AMM satisfactory conditions Magnetic serviceable conditions • Particles within this table, don’t need to be sent for analysis

• Machined chips are serviceable whatever the size

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CFM MCD guidelines AMM Non-Serviceable conditions: Magnetic material - non-serviceable conditions When particles are caught on the EMCD, it’s recommended to install the the Mag Bars to isolate the concerned sump See additional recommendations on next slide

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CFM MCD guidelines AMM Non-Serviceable conditions Magnetic material - non-serviceable conditions These descriptions are applicable for material collected in the Scavenge Screens or after installation of the Magnetic Bars for each sump

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Examples of bearing shoulder wear distress mm

mm

20

20

16

16

12

12

8

8

4

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.5”

.75”

1”

mm

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.25”

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.75”

1”

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.5”

.75”

1”

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Examples of bearing spall distress mm

mm

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20

16

16

12

12

8

8

4

4

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.5”

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mm

mm

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1”

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M50NiL General characteristics • Magnetic

Representative photo - quantity and appearance may vary

20 mm

16 mm

12 mm

8 mm

4 mm

0

0

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0.5”

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1”

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M50 General characteristics • Magnetic Appearance • Metallic

• Small flakes and/or powder

• Dull

• Dark color

Representative photo - quantity and appearance may vary

1 mm

1 mm CFM International / 28 CFM Proprietary Information is subject to restrictions

Bearing spall chips General characteristics • Magnetic Appearance • Metallic

• Flakes

• Flattened

• Oval

• Ragged edges

• Coined

• Smooth/reflective on one side, dull on the other

Representative photo - quantity and appearance may vary

20 mm

16 mm

12 mm

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4 mm

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Gearbox debris General characteristics • Magnetic Appearance • Metallic

• Flakes

• Sharp

• Reflective

• Irregular

Representative photo - quantity and appearance may vary

20 mm

16 mm

12 mm

8 mm

4 mm

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0

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#2 bearing nut spirolock General characteristics • Magnetic Appearance

• Wire

Representative photo - quantity and appearance may vary

1 mm

5 mm

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Forward sump air/oil separator General characteristics • Non-magnetic Appearance

• Resin polyamide material (green or brown color)

Representative photo - quantity and appearance may vary

1 mm

1 mm

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Forward sump abradable General characteristics • Non-magnetic Appearance

• Phenolic or plastic material (greenish-white color)

Representative photo - quantity and appearance may vary

1 mm

1 mm

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Bearing air/oil seal abradable General characteristics • Non-magnetic Appearance

• Glass fiber with polyamide material with grooves • Reddish brown non-metallic

Representative photo - quantity and appearance may vary

1 mm

1 mm CFM International / 34 CFM Proprietary Information is subject to restrictions

AGB/TGB keylock from insert General characteristics • Non-magnetic Appearance

• Flat piece with castellated portion

Representative photo - quantity and appearance may vary

1 mm

1 mm

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AGB bearing cage rivets General characteristics • Magnetic Appearance

• Rivet heads

Representative photo - quantity and appearance may vary

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Sealol seal tangs General characteristics • Magnetic Appearance

• Rectangular tang • Approximate size: 0.12 x 0.16 x 0.06 in (3 x 4 x 1.5 mm)

Representative photo - quantity and appearance may vary

1 mm

1 mm

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TGB oil nozzle General characteristics • Non-magnetic Appearance

• Worn nozzle shown with debris • Nozzle wear due to vespel nut contact

Representative photo - quantity and appearance may vary

1 mm

1 mm CFM International / 38 CFM Proprietary Information is subject to restrictions

IGB shims General characteristics • Non-magnetic Appearance

• Shiny metallic

Representative photo - quantity and appearance may vary

1 mm

1 mm CFM International / 39 CFM Proprietary Information is subject to restrictions

N°4 Bearing snap ring General characteristics • Magnetic Appearance

• Wire

Representative photo - quantity and appearance may vary

1 mm

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#4 bearing cage crimp General characteristics • Magnetic Appearance

• Flakes

Representative photo - quantity and appearance may vary

1 mm 1 mm

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Aft air/oil separator honeycomb General characteristics • Non-magnetic • Hastelloy X Appearance • Pieces of honeycomb can be associated with small aluminum

Representative photo - quantity and appearance may vary

1 mm

5 mm

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Bearing cage General characteristics • Non-magnetic

Representative photo - quantity and appearance may vary

1 mm

1 mm CFM International / 43 CFM Proprietary Information is subject to restrictions

Safety cable crimp sleeve/safety wire General characteristics • Non-magnetic Appearance

• Wire • Crimping sleeve

Representative photo - quantity and appearance may vary

1 mm

1 mm

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Shotpeening media General characteristics • Magnetic Appearance

• Spherical steel shotpeen balls

Representative photo - quantity and appearance may vary

1 mm

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Machining debris General characteristics • Magnetic or non-magnetic Appearance • Metallic

• Irregular

• Reflective

Representative photo - quantity and appearance may vary

1 mm

1 mm CFM International / 46 CFM Proprietary Information is subject to restrictions

Silver plate General characteristics • Non-magnetic Appearance • Metallic

• Foil

• Irregular

• Reflective

• Malleable

Representative photo - quantity and appearance may vary

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Oil inlet cover General characteristics • Non-magnetic Appearance • Metallic

• Filiform

• Silver shavings

• Reflective

• Thread-like

Representative photo - quantity and appearance may vary

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Carbon (coke) General characteristics • Non-magnetic Appearance • Non-metallic

• Jagged edges

• Round

• Usually black

• Solid

• Brittle to hard

• Oily smell

Representative photo - quantity and appearance may vary

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PTFE (Teflon®) seal General characteristics • Non-magnetic Appearance • Non-metallic

• Tan to black in color

• Chunks

• Lightweight for size

Representative photo - quantity and appearance may vary

48 mm 40 mm

32 mm 24 mm 16 mm 8 mm 0 0

1/2”

1”

1-1/2”

2”

2-1/2”

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O-ring (seal or pre-formed packing) General characteristics • Non-magnetic, elastomer Appearance • Non-metallic

• Ragged edges

• Irregular

• Dark

• Brittle to pliable

Representative photo - quantity and appearance may vary

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Carbon seal General characteristics • Non-magnetic Appearance • Non-metallic

• Irregular

• Frayed

• Granular

• Dark grey to black

Representative photo - quantity and appearance may vary

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Grit blasting material General characteristics • Non-magnetic Appearance • Non-metallic

• Quartz-like

• Granular

• Solid

• Irregular

Representative photo - quantity and appearance may vary

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Tumbling media General characteristics • Non-magnetic Appearance • Non-metallic

• Various colors

• Rounded, triangular, • Hard, smooth spherical surface

• Size ranges from a few millimeters to over an inch

Representative photo - quantity and appearance may vary

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Tube cap General characteristics • Non-magnetic Appearance • Non-metallic

• Various colors (yellow, red, etc.)

• Various deformations

Representative photo - quantity and appearance may vary

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Definitions Brittle Easily broken, cracked, or snapped

Machine Curl Material formed in a spiral or winding shape

Chunk A short thick piece or lump

Machined Shaped as if by machine or mill tools

Curls Pieces having a spiral or winding form

Coined Stamped Dull Lacking brilliance, luster or lightness Fibrous Capable of being separated into fibers Filiform Shaped like a filament or thread

Malleable Capable of being extended or shaped Pliable Supple enough to bend without breaking Powder Matter in even and fine particles Reflective Able to throw back light

Flake A thin flattened piece or layer

Round Edges are roughly equidistant from the center

Flattened Thin versus length or width

Sharp Having a thin edge or fine point

Fraying To wear or separate usually at the edges

Shiny Bright in appearance

Fuzz Very fine light particles or fibers Granular Consisting of uniform particles Hard Not easily penetrated Irregular Lacking symmetry or evenness Jagged Having a sharply uneven edge or surface Laminated Composed of layers of united material

Sliver A long slender piece cut or torn off Solid Uniformly close and coherent texture Spall Wedge or irregular chip, flake or fragment Strips Long narrow pieces of material Thin Measuring little in cross section or diameter

Uniform Little variation in form CFM International / 56 CFM Proprietary Information is subject to restrictions

Bearing cross-sections 1

Outer race

4

Rolling element - ball

2

Inner race

5

Cage

3

Rolling element - roller

6

Shoulder

1 6

4

5

2 1 6

3

5

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Appendix

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Safe handling of oil Most lubricants are labeled as potentially harmful when absorbed through the skin or swallowed. Follow your company’s hazardous material procedures as well as Oil Manufacturer’s guidance. CFM56 recommends wearing safety glasses, protective clothing and gloves when handling oil. Latex, pvc, or rubber gloves should be powder-free to avoid contamination when taking or preparing samples for analysis. Note: Cotton gloves are not recommended as they can contaminate the sample and do not protect the hands from contact with oil.

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Turbine jet engine oil identification This photograph depicts the color of fresh oil for many commonly used oils.

Note: Reference only. Oil color may change under different environmental and/or storage conditions.

BPTO 2380

AeroShell 500

AeroJet 5

AeroShell 555

AeroShell 560

Mobil Jet II

Castrol 5000

Castrol 5050

Nycoil 600

BPTO 25

BPTO 2197

Mobil Jet 254

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Scales 40 mm

30 mm

20 mm

10 mm

0

0

10 mm 20 mm 30 mm 40 mm 50 mm 60 mm 70 mm

40 mm

30 mm

20 mm

10 mm

0 0

.5”

1”

1.5”

2”

2.5”

3”

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