Field Guide for Lubrication System Debris · CFM International / 6 Introduction This guide is intended exclusively for the owners and operators of CFM56 aero turbo machinery. It has

Field Guide forLubrication System Debris

Boeing Programs CFM56-2 CFM56-3 CFM56-7

Tool Number: GEK 119193February 2018

Basic

CFM Proprietary Information is subject to restrictions

CFM International / 3

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.



CFM56 Proprietary Information

CFM, CFM56, LEAP and the CFM logo are trademarks of CFM International, a 50/50 joint company between Safran Aircraft Engine (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.



Table of contents

6 Introduction

8 Contact information

10 Handling, collection and inspection

15 Magnetic sensor quantification

17 Scavenge screen localization

21 Scavenge screen quantification

24 CFM MCD inspection guidelines

29 Debris identification

77 Definitions

Bearing cross-sections

79 Appendix

Turbine jet engine oil identification

Scale



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 EASA/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.



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.



Contact information

Customer Support Center (CSC)

GE AviationRegions covered: North America, South America, Asia Pacific and China

Toll-free in U.S.: +1 877-432-3272Phone: +1 513-552-3272China & Asia Pacific: +86 21-3877-7666Email: [email protected]

Safran Aircraft Engines (formerly Snecma)Regions covered: Africa, Middle East and Europe

Tel: +33 (0) 1 64 14 88 66Email: [email protected]. Fax : 33 1 64 14 84 00

Customer Support Portal: https://mycfmportal.com

This guide is produced by CFM Product Support Engineering

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

mailto:[email protected]

mailto:[email protected]

https://mycfmportal.com/



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.



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.



• 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 oilin 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.

Oil sampling guidelines



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



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.



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.



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.

Magnetic sensor quantification

43 5

0 1 2



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

43 5

Magnetic sensor quantification



Identify the sump origin of the debris.

CFM56-2 Scavenge screen localization

AGB

ForwardSump

AFTSump

TGB

Lubrication Unit

FWD




CFM56-3 Scavenge screen localization

AGB/TGB ForwardSump

AFTSump

Lubrication Unit

FWD




CFM56-7B Scavenge screen localization

ForwardSump

Rear Sump

LubricationUnit

Lubrication Unit

FWD

AGB/TGB



Identify the sump origin of the debris.See previous slide for sump localization.

CFM56-7B27A Scavenge screen localization

AGB ForwardSump

Rear Sump

TGB

LubricationUnit

AGB

Scavenge MCDs



This relative scale can be utilized when communicating screen debris levels.

Note: Different engine models will have screens of different sizes and shapes.

1 20

Scavenge screen quantification

3 4 5



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.



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



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)



Satisfactory - ServiceableMarginal - Means continue in services while debris are sent to LabUnsatisfactory - Immediate action is required

CFM MCD guidelines for magnetic particles

When particles are just collected, visual inspect per 10x magnifying lens to identify the category



CFM MCD guidelines

AMM satisfactory conditions

• Particles within this table, don’t need to be sent for analysis

• Machined chips are serviceable whatever the size



CFM MCD guidelines

AMM marginal conditions

Note: For CFM56-7B, engine oil is shared with the starter. Particles analysis is not sufficient to determine status on engine/AGB/TGB serviceability. Starter troubleshooting and engine history review is required to avoid unnecessary engine/AGB/TGB removal



CFM MCD guidelines

AMM unsatisfactory conditions

Note: For CFM56-7B, engine oil is shared with the starter. Particles analysis is not sufficient to determine status on engine/AGB/TGB serviceability. Starter troubleshooting and engine history review is required to avoid unnecessary engine/AGB/TGB removal



20

16

12

8

4

0

.25” .5” .75” 1”

20

16

12

8

4

0

.25” .5” .75” 1”

20

16

12

8

4

0

.25” .5” .75” 1”

20

16

12

8

4

0

.25” .5” .75” 1”

Examples of Bearing shoulder wear distress

mm mm

mm mm



20

16

12

8

4

0

.25” .5” .75” 1”

20

16

12

8

4

0

.25” .5” .75” 1”

20

16

12

8

4

0

.25” .5” .75” 1”

20

16

12

8

4

0

.25” .5” .75” 1”

Examples of Bearing spall distress

mm mm

mm mm



M50NiL

General characteristics

• Magnetic

Representative photo - quantity and appearance may vary

20 mm

16 mm

12 mm

8 mm

4 mm

00 0.25” 0.5” 0.75” 1”



M50


• Magnetic

Appearance

• Metallic

• Dull

• Small flakes and/or powder

• Dark color

1 mm

1 mm




CFM56-7B M50 on Starter Magnetic Plug


• Magnetic

Note: This Magnetic Plug is limited to a CFM56-7B AGB only, not all CFM models

Clean/Acceptable* Light Fuzz/Acceptable*

Moderate Fuzz/Acceptable*

Major Metal/Unacceptable*

*: Refer toCFM56 AMM




Bearing spall chips


• Magnetic

Appearance

• Metallic

• Flattened

• Ragged edges

• Flakes

• Oval

• Coined

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

20 mm

16 mm

12 mm

8 mm

4 mm

00 0.25” 0.5” 0.75” 1”




Bearing Cage


• Magnetic

Note: This finding is limited to a CFM56-3 TGB only, not all CFM models

20 mm

16 mm

12 mm

8 mm

4 mm

00 0.25” 0.5” 0.75” 1”




Gearbox debris


• Magnetic

Appearance

• Metallic

• Reflective

• Flakes

• Irregular

• Sharp

20 mm

16 mm

12 mm

8 mm

4 mm

00 0.25” 0.5” 0.75” 1”




CFM56-3 TGB rivet


• Non-magnetic

Appearance

• Hollow rivet tail


5 mm



CFM56-3 AGB Starter Pad Brg Cage Rivet


• Magnetic

Appearance

• Piece of rivet - 0.67 in (17mm)




No. 2 Bearing nut spirolock


• Magnetic

Appearance

• Wire


1 mm

5 mm



CFM56-3 AGB starter ball bearing cage


• Magnetic

Appearance

• Piece of rivet


1 mm

1 mm



Forward sump air/oil separator


• Non-magnetic

Appearance

• Resin polyamide material (green or brown color)


1 mm

1 mm



Forward sump abradable


• Non-magnetic

Appearance

• Phenolic or plastic material (greenish-white color)


1 mm

1 mm



• Tan to black in color

• Lightweight for size

No. 3 BearingF orward Stationary Air Oil Seal - PTFE (Teflon®)


• Non-magnetic

Appearance

1 mm

1 mm

1 mm

1 mm

Delaminated/Missing Seal Material

Representative photos - quantity and appearance may vary

• Non-metallic

• Chunks




• Non-magnetic

Appearance

0 1/2” 1” 1-1/2” 2”

48 mm

40 mm

8 mm

0

24 mm

32 mm

16 mm

2-1/2”

Other PTFE (Teflon®) seal

• Non-metallic

• Chunks

• Tan to black in color

• Lightweight for size




Epoxy bonding / bushing sleeve / FwdAir/Oil seal


• Non-magnetic

Appearance

• Brown/Reddish

View A-A




CFM56-2/3 No. 3 Brg Aft Stationary Air/Oil Seal - Abradable and Fiberglass


• Non-magnetic

Appearance

• Reddish-Brown Plastic and fibrous debris

• Glass fiber with polyamide


View A-A



Bearing air/oil seal abradable


• Non-magnetic

Appearance

• Glass fiber with polyamide material with grooves

• Reddish brown non-metallic


1 mm

1 mm



CFM56-3 TGB roller bearing crimped retaining ring


• Magnetic

Appearance

• Black, flat curled with machining traces


1 mm 1 mm



AGB bearing cage rivets


• Magnetic

Appearance

• Rivet heads




CFM56-2A/B/C Bearing cage and Rivet of N2 Alternator


• Magnetic

Appearance

• Rivet headsRepresentative photo - quantity and appearance may vary



AGB or TGB Sealol seal tangs


• Magnetic

Appearance

• Rectangular tang

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


1 mm

1 mm



TGB oil nozzle


• Non-magnetic

Appearance

• Worn nozzle shown with debris

• Nozzle wear due to vespel nut contact


1 mm

1 mm



CFM56-3 TGB Ball Bearing Vespel Nut


• Non-magnetic

Appearance

• Filiform, Brown Debris

• Resin Polyimide

TGB


slice



AGB/TGB Input Bevel Gear Roller Bearing CageGeneral characteristics

• Magnetic

Appearance

• Rectangular Silver Plated

TGB Input Bevel GearRoller Bearing


1 mm

1 mm



Key Lock from AGB or TGB Stud or Insert


• Magnetic

Appearance

• Flat piece with castellated portion


1 mm1 mm

1 mm

1 mm



IGB shims


• Non-magnetic

Appearance

• Shiny metallic


1 mm

1 mm



Pins used in Inlet Gear Box Oil Nozzles


• Magnetic

Appearance

• Tapered Hollow Pin




CFM56-7B No. 3 Brg Support or ball Bearing spanner nut locker


• Magnetic

Appearance

• Hexagonal nut 1/4 in.




No. 4 Bearing Outer Race retaining nut Snap Ring


• Magnetic

Appearance

• Wire


1 mm



No. 4 Bearing cage crimp


• Magnetic

Appearance

• Flakes


1 mm

1 mm



Aft air/oil separator honeycomb


• Non-magnetic

• Hastelloy X

Appearance

• Pieces of honeycomb can be associated with small aluminum


1 mm

5 mm



LPT Aft Sump Abradable Coating Material from Air or Oil SealsGeneral characteristics

• Non-magnetic

Appearance

• Grey and Granular


1 mm

5 mm



Oil Inlet Cover Gasket Material


• Graphite Paper with metal lamination

Appearance

• Laminated

Oil Inlet Cover Gasket




Safety cable crimp sleeve/safety wire


• Non-magnetic

Appearance

• Wire

• Crimping sleeve


1 mm

1 mm



Shotpeening media


• Magnetic

Appearance

• Spherical steel shotpeen balls or cut wire


1 mm



1 mm

1 mm

Machining debris


• Magnetic or non-magnetic

Appearance

• Metallic

• Reflective

• Irregular

• Chips with Anodizing




Silver plate


• Non-magnetic

Appearance

• Metallic

• Reflective

• Foil

• Malleable

• Irregular

20 mm

16 mm

12 mm

8 mm

4 mm

00 0.25” 0.5” 0.75” 1”




Oil inlet cover


• Non-magnetic

Appearance

• Metallic

• Reflective

• Filiform

• Thread-like

20 mm

16 mm

12 mm

8 mm

4 mm

00 0.25” 0.5” 0.75” 1”


• Silver shavings



Carbon (coke)


• Non-magnetic

Appearance

• Non-metallic

• Round

• Solid

• Jagged edges

• Usually black

• Brittle to hard

• Oily smell

20 mm

16 mm

12 mm

8 mm

4 mm

00 0.25” 0.5” 0.75” 1”




O-ring (seal or pre-formed packing)


• Non-magnetic, elastomer

Appearance

• Non-metallic

• Irregular

• Ragged edges

• Dark

• Brittle to pliable

20 mm

16 mm

12 mm

8 mm

4 mm

00 0.25” 0.5” 0.75” 1”




Carbon seal


• Non-magnetic

Appearance

• Non-metallic

• Granular

• Irregular

• Dark grey to black

20 mm

16 mm

12 mm

8 mm

4 mm

00 0.25” 0.5” 0.75” 1”


• Frayed



Grit blasting material


• Non-magnetic

Appearance

• Non-metallic

• Granular

• Quartz-like

• Solid

• Irregular

20 mm

16 mm

12 mm

8 mm

4 mm

00 0.25” 0.5” 0.75” 1”




Tumbling media


• Non-magnetic

Appearance

• Non-metallic

• Rounded, triangular, spherical

• Various colors

• Hard, smooth surface

• Size ranges from a few millimeters to over an inch

20 mm

16 mm

12 mm

8 mm

4 mm

00 0.25” 0.5” 0.75” 1”




Tube cap


• Non-magnetic

Appearance

20 mm

16 mm

12 mm

8 mm

4 mm

00 0.25” 0.5” 0.75” 1”

• Non-metallic • Various colors (yellow, red, etc.)

• Various deformations




Definitions

Brittle Easily broken, cracked, or snapped

Chunk A short thick piece or lump

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

Flake A thin flattened piece or layer

Flattened Thin versus length or width

Fraying To wear or separate usually at the edges

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

Machine Curl Material formed in a spiral or winding shape

Machined Shaped as if by machine or mill tools

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

Round Edges are roughly equidistant from the center

Sharp Having a thin edge or fine point

Shiny Bright in appearance

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



6 4

1

5

2

63

1

5

2

Bearing cross-sections

1 Outer race

2 Inner race

3 Rolling element - roller

4 Rolling element - ball

5 Cage

6 Shoulder



Appendix



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.



BPTO2380

AeroShell500

AeroJet 5 AeroShell555

AeroShell560

MobilJet II

Castrol5000

Castrol5050

Nycoil600

BPTO 25 BPTO2197

MobilJet 254

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.



0

0 .5” 1”

10 mm

20 mm

30 mm

40 mm

1.5” 2” 2.5” 3”

0

0 10 mm

10 mm

20 mm

30 mm

40 mm

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

Scales

Field Guide for Lubrication System Debris · CFM International / 6 Introduction This guide is intended exclusively for the owners and operators of CFM56 aero turbo machinery. It has

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