TURBONYCOIL-600-CFM56-2B-STRIP--INSPECTION-REPORT-20-May-2010

ESTER EXPERTISE AND LUBRICANT INNOVATION TURBONYCOIL 600 CFM56-2B STRIP INSPECTION REPORT 20 May 2010_________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 - E-mail : [email protected]

STRIP INSPECTION CFM56-2B / TURBONYCOIL 600 TABLE OF CONTENTINTRODUCTION 3-5The CFM56-2 Turbofan EngineEngine Modular DesignCFM56-2 cut-awayPurpose of the reportREPORT ON STRIP/INSPECTION OF CFMI CFM56-2 6-15LUBRICATED BY TURBONYCOIL 600Fan Major Module inspectionLPT Major Module inspectionAccessory Drive Module InspectionCONCLUSION 16_________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 - E-mail : [email protected]

STRIP INSPECTION CFM56-2B / TURBONYCOIL 600 INTRODUCTIONThe CFM56-2 Turbofan EngineThe CFM56-2 was the first member of the CFM56 family of engine. It pioneered the medium-thrust highbypass turbofan concept, and introduced the one-stage HP turbine design in commercial engines to reducemaintenance costs.Developed and produced by CFM International (CFMI), an equally-owned subsidiary of Snecma of Franceand General Electric of the United States, the CFM56-2 develops 22,000 to 24,000 pounds of thrust.The CFM56-2 was jointly certified in November 1979 by the U.S. Federal Aviation Administration (FAA) andthe French civil aviation authority DGAC (Direction Générale de l’Aviation Civile). The same year, it wasselected by Delta Airlines, United Airlines and US Flying Tigers, to re-engine their DC-8 Super 70s forpassenger, VIP and cargo transport.Today, 110 re-engined DC-8 Super 70s are still in operation worldwide. Since entering service in 1982, theCFM56-2 has set new standards of reliability and endurance, while considerably increasing the aircraft’scapabilities.At the same time, the CFM56-2’s low fuel consumption and improved takeoff performance (for increasedpayload and shorter turnaround), led the U.S., French, British and other major air forces to select this engine.The CFM56-2 powers the KC-135R, C-135FR, KE3, RC-135R, AWACS E3 and E6 aircraft, as originalequipment or retrofit, for tactical or strategic transport, in-flight refueling, and C3I missions. The USAF iscurrently CFMI’s biggest single customer. More than 600 military aircraft powered by CMF56-2 engines arecurrently in operation.Key features :• First high-bypass engine in the 10-ton class• Single-stage HP turbine• Low emission combustor• Low noise engine• First engine to meet FAR 33-6 ingestion requirement• Hydromechanical controls• 60 percent fewer parts than earlier high-bypass design_________________________________________________________________________________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 E-mail : [email protected] 3

STRIP INSPECTION CFM56-2B / TURBONYCOIL 600Engine Modular DesignThe modular design of the engine CFM56-2 is developed hereunder.Fan Major Module Module 1 Fan & BoosterCore Major Module Module 2 N°1 and n°2 bearing support Module 3 Inlet Gear Box (IGB) and n°3 bearingLow Pressure Turbine Major Module 4 Fan frameModuleAccessory Drive Module Module 5 HPC Rotor Assembly Module 6 HPC Front Stator Assembly Module 7 HPC Rear Stator Assembly Module 8 Combustion Case Assembly Module 9 Combustion liner Module 10 HPT Nozzle Assembly Module 11 HPT Rotor Assembly Module 12 HPT shrouds/stage 1 LPT nozzle assembly Module 13 LPT Rotor/Stator Assembly Module 14 LPT Shaft Assembly Module 15 LPT Frame Module 16 Transfer Gearbox (TGB) Module 17 Accessory Gearbox (AGB)A cut-away drawing of the core is also provided for better understanding of the photo positioning._________________________________________________________________________________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 E-mail : [email protected] 4

STRIP INSPECTION CFM56-2B / TURBONYCOIL 600CFM56-2 cut-away : 4 Bearing n°4 Bearing n°212 3 10 15 6 8 5 11 14 12 13 79 Bearing n°3 Bearing n°5 Bearing n°117 16Purpose of the reportThis inspection report and photographs were made to document the in-service experience of Turbonycoil 600(manufactured by NYCO SA) on CFM56 engine series.Turbonycoil 600 is a lubricating oil with a viscosity of 5 cSt at 100°C. It is based on polyol esters with highthermal stability, fortified with carefully selected anti-oxidant, anti-wear and anti-corrosion additives andexhibits low volatility at high temperature, excellent resistance to foaming and a superior lubricity.Turbonycoil 600 is designed for use in gas turbine engines in military and civil aircraft as well as in stationaryindustrial applications. Turbonycoil 600 has been qualified against MIL-PRF-23699 STD in 1985 and SAE-AS5780-SPC more recently. Turbonycoil 600 is validated by all major engine manufacturers (GeneralElectric, Pratt and Whitney, Allison, Rolls-Royce, Allied Signal, Snecma, Klimov, Turbomeca, PZL-Rzeszow)for use in 40 different military engines powering a wide range of combat, transport or surveillance airplanesor helicopters. Turbonycoil 600 is also validated for use on several civil engines such as CFM InternationalCFM56-2, -3, -5A, -5B, -5C and -7, IAE V2500, Rolls Royce RB211…_________________________________________________________________________________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 E-mail : [email protected] 5

STRIP INSPECTION CFM56-2B / TURBONYCOIL 600 REPORT ON STRIP/INSPECTION OF CFMI CFM56-2 LUBRICATED BY TURBONYCOIL 600ENGINE IDENTIFICATION CFM56-2 2B1 (22 kLbs)Engine name plate 711424Operating Thrust F108-CFEngine Serial number 9,785Identification 9,599Take-off power (daN) 22,000Max continuous power (daN) 21,580Rating to thrust (Lb) June 1986Rating max continuous thrust (Lb)Manufacture date French Air Force, maintained by SIMMAD 12,294Operator 4,476Total Time (h) KC-135 (refueller)Total CycleAircraftInspection made on May 20th 2010, in presence of :Snecma Service : Koen Roggen (Program Manager) Johan De Cock (Engineering department)NYCO SA : Eric Piveteau (General Manager) Arnaud Radigue (Business Manager) Olivier Kempff (Account Manager)Note :The engine was removed from the wing for a bird strike and oil leak due to a damaged labyrinth seal.At the time of the removal, the engine had a 25°C E xhaust Gas temperature (EGT) margin, e.g. had usedabout half of its potential lifetime.In the following pages, one will find photographs and comments on each engine module lubricated and/or incontact with Turbonycoil 600._________________________________________________________________________________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 E-mail : [email protected] 6

STRIP INSPECTION CFM56-2B / TURBONYCOIL 600 Fan Major Module InspectionFan Frame – Module 4General view :Oil inlet (Oil injection on bearings)Comments :Fan frame is very clean, free from any kind of deposit, oil decomposition products (no varnish, no coke) anddoes not show any corrosion pits.The oil nozzle, that sprays oil on Bearing n°1, is clean._________________________________________________________________________________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 E-mail : [email protected] 7

STRIP INSPECTION CFM56-2B / TURBONYCOIL 600 Fan Major Module InspectionThrust Bearing (Bearing n°1) – Module 2Ball bearing n°1 general view :Bearing n°1 race :Comments :Bearing information :PN: 305 364 002-0SN : RR 10506This bearing is submitted to high load, but does not suffer from high temperature.No trace of fretting, wear, corrosion or degradation can be seen of the here above photos.Turbine oil residues are of very light color and free from degradation by-products (no coke or varnish)._________________________________________________________________________________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 E-mail : [email protected] 8

STRIP INSPECTION CFM56-2B / TURBONYCOIL 600 Fan Major Module InspectionRoller Bearing (Bearing n°2) – Module 2Roller bearing n°2 and support : n°2 bearin g general viewn°2 bearing general view: n°2 bearing exte rnal raceComments :Bearing information :PN : 305-365-102-0SN : RR 10552No trace of fretting, wear, corrosion or degradation can be seen of the here above photos.Turbine oil varnishes are of very light color and free from degradation by-products.The clear zone on the external bearing race corresponds to the area in contact with the rolling elements._________________________________________________________________________________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 E-mail : [email protected] 9

STRIP INSPECTION CFM56-2B / TURBONYCOIL 600 Fan Major Module InspectionInlet Gear Box – Module 3General view :IGB (other views) :IGB (other views) : IGB back side (view of Bearing 3)_________________________________________________________________________________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 E-mail : [email protected] 10

IGB rear view (other view of bearing n°3) STRIP INSPECTION CFM56-2B / TURBONYCOIL 600 IGB internal shaft couplingComments :Bearing n°3 is the most sensitive one, as it is sub mitted to very high loads and therefore can exhibit somewear degradation and failure (scratching, scaling off…).On IGB, the A check is therefore performed every 400h. This engine being from the initial generation (1986),the alloys were made from more sensitive materials, then the inspection has to be made every 100h.The enclosed pictures are very nice showing that no wear / deterioration has occurred since operation withTurbonycoil 600.The loaded area on the gear teeth flange is clearly visible on the pictures. No trace of micropitting (greystaining) or scuffing can be seen. The oil does provide an adequate protection against wear on these highlyloaded components.The internal shaft coupling, that may be more sensitive to wear due to the limited oil flow in this area, is alsofree from traces of wearTurbine oil residues are of very light color._________________________________________________________________________________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 E-mail : [email protected] 11

STRIP INSPECTION CFM56-2B / TURBONYCOIL 600 LPT Major Module InspectionRoller Bearing (Bearing n°4) – Module 14Roller bearing n°4 :Roller bearing n°4 (reverse) : Roller beari ng °4 race :Comments :Bearing information :PN : 505-335-662-0SN : RR 12877This bearing is the second most sensitive bearing (after bearing n°3) in this engine. It is located in the hotsection, on the LPT Shaft, and is therefore submitted to higher temperature.The High Pressure Turbine compartment runs at 14000 rpm and drives the High Pressure Compressor. Theexternal bearing race is therefore submitted to high stress. In the mean time, the internal race is running at5000 rpm (the Low Pressure Turbine assembly driving the fan through the Shaft).One can see the compression marking on the rollers showing the high stress encountered. However, notrace of wear, corrosion or degradation can be seen on the here above photos. Turbine oil residues are ofvery light color and free from degradation by-products (no coke, no varnish)._________________________________________________________________________________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 E-mail : [email protected] 12

STRIP INSPECTION CFM56-2B / TURBONYCOIL 600 LPT Major Module InspectionRoller Bearing (Bearing n°5) – Module 15Roller bearing n°5 :Roller Bearing n°5 race :Comments :PN : 305-351-902-0SN : RR 10477This oil dampened bearing is located on the LPT frame. It is less stressed but still submitted to highertemperature.No trace of wear, corrosion or degradation can be seen on the here above photos. Turbine oil residues arevery clear and free from degradation by-products._________________________________________________________________________________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 E-mail : [email protected] 13

STRIP INSPECTION CFM56-2B / TURBONYCOIL 600 LPT Major Module InspectionLow Pressure Turbine Frame (Bearing n°5 housing) – Module 15 :Cover of the oil rear sump (internal) : Oil feed line (Cover of the oil rear sump) :LPT Shaft – Module 14 : Comments : No trace of corrosion or degradation can be seen on the here above photos. The oil feed line is the part that is most often plugged with coke deposits, as this part is submitted to high temperature. But here, with Turbonycoil 600, the feed line is free from deposits. Due to high temperatures at the aft end of the turbine this compartment is considered a good indicator of oil thermal stability. Low pressure Turbine Shaft shows no evidence of wear degradation._________________________________________________________________________________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 E-mail : [email protected] 14

STRIP INSPECTION CFM56-2B / TURBONYCOIL 600 Accessory Drive Module InspectionTransfer Gear Box – Module 16 :Spline mesh/connection starter side : Radial gear shaft IGB/TGB :Comments :The Transfer Gear Box is transferring the torque drove from the Low pressure turbine through the Shaft tothe Accessory box. Gear is pretty clean.No trace of wear, corrosion or degradation can be seen on the here above photos. Turbine oil residues arevery clear and free from degradation by-products._________________________________________________________________________________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 E-mail : [email protected] 15

STRIP INSPECTION CFM56-2B / TURBONYCOIL 600 CONCLUSIONInspection conducted on CFM56-2 engine using Turbonycoil 600 for lubrication showed excellent level ofgeneral cleanliness throughout every engine compartments : • Fan Major Module was found to be clean and free from deposits, particulates and lacquer, with no residues on the oil injector. • Bearings n°1 and 2 were found to be pretty clean w ith no trace of wear, fretting or degradation. Oil residues were of very light color like if it was new oil. No evidence of coke or varnish. • Inlet Gear Box visual inspection showed exceptional cleanliness with no evidence of gear stress. • Bearing n°3 was found to be in very good condition . • Low pressure Turbine Module inspection also showed nice results, with no evidence of wear / degradation on bearings n°4 & 5 • Visual inspection showed no significant deposits, either internal or external, on the shaft spline or in oil feed line on the rear turbine bearing support and sump. • The Transfer Gear Box also showed evidence of oil performance with no wear / degradation on gear. • The absence of any corrosion spots on all the inspected components is remarkable, considering the 24 years of service of this engine with long period of time of inactivity._________________________________________________________________________________________________________________________________________________________________________________________PARIS 66, CHAMPS-ELYSEES –BP414 - 75366 PARIS-CEDEX 08 TEL. 33-(0)145615000 - FAX 33-(0)145615013 E-mail : [email protected] 16