Egyptair CFM56-7B

HPC Module

HPC Shroud Slab Headed

Anti-rotation Pin Liberations

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Background

Slab head pin introduced to address HPC honeycomb seal rotation and avoid
radial retention pin liberations
Introduced Jul 2007 in production
SB 72-0678 (5B), 72-0673 (7B) & 72-0645 (5C)
Anti-Rotation pins located in 2 shrouds per stage (3 and 9 oclock positions)

Radial Retention Pins Anti-rotation pin designs

(holds shroud to vane)
Original design New
Slab design
head pin design

Headed
Headedpinpin

Honeycomb
Honeycomb
seal
seal

Anti-Rotation Pins
(prevents seal rotation)

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Slab Head Anti-Rotation Pin Experience
32 slab head anti-rotation pin liberations reported (across all engine models)
CFM56-5C/P (4 liberations) & CFM56-5C (2 liberations) also effected
15 of 32 liberations caused engine removal (HPC blade damage found at routine BSI)
3 liberations resulted in recoverable engine stall
Liberations occurred with both composite or metallic/hybrid bushing system and on
production and overhauled engines
No engines liberated both 3 and 9 oclock pins which would allow seals to rotate leading to
radial retention pin liberation
Liberated pin can damage HPC stage 4-9 blades, stage 3 disk and/or 4-9 spool

Composite bushing system Metallic bushing system Blade and spool damage

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Failure mode definitions and occurrences by configuration
failure mode description
1 J-hook wear through due to RTS contact leading to retention pin liberation
2 honeycomb seal rotation leading to retention pin, seal or bushing liberation
3 retention pin liberation forward through shroud
4 liberation of anti-rotation pin

estimated # engines (5A, 5B, 5C, 7B)

occurance rate
operational event High rates of
configuration intro date failure mode # occurances shop
production overhaul total per engine IFSD stall UER
finding
operational
composite bushing with round anti-
1
2
15
27
0.69%
1.25%
3
4
6
17
6
4
0
2
events led to
EIS 1639 523 2162
rotation pin 3 4 0.19% 1 2 1 0 RTS contact
4 7 0.32% 1 3 2 1
1 0 0.00% 0 0 0 0 on-wing
full metallic bushing system with 2 0 0.00% 0 0 0 0
round anti-rotation pin
Apr-06 801 0 801
3 1 0.12% 0 0 0 1 inspection
4 0 0.00% 0 0 0 0
1 0 0.00% 0 0 0 0
program
hybrid bushing system with round 2 0 0.00% 0 0 0 0
Apr-07 248 523 771
anti-rotation pin 3 0 0.00% 0 0 0 0
4 0 0.00% 0 0 0 0
1 0 0.00% 0 0 0 0
composite bushing with headed 2 0 0.00% 0 0 0 0
anti-rotation pin and wide S3 slot
Jul-07 0 975 975
3 0 0.00% 0 0 0 0 Only 3 anti-
4 16 1.64% 0 1 4 11
1 0 0.00% 0 0 0 0 rotation pin
hybrid bushing system with headed
anti-rotation pin and wide slot
Jul-07 3130 975 4105
2
3
0
0
0.00%
0.00%
0
0
0
0
0
0
0
0
liberations
4
1
16
0
0.39%
0.00%
0
0
2
0
8
0
6
0
have resulted
composite bushing with headed
Jun-10 0 2787 2787
2 0 0.00% 0 0 0 0 in recoverable
anti-rotation pin and narrow slot 3 0 0.00% 0 0 0 0
4 0 0.00% 0 0 0 0 engine stall
1 0 0.00% 0 0 0 0
hybrid bushing system with headed 2 2 0.03% 0 0 1 1
Jun-10 5127 2787 7914
anti-rotation pin and narrow slot 3 0 0.00% 0 0 0 0
4 0 0.00% 0 0 0 0

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Stage 3 headed anti-rotation pin liberation mechanism
Seal slides circumferentially and contacts the side of the pin
Causes pin head to rotate until it contacts the side of the shroud slot
Concurrent shroud rail wear allows seal to move radial inward

Pin wear
from seal

Seal movement
Pin head due to rail wear
rotation and
contact Shroud rail wear
from seal contact

Dim W

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Stage 3 headed anti-rotation pin liberation mechanism

Pin head can rotate 90 degrees past the corner of the shroud
During rotation the pin head slides up the ramp in the shroud
Causes the pin to move axially away from the shroud
Once rotated 90 degrees pin head no longer retained by seal

Shroud rail wear

from seal contact Pin wear into bore
on opposing side
created during
rotation

On-wing photo showing

fully rotated and
partially disengaged pin
Corner of rotated pin wears
into shroud rail forming a
ramp

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Stg 3 narrow versus wide slot shroud geometry
Narrow slot shroud introduced to limit pin head rotation
Improved geometry should eliminate or significantly lower risk of liberation
With narrow slot shroud W (worst case) now greater than stage 2 which has never
liberated
All liberations have occurred with wide slot shrouds

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Narrow slot introduction
Part number of shroud not changed with slot width optimization
Introduction determined by confirmation of slot width at
subsequent shop visit
Production
Wide slot installed for engines manufactured between July 2007 and
June 2010 (3714 engines) ( MSR have 21 engines installed)
Overhaul
Wide slot installed for engines overhauled between Jan 2008 and June
2010 (1949 engines)

CFM56-7B delivery status (Production)

7
Nbr of engines

6
5 (Wide Slot Installed)
4
3
2
1
0
2006 2006 2006 2007 2007 2008 2009 2009 2009 2009 2009 2010 2010 2010 2010 2011 2012 2012 2012 2012 2012
oct nov dc sept nov aot fvr mars aot sept oct sept oct nov dc juin fvr mars avr juil sept
2006 2007 2008 2009 2010 2011 2012
7B26 2 1 2
7B26/3 2 2 2 2 2 2 6 3 2 2 2 2 3
7B26E 2 1 1 2 2

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Stg 3 narrow versus wide slot shroud field experience

Wide slot shroud Narrow slot shroud

CFM56-7B27/3 CFM56-7B27/3

Dimension W increased with narrow slot shroud

which increases contact area and limits pin rotation
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Narrow versus Wide slot histogram

Wide slot = 5663 engines

Narrow slot = 10825 engines

Typical time
of wide slot
composite Typical time of
liberation wide slot
metallic/hybrid
liberation

TSN or TSSV
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Comparison with Radial Retention Pin Liberations
Impact of radial
Radial retention pin likely to liberate retention pin liberation
if both 3 and 9 oclock slab head
anti-rotation pins liberate
Radial retention pin liberations
more severe due to size of pin
Results in more extensive HPC
blade damage
41 radial retention pin liberations
reported across CFM engine models Typical damage from radial retention
pin liberation more severe than anti-
Due to rotor to stator contact with
rotation pin liberation
composite bushings or original anti-
rotation pin design

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VSV System Improvements

New system introduced 2. Hard Anodizing

July 2014 production intro
SB 72-0906 (5B), 72-0958 (7B) & 72-
0763 (5C) cat 7
Improvements
1. Brazed End Blocks Replace Anti-rotation
Pin
Addresses anti-rotation pin liberations
1. Seal End Blocks
Reduced seal sliding and wear
2. Shroud Hard Anodizing 4. Increased Fwd Shroud Clearance
Reduced wear on all surfaces
3. Increased Aft Shroud Clearance
0.070 additional clearance .030
Increased time to 4-9 spool contact
4. Increased Forward Shroud Clearance
0.030 additional clearance
Increased time to shroud to blade .070
platform contact
3. Increased Aft Shroud Clearance
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On-wing Recommendations

No on-wing action recommended for fleet

Limited number of anti-rotation pin liberations have resulted in recoverable
engine stall
Majority of liberations found during routine shop visit
No engines have liberated both 3 and 9 oclock pins which would likely result
in radial retention pin liberation
Perform MPD inspection of HPC blades
CFM56-5B SB 72-0727 (cat 2) recommends 10,000 cycles initial BSI with repeat
at 5,000 cycles re-inspect interval
CFM56-7B MPD recommends 6,600 cycles or 15,000 hours initial and repeat
interval
CFM56-5C MPD does not recommend specific HPC blade inspection interval but
many operators have incorporated a periodic inspection plan
If HPC blade damage found in stages 4-9 perform rotor to stator contact
inspection to verify presence of stage 3 anti-rotation pins
Perform Rotor to stator contact inspection per SB 72-0553 (5B), 72-
0515 (7B) or 72-0427 (5C) when applicable

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2014 ISC Recommendations

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Shop Recommendations

Incorporate new VSV system replacing anti-rotation pin with brazed end
block
SB 72-0906 (5B), 72-0958 (7B) & 72-0763 (5C) cat 7
If system not replaced, measure shroud slot width per ESM 72-32-07,
Inspection 001
Following inspection criteria being added to ESM
Wear on dimension F Stage 3
Minimum Serviceable Limit: --
Maximum Serviceable Limit: 0.230 inch (5,84 mm)
Maximum Repairable Limit: Not repairable
Repair Method: --

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