CFM56-7B

Engine LRU´s

CFM56 Symposium
June 2017 – Milan
Agenda

Engine LRU´s
2

1. Air Turbine Starter

2. HPTACC Valve
3. HMU
4. FFCI
1 3

4
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 Air Turbine Starter

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Air Turbine Starter Fleet Performance
ATS drove 7 significant events in last 12
months
• 4 starter clamp
• 3 ATS
Output shaft decoupling rate stable
Turbine seal leak rate decreasing
Old Starter Clamp failure rate decreasing
• Cat 5 SB 80-0016 penetration
Low time removals stable ~0.26%
(12 month average)

No new failure modes observed on ATS fleet

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Starter Clamp

Starter Clamp attaches Air Turbine Starter to Starter Adapter in AGB

interface
• Cracks at heat affected zone on clamp over-wrap weld can lead to clamp
separations and oil loss at gearbox interface, resulting in IFSD
• Cracking can occur in spot welds and propagate in high cycle fatigue
(HCF)
• Over torque during installation known to increase likelihood of cracking
New, machined V-Band clamp addresses cracking, HCF and over torque,
increasing part reliability
• Category 5 SB 80-0016 introduces improved V-Band Clamp
• No known failure events in new V-Band Clamp operation

CFM recommends adoption of SB 80-0016 to prevent

significant events
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Output Shaft Decoupling
Decoupler prevents back driving of turbine wheel if clutch fails to disengage
• Inadvertent decoupling – disengages despite normal starter operation
• Protects AGB in case of internal ATS damage

Improved design uses wear resistant steel shaft with spring loaded torsion
bar decoupler
• No known decoupling with improved shaft

 CFM SB 80-0014/Honeywell SB 3505945-80-1861 released in 2013

CFM recommends incorporation of SB 80-0014/Honeywell SB

3505945-80-1861 to prevent output shaft decoupling
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Turbine Seal Leakage
Failure event description:
Caused by steel sleeve (liner) shift
• Steel liner moves axially, reduces seal preload and can cause separation of rotor
from carbon seal
• As liner shifts, turbine stack components shift with it (bearings, seal rotor, etc.),
creating a gap for oil leak

Preventative Actions:
Accomplish On-Condition Starter
Inspection for Oil Leakage or
during scheduled ATS inspection
CMM 80-11-79 revised in 2013

Bearing Liner assembly measurement process reduced Turbine Seal

Leak findings by ~32%
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Starter Radial Bearing Failure

Turbine wheel blade liberation leads to rotor

unbalance and thrust bearing failure Wheel
• Blade liberation due to HCF occurs first in 70% Unbalance
of failures
• Statistical assessment indicates random
failure mode
• Multi-faceted root cause investigation did not
identify definitive root cause
• Commercial support available from Honeywell
for confirmed radial bearing failures
Turbine Blade Rubbing

CFM recommends following SIL

D201505000040 (June 2015) Thrust
Bearing
Failure
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ATS Recommendations

CFM recommends incorporation of SB 80-0014/Honeywell SB

3505945-80-1861 to prevent output shaft decoupling

Radial Bearing failure found to be random

• Commercial support available for confirmed failures

Recommend incorporation of Category 5 SB 80-0016, New

Starter Clamp

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 HPTACC Valve

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HPTACC Valve Field Performance
CFM56-7B

No significant events driven HPTACC Valve Shop Findings

(Honeywell Shops Only) March 2016 - February 2017
by HPTACC Valve in last 12 60

months 50

40

Low time removals stable 30

~0.15% (12 month average) 20

10

Fuel leaks leading cause for 0

removals in last 12 months

Fuel Leaks are main contributor for D&Cs caused

by HPTACC Valve
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HPTACC Valve Recommendations
Fuel Leak Root Cause 
Compression set of primary static
seal
Leak Path
• Generally small leaks

HPTACCV Maintenance
Recommendations

• SB 75-0036R2: improved surface

finish, Turcon 19 seal, teflon anodize
• Overhaul at engine shop visit if time > HPTACCV Cross Section
10K hours per WPG
• Operators may consider tailored
program based on individual
experience

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 HMU

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 HMU Field Performance
HMU drove 17 significant CFM56-7B HMU
Findings at Shop Visit (2016)
events in last 12 months

• 10 Fault not confirmed (NFF)

• 2 confirmed (non-HMU & VSV
EHSV)
• 5 under investigation

Main shop findings

• Fuel Metering Valve (FMV)
• FMV Resolver

Low time removals stable

~0.73% (12 month average)
CFM maintaining focus on field events
despite stable removal rate

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HMU Recommendations

EHSV Filter Nickel Braze change completed

• Reference Honeywell SIL
• Service HMU in accordance with WPG workscopes & thresholds
applicable to P/N configuration

Adopt P16 configuration which contains all design

improvements

Determine maintenance interval based on own experience and

operational standard

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 Fuel Filter Clogging Indicator
(FFCI)

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New Fuel Filter Clogging Indicator

FFDPS reliability
• Dormant fault on high time switches
– SB 73-0192 Cat 2, soft time replacement @ 15k FH
• False alarms on ground and in flight causing D&C’s and
Interruptions
FFDPS replaced by FFCI
• Delta Pressure Switch technology replaced by transducer
technology on new Fuel Filter Clogging Indicator (FFCI)
– Transducer technology demonstrated high reliability
• Electrical power needed to supply FFCI
– New J8 harness with 1 extra wire in service since November 2014
– SB 73-0202 Cat 7, introduced in ESN 660560 and higher
– New J8 harness compatible for both FFDPS & FFCI
– Rework available in SB 73-0202

* no power supply – results in disagree fault

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FFCI released September 2016
Modified FFCI
New J8 harness 1st FFCI series entry into service
Entry into service In service evaluation for production and spares

Nov 2014 July 2015 Sept 2016

In-service evaluation
• 2 years experience with 1st FFCI series

FFCI entry into service

• SB 73-0218 Cat7 Issued September 2016
– > 700 units in service,
– 650,000 cumulated FH
– Fleet Leader > 6,000 FH
– 1 removal due to suspected sensor port clogging

FFCI demonstrating improved reliability

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 Summary

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Overall Summary

Air Turbine Starter, HPTACC Valve, HMU and FFCI

• No new failure modes identified
• Low time removals trend stable
• Reliability trend stable
• Majority of known failure modes addressed via technical or
commercial solutions

Maintenance Recommendation
• Observe WPG Test/Overhaul intervals for all LRUs

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 Thank You – Grazie

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