發動機維修 - caa.gov.t 動機維修.pdf · PDF fileEngine Condition Monitor Program ... 0 500 1000 1500 2000 2500 3000 3500 4000 4500 cycle EGTM EGTM vs Cycle ... SN TSN CSN

發動機維修發動機維修發動機維修發動機維修

提報單位提報單位提報單位提報單位 : : : : 華航修護工廠華航修護工廠華航修護工廠華航修護工廠發動機修護部發動機修護部發動機修護部發動機修護部

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� 一一一一、、、、發動機維修管理發動機維修管理發動機維修管理發動機維修管理� Engine Removal時機

� On- Condition Maintenance

� 二二二二、、、、發動機進場計畫發動機進場計畫發動機進場計畫發動機進場計畫

� 三三三三、、、、發動機發動機發動機發動機 Off-Wing Work scope� 四四四四、、、、經驗交流經驗交流經驗交流經驗交流� HPC Rotor Tip Clearance Control(CFM56-5C)

內容:

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發動機維修管理發動機維修管理發動機維修管理發動機維修管理

�Fly To FailureEngine removal only occurs following a significant engine failure event.

�Hard TimeEngine removal are scheduled before the fixed limit is reached.

�Soft Time(off-wing)The recommended maintenance interval when the engine is in

the shop for an unrelated cause. This requires threshold changesbased on threshold inspection.

�On-ConditionThe most cost effective concept based on continuous

inspections, measurement and testing to determine the condition of the engine.

�Engine Removal 時機時機時機時機:

Removal Fail

Removal

FailRemoval

FailRemoval

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�ON-WING ENGINE

� Engine Condition Monitor ProgramEngine Condition Monitor Program

�OFF-WING ENGINE

� Engine Maintenance Program(EMP)Engine Maintenance Program(EMP)

• 定義定義定義定義 module/ 附件的維修時距附件的維修時距附件的維修時距附件的維修時距

• 定義不同維修層級定義不同維修層級定義不同維修層級定義不同維修層級

• 可靠性控制計畫可靠性控制計畫可靠性控制計畫可靠性控制計畫

發動機維修管理發動機維修管理發動機維修管理發動機維修管理

�On-Condition Maintenance

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�Removal reason:

0

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Perform

ance R

estorat

ion

HPT Blade

HPC Blade

#4 Beari

ngLLP

Customer C

onvenience

Combusto

r Dist

ressFOD

Under inve

stigatio

n

LPT Blade

AGB Dam

age

Cause

Qty

�CFM56-5C4�CFM56-7B

發動機進場計畫發動機進場計畫發動機進場計畫發動機進場計畫

�統計機隊主要造成發動機進場原因統計機隊主要造成發動機進場原因統計機隊主要造成發動機進場原因統計機隊主要造成發動機進場原因�Hours/cycles Hours/cycles Hours/cycles Hours/cycles

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�Removal reason:

�CF6-80E1�CF6-80C2


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�進場時間進場時間進場時間進場時間::::�分析發動機可能進場時間分析發動機可能進場時間分析發動機可能進場時間分析發動機可能進場時間

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�進場計畫進場計畫進場計畫進場計畫::::�依進場時間依進場時間依進場時間依進場時間,,,,排定排定排定排定////預測進場計畫預測進場計畫預測進場計畫預測進場計畫�年度計畫年度計畫年度計畫年度計畫////長期計畫長期計畫長期計畫長期計畫�review/review/review/review/修訂修訂修訂修訂

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�Staggering plan:Staggering plan:Staggering plan:Staggering plan:�離峰離峰離峰離峰////高峰調控高峰調控高峰調控高峰調控�Spare engineSpare engineSpare engineSpare engine

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ModuleModuleModuleModule維修維修維修維修Threshold Threshold Threshold Threshold 時間時間時間時間

發動機發動機發動機發動機offoffoffoff----wingwingwingwing維修管理維修管理維修管理維修管理

OnOnOnOn----Wing Wing Wing Wing 發動機情況發動機情況發動機情況發動機情況監控趨勢數據監控趨勢數據監控趨勢數據監控趨勢數據

機長及線上維修報告機長及線上維修報告機長及線上維修報告機長及線上維修報告

試車台測試試車台測試試車台測試試車台測試單元分析單元分析單元分析單元分析

OnOnOnOn----Wing Wing Wing Wing 內視鏡檢內視鏡檢內視鏡檢內視鏡檢查報告查報告查報告查報告

壽命件壽命件壽命件壽命件(LLP)(LLP)(LLP)(LLP)

其他因素考量其他因素考量其他因素考量其他因素考量((((場修時間場修時間場修時間場修時間, , , , 成本等成本等成本等成本等))))

適航指令適航指令適航指令適航指令警戒級服務通告警戒級服務通告警戒級服務通告警戒級服務通告一般服務通告一般服務通告一般服務通告一般服務通告

�考慮因素考慮因素考慮因素考慮因素:

發動機發動機發動機發動機 Off-Wing Work scope

Removal ReasonRemoval ReasonRemoval ReasonRemoval Reason

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� OnOnOnOn----Wing Wing Wing Wing 發動機情況監控趨勢數據發動機情況監控趨勢數據發動機情況監控趨勢數據發動機情況監控趨勢數據((((EHM trend report format)

EGT FF N1 N2 Other Parameters:•De-Rate•Oil pressure•Vib•…….


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�EGTM monitoring

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0蚓

5蚓

10蚓

15蚓

20蚓

25蚓

30蚓

35蚓

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45蚓

50蚓

55蚓

60蚓

65蚓

70蚓

75蚓

80蚓

85蚓

90蚓

0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000

Time on wing (EFH)

Tes

t Cel

l EG

TH

DM

(蚓蚓蚓蚓

)

Test Cell EGTHDM Vs TSSV - 207 SV Data Points

1 Typical CFM deterioration curve

In-House O/H (Ave TOW = 11,303 hrs)Out-Sourced O/H (Ave TOW = 14,590 hrs)

�EGTM monitoring

發動機發動機發動機發動機 Off-Wing Work scopeEGTM

EGTM

EGTM

EGTM

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B1F EGTM deterioration

0

10

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90

100

0 500 1000 1500 2000 2500 3000 3500 4000 4500

cycle

EG

TM

EGTM vs Cycle

指數 (EGTM vs Cycle)


�EGTM monitoring

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B1F EGTM deterioration

0

10

20

30

40

50

60

70

80

90

100

0 5000 10000 15000 20000 25000 30000

Hours

EG

TM

EGTM vs Hours

指數 (EGTM vs Hours)


�EGTM monitoring

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�OnOnOnOn----Wing Wing Wing Wing 內視鏡檢查報告內視鏡檢查報告內視鏡檢查報告內視鏡檢查報告


�OnOnOnOn----wingwingwingwing�Incoming InspectionIncoming InspectionIncoming InspectionIncoming Inspection

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�OnOnOnOn----Wing Wing Wing Wing 內視鏡檢查報告內視鏡檢查報告內視鏡檢查報告內視鏡檢查報告


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�AD/SB


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�試車台測試單元分析試車台測試單元分析試車台測試單元分析試車台測試單元分析::::TEST CELL TEST CELL TEST CELL TEST CELL ---- Watch ListWatch ListWatch ListWatch List


�InInInIn----bound testbound testbound testbound test�OutOutOutOut----bound testbound testbound testbound test

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�ModuleModuleModuleModule維修維修維修維修

FAN module EGT restored HPC module EGT restoredfan blade tip clearance -0.9 CDP seal clearance 4.7fan blade L/E erosion -0.8 4R vent seal 1fan surface finish -0.67 blade-to-case clearance 3.8fan blade pitting -0.12 vane-to-spool clearance 2.48fan blade dirt -0.35 airfoil surface 10.2splitter erosion -0.06 mini-nozzle 1OGV L/E erosion -0.06 5R vent seal 0.8booster airfoil surface finish 0.3 total: 23.98booster shroud erosion 1 LPT module EGT restored total: -1.66 tip clearance 1.58HPT module EGT restored vane airfoil surface 4.41STG-1 blade tip clearance 5.2 blade airfoil surface 3.81STG-2 blade tip clearance 2.6 total: 9.8interstage seal clearance 0.9 HPT-1 nozzle EGT restoredairfoil surface 6.19 airfoil surface 3.21 total: 14.89 A4 area 1.27

total: 4.48EGTM effect for each module ( for overhaul status, unit: Deg C)

module EGTM effect(%)FAN-3%

HPC46%

HPT29%

HPT-1 NZl9%

LPT19%


�Performance effectPerformance effectPerformance effectPerformance effect

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PW4056 Maintenance ProgramModule \ Work scope Recommended average

Cycle/Hours (Soft)Major Performance, Operability, and/or

Durability Improvements

Fan Blades/LPC Module 5,000/20,000EGT margin +3°C; Cruise TSFC –0.8%to –1.3%; N1 margin +1.2% to 1.7%

Fan Case/Intermediate Case 5,000/20,000 Maintains case durability and sufficientsurge margin.

HPC Module 5,000/20,000EGT margin +10°C; Cruise TSFC +1.0;LPC surge margin 2.0%; HPC surge andimprove TSFC.

Diffuser and Combustion/Turbine Nozzle Vane

4,000/16,000Ensures the integrity of the diffuser case.Restores gaspath surface and improvesTSFC.

HPT Module 4,000/16,000

Protects against HPT 1st Stage bladefracture. Improves HPC surge margin; EGTmargin +20°C; Cruise ; Cruise TSFC –1.5%to –2.0%

LPT Module 4,000/16,000 EGT margin +3°C; Cruise TSFC –0.2%to –0.8%

Turbine Exhaust Case 4,000/16,000Ensure adequate oil flow to NO.4 bearingcompartment and adequate scavenging ofthe compartment.

AGB Module5,000/20,000

MGB Module 5,000/20,000


�ModuleModuleModuleModule ThresholdThresholdThresholdThreshold�OEM dataOEM dataOEM dataOEM data�OperatorOperatorOperatorOperator’s experiences experiences experiences experience

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�ModuleModuleModuleModule ThresholdThresholdThresholdThreshold

Module \ Work Scope Performance Full OverhaulFan/Booster Module On Condition 24000 H /6000 CFan Rotor On Condition 10000 H/2500 CFan Stator On Condition On ConditionHPC Module 8000 H/2000 C 24000 H/6000 CCRF Module 12000 H/3000 C 24000 H/6000 CCombustor Module X 16000 H/4000 CHPT Stage 1 Nozzle 8000 H/2000 C 16000 H/4000 CHPT Stage 2 Nozzle 8000 H/2000 C 16000 H/4000 CHPT Rotor 8000 H/2000 C 16000 H/4000 CLPT Module On Condition 24000 H/6000 CAccessory Drives Module On Condition 36000 H/9000 C

CF6-80C2 Engine Maintenance Guide

Component Bench OverhaulMEC 6,000 hours 18,000 hours MFP 18,000 hours

Fuel Nozzles Concurrent with HPC orHPT Overhaul

Fuel and Control

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�LLPLLPLLPLLP�Stub lifeStub lifeStub lifeStub life

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�HPC Rotor Tip Clearance Control(CFM56-5C)�Low on-wing Time:China Airlines shop out experienced HPC blades tip rub issues since Jun, 2010

�Routine BSI � UER

�Tip corner “half-moon” shape material missing

�signature of tip rubbing

經驗交流經驗交流經驗交流經驗交流

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Inst Date Rem DTOFFSN TSN CSN TSI CSI Reason

19-Jun-10 23-Jun-10 A 34767 6362 34 6HPCS3B tip coner missing(N2 seized,blade damaged)

23-Apr-10 13-Aug-10 B 39575 7240 1497 206 HPCS3B tip coner missing(STG 3)26-Jun-00 20-Sep-10 C 36960 6507 8439 1587 HPC blades damage(STG 5/6/8/9)10-Aug-09 27-Sep-10 D 39209 6939 5218 870 HPC blades damage(STG 4)13-Mar-09 20-Sep-10 E 33303 5946 6961 1174 HPC blades damage(Stg 3 & 8 blades)

�Five engines removed due HPC blades tip rubs in 4 months

�spare engine support crisis


�遠低於遠低於遠低於遠低於SVSVSVSV後的預期後的預期後的預期後的預期onononon----wingwingwingwing時間時間時間時間

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02468101214

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Defect

Perc

ent

Coun

t

ParetoChart forDefectname

Low PerformanceHPC bld damage Staggering Nacelle Temp HighT/S


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120

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ance R

estora

tion

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HPC Blade

#4 Bearin

gLLP

Customer C

onvenience

Combustor D

istress

FOD

Under inve

stigatio

n

LPT Blad

e

AGB Damag

e

Cause

Qty

1.Performance Restoration

2.HPT Blade

�Engine removal causeEngine removal causeEngine removal causeEngine removal cause與機隊預期之主要與機隊預期之主要與機隊預期之主要與機隊預期之主要趨勢不符趨勢不符趨勢不符趨勢不符

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0.0000

0.0050

0.0100

0.0150

0.0200

0.0250

0.0300

0.0350

0.0400

0.0450

Nov

-09

Dec

-09

Jan-

10

Feb-

10

Mar

-10

Apr-

10

May

-10

Jun-

10

Jul-1

0

Aug-

10

Sep-

10

Oct

-10

Fleet Basic CAL Basic Fleet Total CAL Total

CAL vs. Fleet CFM56-5C Unplanned Removal Rate12 Month Average

�UER/SV rate UER/SV rate UER/SV rate UER/SV rate 劇增劇增劇增劇增


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�原因探討原因探討原因探討原因探討::::

� Blade-to-case land 間隙太小

� High Vib (Not likely from pure vibration, since corner loss is not widespread)

Tip corner loss在production engine中是已知的 HPC blade損傷形式 (using target grind)

Tip corner loss 可能發生在 HPC stages 1-6,通常在stages 2-4

� 在production engine上增加在HPC STG 3 的間隙0.005”(0.127mm) (minimize tip distress)

�CFM Experiences


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CFM56-5C HPC tip clearance & BSI reportENG S/N 567149567149567149567149 567116 567111567111567111567111 567114567114567114567114 567132 567115567115567115567115 567117567117567117567117 567222 567130 567119567119567119567119

Inst date Aug 18 2009 Sep 02 2009 Oct 05 2009 OC T 26 2009 NOV 24 2009 AP R 23 2010 J UN 22 2010 FEB 23 2010 MAR 23 2010 J un 21 2010

HPC OH OH OH OH OH OH OH PR OH OH

blade length limit(in.) Perf by CAL CAL CHOL CHOL CAL CAL CAL CAL CAL CAL

1 11.8656 11.8680 11.8777 11.8760 11.8714 11.8776 11.8775 11.8787 11.8783 11.8760

2 11.1420 11.1430 11.1517 11.1500 11.1460 11.1527 11.1527 11.1496 11.1529 11.1492

3 10.6589 10.6620 10.6680 10.6660 10.6644 10.6693 10.6689 10.6691 10.6697 10.6672

4 10.2622 10.2670 10.2715 10.2690 10.2687 10.2742 10.2739 10.2735 10.2747 10.2697

5 9.9555 9.9570 9.9625 9.9600 9.9577 9.9649 9.9641 9.9635 9.9644 9.9604

6 9.7131 9.7070 9.7106 9.7100 9.7116 9.7144 9.7118 9.7114 9.7128 9.7096

7 9.5939 9.5910 9.5936 9.5930 9.5917 9.5939 9.5923 9.5918 9.5933 9.5911

8 9.5179 9.5160 9.5180 9.5180 9.5176 9.5170 9.5177 9.5174 9.5184 9.5170

9 9.4896 9.4900 9.4903 9.4900 9.4904 9.4918 9.4900 9.4891 9.4905 9.4900

32 flow path limit(in.) Perf by SRT CHOL CHOL CHOL CHOL CHOL CHOL CHOL CHOL CHOL

1 11.923-11.940 11.9220 11.9230 11.9320 11.9310 11.9260 11.9320 11.9315 11.9330 11.9326 11.9300

2 11.186-11.204 11.1850 11.1860 11.1940 11.1930 11.1880 11.1960 11.1949 11.1920 11.1952 11.1910

3 10.684-10.701 10.6830 10.6840 10.6910 10.6890 10.6870 10.6920 10.6913 10.6920 10.6921 10.6900

4 10.300-10.319 10.2990 10.3010 10.3060 10.3050 10.3030 10.3090 10.3079 10.3080 10.3086 10.3050

5 9.982-9.999 9.9820 9.9830 9.9890 9.9870 9.9840 9.9910 9.9894 9.9890 9.9897 9.9870

33 flow path limit(in.) Perf by SRT CHOL CHOL CHOL CHOL CHOL CHOL CHOL CHOL CHOL

6 9.741-9.754 9.7490 9.7430 9.7450 9.7450 9.7460 9.7480 9.7461 9.7460 9.7468 9.7450

7 9.621-9.633 9.6270 9.6220 9.6250 9.6250 9.6240 9.6250 9.6236 9.6240 9.6248 9.6240

8 9.544-9.557 9.5500 9.5480 9.5480 9.5480 9.5480 9.5480 9.5476 9.5480 9.5484 9.5480

9 9.517-9.527 9.5260 9.5230 9.5220 9.5220 9.5220 9.5230 9.5213 9.5210 9.5216 9.5220

tip clearance limit(in. )

1 0 . 0540 0.0564 0.0550 0.0540 0.0550 0.0546 0.0550 0.0540 0.0543 0.0543 0.0540

2 0 . 0420 0.0430 0.0430 0.0420 0.0430 0.0420 0.0430 0.0420 0.0424 0.0423 0.0420

3 0 . 0220 0.0241 0.0220 0.0220 0.0230 0.0226 0.0230 0.0220 0.0229 0.0228 0.0230

4 0 . 0340 0.0368 0.0340 0.0350 0.0360 0.0343 0.0350 0.0340 0.0345 0.0339 0.0350

5 0 . 0250 0.0265 0.0260 0.0260 0.0270 0.0263 0.0260 0.0250 0.0255 0.0253 0.0270

6 0 . 0340 0.0359 0.0350 0.0350 0.0350 0.0344 0.0340 0.0340 0.0346 0.0340 0.0350

7 0 . 0310 0.0331 0.0310 0.0310 0.0320 0.0323 0.0310 0.0310 0.0322 0.0315 0.0330

8 0 . 0300 0.0321 0.0310 0.0300 0.0300 0.0304 0.0310 0.0300 0.0306 0.0300 0.0310

9 0 . 0310 0.0364 0.0320 0.0310 0.0320 0.0316 0.0310 0.0310 0.0319 0.0311 0.0320

�Task force 成立成立成立成立

�GEGEGEGE以以以以6 6 6 6 sigmasigmasigmasigma方式探討方式探討方式探討方式探討�Review Rotor/stator Review Rotor/stator Review Rotor/stator Review Rotor/stator grindinggrindinggrindinggrinding尺寸尺寸尺寸尺寸


�Rotors & stators Rotors & stators Rotors & stators Rotors & stators 匹配研磨匹配研磨匹配研磨匹配研磨

�Rotors & statorsRotors & statorsRotors & statorsRotors & stators由由由由不同不同不同不同shopshopshopshop研磨研磨研磨研磨////量測量測量測量測

量測值皆在規範內量測值皆在規範內量測值皆在規範內量測值皆在規範內

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M CID

�就就就就“match grind” 經驗經驗經驗經驗,大部分大部分大部分大部分MRO多以此方式多以此方式多以此方式多以此方式

完成但只有少數發生完成但只有少數發生完成但只有少數發生完成但只有少數發生

tip corner loss.

�以此高發生率情況以此高發生率情況以此高發生率情況以此高發生率情況, 顯顯顯顯示在示在示在示在CAL工廠的工廠的工廠的工廠的HSG 量測應有誤差量測應有誤差量測應有誤差量測應有誤差.

A

Chi-Square Test Hypotheses:

Ho: All groups the same

Ha: At least one different

Group Count N Expected Chi-sqCAL 5 28 0.311 70.742

Others 7 1053 11.689 1.881Totals--------> 12 1081

72.623 <-------Chi-Sq

df---> 1 3.841 <---------Critical Chi-Sq

0.000 <--------- p-value

�HPC Tip Rub event Chi-Square Test


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�Possible root causes identified/containment program

� HPC case measurement- MRO 僅量測僅量測僅量測僅量測 12 points , GE 建議量測建議量測建議量測建議量測72 points- ESM 修訂修訂修訂修訂, 要求至少要求至少要求至少要求至少 24 points

� Rotor measurement- Review HSG procedures- Machine calibration interval- 發現雷測量測感應器惡化發現雷測量測感應器惡化發現雷測量測感應器惡化發現雷測量測感應器惡化

� ESM tip clearance calculation check- ESM 要求研磨要求研磨要求研磨要求研磨minimum clearance( rotor- to- stator), “match grinding”- PSE suggest open up 0.002” to accommodate some measurement system issues

M CID A


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IMD A C

�Implementation & Control

Implementation Time Quality Cost

Add wax check procedure

Measure HPC case at 72pointsCalibrate HSG by masterrotor every timeOpen tip clearance by 0.002”


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�Cost Saving� According to CAL SV schedule, there will be 10 SV in next 12

months

�UER cost : USD 15,000)

�HPC repair cost : USD 30,000/each

�Total saving is 10 X USD 45,000 = USD 450,000(per year)


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�EGTM 影響探討影響探討影響探討影響探討 (Quality):


0

10

20

30

40

50

60

70

A B C D E F G H I J K L M N O P Q R S T U

Open clearance

45 C°°°° 42 C°°°°

謝謝謝謝謝謝謝謝

Documents

發動機維修 - caa.gov.t 動機維修.pdf · PDF fileEngine Condition Monitor Program ... 0 500 1000 1500 2000 2500 3000 3500 4000 4500 cycle EGTM EGTM vs Cycle ... SN TSN CSN