VBV System
Lisbon A320/CFM56-5/5B Focus Team Conference
June 2012
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Background
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Fleet data
VBV issue can lead to operational events including ATB & ATO
9 ATOs & 9 ATBs on the 5B fleet through May 2012
Fleet disruptions related to EGT shift, Compressor Vane E/W or fuel
leak at the gear motor location
Main on-wing discrepancies reported
Ball screw actuators (master or slave actuators) hard to rotate
Stop mechanism seized
Flex shaft (main or slave) broken
Gear Motor
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Distribution of removed components
Detail of component removals
5A/B engines
Based on data supplied to CFM since 2009
Gear Motor, Stop Mechanism and Flexshafts are the most removed VBV
components
About 85% of the total removals
VBV components removed since 2009 (Quantity)
180
160
140
120
100
80
60
40
20
0
Gear motor Flex Shaft Stop mec RVDT Slave Act Master Act Main flexshaft
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VBV system event contributors 2011
Rpartition
Defective par cause
components racine
( 2011 events)
(quantit ; pourcentage)
Quantity; percentage
5; 10%
5; 10% 13; 25% Gear Motor
5; 9% Stop Mechanism
Flexible Shaft
12; 23% Slave Actuator
12; 23%
Position Sensor
Master Actuator
Gear Motor, Stop Mechanism and Flex shafts contribute to 71% of the VBV
related events
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Analysis
Stop mechanism
CFM/Honeywell Root Cause analysis on-going
Major observations from investigations:
Nut seized on screw
Fretting damage to screw threads
Bearings difficult to rotate / seized
Significant Lack of grease
Flexible shaft
Typically a secondary damage of ballscrew actuators hard to rotate
Several cases reported without findings on the other VBV components
Gear motor
suffering from the kinematics getting harder to actuate, also from pollution within the fuel.
CFM additional preventive maintenance recommendation:
CFM recommends to apply the SB 75-0043 - regreasing of master and slave
actuators - to relief VBV system.
Re-greasing procedure will improve the VBV system kinematics
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Regreasing procedure of Master and Slave actuators
SB 75-0043
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7 7
Ballscrew on-wing regreasing procedure SB 75-0043
On-wing regreasing procedure
Approved & Issued early May 2012
Master and slave ballscrew actuators concerned
Regreasing reduces the actuation torque of the complete VBV system
Full efficiency if 1st regreasing prior to 3000FH then every 3000FH
Appropriate tooling supplied by Honeywell
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Ballscrew on-wing regreasing procedure SB 75-0043
Procedure sequence
Get access to VBV doors (11 slaves & 1 master)
Prepare Mobil 28 grease hand pump
Localize grease fitting hole of each door & clean it
Apply 0,1 Oz (2,8 g) via the grease fitting hole
Actuate VBV system from 2 Oclock door at least 3 times
open / close to distribute grease into ballscrews make
sure system operates smoothly & freely
Perform RVDT rigging & MCDU check
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Ballscrew on-wing regreasing procedure SB 75-0043
Procedure feedback (tested with operators in April 2012)
Doors near 12 oclock position are the most difficult to get access to. If possible thrust
reverser cowls should be fully deployed
Mirror shall be used in this area
Amount of grease shall be measured pending on customer own tooling
4 hours with 2 mechanics
Mirror to help fitting
greasing hole
Greasing gun
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Regreasing experience
TAM Fleet: 184 Engines
2000 FH to 22000 FH
Implemented the regreasing procedure via Engineering
Order 2 years ago into their Fleet ( 2000- 22000FH)
No VBV-ballscrew-event reported since.
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Regreasing experience
CFM would like to thank all operators for their
support during the development of this procedure
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Troubleshooting improvements
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13 13
Troubleshooting modifications
Objective: Improve the on-wing troubleshooting in case of VBV issue
Current Operate VBV manually Proposal draft Remove GM/SM assy
Check resistance Hard to rotate? replace Operate SM/ freely?
/ RVDT/J8/HMU N
Y replace Operate GM/ freely?
Remove/Insp/replace flexshafts
damaged Inspec Main flexshaft
Operate each VBV slave doors T/S Gear motor & Operate VBV with tooling at Master
manually/ replace any suspect door position/ mesure the torque
Stop mechanism
Remove GM/SM assy
first Under
Evaluation
Check resistance Torque > CMM
/ RVDT/J8/HMU N limit?
replace Operate GM/ freely?
Y
replace Operate SM/ freely? Remove/Insp/replace flexshafts
damaged
replace Operate master door/ freely?
Operate each VBV slave doors
manually/ replace any suspect
Inspec Main flexshaft
New T/S will reduce the time needed by testing of gear motor and stop
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Troubleshooting modifications
Perform T/S of Gear Motor and Stop Mechanism as first T/S operations
Main advantage :
First component inspected are the most removed one decreasing the time
spent for T/S
Development of a system torque check
procedure (after removal of GM and SM)
Introduction of a torque key in the Master
ballscrew Socket to measure the actuation
torque of the system
Maintenance Torque limits to be defined
Maintenance limits defined and to be
substantiated
Trouble Shooting procedure update expected 4Q12
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Maintenance proposition to reduce VBV system
related events
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>>
This document is a Bullet Point presentation. It may be misinterpreted without the proper comments from an appropriate CFM representative.
CFM International Proprietary Information subject to the restrictions on the cover of this presentation
CFM, CFM56, LEAP56, LEAP-X and the CFM logo are trademarks of CFM International, a 50/50 joint company between Snecma and GE
16 16
Fleet status, prediction and go forward
Based on above Weibulls, CFM evaluates a soft time for the VBV system
at 15,000hrs, 2nd C-check
No Maintenance
Overhaul at SV
Soft time
implementation
10,000 hrs /15,000 hours
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Fleet status, prediction and go forward
Introduction of soft time scheduled for sept. 2012
Service Bulletin Cat. 7
Pending efficiency of re-greasing procedure, CFM propose implementation of
15,000 hrs threshold for VBV System Preventive Maintenance
Recommendation to be updated with CFM56-5B fleet re-greasing feedback
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Summary
CFM recommends VBV system overhaul at SV (SB 75-0032, cat 3)
CFM recommends application of re-greasing to the ball screw actuators
using SB 75-0043, cat 7
CFM proposes a modification to the VBV system Trouble shooting.
Available by 4Q12
Based on actual and predicted fleet data, CFM recommends a soft time at
15000 hours, in order to decrease the amount of VBV system related
events
Availability by September 2012
to be updated with CFM56-5B fleet re-greasing feedback
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QUESTIONS / DISCUSSION
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CFM, CFM56, LEAP56, LEAP-X and the CFM logo are trademarks of CFM International, a 50/50 joint company between Snecma and GE 20
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, General Electric and Snecma, Safran
group 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
This document is a Bullet Point presentation. It may be misinterpreted without the proper comments from an appropriate CFM representative.
Lisbon CFM56-5ABC Focus Team June 2012 CFM International Proprietary Information subject to the restrictions on the cover of this presentation
CFM, CFM56, LEAP56, LEAP-X and the CFM logo are trademarks of CFM International, a 50/50 joint company between Snecma and GE 21
