CFMOilDebris PDF

SAA
DIR:-10164377
Field Guide for

Lubrication System Debris
Airbus Programs
CFM56-5A CFM56-5B CFM56-5C
Tool Number: GEK 119194

November 2012
Basic
About this guide
This guide is to aid Operator Line Maintenance Personnel with

the identification of lubrication system debris on CFM56
Engines.
Engine specific limitations and acceptance or non-acceptance
criteria are only found in the Engine Manuals and/or Aircraft
Maintenance Manuals.
CFM International / 3
CFM Proprietary Information is subject to restrictions
CFM56 Proprietary Information

CFM, CFM56, LEAP and the CFM logo are trademarks of CFM
International, a 50/50 joint company between Snecma (Safran
group) and GE. 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, 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.
Table of contents
6
Introduction
Contact information
10
Handling, collection and inspection
15
Magnetic sensor quantification
17
Scavenge screen quantification
20
CFM MCD inspection guidelines
25
Debris identification
60
Definitions
66
Appendix
Bearing cross-sections
Turbine jet engine oil identification
Scale
Introduction
This guide is intended exclusively for the owners and operators
of CFM56 aero turbo machinery. It has been prepared as a guide
for use in the analysis of debris collected from or generated by
the lubrication system of these engines. The purpose of this
guide is to enable quick and accurate identification of
contaminates and debris material.
The visual identification of debris is a valuable skill, but can not
substitute for laboratory analysis to confirm material
identification.
The data presented here does not supersede or replace any FAA
approved documents. This document and the material within it
are subordinate to Aircraft and Engine Maintenance Manuals.
Hardware location
Hardware location is not included for all debris noted. This guide
is produced for multiple CFM engine lines and material from one
engine location may not correspond to a different engine.
Additionally, in the future hardware may be redesigned with
different materials.
Introduction (cont.)
Debris acceptability/serviceability
Some debris may be acceptable to one engine model, but not to
another. Additionally, Engine and Aircraft Maintenance Manual
limits are subject to change. Refer to applicable AMM
Failure mode determination

Determination of failure mode (or root cause) can be difficult.
While certain failures leave clear evidence, many others are
difficult to identify. This guide has included some failure mode
data, but determining root cause often requires information from
many sources not just debris.
Updates to this guide

This guide will be updated and new versions will be published
periodically. Suggestions and recommendations are welcome. If
you have suggestions or interesting debris photos, please contact
the CFM Customer Support Center with your comments. The CSC
will help collect this information for inclusion in the next updated
guide.
Contact information
If assistance is needed with this guide or with material

identification, please contact:
Customer Support Center (CSC)

CFM56 Infrastructure CFM56 Aviation
USA telephone: 1 (877) GEAE-CSC or 1 (877) 432-3272
International telephone: 1 (513) 552-3272
Email: geae.csc@ae.ge.com
This guide is produced by CFM Product Support Engineering
Debris collection
Collection of debris is primarily accomplished via magnetic
detectors and/or scavenge screens. See AMM for proper
assembly and disassembly techniques.
If debris is found, proper tracking and collection is critical to
determining which hardware needs to be inspected or replaced.
Handling, collection and inspection

Debris can be difficult to locate and easy to misplace. In some
cases, oil may be toxic or dangerous. For these reasons, CFM56
recommends the use of specific tools to aid in the safe and
proper handling of debris. Included on the next few pages are
some examples of the tools and tips used by CFM56
professionals to handle, collect and inspect debris.
Note: Visually inspecting debris while it is in the filter is not
recommended. Back-flushing of filter or cutting open per
approved procedures to aid visual identification is preferred.
Oil sampling guidelines

Use a clean glass or plastic
container for oil samples.
Label the container with the

name of the operator, engine mode,
engine serial number, the sample
date and the name of the oil
in use.
If possible, take the sample within
30 minutes of shutdown.
Clean dirt from the outside of the
sampling port prior to taking sample.
Do not sample the initial 20 ml of oil. If
possible, take the sample from the middle, center of the tank.
Preferable minimum sample quantity is 120 ml (which equals

4 oz or cup).
Do not use a funnel that is contaminated, unless it was
thoroughly cleaned with alcohol (or other solvent).
Leave some air in the container for expansion of the sample
during shipping.
Put strong tape over the gap between the container and its lid
to prevent spillage.
Debris collection tools

Collection tools may include tweezers, petri dishes, dowels and
special one-sided tape. Utilization of sterile tools reduces the
likelihood of contamination and improves the accuracy of
laboratory analysis.
Note: Utilizing office, transparency or other tapes is not
recommended because laboratory analysis requires dissolving
the tape which takes time and requires the use of stronger
chemicals. Specially designed carbon tabs are recommended.
Carbon tabs with backing removed

Debris inspection tools

10X (or higher) magnification is recommended, but not always
needed. This photograph shows three suitable examples of
magnifying devices that may be valuable to line maintenance
personnel.
A magnet may also be valuable for identifying the magnetic
properties of debris.
Field magnetic sensor collection
CFM56 strongly recommends sending debris to certified

laboratories for identification; however, the following steps may
be followed if field data is needed and/or if laboratory analysis is
not possible.
Note date, aircraft, engine number/position and chip detector
prior to removing debris.
Lightly press carbon tabs to debris on sensor.

Under controlled conditions, remove debris from carbon tabs
and degrease debris.
Use sieves to determine debris size. If sieves are not available,
place debris on grid and take high-resolution photographs
Note quantity and size of debris.

Refer to Engine and Aircraft Maintenance Manuals for
disposition.

Shoulder wear
This relative scale can be utilized when communicating magnetic
sensor debris levels.
Note: These photographs depict one type of sensor. Different
engine models may have differently shaped sensors.
5

Spall wear
This relative scale can be utilized when communicating magnetic
sensor debris levels.
Note: These photographs depict one type of sensor. Different
engine models may have differently shaped sensors.
5
Scavenge screen quantification

This relative scale can be utilized when communicating screen
debris levels.
Note: Different engine models will have screens of different sizes
and shapes.
5
General characteristics and appearance

Debris identification
The following pages show a range of debris; some of which is
rarely found, but is included for comprehensiveness.
The first two pages of photos (which show debris from events)
are included to help illustrate differences between what may be
seen on the flight line versus what is extracted in a laboratory.
This is followed by photos of magnetic and then non-magnetic
debris.
Appearance descriptions are also provided. Each material is
described as metallic or non-metallic followed by the descriptors
that most readily identify the debris.
Bearing information
The primary objective of debris identification is for the detection
of bearing distress prior to failure. Any bearing debris
identification, either visually or by laboratory analysis, is cause
for immediate concern. The following visual characteristics can
be helpful in distinguishing bearing material.
Many chips of similar size and shape

Magnetic material
Smooth, reflective (silvery) surface on one or both sides
Roughly circular or elliptical flakes, thinner around edges
Material that is hard and brittle
Metal chunks as small dark irregular particles

Pieces of bearing cage material
Chunks of silver plated steel
CFM MCD inspection guidelines

The decision for action must be driven by key factors:
Debris Examination
Visual aspect (shape, color, plated or not, laminated )
Nature (magnetic or non-magnetic)
Size, quantity
Oil sump source
Engine history
Low time/cycle engine since new or overhaul
Recent engine squawks
Maintenance report (past MCD findings, oil circuit
contamination )
Engine trend shift (vibes, oil consumption )
References
Applicable Aircraft Maintenance Manual
CFM56 Non-Destructive Test Manual
Part 10 Chip Analysis (CFMI-TP-NT.11)
CFM MCD guidelines

for magnetic particles
When particles are just collected, visual inspect per 10x
magnifying lens to identify the category
Satisfactory - Serviceable
Marginal - Means continue in services while debris are sent to Lab
Unsatisfactory - Immediate action is required
CFM MCD guidelines

AMM satisfactory conditions
Magnetic serviceable conditions
Particles within this table, dont need to be sent for analysis
Machined chips are serviceable whatever the size
CFM MCD guidelines

AMM Non-Serviceable conditions:
Magnetic material - non-serviceable conditions
When particles are caught on the EMCD, its recommended to
install the the Mag Bars to isolate the concerned sump
See additional recommendations on next slide
CFM MCD guidelines

AMM Non-Serviceable conditions
Magnetic material - non-serviceable conditions
These descriptions are applicable for material collected in the
Scavenge Screens or after installation of the Magnetic Bars for
each sump
Examples of bearing shoulder

wear distress
mm
mm
20
20
16
16
12
12
0
.25
.5
.75
mm
mm
20
20
16
16
12
12
.25
.5
.75
.25
.5
.75
0
.25
.5
.75
Examples of bearing spall distress

mm
mm
20
20
16
16
12
12
0
.25
.5
.75
mm
mm
20
20
16
16
12
12
.25
.5
.75
.25
.5
.75
0
.25
.5
.75
M50NiL
General characteristics
Magnetic
Representative photo - quantity and appearance may vary
20 mm
16 mm
12 mm
8 mm
4 mm
0.25
0.5
0.75
M50
Magnetic
Appearance
Metallic
Small flakes and/or powder
Dull
Dark color
1 mm
1 mm
Bearing spall chips

Magnetic
Appearance
Metallic
Flakes
Flattened
Oval
Ragged edges
Coined
Smooth/reflective
on one side, dull on
the other
20 mm
16 mm
12 mm
8 mm
4 mm
0.25
0.5
0.75
Gearbox debris
Magnetic
Appearance
Metallic
Flakes
Sharp
Reflective
Irregular
20 mm
16 mm
12 mm
8 mm
4 mm
0.25
0.5
0.75
#2 bearing nut spirolock

Magnetic
Appearance
Wire
1 mm
5 mm
Forward sump air/oil separator

Non-magnetic
Appearance
Resin polyamide material (green or brown color)
1 mm
1 mm
Forward sump abradable

Non-magnetic
Appearance
Phenolic or plastic material (greenish-white color)
1 mm
1 mm
Bearing air/oil seal abradable

Non-magnetic
Appearance
Glass fiber with polyamide material with grooves

Reddish brown non-metallic
1 mm
1 mm
AGB/TGB keylock from insert

Non-magnetic
Appearance
Flat piece with castellated portion
1 mm
1 mm
AGB bearing cage rivets

Magnetic
Appearance
Rivet heads
Sealol seal tangs

Magnetic
Appearance
Rectangular tang
Approximate size: 0.12 x 0.16 x 0.06 in (3 x 4 x 1.5 mm)
1 mm
1 mm
TGB oil nozzle

Non-magnetic
Appearance
Worn nozzle shown with debris

Nozzle wear due to vespel nut contact
1 mm
1 mm
IGB shims
Non-magnetic
Appearance
Shiny metallic
1 mm
1 mm
N4 Bearing snap ring

Magnetic
Appearance
Wire
1 mm
#4 bearing cage crimp

Magnetic
Appearance
Flakes
1 mm
1 mm
Aft air/oil separator honeycomb

Non-magnetic
Hastelloy X
Appearance
Pieces of honeycomb can be associated with small aluminum
1 mm
5 mm
Bearing cage
Non-magnetic
1 mm
1 mm
Safety cable crimp sleeve/safety wire

Non-magnetic
Appearance
Wire
Crimping sleeve
1 mm
1 mm
Shotpeening media
Magnetic
Appearance
Spherical steel shotpeen balls
1 mm
Machining debris
Magnetic or non-magnetic
Appearance
Metallic
Irregular
Reflective
1 mm
1 mm
Silver plate
Non-magnetic
Appearance
Metallic
Foil
Irregular
Reflective
Malleable
20 mm
16 mm
12 mm
8 mm
4 mm
0.25
0.5
0.75
Oil inlet cover

Non-magnetic
Appearance
Metallic
Filiform
Silver shavings
Reflective
Thread-like
20 mm
16 mm
12 mm
8 mm
4 mm
0.25
0.5
0.75
Carbon (coke)
Non-magnetic
Appearance
Non-metallic
Jagged edges
Round
Usually black
Solid
Brittle to hard
Oily smell
20 mm
16 mm
12 mm
8 mm
4 mm
0.25
0.5
0.75
PTFE (Teflon) seal

Non-magnetic
Appearance
Non-metallic
Tan to black in color
Chunks
Lightweight for size
48 mm
40 mm
32 mm
24 mm
16 mm
8 mm
0
0
1/2
1-1/2
2-1/2
O-ring (seal or pre-formed packing)

Non-magnetic, elastomer
Appearance
Non-metallic
Ragged edges
Irregular
Dark
Brittle to pliable
20 mm
16 mm
12 mm
8 mm
4 mm
0.25
0.5
0.75
Carbon seal
Non-magnetic
Appearance
Non-metallic
Irregular
Frayed
Granular
Dark grey to black
20 mm
16 mm
12 mm
8 mm
4 mm
0.25
0.5
0.75
Grit blasting material

Non-magnetic
Appearance
Non-metallic
Quartz-like
Granular
Solid
Irregular
20 mm
16 mm
12 mm
8 mm
4 mm
0.25
0.5
0.75
Tumbling media
Non-magnetic
Appearance
Non-metallic
Various colors
Rounded, triangular, Hard, smooth

spherical
surface
Size ranges from

a few millimeters
to over an inch
20 mm
16 mm
12 mm
8 mm
4 mm
0.25
0.5
0.75
Tube cap
Non-magnetic
Appearance
Non-metallic
Various colors
(yellow, red, etc.)
Various
deformations
20 mm
16 mm
12 mm
8 mm
4 mm
0.25
0.5
0.75
Definitions
Brittle Easily broken, cracked, or
snapped
Machine Curl Material formed in a

spiral or winding shape
Chunk A short thick piece or lump
Machined Shaped as if by machine or

mill tools
Curls Pieces having a spiral or winding

form
Coined Stamped
Dull Lacking brilliance, luster or
lightness
Fibrous Capable of being separated
into fibers
Filiform Shaped like a filament or thread
Malleable Capable of being extended

or shaped
Pliable Supple enough to bend
without breaking
Powder Matter in even and fine
particles
Reflective Able to throw back light
Flake A thin flattened piece or layer
Round Edges are roughly equidistant

from the center
Flattened Thin versus length or width
Sharp Having a thin edge or fine point
Fraying To wear or separate usually at

the edges
Shiny Bright in appearance
Fuzz Very fine light particles or fibers

Granular Consisting of uniform particles
Hard Not easily penetrated
Irregular Lacking symmetry or evenness
Jagged Having a sharply uneven edge or
surface
Laminated Composed of layers of united
material
Sliver A long slender piece cut or

torn off
Solid Uniformly close and coherent
texture
Spall Wedge or irregular chip, flake
or fragment
Strips Long narrow pieces of material
Thin Measuring little in cross section
or diameter
Uniform Little variation in form

Bearing cross-sections
1
Outer race
Rolling element - ball
Inner race
Cage
Rolling element - roller
Shoulder
1
6
2
1
6
2
Appendix
Safe handling of oil

Most lubricants are labeled as potentially harmful when absorbed
through the skin or swallowed. Follow your companys hazardous
material procedures as well as Oil Manufacturers guidance.
CFM56 recommends wearing safety glasses, protective clothing
and gloves when handling oil. Latex, pvc, or rubber gloves should
be powder-free to avoid contamination when taking or preparing
samples for analysis.
Note: Cotton gloves are not recommended as they can
contaminate the sample and do not protect the hands from
contact with oil.
Turbine jet engine oil identification

This photograph depicts the color of fresh oil for many commonly
used oils.
Note: Reference only. Oil color may change under different

environmental and/or storage conditions.
BPTO
2380
AeroShell
500
AeroJet 5
AeroShell
555
AeroShell
560
Mobil
Jet II
Castrol
5000
Castrol
5050
Nycoil
600
BPTO 25
BPTO
2197
Mobil
Jet 254
Scales
40 mm
30 mm
20 mm
10 mm
10 mm 20 mm 30 mm 40 mm 50 mm 60 mm 70 mm
40 mm
30 mm
20 mm
10 mm
0
0
.5
1.5
2.5

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SAA

Field Guide for

CFM56-5A CFM56-5B CFM56-5C

Tool Number: GEK 119194

About this guide

This guide is to aid Operator Line Maintenance Personnel with

CFM56 Proprietary Information

Handling, collection and inspection

Magnetic sensor quantification

Scavenge screen quantification

CFM MCD inspection guidelines

Failure mode determination

Updates to this guide

If assistance is needed with this guide or with material

Customer Support Center (CSC)

Handling, collection and inspection

Oil sampling guidelines

Label the container with the

Preferable minimum sample quantity is 120 ml (which equals

Debris collection tools

Carbon tabs with backing removed

Debris inspection tools

Field magnetic sensor collection

CFM56 strongly recommends sending debris to certified

Lightly press carbon tabs to debris on sensor.

Note quantity and size of debris.

Magnetic sensor quantification

Magnetic sensor quantification

Scavenge screen quantification

General characteristics and appearance

Many chips of similar size and shape

Metal chunks as small dark irregular particles

CFM MCD inspection guidelines

CFM MCD guidelines

CFM MCD guidelines

Machined chips are serviceable whatever the size

CFM MCD guidelines

CFM MCD guidelines

Examples of bearing shoulder

Examples of bearing spall distress

Representative photo - quantity and appearance may vary

Small flakes and/or powder

Representative photo - quantity and appearance may vary

Bearing spall chips

Representative photo - quantity and appearance may vary

Representative photo - quantity and appearance may vary

#2 bearing nut spirolock

Representative photo - quantity and appearance may vary

Forward sump air/oil separator

Resin polyamide material (green or brown color)

Representative photo - quantity and appearance may vary

Forward sump abradable

Phenolic or plastic material (greenish-white color)

Representative photo - quantity and appearance may vary

Bearing air/oil seal abradable

Glass fiber with polyamide material with grooves

Representative photo - quantity and appearance may vary

AGB/TGB keylock from insert

Flat piece with castellated portion

Representative photo - quantity and appearance may vary

AGB bearing cage rivets

Representative photo - quantity and appearance may vary

Sealol seal tangs