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TEST MANUAL
LEP
Part 7
Page 1
May 31/99
PART 7 - BORESCOPE INSPECTION
LEP
Part 7
Page 2
May 31/99
PART 7 - BORESCOPE INSPECTION
TABLE OF CONTENTS
Section Page
CONTENTS
Part 7
Page 1/2
Feb 29/96
BORESCOPE INSPECTION
1. General.
2. Safety.
WARNING: DO NOT EXPOSE YOUR EYES TO THE FULL INTENSITY OF THE XENON OR
GAS ARC LIGHT SOURCE.
WARNING: ALL STANDS AND GROUND EQUIPMENT SHALL HAVE SAFETY LOCKS AND
RAILINGS. DO NOT IMPROVISE WITH LADDERS AND BOARDS.
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A. Tools and Equipment.
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(2) Standard Tools.
Description Manufacturer
B. Rigid Borescope Set, 856A1320, and Light Source Set, 856A1322. See
figure 1.
(a) Light source - 110 VAC 60 Hz, 220 VAC 50 Hz, or 110 VAC 400
Hz.
(a) The rigid borescope set, except for the light source, is
stored in a carrying case and must be assembled prior to use.
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Rigid Borescope Set
Figure 1
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Rigid Borescope Probe Specifications
Figure 2
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CAUTION: BEFORE CONNECTING THE POWER SUPPLY TO A 110 VAC 60 HZ
POWER SOURCE, BE SURE THE ON-OFF SWITCH IS IN THE OFF
POSITION AND LIGHT INTENSITY CONTROL IS SET TO MINIMUM.
ENSURE PROJECTOR AND POWER SUPPLY ARE PROPERLY GROUNDED.
(b) Select desired probe. Connect the fiber bundle to the probe
and to the light projector. Connect the light projector
electrical cable to a grounded power source.
(e) When using the optional television camera adapter, attach the
C-mount to the TV camera adapter and connect the camera
assembly (vidicon and low light intensifier) to the C-mount.
Connect the TV camera electrical cable to the camera and
camera control unit. Attach the TV camera adapter to the
eyepiece of the probe.
(3) Operating information for the use of the rigid borescope set is as
follows:
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(a) Probe 1 is primarily used for defect assessment of the
combustion chamber and high pressure turbine (HPT) nozzle.
This probe contains a variable focus adjustment in the form of
a knurled ring between the eyepiece and the fiber light bundle
disconnect fitting. This is the high magnification probe and
can be used to define or access most defects in the combustion
chamber or HPT nozzle. For photo recording purposes a visually
sharp focus should be obtained prior to coupling of the camera
and adapter to the borescope. Fine adjustments may then be
accomplished through adjustment of the camera adapter. This
probe will require more exposure time than the other probes
due to increased focal length and therefore less light
transmission. The depth of field and field of view are
decreased because of the magnification provided in the probe
optics.
1 For close-up inspection, less than 0.25 in. (6,4 mm) away
from the probe optics window, the magnification adapter
should be utilized. The magnification adapter provides
variable focus as well as magnification. The magnification
of 2 to 1 is only obtained at 2.0 in. (50,8 mm) from optics
to object distance. The magnification factor decreases for
object distances greater than 2.0 in. (50,8 mm); object to
optic spacing.
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2 For objects less than 2.0 in. (50,8 mm) from the probe lens
window, adjust the magnification adapter to bring the
object clearly into focus. Only fine adjustments are
required on the camera adapter. Use of the magnification
adapter for photo recording will require more exposure time
for a given probe, than photos taken without its use. The
magnification adapter is not recommended for use with probe
1 during photo recording.
(f) Light projection provides the light source for the fiber
bundle probes. Place the power unit switch to ON. The red
indicator light should glow. Adjust the intensity of the light
source to provide the required illumination after the probe is
inserted into the engine port.
(g) Two light sources are built into the power unit. The 150-watt
lamp is used for visual inspection of objects close to the
distal end of the probe. The 1000-watt high intensity lamp is
used for photography as well as visual inspection of
combustors and HPT nozzle vanes.
C. Fiberscope Set, 856A1321 and Borescope Guide Tube, 856A1310. See figure
3.
(1) The flexible fiber optic system has an articulated distal tip. The
light for viewing is conducted from the projector to the probe
through an integrally attached fiber light bundle. The distal end
can be angulated over a range of 180 degrees of arc vertically at
the bending point. The system contains the following features.
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Fiberscope Set
Figure 3
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(a) Optical system specifications.
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4 Temperature range - 0°F to 200°F (- 18°C to 93°C)
continuous operation.
(a) Connect the fiber light bundle from probe to light projector.
Connect light projector to power source. Be sure that the
power supply and power outlet is grounded.
(b) Check the scope for damage before using. A slightly damaged
scope, such as partial loss of tip control can result in
getting the scope hung up and finally resulting in severe
damage.
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(c) Although they are safer than ones with distal tip bulbs,
scopes are not explosion proof. They ~ should not be used
where highly volatile gases or explosive dust could reach the
hot projection lamp of the external light source.
(e) When cleaning the scope, use lens tissue only on glass
surfaces. Scopes should be kept clean at all times.
(i) Do not force the control knob. Use the knob to guide the tip
through curves, using tip touch to insert and also to remove
or reposition the fiber probe. Do not merely push through
guide tubes nor yank out when removing.
(k) Bending section is flexible in one plane only. This plane must
be oriented to the curves in the guide tube. The plane can be
established by the articulation control. Do not bend in a 90
degree plane to the tip articulation plane.
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(l) Do not insert the scope too far into the engine. If engine
rotor is rotated the tip might be cut.
(n) When storing the scope, use care when closing the protective
case. If the fiber bundles are closed within the case edges,
damage will result. Never leave scope laying on floor where it
might be stepped on or run over.
A. Support Equipment.
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Engine Tool number
R CFM56-2/A/B/C 856A1142
CFM56-3 856A2002
R CFM56-5/A/B/C 856A1488
R CFM56-7B 856A1815
(b) Align the leading edge of the No. 1 fan blade with the T12
temperature sensor located in the fan frame at 1: 30 o'clock,
aft looking forward.
(c) The low pressure rotor is now in the zero referenced position
for inspection.
(b) Remove the borescope port ( S4) plug between the 4 and 5
o'clock position on the compressor case.
(c) Put the rigid borescope probe with the 90° right angle viewer
and a 60° field of vision in the borescope port, and lock aft
to the stage 4 blade platform.
(d) While you lock in the borescope, turn the core engine rotor
clockwise (forward looking aft).
(e) Turn the rotor until you can see the locking lug of the first
blade slot.
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Zero Index Position of Core Engine Rotor (typical)
Figure 5
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(f) Continue to turn the rotor until you see the second locking
lug. The second locking lug is 2 blades past the first locking
lug.
(g) Align the leading edge of the first blade past the second
locking lug with the leading edge of the nearest stage 4 vane.
This is the zero index point and blade number 1 for inspection
of all stages of the compressor rotor.
5. Inspection Techniques.
A. Description.
(1) The CFM56 booster has one borescope port in the stage 3 (a second
port is provided in stage 4 for CFM56-5B/5C only) for inspection.
(2) The primary probe recommended for CFM56 inspection is probe 2, wide
angle fixed field, 90 degree angle of view with 60 to 65 degree
field of view. The magnification of this probe is 1 x 1 at 2 in.
(25,4 x 25,4 at 51 mm). Therefore, objects viewed closer than 2
in. (51 mm) from the distal lens are magnified. Those objects
viewed further away than 2 in. (51 mm) are decreased in image
size, relative to actual dimensions of the object. The
magnification is variable relative to blade position due to the
changing viewing distances as a rotor is turned and the blade
passes the relatively fixed borescope. The probe is turned or
rotated to view the passing blade.
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Along with the varying magnification, the angle of incidence of
the illumination beam changes as the blades pass the fixed viewing
port positions. These views are further varied by probe immersions
into the engine (radially), thus producing/providing a third
variable, the aspect of the object.
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B. Resolution Check of Borescope and Fiberscope Using Borescope Resolution
Monitor, 856A1323.
NOTE: If the person performing the testing has corrected vision, then
the appropriate eyewear (eyeglasses, contact lenses, etc.)
should be worn.
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Borescope Resolution Monitor
Figure 6
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Resolution Target
Figure 7 (Sheet 1 of 2)
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Resolution Target
Figure 7 (Sheet 2 of 2)
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(i) Align borescope so resolution target is centered in field of
view. If you peer through borescope and only part of
resolution target is illuminated in your field of view, (i.e.
half of field of view resembles a half moon) borescope is not
serviceable for engine inspection.
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(2) Test fiberscope as follows. See figures 6 and 7.
WARNING: NEVER LOOK DIRECTLY INTO THE LIGHT BUNDLE OUTPUT. THIS
COULD RESULT IN INJURY TO PERSONNEL.
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(i) Check fiberscope with objective window aligned and centered in
field of view. If only part of target is illuminated in field
of view (i.e. half of field of view resembles a half-moon),
fiberscope is defective and is not serviceable for engine
inspection.
C. Procedure.
(a) Position the rotor to obtain the best view of the defect,
relative to assessment of the maintenance manual limit, e.g.;
leading edge impact, tip (distortion) curl, leading edge or
trailing edge distortion, etc. Usually normal (at right angle)
to the defect and centered in the field of view.
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(b) Obtain a Polaroid photo of the defect.
(c) Using a full scale cross section of the engine, for reference,
locate a scale (machinist 6 in. scale marked in 0.010 in.
increments) in the relative axial and circumferential position
outside the HPC case, withdraw the borescope probe with camera
attached.
(d) Hold the borescope probe aligned with the centerline (same
position, axial, angle of look, and circumferential
orientation as the defect photo was obtained) of the borescope
port and obtain a photo of the measurement scale.
(a) Position the rotor at the optimum rotation angle to view the
defect.
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(e) Measure the marked defect.
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Engine Temperature for Borescope Inspection after Engine Shutdown
Following Normal Flight Cycle
Figure 8
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BORESCOPE INSPECTION OF LOW PRESSURE COMPRESSOR
1. Requirements.
A. On Condition Maintenance.
B. Special Inspection.
2. Procedure.
ENGINE REFERENCE
3. Inspection Criteria.
A. General.
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(1) On Condition (Scheduled Inspection).
(c) Dents.
(d) Erosion.
(f) Pits.
4. Documentation of Defects.
A. General.
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The propagation of the damage can then be pictorially illustrated
during subsequent inspections. The rotor blade maps are oriented
about the zero reference for inspection continuity. The inspection
records and maps will remain with the engine folder until the
damaged parts are repaired or replaced.
B. Mapping Defects.
(1) Record individual blade damage on booster blade maps. See figure 2.
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R
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R CFM56-2 Stage 2 Booster Rotor Map of Damaged Blades
R Figure 4 (Sheet 1 of 6)
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R
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BORESCOPE INSPECTION OF HIGH PRESSURE COMPRESSOR
1. Requirements.
A. On Condition Maintenance.
B. Special Inspection.
2. Procedure.
ENGINE REFERENCE
CFM56-2 72-31-00, Maintenance Practices
CFM56-3 TASK 72-00-00-216-049-C00
CFM56-5A TASK 72-31-00-290-001
CFM56-5B TASK 72-31-00-290-002
CFM56-5C TASK 72-31-00-290-801
R CFM56-7B TASK 72-00-00-200-804
3. Inspection Criteria.
A. General.
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(1) on condition (Scheduled Inspection).
(a) Cracks.
(c) Dents.
(d) Erosion.
(f) Pits.
(i) Dirt.
4. Documentation of Defects.
A. General.
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The propagation of the damage can then be pictorially illustrated
during subsequent inspection. The rotor blade maps are oriented
about the zero reference for inspection continuity. The inspection
records and maps will remain with the engine folder until the
damaged parts are repaired or replaced.
B. Mapping Defects.
(1) Record individual blade damage on HPC blade map. See figure 2.
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R
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Compressor Blade Map
Figure 2
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R
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R
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R
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BORESCOPE INSPECTION OF COMBUSTION SECTION
1. Requirements.
A. On Condition.
B. Special Inspections.
2. Procedure.
ENGINE REFERENCE
3. Inspection Criteria.
A. General.
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B. On Condition (Scheduled Maintenance).
(1) Discoloration.
(c) Use of the Xenon arc lamp with the distal light type
borescopes tend to cast a bluish coloration on the viewed
hardware. Carbon streaks have been misinterpreted as cracks
and carbon deposits have bean misinterpreted as holes or burn
through.
C. Special Inspections.
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(2) Impact damage observed on high pressure turbine (HPT) rotor blades.
4. Documentation of Defects.
A. General.
B. Mapping Defects.
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C. Photo Recording of Damage.
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R Single Annular Combustion Section Inspection Record
Figure 1
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R
1. Requirements.
A. On Condition.
B. Special Inspections.
2. Procedure.
ENGINE REFERENCE
3. Inspection Criteria.
A. General.
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B. On Condition (Scheduled Maintenance).
(1) Discoloration.
(a) Cracks.
(b) Burns.
Cracks.
Cracks.
(a) Cracks.
(c) Burns.
(a) Burns.
(a) Burns.
(b) Cracks.
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C. Special Inspections.
4. Documentation of Defects.
A. General.
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B. Mapping Defects.
(1) Photos of the HPT nozzle vanes require time exposures unless
extremely fast ASA film is used. It is recommended that the probe
(rigid optic fiber light borescope) be used for photo recording.
This probe has the greatest fiber light transmission capability.
(2) Care should be taken to center the light beam on the vane leading
edge in question, eliminating as much glare or reflective lighting
from the inner combustion liner. Too much immersion of the probe
will show liner high-lighting and tend to wash out the HPT nozzle
vane photo detail.
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High Pressure Turbine Nozzle Inspection Report
Figure 1
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High Pressure Turbine Nozzle Map of Damaged Vanes (Typical)
Figure 2
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R
1. Requirements.
A. On Condition.
B. Special Inspections.
2. Procedure.
ENGINE REFERENCE
3. Inspection Criteria.
A. General.
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B. On Condition (Scheduled Inspection).
Cracks.
(a) Cracks.
(b) Cracks.
(a) Cracks.
(b) Distortion.
(c) Burning.
(a) Cracks.
(b) Plugging.
C. Special Inspection.
(1) General.
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(2) Core stall (N2).
(3) Overtemperature.
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4. Documentation of Defects.
A. General.
B. Mapping Defects.
(1) Record individual blade damage on HPT blade map. See figure 2.
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C. Photo Recording of Damage.
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R
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R
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HPT Rotor Blade Map (Typical)
Figure 2
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R
1. Requirements.
A. On Condition.
B. Special Inspections.
2. Procedure.
ENGINE REFERENCE
3. Inspection Criteria.
A. General.
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B. On Condition (Scheduled Inspection).
(a) Using the fiber light type rigid optic borescope probe 2 (wide
angle scope) inspect the total airfoil, platform, and tip
shrouds for evidence of cracks. For tip shroud condition, the
retrograde or probe 4 is recommended. Use of the magnification
adapter is recommended for final assessment of possible or
suspect cracks in the blade tip shrouds.
(a) Nicks and/or dents in the leading edge, trailing edge, airfoil
surfaces (convex/concave) and/or the platforms must be
assessed. Note and record the presence of these defects
relative to the percent span and percent chord for magnitude
and location on the blade. Note also the condition of the
blade material adjacent (at extremities of defect) to the
observed defect. Note any cracking or sharpness of dents
and/or nicks.
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(3) Wear.
C. Special Inspections.
R The LPT stage 1 and stage 4 blades (stage 5 for CFM56-5C) must be
R inspected.
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R 4. Documentation of Defects.
A. General.
R B. Mapping Defects.
R (1) Record individual blade damage on the LPT blade map. See figure 3.
R (2) Record damage detected on the appropriate LPT rotor stage map. See
R figures 4 through 8. The blade numbering relative to angular
R position applies only when the low pressure rotor is indexed as
R defined in section 72-00-00.
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R C. Photo Recording of Damage.
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LPT Blade Overtemperature Inspection
R Figure 1 (Sheet 1 of 5)
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LPT Blade Overtemperature Inspection
R Figure 1 (Sheet 2 of 5)
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LPT Blade Overtemperature Inspection
R Figure 1 (Sheet 3 of 5)
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LPT Blade Overtemperature Inspection
R Figure 1 (Sheet 4 of 5)
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LPT Blade Overtemperature Inspection
R Figure 1 (Sheet 5 of 5)
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CFM56-2/-3 LPT Section Inspection Record
Figure 2 (Sheet 1 of 3)
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R
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LPT Blade Map (Typical)
Figure 3
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R
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R
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R
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R
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Figure 7 (Sheet 1 of 3)
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R
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R
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