PW100 BORESCOPE

September 2014

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 EXPORT CLASSIFICATION
Export Control Classification
Contains no Technical Data ( X )
Classification
* Data is subject to the jurisdiction of the Export and Import Regulation
Number
Controls Bureau of the Department of Foreign Affairs and Canadian ECL(s)*
International Trade of Canada, Department of Commerce of the
and/or Department of State of the United States . ECCN(s)*
** Data is not subject to the jurisdiction of the Department of P-ECCN(s)** 9E991
Commerce of the or Department of State of the United States but USML(ITAR)*
would become subject if exposed to any US involvement.
P-USML**
Date: 03 Apr 2014
Badge: PW47119

PROPRIETARY NOTICE
This document is the property of Pratt & Whitney Canada Corp. (“P&WC”). You may not possess, use, copy
or disclose this document or any information in it, for any purpose, including without limitation to design,
manufacture, or repair parts, or obtain TCCA, FAA, or other government approval to do so, without P&WC's
express written permission. Neither receipt nor possession of this document alone, from any source,
constitutes such permission. Possession, use, copying or disclosure by anyone without P&WC's express
written permission is not authorized and may result in criminal or civil liability.

DISCLAIMER
This presentation has been compiled to offer guidelines, and to provide assistance, in performing
Borescope Inspection of all PW100 engines.
In all cases, the relevant PW100 Engine Maintenance Manual should be used when making reference
to equipment, procedures, inspection criteria and acceptance limits.
The content is this training material may not be updated.

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Export
Export control classification:
Classification: 9E991data
No Technical P&WC PROPRIETARY INFORMATION
 SUPPORTS
Primary: CM/FSR CHANDRA GUNAWAN
• Chandra.Gunawan@pwc.ca
• Telp: +62-8158742000

Back Up: FSR BUDI SUSILO

• Budi.Susilo@pwc.ca
• Telp: +628158099890

Customer First Centre (CFirst), 24/7/365

• Tel +1 450 647 8000
• Int’l toll free +8000 268 8000
• Fax +1 450 647 2888
• CFirst@pwc.ca

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 CONTENT
• Rereferences and the use of EMM
• Introduction of Borescope Inspection (BSI) and PW100 Engine Layout
• Borescope Guide Tube and the Usage
• BSI for scheduled inspection, unscheduled inspection, and fault isolation
• BSI, Procedures
• Borescope Access Ports (LP Impeller, HP Impeller, Hot Sections, ICC Air
Plenum, RGB, No 6/7 Bearing Vent Transfer Tube)
• Damage Description
• Borescope Inspection and Examples
1. LP/HP Impeller
2. Combustion Chamber and SED
3. HPT, LPT, PT-1, PT-2, HPT Segment Shrouds
4. RGB
5. No 6/7 Bearing Vent Transfer Tubes
• Sample of BSI Report

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 REFERENCE

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 PW127M ENGINE OVERVIEW
• 3 Spool (LP, HP & PT)
• Single stage centrifugal LP & HP compressors
• Reverse Flow Combustion Chamber
• 14 Fuel Nozzles
• Single stage HP turbine – 38 blades
• Single stage LP turbine – 47 blades
• 2 stage power turbine. PT-1 turbine: 66 blades and
PT-2 turbine: 71 blades
• Reduction Gear Box (RGB)

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 ENGINE LAY OUT

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 ENGINE BEARINGS

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ENGINE LAY OUT

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 PRECAUTIONS
• The 1st stage LP compressor blades may have sharp edges. Be
careful when turning by hand to avoid cuts. Use gloves.
• Make sure staging and platforms are safe, it is possible to become
disorientated when peering down a borescope and loose your balance.
• Make sure the tip of the borescope is securely attached. You do not
want it to drop off inside the engine!
• Make sure the borescope is clean before borescoping the RGB to
ensure that no dirt or grit is introduced into the bearings.
• Do not use a steel braided borescope to inspect the reduction gears as
it can damage the bearing.

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 BORESCOPE INSPECTION
When we are to perform BSI?
1. Scheduled inspection: every 1500 hours, best
practice: in line with fuel nozzle replacement
2. As called for by ECTM
3. For trouble shooting/fault isolations: propeller lock up,
low ITT margin, etc.

For scheduled BSI:

1. Hot section area: inspect HP turbine vanes, HP
turbine shroud segments, HP turbine blades,
combustion chamber and small exit duct.
2. No. 6/7 Bearing Vent Transfer Tube: visual or BSI
3. LP Impeller: visual or BSI

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 UNSCHEDULED INSPECTION AND BSI
• Performance Deterioration
• Inspection after an Overtorque
• Bird Strike or Soft Material Ingestion
• Chip Detector Indication
• Main oil filter bypass indicator activated
• RGB oil filter bypass indicator activated
• Aircraft flown through a cloud of volcanic ash
• Oil Fire in Exhaust Duct
• Intercompressor case fire warning
• Engine Vibration or Cracked External Tubes

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 BSI AND FAULT ISOLATION
Fault Isolation
• Engine fails to start
• Slow acceleration
• High oil consumption
• Smoke from Exhaust on start-up or shut down/engine flooded with
oil/oil odour in cockpit
• Low or loss of oil pressure
• Excessive fuel consumption
• Performance deterioration or ECTM trend shift
• Engine stall
• Propeller Lock Up
• Engine overtorque

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 BORESCOPE GUIDE TUBES
Borescope guide tubes:
1. PWC34910-800: to access
HPT area via fuel nozzle port
2. PWC34910-802: to access
HPT area via ignitor port
3. PWC34810-804: to access
LPT and PT area via
thermocouple port

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 PROCEDURES
• PT Rotor & RGB - turn propeller slowly and slow increment
• LP Rotor - turn LP compressor with suitable implement, e.g. pusher
stick PWC34939
• HP rotor - via port on rear of starter shaft, ¼’’ drive (some people use
the cooling fan on starter to turn the HP rotor, but do it at your own risk)
• Boroscope assembly refer to EMM for P/N or company supplied
• Boroscope / videoscope. Holding fixture PWC34913 recommended with
• boroscopes. Some RGB inspections require approved equipment
PWC34910-102
• Puller-PWC37651 (RGB access)
• Puller PWC37651 or PWC30128-15 (LP impeller access)
• Pusher - PWC 34939 - LP compressor
• Lever - PWC 37823 – (Access to starter drive cover 3/8 drive)
• Guide Tube- PWC 34910-800 (Fuel nozzle boss / igniter boss)
• Flexible guide tube PWC34910-802 (LP blade T/E and PT1)

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 PROCEDURES
When capturing damage:
• Find a feature of known size, eg cooling to compare
• Capture images from as far as possible away from subject
• Close up pictures are rarely of any use,
• Don’t take pictures of holes, it is the remaining material that is of interest
• Always take pictures to show typical condition, this information is needed to
understand future deterioration rates.
• Video capture provides and excellent record for internal work packs
– Videos are difficult to distribute due to size
– If damage is noted during video, capture still images
– Keep videos as short as possible eg 1 for HPT Blade, 1 for HPT Shroud etc

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 CAPTURING IMAGE
What is this ?? Oh..now I know !

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 BORESCOPE
ACCESS PORTS

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 LP IMPELLER ACCESS PORTS

There are three different access routes

1. Inspection through the Air Intake
Duct
2. Inspection through the Rear Inlet
Case Port
3. Inspection through the Diffuser
Duct Port
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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 HP IMPELLER ACCESS PORT
Borescope inspection of
the HP Impeller is carried
out by removing the most
accessible diffuser exit
duct.
The Impeller should be
rotated by removing the
starter-generator drive
cover and installing a
square drive socket
extension.

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 ICC AIR PLENUM ACCESS PORT
Three access ports: from NL
Speed Probe, opposing Blanking
Tube or ICC drain plug.

Inspect the bottom of the air

plenum chamber for debris, as
follows:
HP Impeller Shroud retaining
bolts - See relevant EMM for
allowable quantities and
disposition.
Other debris - Remove using a
magnet and send to an approved
laboratory for analysis.

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 ICC AIR PLENUM ACCESS PORTS

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 COMBUSTION CHAMBER LINER ACCESS
Access to the Inner and
Outer Combustion Liners is
carried out through any of
the Fuel Manifold Adapter
ports or through either of the
Igniter Plug ports.

The entire Combustion

Chamber, formed by the
Small Exit Duct and Inner
and Outer Liner assemblies,
can be inspected through
four approximately equally
spaced Fuel Nozzle ports.

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 HPT VANES AND HPT ACCESS PORT
Access is through any of the
Fuel Manifold Adapter ports or
through either of the Igniter
Plug ports.

Fuel Manifold port - Insert

guide tube into port, turning it
counterclockwise until fully
installed
Right Igniter port - Insert guide
tube into port in an upward
direction, turning it
counterclockwise until fully
installed.

Left Igniter port - Insert guide

tube into port in a downward
direction, tuning it
counterclockwise until fully
installed
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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 LPT BLADES & STATOR ACCESS PORT
Borescope Inspection of the LP Turbine
Blades and Stator is carried out by
removal of the T6 Thermocouples and
by using a flexible guide tube.

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 PT-1 STATOR AND BLADE ACCESS PORT
Borescope Inspection of the Stage
1 PT Stator and Blades is carried
out by removal of the T6
Thermocouples and by using a
flexible guide tube.

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
PT-2 BLADE ACCESS PORT
Borescope Inspection of the
Stage 2 PT Blades is carried
out by removal of the port cover
on the left-side (view from rear),
or by loosening the No 5
Bearing Vent Tube on the right-
side, of the Turbine Support
Case.

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 RGB INPUT SHAFT ACCESS-POST SB21149
Borescope Inspection of the Input
Shaft installed in post SB21149
Gearboxes is carried out by removal
of the cover on either side of the
Reduction Gearbox Rear Housing.
In order to view all gearteeth the
fiberscope should be fully removed,
the Propeller turned 5 degrees
clockwise and then re-inserted as
above.

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 NO 6/7 BEARING VENT TRANSFER TUBE ACCESS
Disconnect and remove No. 6 and 7
bearing vent tube assembly from
transfer tube (Ref. 72-01-50).
Inspection can be done by visual or
borescope

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 BORESCOPE
INSPECTION AND
EXAMPLES

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 DAMAGE DESCIPTION
Hairline cracking
a crack or linear indication which is not open
more than .001”

Converging cracking
a crack which has presently propagated to a
condition which will result in a potential
material loss. Minor cracking, say in the outer
ring may be of a converging nature but would
not result in such a condition will be
acceptable as is.

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 DAMAGE DESCRIPTION

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 DAMAGE DESCRIPTION

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 LP IMPELLER INSPECTION
Visually inspect impeller for
dents and nicks .
1. If any FOD has caused the
engine to become prone to
engine surges or causes
unusual compressor
whining, the engine must
be removed immediately.
2. Inspection of the LP
impeller may be carried out
viewing the impeller
through the air intake duct.
Use of a borescope is
optional.

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 LP IMPELLER INSPECTION

Bent LP impeller airfoil tips (1.000 X

0.125 in. max) can be repaired by cutting
blade tip triangularly.
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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 HP IMPELLER INSPECTION
Nicks smaller than 0.004 in are
serviceable.
Nicks greater than 0.004 in
should be monitored as per the
relevant EMM.
Any crack or tear associated with
a nick or dent requires
immediate engine removal.

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 HP IMPELLER INSPECTION

C=22.9 mm

What is estimate size of the nick?

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 CC OUTER LINER REFERENCE

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 CC INNER LINER REFERENCE

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 CC INSPECTION CRITERIA
Area a: one hole of 0.25 in diameter or
multiple holes up to 0.050 sq.in
Area b: one hole of 0.5 in diameter or
multiple holes up to 0.2 sq.in
Area c: multiple holes up to 2 sq.in.
provided there are no cracks or holes in
the associated bottom support.
Cooling rings eroded and/or cracked
and/or having material missing due to
metal break away are acceptable.
Cracks in the walls of the inner and outer
liner assemblies are acceptable, provided
the total surface area of the crack openings
does not exceed the area allowed for
holes.
Plasma top coating (ceramic) loss are
acceptable

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 EX-1: CC BSI
Is it outer or inner liner ?
Is it at Area “a”, “b”, or “c” ?
Is it allowable or not allowable?
What is the size of missing
material (approx)?

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 EX-2: CC BSI
Is it outer or inner liner ?
Is it at Area “a”, “b”, or “c” or
cooling ring?
Is it allowable or not allowable?

Carbon build up due to poor fuel

nozzle. Please contact P&WC.

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 EX-4: CC BSI
Area c: multiple holes with total
surface area less than 2.000
sq.in. provided there are no
cracks or holes in the
associated bottom support.

Q: how big the area of missing

material?

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 SMALL EXIT DUCT (SED) INSPECTION

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 SMALL EXIT DUCT (SED) INSPECTION
• Ceramic coating loss is
acceptable. . Cracks on the heat
shield, erosion and/or holes
having a total surface area less
than 0.500 sq.in
• Open cracks, erosion and/or holes
on the heat shield having a total
surface area less than 2.000
sq.in. are acceptable.
• Non converging cracks on the
inner flange support are
acceptable.

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 EXAMPLE 1: SED INSPECTION
Acceptable cracking of
heatshield. Cracks,
erosion and/or holes
having total surface area
less than 2.00 sq. in are
acceptable providing
there are no holes or
cracks in the inner flange
support. Repeat
inspection within 500
flight hours.

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
HP VANES INSPECTION
Area to inspect: LE, TE, inner and
outer platform.
Inspection criteria: hairline cracks,
converging cracks, burnt, missing
material, erosion and coating loss

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 HP VANE DAMAGE
Category 1: Category 2:
Minor damage, allowable and repairable.

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 HP VANE DAMAGE
Category 3: Category 4:
Minor damage, allowable but not- Non-repairable damage requiring more
repairable. frequent monitoring.

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 HP VANE DAMAGE, CAT-5
Category 5:
Unserviceable condition requiring
scheduled engine. Carry out a
detailed borescope inspection of the
combustion chamber, HP turbine
blades, HP turbine shrouds, LP
turbine vanes and LP turbine blades
for evidence of widespread damage.
Engine removal is recommended
within 50 hours for economic
reasons.

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 HPT BLADES INSPECTION
The condition of HP turbine blade airfoils and
tips is critical to obtain rated power. An
increase in turbine tip clearance can
increase (ITT/T6) and reduce Nh rotor
speed.
Area to inspect: LE, TE, tip, platform and
airfoil surface
Inspection criteria: cracks, tip rubbings,
erosion, coating loss, corrosion

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 HPT BLADES INSPECTION (1)
HPT Blades acceptable
damage (see next figure) for
further service, provided
engine performance is within
limit.

Acceptable HP Turbine Blades. No

evidence of cracking or erosion to the
leading edges or tips.
No rub at blade tip.
Minor acceptable discoloration of
leading edges as a result of ceramic
from Small Exit Duct or Combustion
Liners.
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 HPT BLADES INSPECTION (2)
Damages exceeding previous figure,
but no more than this figure, are
acceptable for further service, providing
engine performance is within limits. A
repeat borescope inspection and power
assurance check must be carried out
within 300 flight hours.

Leading edge/tip erosion acceptable

providing internal core passages are NOT
visible and engine performance is within
limits. A repeat borescope inspection and
power assurance check must be carried
out within 100 flight hours.

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 HPT BLADES INSPECTION (3)
Erosion/oxidation as shown is
acceptable for further service, providing
internal cooling air passages are not
visible and engine performance is
within limits. A repeat borescope
inspection and power assurance check
must be carried out within 300 flight
hours.

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 HPT BLADES INSPECTION (4)
Corrosion that goes through the HP
blade platform as shown is not
acceptable and an HSI is
recommended to be carried out. For
scheduling purposes, the HSI can be
delayed for a maximum of 100 flight
hours, providing engine performance is
within limits.

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 HPT BLADES CORROSION

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 HPT BLADES CORROSION
Stage 1: Stage 2:

Stage 3: Stage 4:

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Export control classification: 9E991 P&WC PROPRIETARY INFORMATION
 HPT BLADES
Leading edge/tip erosion and
open cracks at blade tip are
acceptable, providing internal
cooling air passages are not
visible. Cracks found on
other airfoil surfaces, apart
from blade tip are not
acceptable.

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 HPT SHROUD SEGMENTS INSPECTION
There are five (5) categories:
• Cat-1: silver-grey heat
discoloration with no axial cracks,
slight changes to surface texture
may be visible.
• Cat-2: silver-grey heat
discoloration and/or initiation of
dark gray spotting, hairline axial
crack, slight tip rubbings are
acceptable.
• Cat-3: curling and/or heat
discoloration, partial coating
delamination and/or multiple
small or long axial cracks.
• Cat-4: see next page
• Cat-5: see next page

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 HPT SHROUD SEGMENT INSPECTION
Cat-2:
Silver-grey heat
discoloration and/or
initiation of dark gray
spotting, hairline axial
crack, slight tip rubbings
are acceptable.

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 HPT SHROUD INSPECTION
Cat-3:
Curling and/or heat discoloration, partial
coating delamination and/or multiple
small or long axial cracks.

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 HPT SHROUD SEGMENTS INSPECTION
Cat-4:
Curling and/or loss of thermal
barrier coating, erosion and
oxidation as shown at photo.

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 HPT SHROUD SEGMENTS INSPECTION
Cat-5:
• major rubbing with curling and/or
loss of thermal barrier coating.
• Complete loss of thermal barrier
coating and erosion through
shroud segment parent material.
• Shroud segment trailing edge may
also be completely missing,
exposing the turbine support case
attachment rim. .

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 LPT VANE, LPT BLADE & SEGMENTS
LPT Blades and Disc

LPT SEGMENT SHROUDS LPT Vane

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 PT-1 BLADE AND PT-2 BLADE
PT-1 STATOR

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 LP STATOR ASSY
Burnt areas of the LP Stator
produce an increase in flow area,
decrease NL speed and increase
ITT/T6. Providing ITT/T6 is below
maximum limit there is no need to
carry out an HSI regardless of the
amount of damage, providing the
structural integrity is not affected.

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 LP TURBINE BLADES
LP Blades in good
condition. No evidence of
sulphidation or rubbing of
Blade tip.

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 LPT BLADES CORROSION
If the damage is more than the limits
shown below, LP turbine blades are not
acceptable and HSI is recommended
within 100 flight hours

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 PT-1 STATOR
Damaged areas on the
Stage 1 PT Stator
produce an increase in
flow area which
increases NL speed and
decreases ITT/T6.
Providing NL stays within
limits or the engine does
not surge, there is no
need to change the
stator irrespective of the
amount of damage,
unless the structural
integrity of the vanes is
affected.

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 PT-1 BLADES
Yellow deposits more
concentrated on Blade
concave airfoil near platform,
associated with coating
blisters and surface bubbles.
Generally seen on engines
operating in a hostile
environment. If corrosion of
the airfoil base material is
found the disc assembly must
be replaced within 50 flight
hours.

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 RGB INPUT SHAFT

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 RGB INPUT SHAFT
Breakdown of functional
surfaces in contact with
each other usually in the
form of irregular sharp
edged, relatively deep
cavities, with edge
condition having
indications of further
progression.

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 NO 6/7 BEARING VENT TUBE ACCESS PORT
Disconnect and remove No. 6/ 7
bearing vent tube assembly from
transfer tube (Ref. 72-01-50).
Inspection can be done by visual or
borescope.
Inspect for oil coking.

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 ICC AIR PLENUM BSI
Inspection criteria:
1. Inspect HP Impeller shroud retaining
bolts, maximum of 3 bolts missing.
2. Inspect the bottom area for debris. If
found, remove it with magnet and send it
for analysis.
3. Inspect for oil accumulation, it may
cause oil smoke in the cabin

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 ICC AIR PLENUM INSPECTION

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 BSI AND

QUESTIONS?
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 QUIZ
• How to access LP Impeller and how to rotate it?
• How to access Combustion Chamber?
• How to access HPT area and how to rotate it?
• How to access LPT area and how to rotate it?
• How to access PT-1 area and how to rotate it?
• How to rotate RGB input shaft?
• For scheduled interval BSI, which area to inspect?
• How many guide tubes available for hot section BSI? What are the
purpose?

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 PLEASE IDENTIFY

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 PLEASE IDENTIFY

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