GEnx Borescope Inspection Guide

Examples from Severe Environment Operations

GEK 133720_R1
Inclusive of phase 2 hardware configuration
Release Date: September 2018
GE Designated: -CONFIDENTIAL-

This technical data is considered subject to the Export Administration Regulations (EAR) pursuant to 15
CFR Parts 730-774. Transfer of this data by any means to a Non-U.S. Person, whether in the United
States or abroad, without the proper U.S. Government authorization (e.g., License, exemption, NLR, etc.),
is strictly prohibited.

ECCN 9E991, NLR

Rationale: No 9E003 or other LRC ECCN technology
BSI Guide - Objectives
Following pages show in service findings to help define inspection criteria for following GEnx series engine
parts:
• Combustor
• HPT Blades
• HPT Nozzles
• HPT Shrouds
• HPC Blades
• OGV
Photos are examples of conditions to help inspectors understand what they are seeing while accomplishing
the borescope. The content of this guide is reflective of hot section conditions seen as a result of Severe
Environment operations and may not be representative of what is seen by other operators.
This document is not to determine serviceability of the part being inspected.
All serviceability evaluation must be carried out with reference to AMM limits or SB directive.

This guide is provided for general information purposes only and does not purport to be an exhaustive document. For any specific queries please
liaise with your GE Field Service team. This guide is provided without any liability on the part of the General Electric Company and its affiliates.

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GEnx Borescope Inspection Guide
Examples from Severe Environment Operations
Contents
Component Page
1. Combustor 7
2. HPT Stage 1 Blade 27
3. HPT Stage 1 Nozzle 39
4. HPT Stage 1 Shroud 46
5. HPC Blades 51
6. OGV 56

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SEO Hot Section Distress Driven by CMAS
What is CMAS?
CMAS = Calcium-Magnesium Alumina-Silicates molten glass
CMAS forms when TBC surface temperature is above
dust melting point
CMAS = f(OAT, TO derate, climb, derate, climb taper, coarse aerosols)

Repetitive melt + solidify (cycles) causes TBC to spall.

Base metal then exposed to thermal stress.
Metal thermal stress leads to erosion and/or cracks
which eventually cause an unserviceable condition.

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 The Effects of Particulate Matter Characterized
Life Consumption

Cycles/Hours
TBC intact TBC intact TBC missing TBC missing & surface roughening
Internals clean Some internal dirt More internal dirt More internal dirt
No flow reduction Some flow reduction More flow reduction More flow reduction

PM coats internal cooling passages Chemical attacks on surfaces

• Insulates internal walls • Accelerates TBC spallation
• Typically 3 to 15 mils thick • Accelerates corrosion
• Plugs cooling passages which reduces cooling flow 10% • Roughens flowpath surfaces…
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Tips for Improved Inspection Quality:
• MPD borescope feedback is important for leading indication of hot section
hardware condition and TOW predictions
• Videos and photos are equally important, video of complete inspection
recommended with photos of questionable conditions
• Avoid taking low quality photos (e.g. snapshots from videos)
• If possible, attach cup number or specify circumferential location during
combustor inspections
• Document all areas of combustor distress.
• Turn rotor slowly and use flexible borescope for HPT blade inspections
• Focus closely on HPT blade convex side to identify cavity 6/7 cracks

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 Combustor
This guide is provided for general information purposes only and does not purport to be an exhaustive document. For any specific
queries please liaise with your GE Field Service team. This guide is provided without any liability on the part of the General Electric
Company and its affiliates.

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 Combustor
In-service conditions observed

1. Areas of TBC missing from inner/outer combustion

liners
2. Cracks found on the inner combustion liner
3. Cracks found on the outer combustion liner
4. Areas of TBC missing and cracking around Ignitor and
BSI Ports
5. Fuel nozzle TBC loss and material erosion
6. Mixer material erosion and disengagement (only
viewed when GEnx-1B SB 72-0239 applies)

Required inspection actions

1. Routine MPD inspections

2. SB 72-0239 when applicable (1B only)

Note

A. Use of rigid borescope probe with various angle

viewers recommended. A flexible probe maybe
required to accurately assess some TBC loss and
erosion.
Serviceability evaluation must be carried out using B. All areas of any damage, cracks and assessment of
AMM/SB limits. exposed cooling holes will require accurate
measurement to allow evaluation against AMM limits.
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Combustor Liner – Damage Progression
TBC loss Initial material crack

TBC erosion
beginning

Crack propagation
with material erosion

Crack
Crack propagation with
propagation distortion and material loss
Typical damage progression in both the inner and outer combustor liners. TBC erosion creates areas of TBC
loss which often develop cracks. Cracks propagate and can eventually cause distortion and material loss.
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Inner Liner Defects
Inner
BSIliner
hole
TBC loss TBC
crack
Liner loss
crack

Fuel TBC loss

nozzle
Discoloration
Inner liner crack originating from area of TBC loss and erosion leading to material
Nugget TBC loss on inner liner TBC loss loss on the inner liner
TBC loss
TBC loss TBC
loss

Liner Material
crack loss Liner crack
Fuel nozzle
Inner liner crack originating from area of TBC loss and erosion leading to cracking
Typical TBC loss on the inner liner TBC loss and material loss on the inner liner

The combustor inner liner may commonly develop areas of TBC erosion and loss. These areas of TBC loss
can typically develop cracks in the liner. Further cracking and erosion can lead to serious material loss.
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Outer Liner Defects
Crack and
TBC loss BSI hole
TBC loss
Outer liner
(cold side)

Thru crack

Crack and Outer liner

TBC loss crack

Outer liner
BSI hole (cold side)

Thru crack
TBC loss
Typical outer liner TBC loss. Areas of TBC Outer liner cracking found around Ignitor Liner thru cracks visible on cold side of
loss commonly develop cracks. and BSI holes. outer liner

Combustor outer liner cracking typically develops in areas of TBC loss and can be commonly seen around
Ignitor and BSI holes. The outer liner may develop thru cracks which are also visible on the cold side of the
outer liner.
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Crack Length Measurement Technique

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GEnx Combustor Assembly View
NOTE: These views are to be used as a guide to support measurement of the length of cracks between
multi-holes in the inner and outer liners.
Aft Cooling
Forward Cooling Row 23
Row 1

Aft Cooling
Forward Cooling Region Outer Liner
Region
Applies to 2258M80G01, G04, G06, G07,
G08, G09, G10, G12, G13, 2745M50G01
and 2758M50G01 combustor assembly Inner Liner
configurations.

Aft Cooling
Region
Aft Cooling
Row 20
Forward Cooling
Region

Forward Cooling Row 1

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Outer Liner – Round (G08) or Shaped Holes (G06 and G10)
2255M81G06/G08/G10
Rows 1-12
FWD FLANGE

Diagonal Circumferential
1 2

Axial

AFT RING

Two zones of holes: Hole to hole spacing:

Zone 1 is non preferential Axial = 0.45 (2 rows)
Zone 2 is preferential Diagonal = 0.25
Circumferential (1) = 0.24
Circumferential (2) = 0.22
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Outer Liner – Shaped to Round Holes
2255M81G06/G08/G10
Rows 12-13
FWD FLANGE

3 4
Diagonal

AFT RING

Two zones of holes: Hole to hole spacing:

Zone 3 is non preferential Diagonal (3) = 0.25
Zone 4 is preferential Diagonal (4) = 0.26

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Outer Liner – Shaped Holes
2255M81G06/G08/G10
Rows 13-23
FWD FLANGE

Diagonal

Circumferential
5 6 Axial

AFT RING

Two zones of holes: Hole to hole spacing:

Zone 5 is non preferential Axial = 0.45 (2 rows)
Zone 6 is preferential Diagonal = 0.25
Circumferential (5) = 0.24
Circumferential (6) = 0.22
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Outer Liner – Shaped Holes
2753M63G01
Rows 1-28
FWD FLANGE

1
Zone Rows Axial Height (in)
2
1 1-3 0.34 1 Cup
3 Circumferential
Axial 2 3-9 0.975 Width: Approx
3 9-15 1.10 4.500 in

4 4 15-28 3.00

AFT RING Four zones of holes:

Circumferential Zone 1, 3, and 4 have shaped holes
Zone 2 has shaped slots
PHASE 2
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Inner Liner – Round Holes
2255M82G06
Rows 1-20
AFT RING

Diagonal

Circumferential

Axial

FWD FLANGE

One zone of holes: Hole to hole spacing:

non preferential Axial = 0.42 (2 rows)
Circumferential = 0.20
Diagonal = 0.23
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Inner Liner – Shaped Holes and Slots
2255M82G09
Rows 1-8
AFT RING
Diagonal

Circumferential
2
1
Axial

FWD FLANGE

Two zones of holes: Hole to hole spacing:

Zone 1 has shaped holes Axial = 0.42 (2 rows)
Zone 2 has shaped holes Circumferential = 0.18
PHASE 1 Diagonal = 0.23
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Inner Liner – Shaped Holes
2255M82G09
Rows 9-11
AFT RING

Axial
3

Circumferential

FWD FLANGE

One zone of holes: Hole to hole spacing:

non preferential Axial = 0.39 (2 rows)
Circumferential = 0.18
PHASE 1
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Inner Liner – Shaped Holes
2255M82G09
Rows 8-12 Diagonals
Row 12
AFT RING

Row 11
3
Row 10

Row 9

FWD FLANGE Row 8

Row Min Max Average
One zone of holes:
non preferential 8-9 0.18 0.27 0.23
9-10 0.20 0.23 0.22

PHASE 1 10-11 0.21 0.24 0.23

11-12 0.23 0.26 0.24 21
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Inner Liner – Round Holes
2255M82G09
Rows 12-20
AFT RING

4 Diagonal

Circumferential

Axial

FWD FLANGE

One zone of holes: Hole to hole spacing:

non preferential Axial = 0.49 (2 rows)
Circumferential = 0.23
PHASE 1 Diagonal = 0.27
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Inner Liner – Shaped Holes
2753M64G01
Rows 1-26
Zone Description Rows Axial Circum.
AFT RING Height Width (in)
(in)
FWD AFT
5
1 Single row of 1 -- 1.57 --
shaped holes
Axial
4 2 Shaped holes b/w 2-9 1.10 1.07 1.08
round hole patches
3 Round hole patch 2-9 1.10 1.88 1.93
2 3 2 (one per cup)
1 4 Shaped holes 9-17 1.42 3.02 3.18
middle of liner
FWD FLANGE
5 Shaped holes AFT 17-26 1.76 3.18 3.53
end of liner
Circumferential

PHASE 2 23
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Fuel Nozzle TBC & Material Loss
Cooling holes
exposed

TBC
and
TBC erosion material
loss,
Beginning exposing
New TBC erosion and loss cooling holes

Cooling
holes
exposed

TBC and
TBC loss
material
loss
TBC and material loss exposing cooling 3rd row cooling hole TBC loss and major
Typical TBC erosion on the fuel nozzle holes material loss

Top row shows typical damage progression of fuel nozzle. Typical fuel nozzle defects seen are TBC and
material loss, which expose multiple cooling holes.
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Combustor Mixer (GEnx-1B SB 72-0239 Only)
Tab material Mixer vane
erosion damage

Loss of mixer
Wear and material retention can
erosion on mixer damage adjacent
tabs mixer vanes

Misaligned tabs Material erosion

Mixer tab
liberation

Material wear can Mixer vane material

lead to tab erosion and mixer
misalignment tab liberation

Typical damage progression in the mixer shows wear and material erosion of the mixer tabs (top left).
Erosion of these tabs can lead to mixer disengagement (bottom left), which can cause additional damage to
adjacent mixers.
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Combustor Mixer (GEnx-1B SB 72-0239 Only)
Damaged bolt Missing vanes
head

Misaligned tabs

Misaligned mixer
tabs, leading to Missing vanes, often
contact and erosion caused by misaligned
of bolt head tab contact

Mixer damage

Lifted mixer

Mixer damage and

material loss Lifted mixer

Misaligned tabs can be typically seen in combustor mixers and can lead to additional mixer damage,
including missing vanes, material erosion, and lifted mixers
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 HPT Stage 1 Blade
This guide is provided for general information purposes only and does not purport to be an exhaustive document. For any specific
queries please liaise with your GE Field Service team. This guide is provided without any liability on the part of the General Electric
Company and its affiliates.

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HPT Stage 1 Blade
In-service conditions observed

1. TBC loss and material erosion

2. Cracking on concave and convex surfaces
3. Material loss and mid chord burn out

Required inspection actions

1. Routine MPD inspections

2. GEnx-1B SB 72-0267
3. GEnx-2B SB 72-0233

Note

A. Use of automated rotor turning equipment

recommended to assist in providing optimum view of
blades and ensuring all 62 blades inspected. View
from leading rearwards and trailing edge forwards
required for full assessment.
B. Damaged areas and cracks will require accurate
measurement to allow evaluation against AMM limits.

Serviceability evaluation must be carried out

using AMM/SB limits.
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HPT Blade Erosion & Missing TBC
TBC loss Material Loss

TBC loss
Material
Erosion Various TBC loss
TBC loss and and material
material erosion erosion on convex
on blade tip surface

TBC loss

AREA X

TBC loss along

leading edge,
trailing edge, and Typical TBC loss on
area X TBC loss leading edge LEADING EDGE

TBC loss typically occurs on the leading edge, trailing edge or blade tips. Areas of TBC loss can develop
material erosion.
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HPT Blade Concave & Convex Surface Cracking
Material Convex surface
Loss crack
Concave
surface
crack
Crack
developing
along face of Typical small crack
concave developing on convex
surface TRAILING EDGE surface

Concave TBC Loss Convex surface

surface crack
crack

Cracks
commonly
found near tip
of blade
(concave Close-up of convex
surface) surface crack

Cracks can develop on both the concave and convex surfaces. Cracks are typically very small and can be
difficult to see, so care is needed when inspecting blades.
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HPT Stage 1 Blade Convex Side Cavity 6/7 Crack Identification

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HPT Stage 1 Blade Convex Side Cavity 6/7 Crack Identification

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 R1 R2 R3 R4 R4 R5 R6 R7

HPT Blade Crack

0.110” 0.127” Measurement 0.157”

0.176”
Dimensions

0.221”

0.142” 0.142” 0.142”

0.142”
All dimensions measured
0.107”
between round hole centerlines 0.096”
0.142”
at airfoil surface.

(These dimensions should be used as a scaling

guide, not for exact crack measurement)

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 R8 R9 R9 R10 R11 R12 R15
R10 R11 R12 R15
R7
HPT Blade Crack
0.204” Measurement 0.104”
0.126” 0.156”
0.097” 0.112”

0.230”
0.275”
0.422”
Dimensions

0.122”

0.214” All dimensions measured

0.249”
0.223” between round hole centerlines 0.104” 0.126”
0.156”
0.097”
0.131”
0.407” at airfoil surface.

(These dimensions should be used as a scaling

guide, not for exact crack measurement)

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 R14 R13
R14 R13

0.198”
HPT Blade Crack
Measurement 0.099”

0.184”
Dimensions 0.123”

0.106”
0.192”
PHASE 1 0.100”
0.138”
All dimensions measured
between round hole centerlines 0.133”
0.197” at airfoil surface. 0.100”

(These dimensions should be used as a scaling

guide, not for exact crack measurement)

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R1 R2 R3 R4
R7 R8 R9 R10 R11 R12 R13 R14

HPT Blade Crack R6

Measurement
Dimensions R5

PHASE 2
All dimensions measured at
airfoil surface.

(These dimensions should be used as a scaling

guide, not for exact crack measurement)

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R10 R11 R12 R13 R14 R10 R11 R13

HPT Blade Crack

Measurement 0.115”

Dimensions
0.155” 0.93”

PHASE 2 0.133”

0.133”
All dimensions measured at 0.1”

airfoil surface. 0.111”

(These dimensions should be used as a scaling

guide, not for exact crack measurement)

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HPT Blade Material Loss & Mid Chord Burn Out
Material TBC and material loss of the trailing
loss of edge
the
trailing
edge
(Root to
tip view)

BLADE TIP
Material loss of Mid chord burn out arises from
the trailing material loss TRAILING EDGE
edge (Tip to
root view)
TRAILING EDGE

Typical material loss occurring at the tip of the trailing edge. Further material loss can lead to mid chord
burn our (bottom right)
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 HPT Stage 1 Nozzle
This guide is provided for general information purposes only and does not purport to be an exhaustive document. For any specific
queries please liaise with your GE Field Service team. This guide is provided without any liability on the part of the General Electric
Company and its affiliates.

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 HPT Stage 1 Nozzle
In-service conditions observed

1. TBC loss and material erosion on the leading edge and

convex surface
2. Cracks on leading edge and convex surface
3. Burnt or missing material on leading edge and convex
surface

Required inspection actions

1. Routine MPD inspections

2. No applicable SBs

Note

A. Use of rigid borescope probe with various angle

viewers used during combustor inspection for nozzle
leading edge. Trailing edge inspected via stage 1 blade
port using 6mm flexible scope through 360°
B. All areas of any damage, cracks and assessment of
exposed dome cooling holes will require accurate
measurement to allow evaluation against AMM limits.

Serviceability evaluation must be carried out using

AMM/SB limits.
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HPT Stage 1 Nozzle TBC Loss
TBC loss TBC loss

Typical TBC loss

on nozzle leading TBC loss on convex
edge surface

TBC loss
LEADING EDGE
TBC loss

TBC loss and

erosion on TBC loss on convex
leading edge surface

Nozzle TBC loss typically occurs on the leading edge and on the convex surface. Erosion and material
burning may accompany areas of TBC loss.
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HPT Stage 1 Nozzle Cracking & Material Loss
Crack from Cracks and
area of TBC material
loss loss

TBC loss
Close-up of TBC
Crack originating loss, material
from area of TBC loss, and
loss on the cracking on
convex surface convex surface

TBC loss Cracks from areas

of TBC loss
Leading edge
crack

Leading edge Cracks from areas

crack (left) of TBC loss on both
Leading edge TBC leading edge and
loss (right) convex surface

Typical cracks originating from areas of TBC loss. Common locations of cracking are the leading edge and
the convex surface.
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HPT Stage 1 Nozzle Convex Panel Lifting
TBC loss Internal
Cooling
Internal Baffle
Cavity Exposure
Exposure

Close-up of
crack
TBC loss and exposing
excessive internal
cracking cavity

Hole
Cooling Baffle Hole
Exposure

Hole from
excessive
cracking
Panel lifting exposing internal exposing
cooling baffle internal cavity

Excessive cracks originating from areas of TBC loss. Cracks can expand and expose internal cavity.
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HPT Stage 1 Nozzle Braze Joint Cracking
Braze Joint
Missing TBC
Crack

Crack Braze crack

versus crack
Braze crack in parent Crack in Parent
and oxidation material Material

Missing TBC

Braze crack
Braze crack measurement
and oxidation
Crack technique

Braze joint cracking is serviceable and allowed.

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HPT Stage 1 Nozzle Measuring Missing Material
Crack
Length

Hole
Area Crack
Step

Mark circumference to calculate internal Mark complete edge to edge of crack to

area of hole determine length
Mark complete top surface to top surface
to measure step of crack

Typical measuring techniques for missing material such as holes and cracks. Missing material is defined as a
hole or opening in the cavity.
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 HPT Stage 1 Shroud
This guide is provided for general information purposes only and does not purport to be an exhaustive document. For any specific
queries please liaise with your GE Field Service team. This guide is provided without any liability on the part of the General Electric
Company and its affiliates.

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 HPT Stage 1 Shroud
In-service conditions observed

1. Oxidation/corrosion build up on all surfaces

2. Material loss

Required inspection actions

1. Routine MPD inspections

2. No applicable SBs

Note
S2 NOZZLE
LEAD EDGE A. Use of flexible borescope probe of 4m length required
2.297”
with locally manufactured guide tube per AMM
AFT B. All areas of any damage, cracks and assessment of
TRAIL EDGE
2.413” exposed dome cooling holes will require accurate
measurement to allow evaluation against AMM limits.
STAGE 1
SHROUD 1.730”

LEAD EDGE
FWD
Serviceability evaluation must be carried out using
AMM/SB limits.
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HPT Stage 1 Shroud Oxidation & Material Loss

STAGE
2 NOZZLE
STAGE 2
SHROUD NOZZLE
Oxidation
SHROUD

Material loss

Oxidation leading to material loss, creating gap between shroud

Oxidation and erosion on shroud surface and stage 2 nozzle

Typical HPT shroud oxidation and corrosion. Material loss can create separation between the shroud and
the stage 2 nozzle.
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HPT Stage 1 Shroud Oxidation & Material Loss
SHROUD

Oxidation Oxidation

SHROUD

STAGE
2 NOZZLE

Material Loss
Material Loss
STAGE
2 NOZZLE

Oxidation and material loss on stage 2 nozzle and shroud surface Oxidation shroud surface and material loss on stage 2 nozzle

Typical HPT shroud oxidation and corrosion. Material loss can create separation between the shroud and
the stage 2 nozzle.
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HPT Stage 1 Shroud Borescope Preference
AFT Looking FWD view

Not interpretable for area

WRONG O
Preferred radial out view

Needed for interpretation

Yes
No

Example borescope placement CORRECT P

Make sure to use a radial out view to not distort interpretation of oxidation area
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 HPC Blades
This guide is provided for general information purposes only and does not purport to be an exhaustive document. For any specific
queries please liaise with your GE Field Service team. This guide is provided without any liability on the part of the General Electric
Company and its affiliates.

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 HPC Blades
In-service conditions observed

1. Dust buildup on leading edge

2. Coating cracks

Required inspection actions

1. Routine MPD inspections

2. No applicable SBs

Note

A. Use of rigid borescope probe with various angle

viewers recommended. A flexible probe may be
required to accurately assess some material loss and
erosion.
B. All areas of any damage will require accurate
measurement to allow evaluation against AMM limits.

Serviceability evaluation must be carried out using

AMM/SB limits.
52
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HPC Stage 9 Blade Dust Buildup & Coating Cracks
Dust buildup

Dust buildup

Tip
corner
crop

Coating cracks
Notch cut

A tip corner crop indicated a blade which

Very common dust buildup found on
has a notch cut. Both are cuts per the Cracking found on blade coating. The other
leading edge
engineering drawing and are not side of the blade must be inspected for
indications of material loss. thru crack to determine material cracking.

Dust typically builds up on the leading edge of the HPC stage 9 blades. Tip corner crop cuts are used to
indicate blades with notch cuts and are not indicative of material loss. Additionally, apparent cracks may
not be material cracks, only cracks on the coating
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HPC Blade Platform Gaps
Gap
Gap

*For scaling reference ONLY

Gap
Stage 9 blade gap

Stage 10 blade gap

Gaps between stages 6-10 blade platforms is a normal, serviceable condition. During borescope inspection,
gaps between blade platforms may be visible. There is no gap size limit.
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HPC Blade Deposits

Salt
Deposit
Deposit

Deposits on stage 7 blade

Salt
Deposit
Deposit

Deposits on stage 8 blade Deposits on stage 10 blades

Deposits on stage 9 blades

Salt/sand deposits are typical blade surface conditions. Environmental deposits are a normal, serviceable
condition and can be removed by water-wash.
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 OGV
This guide is provided for general information purposes only and does not purport to be an exhaustive document. For any specific
queries please liaise with your GE Field Service team. This guide is provided without any liability on the part of the General Electric
Company and its affiliates.

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OGV
In-service conditions observed

1. OGV forward rail thickness

2. OGV flow path inspection

Required inspection actions

1. Routine MPD inspections

2. GEnx-1B SB 72-0392
3. GEnx-2B SB 72-0331
4. GEnx-1B SB 72-0348
5. GEnx-2B SB 72-0290

Note

A. Use of flex borescope probe with measurement

capability recommended.
B. FWD rail thickness measurement will require
accurate measurement to determine CIS inspection
interval.

Serviceability evaluation must be carried out using AMM/SB limits .

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OGV Forward Rail Inspection – Thickness Measurement

Inspection
Hole
HIGH
LOW RESULT RESULT
Borescope should be positioned through 3/16” inspection hole
drilled in HPC slider.

Obtain 5 measurements, discard the high and low. Average the

remaining 3 measurements for final result.

BSI probe should be perpendicular to top of rail for proper measurement. Need vertical view of FWD rail.
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OGV Cockle Spring In Flow Path
Cockle Cockle
Spring Spring

Piston
Ring

Cockle spring
Example of blocking flow
cockle spring path

Cockle Cockle
Spring Spring

Cockle
spring Cockle spring
blocking blocking flow
flow path path

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OGV Piston Ring In Flow Path
Cockle
Spring

Piston Ring
Piston
Ring

Piston ring in
flow path,
HPC stage 10
Example of blade
cockle spring damage

Piston Ring

Piston Ring

Piston ring
Piston ring blocking flow blocking flow
path path

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