TASK 70-35-24-300-501-A01 "Replace Welded Fittings, Repair 1 (VRS7001)"

DMC:V2500-00-70-35-24-01A-920A-D|Issue No:001.00|Issue Date:2013-03-20

Export Control

EAR Export Classification: Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3), except for the following Service Bulletins which are currently published as EAR Export Classification 9E991: SBE70-0992, SBE72-0483, SBE72-0580, SBE72-0588, SBE72-0640, SBE73-0209, SBE80-0024 and SBE80-0025.

Copyright

© IAE International Aero Engines AG (2001, 2014 - 2021) The information contained in this document is the property of © IAE International Aero Engines AG and may not be copied or used for any purpose other than that for which it is supplied without the express written authority of © IAE International Aero Engines AG. (This does not preclude use by engine and aircraft operators for normal instructional, maintenance or overhaul purposes.).

Applicability

All

Common Information

TASK 70-35-24-300-501-A01 "Replace Welded Fittings, Repair 1 (VRS7001)"

General

This TASK details the procedure for the replacement of welded fittings.

Refer to the SPM TASK 70-35-24-300-501 (VRS7001 Repair 001) for the following:

(1) Effectivity

(2) Equipment and Materials

(3) General

All illustrations/Figs ref to the SPM TASK 70-35-24-300-501-D01

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NONE

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-204 WELDING FILLER WIRELOCALCoMat 03-204
CoMat 05-135 POLISHING BOBLOCALCoMat 05-135
CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)LOCALCoMat 06-063
CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)LOCALCoMat 06-064

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 70-35-24-350-001 Prepare the Damaged Tube

    1. Refer to Fig. 70-35-24-990-003 and Fig. 70-35-24-990-004

    2. Locally manufacture suitable jig.

      3. Cut off defective fitting on scrap side of existing weld joint.

        1. Use small hacksaw or pipe cutter.

        1. Use standard workshop equipment.

      4. Dress end of tube to accept new fitting with a maximum of 0.003 in. (0.076 mm) diametrical clearance in integeral filler filler bore.

      1. Use jig to establish correct axail position of fitting.

      5. Remove remains of previous weld underbead.

      1. Use a small round file.

    2. SUBTASK 70-35-24-110-001 Chemically Clean

      1. Chemically clean the components.

      1. Use Chemical cleaning equipment.

    3. SUBTASK 70-35-24-350-002 Fit New Parts

    1. Refer to Fig. 70-35-24-300-003 and Fig. 70-35-24-300-004.

      2. Fit new nuts and/or retaining plates/rings, as necessary.

      1. Refer to IPC.

    4. SUBTASK 70-35-24-310-001 Tack Weld the Components

    1. Refer to Fig. 70-35-24-990-003 and Fig. 70-35-24-990-004.

      2. Prepare the surfaces for weld.

      1. Refer to the SPM TASK 70-31-02-310-501-001, SUBTASK 70-31-02-120-001.

      3. Clean the repair area.

        1. Refer to the SPM TASK 70-11-26-300-503.

        1. Use chemical cleaning equipment.

      4. Position components in jig and tack weld.

      1. Refer to the SPM TASK 70-31-02-310-501-001SUBTASK 70-31-02-310-009.

    5. Check for position of fitting.

    6. Weld Data.

      7. Type of weld.

      1. Argon Arc DC.

      8. Filler wire.

      9. Electrode, Argon backing flow, Argon torch flow and Current.

        1. Use orbital welding equipment.

        1. To be determined by a suitable test piece.

    5. SUBTASK 70-35-24-310-002 Weld the Components

      1. Argonarc weld the components.

        1. Refer to Step for weld data.

        1. Use orbital welding equipment.

    6. SUBTASK 70-35-24-140-001 Clean the Repair Area

      1. Remove weld discoloration by light polishing.

      1. Use CoMat 05-135 POLISHING BOB or similar, with standard workshop equipment.

    7. SUBTASK 70-35-24-230-001 Do a Crack Test

      1. Do a local penetrant crack test on the weld joint.

    8. SUBTASK 70-35-24-220-001 Examine the Repair

      1. Visually examine and measure the dimensions, using the jig.

      1. Refer to the SPM TASK 70-31-02-310-501-003.

    9. SUBTASK 70-35-24-260-001 Radiographically Examine the Weld

      1. Radiographically examine the weld.

      1. Refer to the SPM TASK 70-26-01-260-501 and TASK 70-31-02-310-501-003SUBTASK 70-31-02-260-003.

        Use radiographic equipment.

    10. SUBTASK 70-35-24-350-003 Fit New Parts

    1. Refer to Fig. 70-35-24-990-003.

      2. Where applicable, fit new nuts, thrust wires and /or helicoil inserts.

      1. Refer to the I P C.

    11. SUBTASK 70-35-24-780-001 Do an Air Leak Test on the Tube

      1. WARNING

        DO NOT PRESSURIZE THE TUBE ABOVE THE MAXIMUM PRESSURE.

        WARNING

        STOP THE PRESSURE TEST IF A LEAK IS FOUND. DO NOT REPAIR THE LEAK, OR ADJUST THE ADPATERS OR THE BLANKS WHILST THE TUBE IS PRESSURIZED.

        Connect the tube to the pneumatic pressure test rig.

      1. Install an applicable adapter to a tube end connection on the tube. Install an applicable blank or blanks to the remaining tube end connections on the tube. Connect a dry compressed air supply, that has a pressure gauge and regulator valve, to the adapter.

    2. Put the tube into a tank of water.

      3. Pressurise the tube.

      1. Slowly in crease the pressure in the tube to 14.5 psi (100 KPa).

      4. Hold the pressure in the tube.

      1. Hold the pressure in the tube for a minimum of 1 minute.

      5. Examine the tube for leaks.

      1. Reject if the tube has leaks.

    6. Decrease the pressure in the tube to zero.

      7. Disconnect the tube.

      1. Disconnect the tube from the outlet of the pneumatic testing rig. Remove the pressure blanking cap and/or plugs from the tube.

    12. SUBTASK 70-35-24-780-005 Do a Hydraulic Pressure Test (If Required)

      1. WARNING

        BLEED ALL THE AIR FROM THE TUBE BEFORE THE HYDRAULIC PRESSURE TEST IS STARTED.

        WARNING

        MAKE SURE THAT THE SAFETY GUARDS ARE IN POSITION AROUND THE TUBE BEFORE DOING THE HYDRAULIC PRESSURE TEST.

        WARNING

        STOP THE PRESSURE TEST IF A LEAK IS FOUND. DO NOT REPAIR THE LEAK, OR ADJUST THE ADPATERS OR THE BLANKS WHILST THE TUBE IS PRESSURIZED.

        WARNING

        BE CAREFUL WHEN YOU USE COMPRESSED AIR. PUT ON PROTECTIVE CLOTHING AND GOGGLES.

        CAUTION

        DO NOT PRESSURIZE THE TUBE ABOVE THE MAXIMUM PRESSURE GIVEN. IT CAN CAUSE DAMAGE TO THE TUBE. IF THE PRESSURE IN THE TUBE GETS TO MORE THAN THE MAXIMUM GIVEN, REJECT THE TUBE.

        Connect the tube to the hydraulic pressure test rig.

      1. Install an applicable adapter to a tube end connection on the tube. Install an applicable blank or blanks to the remaining tube end connections on the tube. Connect the hydraulic pressure test equipment to the adapter.

      2. Bleed air from the tube.

      1. Open the bleed screw and apply the minimum pressure necessary to bleed the air from the tube. Close the bleed screw when the fluid from the bleed screw has no air in it.

      3. Slowly increase the pressure in the tube to the required test pressure.

      1. Refer to the relevant Chapter/Section for the testing pressure.

      4. Let the pressure remain in the tube for 2 minutes.

      1. Make sure the tube has no leaks. If the tube has leaks - reject the tube.

      5. Decrease the pressure in the tube to zero.

      1. Decrease the pressure in the tube to zero. Stop the hydraulic pressure testing rig. Open the bleed valve.

      6. Disconnect the tube from the outlet of the hydraulic pressure testing rig and the bleed valve adapter.

      1. Disconnect the adapter and blank or blanks from the tube.

      7. Examine the tube.

      1. If the tube is damaged - Reject.

    8. Remove unwanted fluid from the tube with clean, dry compressed air.

    13. SUBTASK 70-35-24-350-004 Identify the Repair

      1. Make a mark VRS7001/1 adjacent to the part number.

        1. Refer to the SPM TASK 70-09-00-400-501, SUBTASK 70-09-00-400-001.

        1. Use electrolytic etch equipment.

        2. Alternatively it is permitted to use vibro engraving equipment on cast or forged surfaces only.

Requirements After Job Completion

Follow-On Conditions

NONE
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 03-204
Type:sp01
Supply Short Name:CoMat 03-204 WELDING FILLER WIRE
Supply Name:CoMat 03-204 WELDING FILLER WIRE
Specification Groups:
Doc NumberType
OMAT:306MSRR9500/2 B.S.2901:1970 347 S96/FORM. BSS2901 A8Nb
Suppliers:
ManufacturerRemarks
LOCAL
22994
IE306
Manufacturer Code:LOCAL
Supply Number:CoMat 05-135
Type:sp01
Supply Short Name:CoMat 05-135 POLISHING BOB
Supply Name:CoMat 05-135 POLISHING BOB
Specification Groups:
Doc NumberType
OMAT: 505MEDIUM HARD FELT CROWN 59/65 W. STRENGTH. LEATHER WASHERS
Suppliers:
ManufacturerRemarks
LOCAL
0A7F7
IE446
K6835
Manufacturer Code:X222X
Supply Number:CoMat 06-063
Type:sp01
Supply Short Name:CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)
Supply Name:CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)
Specification Groups:
Doc NumberType
It is not permitted to mix the selected CoMat 06‐063 letter suffix material with other CoMat 06‐063 letter suffix materials. Where CoMat 06‐063 is specified with no suffix, use one of the CoMat 06‐063 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:X222X
Supply Number:CoMat 06-064
Type:sp01
Supply Short Name:CoMat 06-064FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)
Supply Name:CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)
Specification Groups:
Doc NumberType
It is not permitted to mix the selected CoMat 06‐064 letter suffix material with other CoMat 06‐064 letter suffix materials.Where CoMat 06‐064 is specified with no suffix, use one of the CoMat 06‐064 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X