TASK 70-35-24-300-501-D01 "Replace Damaged Section Of Tube, Axially Greater than 0.500 in (12.70 mm), By insertion, Repair 1 (VRS7001)"

DMC:V2500-00-70-35-24-04A-920A-D|Issue No:003.00|Issue Date:2019-05-01

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-D01 "Replace Damaged Section Of Tube, Axially Greater than 0.500 in (12.70 mm), By insertion, Repair 1 (VRS7001)"

General

This TASK details the procedure for the replacement of a section of tube with axial damaged greater than 0.500 in. (12.70 mm) by insertion.

Refer to VRS7001 TASK 70-35-24-300-501 (REPAIR 001) for the following.

Effectivity.

Equipment and Materials.

General.

All illustrations/Figs ref the SPM TASK 70-35-24-300-501-D01 (REPAIR 001).

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NONE

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 10-042 OILLOCALCoMat 10-042
CoMat 02-347 METALLIC FILLERIE424CoMat 02-347
CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADELOCALCoMat 01-025
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

NameManufacturerPart Number / IdentificationQuantityRemark
Refer to TASK 70-35-24-300-501 for repair parts. Alternatively use the spare tubes made of AMS5570, AMS5571, AMS5556 Type 1, and AMS5557 Type 1 with appropriate wall thickness and diameter as a repaired tube.

Safety Requirements

NONE

Procedure

    1. SUBTASK 70-35-24-350-009 Prepare Damaged Tube

    1. Refer to Figure, Figure, and Figure.

    2. Locally manufacture suitable jig.

      3. Mark off section of tube to replaced.

      1. Refer to SPM TASK 70-35-24-300-501 for limitations.

      4. Cut away defective section of tube to be replaced.

        1. Use a small hacksaw or pipe cutter.

        1. Use standard workshop equipment.

      5. Dress the tube ends square to the axis.

        1. Use jig to make sure the overall length of the tube is correct.

        1. Use small hand file.

      6. Deburr the tube ends.

      1. Use a small file.

    2. SUBTASK 70-35-24-350-010 Prepare Repair Part

      1. If you will not use a bending mandrel in the tube when you bend the tube, do the subsequent procedure.

        1. Coat the tube internal surfaces with a film of CoMat 10-042 OIL.

        1. Apply by total immersion of the tube or by filling and emptying the tube.

        2. Allow to drain.

        2. Plug the tube at one end and pre-heat in a water bath to a temperature above the melting point of the filler.

        1. Do not allow water to enter into the tube which may break the oil film and result in the metallic tinning of the bore surfaces.

      3. Immerse the tube partially in hot water.

      4. Melt the CoMat 02-347 METALLIC FILLER and allow it to flow gently into the tube.

      5. Quench the filled tube in a cold water bath.

    3. SUBTASK 70-35-24-350-011 Shape the Tube

      1. Bend the tube to suit location, as necessary.

      1. Use locally manufactured suitable jig.

      2. Pre-heat the tube to 122 deg F (50 deg C).

        3. Use suitable lubrication and bending mandrels or blocks.

        1. As an alternative to a bending mandrel in the tube, it is permitted to use CoMat 02-347 METALLIC FILLER in the tube. Refer to Step.

      2. Trim the tube to the required length and deburr ends.

      1. Use a small file.

    4. SUBTASK 70-35-24-350-012 Remove the Metallic Filler

      1. If the tube is filled with metallic filler from Step, do the subsequent procedure.

      1. Remove the metallic filler by immersing the tube in boiling water and allow to drain.

        2. Remove any residues of metallic filler which may remain in the tube by filling the tube with or immersing the tube in nitric acid solution.

          1. Dilute to a concentration of 500 gms per litre.

          2. Refer to SPM TASK 70-33-89-100-501.

          3. Other brazed tube features that do not require to be replaced must be protected from acid attack.

    5. SUBTASK 70-35-24-310-005 Weld the Components

      1. Prepare the surfaces for weld.

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

      2. Clean the repair area.

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

        1. Use chemical cleaning equipment.

      3. For orbital welding assemble the tube portions in the jig with the replacement section and two appropriate sized Tee rings in the correct position.

        1. Refer to TASK 70-35-24-300-501 (REPAIR 001), for repair parts.

        1. Thickness of Tee ring allows for weld shrinkage at each joint.

        2. Assembly will therefore be oversize on length at this stage.

    4. For manual welding assemble the tube portion in the jig with the replacement section in the correct position.

      5. Tack weld the components.

    6. Check for position of components.

      7. Argonarc weld

      1. See welding data.

    8. Welding Data

      9. Type of weld

      1. Argonarc DC

      10. Filler wire

      11. Torch, Electrode, Argon backing flow, Argon torch flow, and Current

      1. NOTE

        Refer also to SPM TASK 70-31-02-310-501-001.
        An orbital weld will give a neater result, but is not mandatory.

        Use orbital welding equipment. To be determined by a suitable test piece.

    6. SUBTASK 70-35-24-140-003 Clean the Repair Area

      1. Remove weld discoloration by lightly polishing.

    7. SUBTASK 70-35-24-220-004 Examine the Repair

      1. Visually examine and measure the dimension using the jig.

    8. SUBTASK 70-35-24-230-004 Do a Crack Test

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

    9. SUBTASK 70-35-24-260-003 Radiographically Examine the Weld

      1. Radiographically examine the weld.

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

    10. SUBTASK 70-35-24-780-004 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. Pressurize the tube.

      1. Slowly increase 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 one 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.

    11. SUBTASK 70-35-24-780-007 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 two 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.

    12. SUBTASK 70-35-24-350-013 Identify the Repair

      1. Make a mark VRS7001/4 adjacent to the part number.

        1. Refer to 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.

    13. Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised General information. Added spare. Revised step. Added step. (17VU533)

Link not Found
Manufacturer Code:IE424
Enterprise Name:MINING AND CHEMICAL PRODUCTS LTD
BU Name:MINING AND CHEMICAL PRODUCTS LTD
Building:FINEDON ROAD INDU STRIAL ESTATE
Street:1-4 NIELSON ROAD
City:NORTHANTS
State:WELLINGBOROUGH
Country:ENGLAND
Phone Number:44-1933-225766
Fax Number:44-1933-227814
Email:info@mcp-group.co.uk
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Link not Found
Manufacturer Code:5FCA4
Supply Number:CoMat 01-025
Type:sp01
Supply Short Name:CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADE
Supply Name:CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADE
Specification Groups:
Doc NumberType
orTECHNICAL GRADE SP.GR. 1.42 NITRIC ACID
orTECHNICAL GRADE 42 BAUME NITRIC ACID
TECHNICAL GRADE 67.5 WT% NITRIC ACID
Suppliers:
ManufacturerRemarks
5FCA4
K6835
LOCAL
U0PR4
U0SV8
U6726
V272V
Manufacturer Code:IE424
Supply Number:CoMat 02-347
Type:sp01
Supply Short Name:CoMat 02-347 METALLIC FILLER
Supply Name:CoMat 02-347 METALLIC FILLER
Specification Groups:
Doc NumberType
OMAT:2/109MCP 70 ALLOY
Suppliers:
ManufacturerRemarks
IE424
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
Manufacturer Code:LOCAL
Supply Number:CoMat 10-042
Type:sp01
Supply Short Name:CoMat 10-042 OIL
Supply Name:CoMat 10-042 OIL
Specification Groups:
Doc NumberType
PMC 9852WINSOR L1CoMat 10-A MIL-PRF-6081 GRADE CoMat 10
Suppliers:
ManufacturerRemarks
LOCAL
81349
1M647