Preliminary Requirements

Safety Requirements

WARNING

IT IS THE RESPONSIBILITY OF THE OPERATOR TO OBTAIN AND OBSERVE THE MANUFACTURER'S MATERIAL SAFETY DATA SHEETS FOR CONSUMABLE MATERIALS SAFETY INFORMATION (SUCH AS HAZARDOUS INGREDIENTS; PHYSICAL/CHEMICAL CHARACTERISTICS; FIRE, EXPLOSION, REACTIVITY, AND HEALTH HAZARD DATA; PRECAUTIONS FOR SAFE HANDLING; AND USE AND CONTROL MEASURES), AND ALSO TO TAKE LOCAL REGULATIONS INTO CONSIDERATION.

Procedure

1. SUBTASK 70-72-01-720-001 Standard Conversion and Definitions of Terms

   1. The terms and symbols shown below are used many times in equations and calculations for airflow testing. The definitions are applicable during this TASK.

      FP = Flow Parameter, usually written as F/P or F.P. Used as an alternative of.

      W x the square root of T3 all divided by Pa.

      or

      W x the square root of T3 all divided by P3.

      FPcp = Calibration Point Flow Parameter, the flow parameter displayed by a master tool when it is operating at PRdes.

      FPdes = Design Flow Parameter, the flow parameter at which an engine part or correlation master tool is designed to operate.

      K = A constant for sonic nozzle flow parameter, got at the time of nozzle calibration, which is the relation between the nozzle inlet pressure in psia and weight of the air in PPS which flows through the nozzle when air velocity at the nozzle throat is Mach 1.0 (sonic, nozzle choked).

      KT = Sum of K for two or more sonic nozzles operated in parallel at the same inlet pressure.

      Pa = Atmospheric pressure in psia.

      Pd = Pressure, in psia, in the acoustic damper or contained during airflow test.

      P1 = Sonic nozzle inlet pressure, in psia, measured by the P1 pressure gage.

      P3 = Engine part inlet pressure, in psia, is measured by the P3 pressure gage from a part in the airflow test fixture. P3 pressure is also accepted as sonic nozzle discharge or outlet pressure.

      PPS = Pounds per second (that is, pounds/second).

      PR = Pressure Ratio, usually written as P/R or P.R. Used as an alternative of P3/Pa.

      PRcp = Calibration Point Pressure Ratio, the pressure ratio displayed by a master tool when it is operating at FPdes.

      PRdes = Design Pressure Ratio, the pressure ratio at which an engine part or correlation master tool is designed to operate.

      T3 = Temperature in degrees Rankine, usually written without the subscript 3.

      W = Airflow in pounds per second (that is, in pounds/second).

   2. The standard conversions used during airflow testing are shown below.

      1. To change barometer pressure to psia:

         Barometer (inches of mercury) x 0.4912 = psia.

         Barometer (millimeters of mercury) x 0.0193 = psia.

      2. To change temperature, deg F or deg C, to deg R:

         deg R = deg F + 460 (459.688).

         deg R = (1.8 x deg C) + 492 (491.688).

      3. To change gage pressure to absolute pressure and absolute pressure to gage pressure:

         psia = psia + Pa (psia).

         psig = psia - Pa (psia).

         NOTE

         The factor 800.75 (800.7473) is got from 60 seconds per minute (that is, seconds/minute) divided by 0.07493 which is the density of air at standard pressure (29.92in. Hg) and temperature (70 deg F).

      4. To change pounds per second (that is, pounds/second) to Standard Cubic Feet per Minute (SCFM) (that is, Standard Cubic Feet/Minute):

         SCFM = PPS x 800.75

2. SUBTASK 70-72-01-720-002 Procedure for Leak Check of Test Bench

   1. This airflow testing section provides full, step-by-step procedures for doing each airflow test that is necessary. In each of the airflow test procedures, one of the steps needs an air leakage test done, in which a leak test tool (engine part with the air exit holes sealed) replaces the engine part or in which rubber stoppers are used to seal the air exit holes in the engine part or master tool. These air leakage tests are used to detect leakage which is related to or caused by constant use of the airflow test fixtures. Leakage at the quick-disconnects which attach the fixture to the test bench or leakage at the rubber gasket or grommet which seals the interface between the engine part and the airflow test fixture are examples of this type of leakage.

   2. A leak check of the entire test bench to detect external leakage is only extending the daily leak check procedure provided in Step thru Step to cover not only quick-disconnects and gasket or grommet at the engine part-to-fixture interface, but also all other joints, fittings and couplings in the entire test bench.

   3. A leak check to detect internal leakage is important only at the ball valves which are used to select sonic nozzles. (Refer to the SPM TASK 70-72-02-720-501 for the schematics for IAE 6P16080 Test bench 1 off). Air leaks which pass the closed ball valves would affect the P3 gage pressure but would not be measured by the active nozzle/nozzles. Thus, an error would be introduced into the airflow test results.

   4. Frequency of Leak Check.

      1. A leak check of the entire test bench must be done.

         1. When the test bench is new and before the five-point calibration procedure.

         2. After any test bench maintenance, in which a joint or fitting is disturbed, such as replacement of gages or other components.

         3. After disassembly for cleaning the nozzles and the flow straighteners or modification to the test bench.

   5. Air leakage limits.

      1. During the leak check of the full test bench, the limit is zero for both internal and external leakage at all joints, fittings, valves, connections, etc, which includes the quick-disconnect fittings used to attach blade and vane airflow test fixtures to the test bench and gaskets or grommets which seal the interface between the engine part and the airflow test fixture.

      2. The daily leak check is intended primary to detect leakage at the airflow test fixture gasket or grommet and quick-disconnects. The leakage limit is given in the Engine Manual and is given as a rate of pressure drop in the isolated system.

   6. Procedure.

      1. Refer to the engine part airflow test instructions in this SUBTASK for:

         1. Tool numbers of the airflow test fixture, leak test tool, airfoil sealing fixture and correlation master tool.

         2. Procedure to set up the test bench to do a specific airflow test.

         3. Procedure for the daily leak test which is done just before airflow testing a quantity of engine parts.

      2. 

         CAUTION

         DO NOT USE THE RATE OF PRESSURE DROP AS AN INSPECTION CONDITION.

         At the place in the daily leak test procedure where the system has been pressurized to 9 psia (62.1 kPa) and isolated, use CoMat 10-045 LEAK CHECK FLUID, BUBBLES-TYPE to inspect for air leakage at all the joints, fittings, couplings, valves, etc, in the full test bench, where a possible external leakage can occur. Repair as necessary to stop external leakage.

      3. Check for internal leakage at the ball valves. (Refer to the SPM TASK 70-72-02-720-501 for the schematics for IAE 6P16080 Test bench).

         1. With external leakage stopped, pressurize the IAE 6P16080 Test bench to 9 psia (62.1 kPa).

         2. Close all ball valves.

         3. Adjust pressure regulator to increase pressure upstream of ball valves to 50 psia (34.7 kPa) as shown by the P1 gage.

         4. An increase pressure downstream of the ball valves, as shown by the P3 gage, is a result of air leakage part one or more of the ball valves.

      4. To locate the leaking ball valve:

         1. Remove the sonic nozzles and inlet flow straighteners.

         2. Make a jumper hose which will connect to each ball valve. The other end of the jumper hose can be immersed in water or connected to the P3 gage.

         3. Pressurize again the upstream side of the ball valves to 50 psia to locate the leaking valve.

         4. Repair or replace valves as necessary.

3. SUBTASK 70-72-01-720-003 Pressure Caused by Acoustic Damper or Enclosure

   1. For engine parts, such as turbine cooling air ducts and turbine vane ring assemblies, which must have high airflow, an acoustic device is supplied to decrease the noise hazard.

      1. Some test benches have an acoustic chamber, in with the test bench, which fully contains both the engine part and airflow test fixture. Air flows from the engine part into the acoustic chamber and then out of the chamber through the muffler, which exhausts into the room in which the test bench is located, or through the duct work to the outside of the building.

         NOTE

         IAE recommends that the test benches be manufactured without an acoustic chamber which is a part of the test bench and, that an isolated cylindrical acoustic damper be used that is not a part of a test bench.

      2. For test benches without an acoustic chamber, which is a part of the test bench, an acoustic damper is supplied which is isolated from the test bench. The acoustic damper is a cylinder, open at both ends and lined with acoustic material, which is placed around the engine part and airflow test fixture before the start of the airflow test. Air flows from the engine part into the inside diameter of the damper and then out the open top into the room in which the test bench is located.

      3. When an acoustic device is used, air that flows from the engine part is slowed down by not only the normal resistance caused by atmospheric pressure but also resistance (back pressure) caused by the acoustic device. The pressure caused by the acoustic device must be measured as follows:

         1. As part of the five-point (basic) test bench calibration.

         2. The first time the device is used.

   2. To measure the pressure caused by an acoustic device, an aneroid barometer must be adjusted to measure pressure inside the acoustic device while air is flowing.

      1. One method to do the pressure measurement for a cylindrical acoustic damper can be seen in Figure. The identity of the numbered arrows are given below.

         1. Arrow number 1 identifies the cabinet.

         2. Arrow number 2 identifies the airflow test fixture with a cooling air duct assembly mounted on it.

         3. Arrow number 3 identifies the locally made acoustic damper. The approximate dimensions are, outside dimension (OD) 40.00 inches (1016 mm), height 36 inches (914.40 mm) open at both ends and lined with acoustic material 2 inches (50.80 mm) thick. It also has three equally spaced lifting eyes attached to one end.

         4. Arrow number 4 identifies the temporarily attached small diameter hose 0.125 inch (3.18 mm) ID, taped to the inner wall of the damper.

         5. Arrow number 5 identifies the position of the open end of the hose 10 to 12 inches (254.00 to 304.80 mm) above the bottom of the damper.

         6. Arrow number 6 identifies the hose which connects to the aneroid barometer.

      2. A pressure tap, which can be put through the wall of an acoustic chamber, can be seen in Figure. The identity of the numbered arrows are given below.

         1. Arrow number 1 identifies the outer wall of the acoustic chamber.

         2. Arrow number 2 identifies the acoustic material which lines the chamber walls.

         3. Arrow number 3 identifies the position where you drill a hole in the chamber wall to accept a metal tube with an OD of 0.125 inch (3.18 mm) and an inside dimension (ID) of 0.063 inch (1.59 mm).

         4. Arrow number 4 identifies the position of the tube 10 to 12 inches (254.00 to 305.00 mm) above the floor of the chamber.

         5. Arrow number 5 identifies the length of tube that goes into the chamber by approximately 0.250 inch (6.35 mm). The tube is to be attached with epoxy cement or silicone rubber.

         6. Arrow number 6 identifies a hose that connects the tube to the aneroid barometer.

   3. Calculation of the pressure caused by an acoustic device.

      1. With a barometer adjusted as in Step B and before the start of the airflow test (while no air flows), the pressure inside the acoustic device will be atmospheric, Pa.

      2. During the airflow test, while air flows, the barometer will measure the pressure inside the acoustic device, which is identified by Pd.

      3. The difference between Pd and Pa is the pressure caused by the acoustic device.

   4. Limit on the pressure caused by the acoustic device.

      1. The pressure caused by an acoustic device must be less than:

         0.1 psia, or

         0.2 (0.203) inch of Hg, or

         5.2 (5.181) millimeters of Hg.

         In practice, when air is flowing, the increase in pressure (above atmospheric) measured by the barometer must be less than the above limit.

      2. Acoustic devices, which cause pressure of 0.1 psia (0.2 inch Hg or 5.2 mm Hg) or more, must be changed to decrease the pressure less than the limits.

4. SUBTASK 70-72-01-720-004 One-Point Test Bench Calibration

   NOTE

   The engine part inspection TASK in the Engine Manual gives specific airflow test limits; Step thru Step give full, step-by-step procedures to do each airflow test necessary. In each airflow test procedure, one of the steps needs a one-point test bench calibration. This SUBTASK gives the general procedure for the one-point test bench calibration.

   1. General.

      1. At the time when the five-point (basic) test bench calibration was last completed, the test bench was accepted if a performance of between within plus or minus 3 percent of the IAE master test bench (that is, a difference or error as large a 3 percent was accepted) was displayed.

      2. The cause of the one-point test bench calibration is to temporarily adjust out of the test bench as much of the remaining 3 percent difference as possible so that, when engine parts are airflow tested, the test bench will function as close as possible to the way the IAE master test bench would function.

      3. Correlation master tools are calibrated on the IAE master test bench by either the flow parameter or the pressure ratio procedure of testing, as specified by the operator. It does not matter which procedure was used, after the calibration data was plotted and a curve was drawn, one specific point on the curve was defined.

         1. For correlation master tools calibration by the flow parameter procedure, the specific point is the point through which the design pressure ratio (PRdes) line and the calibration curve meet each other. The flow parameter at this specific point (FPcp) is also given and the values of PRdes and FPcp are marked on the master tool.

            NOTE

            Refer to the SPM TASK 70-72-02-720-501 for an analysis of the correlation master against work master tools.

         2. For correlation master tools calibrated by the pressure ratio procedure, the specific point is the point through which the design flow parameter (FPdes) line and the calibration curve meet each other. The pressure ratio at this specific point (PRcp) is also given and the values of FPdes and PRcp are marked on the master tool.

      4. If the person uses a dual master system, the work master tools calibrated by the person on his test bench, they are calibrated and marked in the same way.

      5. The one-point test bench calibration copies the master tool calibration at this one specific point, the coordinates of which are marked on the master tool.

      6. Two things shown during the one-point test bench calibration are:

         1. The general health or condition of the test bench is checked by finding if the flow parameter displayed by the master tool is still between plus or minus 3 percent of the flow parameter which was displayed by the tool when it was calibrated on the IAE master test bench.

            NOTE

            The reason for supplying the test bench with P1 and P3 gages, which have dials which turn, is to make possible the step of adjusting minor deviations out of the operator's test bench so that, at this one specific point, the correct relation is between the P1 and P3 gage pressures. Without dials which turn, it would be necessary to calculate a correction factor and to apply this factor as each engine part is tested. This is a time-consuming process which could give an error.

         2. The remaining difference of between plus or minus 3 percent limit can be adjusted out so that, immediately before testing a quantity of engine parts, the test bench is done just as the IAE master test bench would function.

   2. Frequency.

      1. The one-point test bench calibration must be done for a specific type of airflow test.

         1. Immediately before doing the airflow test on a quantity of engine parts.

            NOTE

            During fast weather changes, atmospheric pressure can change (increase or decrease) 0.1 psig (0.7 kPa) in as little as 15 minutes.

         2. If using a manual or non-automated flow bench while testing a quantity of engine parts, when atmospheric pressure changes 0.1 psig (0.2 inch Hg or 5.2 mm Hg or 0.7 kPa) from what it was at the time when the last one-point test bench calibration was done.

   3. Procedure.

      1. Set up the test bench to do a specific airflow test on a specific type of engine part. Use the instructions in the applicable paragraphs that follow.

      2. Do the air leakage check as given in the applicable paragraphs that follow. Refer to the Engine Manual for test limits:

         1. Leakage limit before the one-point test bench calibration is zero.

            NOTE

            Refer to the SPM TASK 70-72-02-720-501 for an analysis of the correlation master against the work master tools.

            NOTE

            Use the work master tool in regular testing of engine parts and regular test bench calibration.

      3. Remove the leak test tool and install the work master tool.

         NOTE

         These procedures are correct when no acoustic device is used and when an acoustic device, if used, causes pressure at the engine part outlet less than 0.1 psig (0.2 inch Hg or 5.2 mm Hg or 0.7 kPa) above ambient atmospheric.

      4. Sample worksheets 1, (Refer to Figure) and 2, (Refer to Figure) give a step-by-step procedure to complete the one-point test bench calibration. The subsequent items give the use of the worksheets:

         NOTE

         In order to correctly compare between the function of the master tool on the IAE master test bench and the function of the master tool on the person's test bench, the one-point test bench calibration must always be tested by the same procedure as was used when the master tool was calibrated.

         NOTE

         After the one-point test bench calibration has been completed, the engine parts can be airflow tested by two procedures for which airflow test limits are available in the Engine Manual.

         1. Use sheet 1 of the worksheet, (Refer to Figure) which agrees with the method of testing used to calibrate the master tool.

         2. In step 1, use nozzle throat diameter(s) and "K" factor(s) applicable to the actual sonic nozzle(s) in the test bench which will be used to test the engine parts.

         3. In step 4, do not correct the barometer reading for altitude, because the pressure ratio is based on ambient, not sea level, atmospheric pressure. It is not necessary to correct the aneroid or mercury barometers to 32 deg F (0 deg C) as the correction is very small.

         4. In step 6, three different values of flow parameters must be replaced into the equation to calculate the three different P1 gage pressures.

         5. In step 7, after the P3 gage dial has been locked, it stays locked until there is a change in atmospheric pressure, change in the type of airflow test or engine part that is being tested. After which, the calibration of the test bench is necessary again.

         6. In step 8, when the airflow is adjusted to the P3 gage, permit some time for the pressure to become stable and then re-set the P3 gage pressure before you continue to step 9. The smaller the sonic nozzle diameter, the more time will be necessary to reach a stable condition.

            NOTE

            If the P1 gage pressure is higher than the value of 103 percent of FP, the possible cause is air leakage. If the P1 gage pressure is lower than the value of 97 percent of FP, the possible cause is contamination of the work master tool, such as clips or rubber seal shavings blown into the work master tool. If one of the two or both occurs, clean the fixture and use the correlation master tool to trouble shoot the system.

         7. In step 9, a satisfactory general condition of the test bench is indicated if the result of P1 gage pressure, before the gage adjustment, falls between the range of the P1 calculated for 97 percent and 103 percent of flow parameter. If the result of the P1 gage pressure is not between the limits, use of the test bench must be stopped until the problem is found and corrected.

         8. In step 9, after the P1 gage dial has been locked, it stays locked until there is a change in atmospheric pressure or a change in the type of airflow test on the engine part that is being tested is necessary for the recalibration of the test bench.

         9. In step 10, to make easy the task of keeping track of the change in atmospheric pressure, a locally made marker can be temporarily attached to, or adjacent to, the barometer. The device should have a mark to show the current position of the barometer needle or mercury column and also have a mark at the equivalent of plus 0.1 psia (0.7 kPa) and one at the equivalent of minus 0.1 psia.

      5. To show the use of worksheets, sample worksheets 1 (Refer to Figure) and 2 (Refer to Figure) have been completed on the basis of these figures:

         1. Example 1, worksheet 1 (Sheet 2), Figure.

            Master tool calibrated by : PR procedure.

            Design FP : 0.0676.

            Cal. Pt. PR : 1.380.

            Sonic Nozzles - Throat diameter : 0.125 plus 0.177.

            (K Factor) : (0.00647 plus 0.01300).

            Total "K" : 0.01947.

            Atmospheric pressure : 29.860 inches Hg.

         2. Example 2, worksheet 2 (Sheet 2), Figure.

            Master tool calibrated by : FP procedure.

            Design PR : 1.300.

            Cal. Pt. FP : 0.00971.

            Sonic nozzles - Throat diameter : 0.088.

            (K Factor) : 0.00323.

            Total "K" : 0.00323.

            Atmospheric pressure : 792.5 mm Hg.

5. SUBTASK 70-72-01-720-005 Five-Point Test Bench Calibration

   1. General.

      1. The five-point (basic) test bench calibration has two objectives:

         1. To find if there are any defects in the way that the test bench was made, for example:

            1. Plumbing - the internal dimensions of which are too small and/or with bends with radius not sufficient.

            2. Valves - the internal design of which prevents or twists the airflow.

         2. To compare performance of the operator's test bench to the performance of the IAE master test bench.

      2. The five-point (basic) test bench calibration is a copy on the operator's test bench, or the procedure by which all of the operator's correlation master tools were calibrated on the IAE master test bench.

         1. The curves and supporting data which go with each correlation master tool, document the performance of the master tool on the IAE master test bench.

         2. The operator can operate the master tool on his test bench at a series of check points (minimum of five) and compare the performance of the master tool on his test bench against the performance of the master tool on the IAE master test bench. The operator can find the quantity of the master tool performance difference. Because the airflow properties of the master tool are thought to stay constant, all master tool performance difference is really a test bench performance difference.

   2. Correlation limits.

      1. During the five-point or basic calibration, the operator's test bench must agree to the IAE master test bench to between plus or minus 3 percent of the flow parameter. The flow parameter shown by the correlation master tool on the operator's test bench must be between plus or minus 3 percent of the flow parameter shown by the master tool at the time it was calibrated or the IAE master test bench.

         1. A difference in master tool performance greater than plus or minus 3 percent shows an unsatisfactory result in the operator's test bench which must be located and corrected before the test bench can be used to airflow test engine parts.

         2. The possible causes for a master tool performance difference in excess of the plus or minus 3 percent limit are:

            1. Air leakage (external or internal).

            2. Plumbing (metal tube or hose) whose inner diameter is too small.

            3. Plumbing with bends whose radius are two small.

            4. Unsatisfactory flow capacity of the filter or dryer and dirty master tools.

   3. Frequency of five-point calibration.

      1. The five-point test bench calibration must be done.

         1. When the test bench is new, before its first use for airflow testing engine parts.

            NOTE

            It is not necessary to do the five-point test bench calibration after small maintenance. Small maintenance includes: calibration of gages, disassembly for cleaning of the inside of the nozzles or flow straighteners, or the replacement of items with new items which are the same as the ones removed.

         2. After major changes to the test bench (for example, adding sonic nozzles, plumbing changes or welding fittings to manifolds).

   4. Specification for the five-point test bench calibration.

      1. The five-point test bench calibration must be done as many times as necessary to use all sonic nozzles installed in the test bench.

         1. Where possible, select airflow tests and correlation master tools which will use individual nozzles, not nozzles operated in parallel.

      2. The five-point test bench calibration must be done using the same procedure of testing as was used to calibrate the correlation master tool.

      3. To compare the results obtained during the five-point test bench calibration, they must be plotted on a copy of the calibration curve which is with the correlation master tool.

   5. Procedure - General.

      1. Make a decision on which sonic nozzle, or combination of nozzles, will be used for the first five-point test bench calibration.

      2. Refer to Step to select the airflow test instructions for an engine part which will use the selected nozzle on nozzle combination.

         1. The airflow test instructions, for each airflow test of each engine part, contain tables applicable to the procedure of testing which specify the recommended sonic nozzle throat diameter, fixture tool numbers and correlation master tool number.

      3. Set up the test bench to do the airflow test selected in step (2).

         1. For the IAE IAE 6P16080 Test bench 1 off, use a jumper hose to connect the P1 and P3 gages to the applicable circuit.

         2. Attach the correct airflow test fixture, if necessary. Refer to the instructions in the selected airflow test in the Engine Manual.

         3. Adjust or calibrate the airflow test fixture, if necessary. Refer to the instructions in the selected airflow test in the Engine Manual.

      4. Do the air leakage check specified in the selected airflow test. Then do an air leakage check on all the test bench that is specified in Step. Before the five-point test bench calibration, both external and internal air leakage must be zero.

      5. Remove the leak test tool from the airflow test fixture and install the correlation master tool.

      6. From the calibration curve and supporting data which accompany the correlation master tool, find the procedure for testing which was used to calibrate the correlation master tool.

      7. Continue the five-point test bench calibration which uses the procedure which is the same as the procedure used to calibrate the master tool. Refer to Step, paragraph F or paragraph G.

         NOTE

         1. This continues from SUBTASK 70-72-01-720-005 paragraph E, calibration procedure.

         2. To illustrate this procedure, two examples will be carried through the procedure, both done on the understanding that the test bench is being calibrated with a typical correlation master tool A, applicable to the turbine cooling air duct.

   6. Correlation master tool that is calibrated by the flow parameter procedure of testing.

      1. From the calibration curve or supporting data, find the master tool design pressure ratio.

         Example: For a typical correlation master tool A, the design pressure ratio is 1.430.

         NOTE

         Take the barometer readings to be 30.00 inches Hg and 29.75 inches Hg.

      2. Convert the atmospheric pressure into psia. Refer to the standard conversions in Step.

         Example 1 : 30.00 x 0.4912 = 14.736 psia.

         Example 2 : 29.75 x 0.4912 = 14.613 psia.

      3. Calculate the master tool inlet (P3) pressure at design pressure ratio and current atmospheric pressure using the equation.

         P3 = PRdes x Pa (psia).

         Example 1 : 1.430 x 14.736 = 21.072 psia.

         Example 2 : 1.430 x 14.613 = 20.897 psia.

      4. Round off the P3 pressure calculated in step (3) to the nearest 0.5 psi.

         Example 1 : 21.072 rounds off to 21.0.

         Example 2 : 20.897 rounds off to 21.0.

      5. Select a minimum of four more values of P3 pressure, in 0.5 psi increments, which bracket the master tool inlet pressure, after rounding off in step (4).

         Table 2. Example:

         	22.0
         	21.5
         	21.0 From step (4)
         	20.5
         	20.0
         	NOTE To accurately calculate the curve, a minimum of five-points must be used, this gives the name of the procedure. More points (7 or 9) can be used.

      6. Unlock the dial of both P1 and P3 gages and turn the dial to make both gages read the current atmospheric pressure in psia. Lock the dial of both gages.

      7. If calibration includes a correlation master tool and airflow test where an acoustic devise is usually used, adjust the acoustic device for measurement of the pressure in the device. Refer to Step. Close the doors of the acoustic chamber or place a cylindrical type damper around the engine part.

      8. Operate the correlation master tool on the test bench. Turn the air on. Carefully adjust the airflow to set the P3 gage to each of the values selected in step (5). If an acoustic device is being used, start with the highest value of P3.

      9. If an acoustic device is being used, with P3 set at the highest value, check that the pressure caused by the acoustic device is in the limit. Refer to Step.

         1. If the pressure in the acoustic device, while the air flows, is higher than the limit, stop the test bench calibration until the acoustic device has been changed so that it is in the limit. Refer to Step.

         2. If the pressure in the acoustic device, while the air flows, is in the limit, continue to the steps that follow:

            NOTE

            Accept that the subsequent P1 gage pressures occur when P3 is set at values selected in step (5). Note that, although the selected P3 gage pressures are the same in both examples, the different atmospheric pressures selected in step (2) will cause different resulting P1 gage pressures.

      10. At each value of P3, record the resulting P1 gage pressure. Turn off the air.

          1. At a selected P3 of:

             22.0 - Example 1, Resulting P1 = 72.50 : Example 2, Resulting P1 = 68.55.

             21.5 - Example 1, Resulting P1 = 70.03 : Example 2, Resulting P1 = 66.57.

             21.0 - Example 1, Resulting P1 = 67.49 : Example 2, Resulting P1 = 64.11.

             20.5 - Example 1, Resulting P1 = 64.70 : Example 2, Resulting P1 = 61.50.

             20.0 - Example 1, Resulting P1 = 61.83 : Example 2, Resulting P1 = 58.71.

      11. Change the five P3 gage pressures, selected in steps (4) and (5), to the pressure ratio; use the equation: PR = P3/Pa.

          1. Example 1: Atmospheric pressure in psia (Pa) is 14.7.

             PR = 22.0/14.7 = 1.497.

             PR = 21.5/14.7 = 1.463.

             PR = 21.0/14.7 = 1.429.

             PR = 20.5/14.7 = 1.395.

             PR = 20.0/14.7 = 1.361.

          2. Example 2: Atmospheric pressure in psia (Pa) is 14.6.

             PR = 22.0/14.6 = 1.507.

             PR = 21.5/14.6 = 1.473.

             PR = 21.0/14.6 = 1.438.

             PR = 20.5/14.6 = 1.404.

             PR = 20.0/14.6 = 1.370.

      12. Change the five resulting P1 gage pressures, recorded in step (10), to the flow parameter; use the equation: FP = (KT x P1)/P3.

          NOTE

          Airflow test equipment documents can refer to a square root temperature factor to be used if the difference in temperature between the air at the sonic nozzle inlet and air at the master tool inlet is more than 3 degrees Rankine. If has been shown that, in test benches built with IAE instructions, the temperature difference is never more than 3 degrees Rankine. Although temperature measurement ports or bosses are included in the test bench, they are not being used and no temperature correction is necessary.

      13. Example 1: Use "K" Factor of 0.416.

          FP = (0.416 x 72.50)/22.0 = 1.371.

          FP = (0.416 x 70.03)/21.5 = 1.355.

          FP = (0.416 x 67.49)/21.0 = 1.337.

          FP = (0.416 x 64.70)/20.5 = 1.313.

          FP = (0.416 x 61.83)/20.0 = 1.286.

      14. Example 2: Use "K" Factor of 0.417.

          FP = (0.417 x 68.85)/22.0 = 1.305.

          FP = (0.417 x 66.56)/21.5 = 1.291.

          FP = (0.417 x 64.11)/21.0 = 1.273.

          FP = (0.417 x 61.50)/20.5 = 1.251.

          FP = (0.417 x 58.71)/20.0 = 1.224.

      15. With the use of the pressure ratio calculated in step (11) and the flow parameters calculated in step (12) as coordinates, plot the test points which specified the function of the master tool and draw a curve through the point. To make it easy to compare, plot the data on a copy of the master tool calibration curve. Refer to Figure.

      16. Make an analysis on the condition of the operator's test bench.

          NOTE

          On Figure, the curve shown by the points in Example No. 1 falls approximately 1.5 percent above the calibration curve, well in the plus 3 percent of the FP limit. The test bench is acceptable.

          1. If the curve which shows the master tool performance on the operator's test bench falls between the plus 3 percent of FP and minus 3 percent of FP curves, the test bench is acceptable.

             NOTE

             On Figure, the curve shown by the points in Example No. 2 is not in the plus or minus 3 percent of the FP band (about 0.9 percent below minus 3 percent of the FP curve). Corrective action is necessary.

             NOTE

             Do not do corrective action until the calibration procedure in Step paragraphs E and F, has been done a sufficient number of times to use all the nozzles applicable to blades and vanes, so that results of all calibration curves can be compared.

             NOTE

             The flow properties of the test bench must be the same. For example, if the test bench flows low when using the 0.250 inch (6.35 mm) nozzle, it would be expected to flow low also when using the 0.117 inch (2.97 mm) nozzle or some other combination of nozzles.

          2. If the curve which shows the master tool performance on the operator's test bench is not in the plus or minus 3 percent of the FP the band, (that is; above plus 3 percent of the FP or below 3 percent of the FP) corrective action is necessary to make the test bench acceptable.

      17. Do the calibration procedure again. Refer to Step paragraphs E and F, as necessary, to use all the sonic nozzles installed in the test bench.

      18. Do corrective action, as necessary, and do again the calibration procedure until the results of the calibration show that the operator's test bench flows between plus or minus 3 percent of the IAE master test bench.

      19. If the operator selects to use the dual system of both correlation master and work master tools, the set of work master tools must be calibrated immediately after completion of the five-point test bench calibration.

      20. Keep the correlation master tools and work master tools in applicable protective containers.

          NOTE

          This continues from Step paragraph E, calibration procedure.

          NOTE

          To illustrate this procedure, an example will be carried through the procedure on the understanding that the test bench is being calibrated with a typical correlation master tool B, applicable to the first stage turbine vane.

   7. Correlation master tool calibrated by the pressure ratio method of testing.

      1. From the calibration curve or supporting data, find the master tool calibration point pressure ratio (PRcp).

         Example: Accept that, for this master tool, the PRcp is 1.380.

         NOTE

         The rounding-off process is to make the calculations and plotting of points on the graph easy. If PRcp occurs to fall in the middle position between tenths, for example, 1.350, it can be rounded-off to the higher or lower tenth (1.300 or 1.400).

      2. Round-off the master tool calibration point pressure ratio to the nearest tenth.

         Example: 1.380 rounds-off to 1.40.

      3. Use a minimum of four more pressure ratios, in increments of 0.1, which bracket the master tool PRcp, after rounding-off as in step (2).

         Table 3. Example:

         	1.200
         	1.300
         	1.400 From Step (2)
         	1.500
         	1.600
         	1.700
         To accurately calculate the curve, a minimum of five points must be used, this gives the name of this procedure. More points (7 or 9) can be used. To illustrate, one more point (1.700) has been included in this example.

      4. Change atmospheric pressure into psia, refer to Step.

         	Example: Take the barometer reading of 30.00 inches Hg.
         	30.00 x 0.4912 = 14.736 psia

      5. Calculate P3 (engine part inlet) gage pressure which will result in operating the master tool at each of the pressure ratios selected in step (3). Use the equation shown below:

         1. The equation used to calculate P3 gage pressure is: P3 = PR x Pa.

            Examples:	P3 = 1.200 x 14.736 = 17.68 psia
            	P3 = 1.300 x 14.736 = 19.16 psia
            	P3 = 1.400 x 14.736 = 20.63 psia
            	P3 = 1.500 x 14.736 = 22.10 psia
            	P3 = 1.600 x 14.736 = 23.58 psia
            	P3 = 1.700 x 14.736 = 25.05 psia

      6. Release the dial of both P1 and P3 gages and turn the dial to make both gages read the current atmospheric pressure in psia as in step (4). Lock the dial of both gages.

      7. If the calibration includes a correlation master tool and airflow test where an acoustic device is normally used, adjust the acoustic device for measurement of the pressure in the device as in Step. Close the doors of the acoustic chamber or place a cylindrical acoustic damper around the engine part.

      8. Operate the correlation master tool on the test bench. Turn the air on. Carefully adjust the airflow to set the P3 gage to each of the values calculated in step (5). If an acoustic device is being used, start with the highest value of P3.

      9. If the acoustic device is being used, with P3 set at the highest value, check that the pressure caused by the acoustic device is between the limits, refer to Step.

         1. If the pressure in the acoustic device, while air flows, is higher than the limit, stop the test bench calibration until the acoustic device has been changed so that it is in the limit. Refer to Step.

         2. If the pressure in the acoustic device, while air flows, is between limits, continue to the steps that follow:

      10. At each value of P3, record the resulting P1 gage pressure. Turn the air off.

          Example: Accept that the P1 gage pressures that follow result when P3 is set at each of the values calculated in step (5).

          1. At a P3 of:

             17.68 : Resulting P1 = 38.08.

             19.16 : Resulting P1 = 45.41.

             20.63 : Resulting P1 = 52.35.

             22.10 : Resulting P1 = 59.14.

             23.58 : Resulting P1 = 65.55.

             25.05 : Resulting P1 = 71.28.

             NOTE

             Airflow test equipment documents can refer to a square root temperature factor to be used if the difference in temperature between the air at the sonic nozzle inlet and air at the master tool inlet is more than 3 degrees Rankine. If has been shown that, in test benches built with IAE instructions, the temperature difference is never more than 3 degrees Rankine. Although temperature measurement ports or bosses are included in the test bench, they are not being used and no temperature correction is necessary.

      11. Convert the resulting P1 gage pressures to a flow parameter by the use of the equation: FP = (KT x P1)/Pa.

          Let the sonic nozzles have a total or effective K factor of 0.01931. Then.

          FP = (0.01931 x 38.08)/14.736 = 0.0499.

          FP = (0.01931 x 45.41)/14.736 = 0.0595.

          FP = (0.01931 x 52.35)/14.736 = 0.0686.

          FP = (0.01931 x 59.14)/14.736 = 0.0775.

          FP = (0.01931 x 65.55)/14.736 = 0.0859.

          FP = (0.01931 x 71.28)/14.736 = 0.0934.

      12. With the use of the pressure ratios selected in step (3) and the flow parameters calculated in step (11) as coordinates, plot the test points which specified the function of the master tool and draw a curve through the points. Plot the data on a copy of the master tool calibration curve. Refer to Figure.

      13. Make an analysis on the condition of the test bench.

          1. If the curve which shows the master tool performance is between plus and minus 3 percent of the FP curves, the test bench is acceptable.

             Example: In Figure, the curve shown by the points in the example is approximately 1.5 percent below the calibration curve, well in plus or minus 3 percent of the FP band. The test bench is acceptable in this calibration.

             NOTE

             Do not do corrective action until the calibration procedure in Step paragraphs E and F, has been done a sufficient number of times to use all the nozzles applicable to blades and vanes, so that results of all calibration curves can be compared.

             NOTE

             The flow properties of the test bench must be the same. For example, if the test bench flows low with the 0.250 inch (6.35 mm) nozzle, it would be expected to flow low also with the 0.177 inch (2.97 mm) nozzle or some other combination of nozzles.

          2. If the curve which shows master tool performance falls outside 3 percent of the FP band (that is, above the plus 3 percent or below the minus 3 percent curve), corrective action is necessary to make the test bench acceptable.

      14. Do the calibration procedure again. Refer to Step paragraphs E and G, as necessary to use all sonic nozzles installed in the test bench.

      15. Do corrective action as necessary and do again the calibration procedure until the results of the calibration show that the operator's test bench flows in plus or minus 3 percent of the IAE master test bench.

      16. If the operator selects to use the dual system of both correlation master and work master tools, the set of work master tools must be calibrated immediately after completion of the five-point test bench calibration.

      17. Keep the correlation master tools and work master tools in applicable protective containers.

6. SUBTASK 70-72-01-720-006 Airflow Testing Engine Parts - General

   NOTE

   Refer to the SPM TASK 70-72-00-720-501 for an analysis of the two procedures used to airflow test the engine parts. These two procedures are called the pressure ratio (PR) procedure and the flow parameter (FP) procedure.

   1. The procedure can be broken up into basic steps which apply to airflow testing all engine parts by one of the two procedures of testing. These steps are:

      1. Find the airflow test instructions applicable to the engine part and select the procedure of testing to be used.

      2. For some engine parts, special air holes are removed from some airflow tests. For example, air holes in the leading edge of some turbine vanes are airflow tested apart. The applicable paragraphs that follow in this section will give which holes or sets of holes must be sealed off for a specified airflow test and how to do it. This can be done by a special tool or by plater's wax, tape, etc.

      3. Set up the test bench to do the specified airflow test.

         1. Attach the correct airflow test fixture to the test bench.

         2. For turbine blades and vanes, open the valves as necessary to select the correct sonic nozzle diameter for test.

         3. Hook up hoses as necessary to connect the P1 and P3 gages.

      4. Do a leak test to check the condition of the gasket or the grommet which seals the interface between the engine part and airflow test fixture and to check for leaks at other points such as quick disconnects between the test bench and the fixtures.

         1. Install a leak test tool into the fixture or use rubber stoppers to seal all holes in the engine part or correlation master tool.

         2. Slowly turn the air on and pressurize the closed system to 9 psig. Turn the air off to isolate the pressurized system.

         3. Monitor the rate of pressure drop on the P3 gage to give the quantity of leakage. A rate of pressure drop of 1 psia or less every 10 seconds is permitted.

      5. Do the one-point test bench calibration, given in Step.

         NOTE

         These procedures are correct only if the acoustic device causes a pressure at the engine part outlet of less than 0.1 psia (0.2 inch Hg or 5.2 mm Hg) above ambient atmospheric, or if no acoustic device is used during the airflow test.

      6. Test the engine parts. If using a manual or non-automated flow bench, do the steps on Sample Worksheet 3 (refer to Figure,) for the Pressure Ratio Procedure, or do the steps on Sample Worksheet 4 (refer to Figure) for the Flow Parameter Procedure.

   2. If using a manual or non-automated flow bench, Sample Worksheet 3 (refer to Figure) and Sample Worksheet 4 (refer to Figure) give a step-by-step procedure to complete the airflow test of the engine parts. These worksheets are general in type and can be adapted to any engine part. The subsequent items show the use of the worksheets.

      1. Select the worksheet that agrees with the selected test procedure.

      2. In Step, use the nozzle throat diameter and K factor applicable to the actual nozzle in the test bench that will be used to test the engine parts.

      3. In step 2, the chart airflow test limits has one more vertical column on the right for special conditions (such as, repair limits) and horizontal lines for up to three classes of parts.

      4. In step 5, spaces are supplied for you to write the airflow test limits so that calculated gage pressures agree with the limits.

         NOTE

         1. When you test turbine blades and vanes by the flow parameter procedure, in sequence to set the P3 gage to the pre-calculated value, it will be necessary to adjust the flow control pressure regulator for almost every part.

         2. When you test turbine blades and vanes by the pressure ratio procedure, after the flow control pressure regulator has been set to give the pre-calculated P1 gage pressure, the pressurization will be done again automatically, part after part. This is the why IAE recommends the pressure ratio procedure to test blades and vanes.

      5. In step 6, when you adjust the airflow to set a gage pressure, give sufficient time for the pressure to become stable before you read the other gage.

      6. In step 7, spaces are given to write the same group of gage pressure as were selected in step 5.

   3. Fifteen minutes after you start the procedure to test the engine parts, do these checks:

      1. Do a check of the barometer to find the change in atmospheric pressure, if any, because it was recorded on the Sample Worksheet 3 (See Figure) or Sample Worksheet 4 (See Figure).

         1. If the atmospheric pressure has changed by 0.1 psia (0.2 inch Hg or 5.2 mm Hg) or more:

            1. Stop the engine parts test.

            2. Do the leak test.

            3. Do a new one-point test bench calibration.

            4. Calculate the new gage pressures to use as limits on parts to be tested.

         2. If atmospheric pressure has changed less than 0.1 psia (0.2 inch Hg or 5.2 mm Hg), go to step (2).

      2. Install the leak test tool in the airflow test fixture and do a check for air leakage.

         1. If leakage is there, repair or replace the rubber gasket or the grommet in the airflow test fixture, or repair the test bench as necessary and do step (1) again.

         2. If no leakage is there, start to test the engine parts.

            NOTE

            The continuous 15-minute cycle, when you check the change in the atmospheric pressure, must be done to make sure that the gage pressures used as limits are sufficiently accurate. An atmospheric pressure change without a change in pre-calculated gage pressure causes an error into the airflow test results. For example, if the engine part PR is 2.470 in the equation P3 = PR x Pa, then a 0.1 psia change in atmospheric pressure becomes a 0.247 psia error in P3 gage pressure or approximately a 0.7 percent error. The continuous 15-minute check cycle of the installation of the leak test tool is necessary to monitor the condition of the rubber seal or the grommet on the airflow test fixture. If three or four engine parts are rejected one after another for high flow, do not wait the full 15 minutes before you use the leak test tool.

      3. After every fifteen minutes of the test on the engine parts, do step (1) and step (2) again.

7. SUBTASK 70-72-01-720-007 Airflow Testing the Stage 1 HPT Vane Cluster Assembly or the Vane Assembly

   NOTE

   1. Do all the inspections and repairs on the vane cluster assembly or vane assembly before you do the airflow check.

   2. Do the procedure in the sequences given for accurate airflow data. Make sure you do all the steps.

   3. This procedure is for the A1/A5/D5 models.

   1. Refer to: Figure, Figure and Figure

      NOTE

      1. To get accurate results, you must leak check and calibrate the test bench. The vane performance and engine efficiency are directly related to the correct airflow procedure.

      2. If the test bench has absolute pressure gages, add the psig value given in the procedure to the ambient atmospheric pressure to get the psia value.

   2. Set up and leak check the vane airflow fixture and the test bench.

      1. Select the sonic nozzle with the correct throat diameter. Use the mathematical method of nozzle selection given in TASK 70-72-02-720-501, SUBTASK 70-72-02-720-007.

      2. Set up the IAE IAE 6P16080 Test bench 1 off. Refer to Figure.

         1. Install and attach the airflow fixture to the test bench with bolts.

         2. Connect and tighten the test bench pressure sense line to the small tee on the rear of the fixture.

            NOTE

            The airflow path must be from the shop air supply, through the sonic nozzle on the test bench, into the airflow fixture and out through the vane.

         3. Connect and tighten the test bench air line to the large tee on the rear of the fixture.

         4. Close the No. 1 thru No. 4 inlet valves and the No. 5 thru No. 8 P3 valves on the fixture.

         5. Retract the horizontal and vertical clamps to a fully retracted position.

      3. Set up the test bench to do the airflow check on the vane cluster assembly or the vane assembly. Make sure the P1 gage is connected to the sonic nozzle inlet pressure and the P3 gage is connected to read the inlet pressure.

      4. If the test bench has absolute P1 and P3 pressure gages with adjustable dials, adjust the gages to indicate the ambient atmospheric pressure, or set the gages to zero if the gages indicate psig (at zero air pressure).

         NOTE

         A different worksheet is necessary for each airflow parameter.

      5. Calculate the values for the pressure ration method of airflow check; use an applicable airflow test limit table. Refer to the Engine Manual TASK 72-44-20-200-000 (INSPECTION-000). Use the pressure ratio method worksheet procedure in Figure.

      6. Do a shut off valve leak check on the test bench.

         1. Make sure the No. 1 through No. 4 inlet valves and the No. 5 thru No. 8 P3 valves on the airflow fixture are closed.

         2. Close all the shutoff valves on the test bench.

         3. Pressurize the system upstream of the shutoff valves when you set the P1 to the Maximum bench capacity.

         4. Look at the P3 gage for a pressure increase.

         5. The shutoff valve leakage will cause a pressure increase on the P3 gage.

         6. The maximum pressure increase is 0 psig (0 kPa) for one minute.

         7. 

            WARNING

            RELEASE ALL PRESSURE REMAINING AT THE END OF THE TEST OR BEFORE YOU DO REPAIRS. INJURY TO THE OPERATOR CAN OCCUR IF THE PRESSURE IS NOT RELEASED.

            Release the pressure in the system upstream of the shutoff valves.

         8. If the P3 indication is unsatisfactory, repair as necessary and do the leak check again.

            NOTE

            Do the leak check each day, before any airflow check is done or the test bench is repaired.

      7. Do a leak check on the airflow fixture.

         1. Make sure the four inlet valves and the four P3 valves are closed on the fixture.

         2. If the test bench has absolute P1 and P3 pressure gages with adjustable dials, adjust the dials to indicate atmospheric pressure or zero the gages if the gages indicate psig (at zero air pressure).

         3. Slowly open the air supply line and pressurize the system to 9 psig (62.1 kPa) on the P3 pressure gage. Close the valve to isolate the system.

         4. Look at the P3 gage for a pressure decrease.

         5. The maximum acceptable rate of pressure decrease in the isolated system is 1.0 psig (6.9 kPa) in 30 seconds.

         6. If the rate of pressure decrease is more than 0.5 psig (3.4 kPa) for one minute, use CoMat 10-045 LEAK CHECK FLUID, BUBBLES-TYPE to find the source of the leak. The leaks must be repaired to get accurate vane airflow results.

         7. 

            WARNING

            RELEASE ALL PRESSURE REMAINING AT THE END OF THE TEST OR BEFORE YOU DO REPAIRS. INJURY TO THE OPERATOR CAN OCCUR IF THE PRESSURE IS NOT RELEASED.

            Release the pressure in the system upstream of the shutoff valves.

      8. Do an airflow restriction check on the airflow fixture each time the fixture is installed.

         1. Fully open the No. 1 thru No. 4 inlet valves and the No. 5 thru No. 8 P3 valves.

         2. Set the P1 equal to the pressure related with the one largest individual vane flow parameter (refer to the applicable airflow test limit table in the Engine Manual TASK 72-44-20-200-006 (INSPECTION-006) and Figure for the calculations of the P1 pressure) without the vane cluster assembly or vane assembly in the fixture.

         3. Look at the P3 indication.

         4. The maximum P3 indication of 0.5 psig (3.4 kPa) is acceptable, but you should try to minimize the restriction for more accurate airflow results.

         5. A P3 indication of more than 0.5 psig (3.4 kPa) restriction is not acceptable.

         6. Correct the cause of the restriction and do the check again. The cause of the restriction can be:

            1. An insert with damage.

            2. Grease.

            3. Kinked hoses.

            4. Unwanted objects.

         7. Do the check again.

            NOTE

            The two primary errors caused when you do the airflow check are:

            1. The air will leak at the interface between the engine part that is tested and the rubber grommets or the gaskets that seal the engine part to the air flow fixture.

            2. The allowance for atmospheric pressure changes that are not made in the calculated gage pressure.

   3. Do the airflow check on the vane cluster assembly or the vane assembly.

      1. Do the airflow check on the vane cluster assembly or vane assembly front air passage(s). Refer to Figure.

         1. Install the airflow master in the airflow insert set.

         2. Install and attach the master and the insert set in the airflow fixture. Adjust the two clamps to make sure of a minimum clamp force to hold the master in position.

         3. Fully open the No. 1 thru No. 4 inlet valves and the No. 5 thru No. 8 P3 valves.

         4. Look for air leakage at the connections and seals on the fixture, the insert set and the master. No leakage is permitted.

         5. Set up the test bench to do the airflow check by the applicable limits. Refer to the Engine Manual TASK 72-44-20-200-000 (INSPECTION-000) and Figure.

         6. Do a one-point test bench calibration by the procedure given in Step. Refer to the Engine Manual TASK 72-44-20-200-000 (INSPECTION-000) and Figure.

         7. Remove the airflow master from the insert set.

         8. Install the vane cluster assembly or the vane assembly in the insert set and attach to the fixture with the two clamps.

         9. Look for air leakage at the connections and seals on the fixture, the insert set and the master. No leakage is permitted.

         10. Do the airflow check by the applicable limits. Refer to the Engine Manual TASK 72-44-20-200-000 (INSPECTION-000) and Figure.

         11. Accept the airflow on the vane front air passage(s) if the flow is within the limits given in step 9. of Figure.

             NOTE

             Go to step (3) if you have done the airflow operation for 15 minutes.

         12. Remove the vane cluster assembly or the vane assembly and the insert set from the fixture.

      2. Do the airflow check on the vane cluster assembly or the vane assembly rear air passage(s). Refer to Figure.

         1. Install the airflow master in the airflow insert set.

         2. Install and attach the master and the insert set in the airflow fixture. Adjust the two clamps to make sure a minimum clamp force to hold the master in position.

         3. Fully open the No. 1 thru No. 4 inlet valves and the No. 5 thru No. 8 P3 valves.

         4. Look for air leakage at the connections and seals on the fixture, the insert set and the master. No leakage is permitted.

         5. Set up the test bench to do the airflow check by the applicable limits. Refer to the Engine Manual TASK 72-44-20-200-000 (INSPECTION-000) and Figure.

         6. Do a one-point test bench calibration by the procedure given in Step. Refer to the Engine Manual TASK 72-44-20-200-000 (INSPECTION-000) and Figure.

         7. Remove the airflow master from the insert set.

         8. Install the vane cluster assembly or the vane assembly in the insert set and attach to the fixture with the two clamps.

         9. Look for air leakage at the connections and the seals on the fixture, the insert set and the master. No leakage is permitted.

         10. Do the airflow check by the applicable limits. Refer to the Engine Manual TASK 72-44-20-200-000 (INSPECTION-000) and Figure.

         11. Accept the airflow on the vane front air passage(s) if the flow is within the limits given in step 9, of Figure.

         12. Remove the vane cluster assembly or the vane assembly and the insert set from the fixture.

             NOTE

             Go to step (3) if you have done the airflow operation for 15 minutes.

         13. Do the airflow check again on any vane cluster assembly or any vane assembly that remains.

      3. Fifteen minutes after you start the vane airflow operation do the checks that follow:

         1. Check the barometer to find if any change in the atmospheric pressure occurred since it was written on the worksheet.

         2. If the atmospheric pressure changed less than 0.1 psia (0.7 kPa) or less than 0.2 inch Hg (5.2 mm Hg) go to step (d).

         3. If the atmospheric pressure changed more than 0.1 psia (0.7 kPa) or more than 0.2 inch Hg (5.2 mm Hg), stop the test on the vanes. Do a one-point test bench calibration and calculate the new gage pressure by the procedure given in Step. Use the new limits when you check the vanes.

         4. Close the eight valves on the airflow fixture and check for air leakage.

         5. If there is no leakage, open the eight valves and start the airflow check again.

         6. If there is leakage, repair or replace the insert set or repair the test bench as necessary and do Step (d) again.

            NOTE

            The continuous 15-minute cycle, when you check the change in the atmospheric pressure, must be done to make sure that the gage pressures that are used as limits are accurate. An atmospheric pressure change without a change in the pre-calculated gage pressure causes an error in the airflow test results. For example, in the equation PR x Pa = P3; if the vane PR is 2.470 psia (17.0 kPa) then a 0.1 psia (0.7 kPa) or 0.2 inch Hg (5.2 mm Hg) change in the atmospheric pressure becomes a 0.247 psia (1.7 kPa) error in the P3 pressure. This is approximately a 0.7 percent error. The continuous 15-minute cycle, when you install the locally made plug, is necessary to monitor the condition of the airflow insert on the airflow fixture. If three or four vanes, one after the other, are rejected for high flow, do not wait the full 15 minutes to do the checks.

         7. After each 15 minutes of the airflow operation, do these checks again.

      4. Airflow the vane cluster assembly or the vane assembly that shows more airflow than the limits. Refer to the worksheet Step 9. for the vanes marked plus (+). Refer to Figure.

         1. Do the airflow check again. Find if the high airflow was caused by the vane or by air leakage in the test set up.

         2. If the vane cluster assembly or the vane assembly has high airflow, do the airflow check procedure again.

         3. Reject all the vanes that have airflow more than the limits given on the worksheet Step 9. Refer to Figure.

      5. Do the procedure that follows on the vane cluster assembly or the vane assembly that has less airflow than the limits. Refer to the worksheet Step 9. for the vanes marked minus (-). Refer to Figure.

         1. Ultrasonic clean the vanes by the procedure given in the SPM TASK 70-13-01-100-501 but flush the inside of the vanes with hot water. Flush and air dry fully. If necessary, use 0.017 inch (0.432 mm) diameter wire or equivalent to put into the trailing edge cooling air slot to clean the air passage.

         2. Do the airflow check procedure again.

         3. Reject all the vanes that have less airflow than the limits given on the worksheet Step 9. Refer to Figure.

      6. Two hours after you start the airflow operation, do a one-point test bench calibration for each airflow parameter by the procedure given in Step. Refer to the airflow test limit table in the Engine Manual TASK 72-44-20-200-000 (INSPECTION-000) and Figure.

8. SUBTASK 70-72-01-720-008 Airflow Testing the Stage 1 HPT Blade Assembly

   NOTE

   1. Do all the inspections and repairs on the vane cluster assembly or vane assembly before you do the airflow check.

   2. Do the procedure in the sequences given for accurate airflow data. Make sure you do all the steps.

   3. This procedure is for the A1/A5/D5 models.

   1. Refer to: Figure, Figure and Figure

      NOTE

      To get accurate results, you must leak check and calibrate the test bench. The blade performance and engine efficiency are directly related to the correct airflow procedure.

      If the test bench has absolute pressure gages, add the psig value given in the procedure to the ambient atmospheric pressure to get the psia value.

   2. Set up and leak check the blade airflow fixture and the test bench.

      1. Select the sonic nozzle with the correct throat diameter. Use the mathematical method of nozzle selection given in the SPM TASK 70-72-02-720-501, SUBTASK 70-72-02-720-007.

      2. Set up the IAE 6P16080 Test bench 1 off (Refer to Figure):

         1. Install and clamp the flange of the airflow base to the test bench.

         2. Retract the two clamps on the airflow fixture to a fully retracted position.

         3. Install the fixture on the base and align the two open holes in the base with the two holes on the fixture. Move the horizontal clamp block on the fixture until the two holes in the block align with the two holes in the base. Install and tighten the four bolts. Connect and tighten the test bench pressure sense line to the small boss on the side of the base.

            NOTE

            The airflow path must be from the shop air supply, through the sonic nozzle on the test bench, into the airflow fixture and out through the blade.

         4. Connect and tighten the test bench air line to the large boss on the side of the base.

      3. Set up the test bench to do the airflow check on the blade assembly. Make sure the P1 gage is connected to read the blade assembly inlet pressure.

      4. If the test bench has absolute P1 and P3 pressure gages with adjustable dials, adjust the gages to indicate the ambient atmospheric pressure, or set the gages to zero if the gages indicate psig (at zero air pressure).

         NOTE

         A different worksheet is necessary for each airflow parameter.

      5. Calculate the values for the pressure ratio method of airflow check. Refer to the airflow limits tables in the Engine Manual TASK 72-45-14-200-000 (INSPECTION-000). Use the pressure ratio method worksheet procedure in Figure.

      6. Do a shutoff valve leak check on the test bench:

         1. Install a locally made plug into the airflow fixture.

         2. Close all the shutoff valves on the test bench.

         3. Pressurize the system upstream of the shutoff valves when you set the P1 to the maximum bench capacity.

         4. Look at the P3 gage for a pressure increase.

         5. The shutoff valve leakage will cause a pressure increase on the P3 gage.

         6. The maximum pressure increase is 0 psig (0 kPa) for one minute.

         7. 

            WARNING

            RELEASE ALL PRESSURE REMAINING AT THE END OF THE TEST OR BEFORE YOU DO REPAIRS. INJURY TO THE OPERATOR CAN OCCUR IF THE PRESSURE IS NOT RELEASED.

            Release the pressure in the system upstream of the shutoff valves.

         8. If the P3 indication is unsatisfactory, repair as necessary and do the leak check again.

            NOTE

            Do the leak check each day, before the airflow check is done or the test bench is repaired.

      7. Do a leak check on the airflow fixture.

         1. If the test bench has absolute P1 and P3 pressure gages with adjustable dials, adjust the dials to indicate ambient atmospheric pressure or zero the gages if the gages indicate psig (at zero air pressure).

            NOTE

            If the test bench has absolute pressure gages, add 9 psig (62.1 kPa) to the atmospheric pressure (in psia) to find the leak check pressure.

         2. Slowly open the air supply line and pressurize the system to 9 psig (62.1 kPa) on the P3 pressure gage. Close the valve to isolate the system.

         3. Look at the P3 gage for a pressure decrease.

         4. The maximum acceptable rate of pressure decrease in the isolated system is 1.0 psig (6.9 kPa) in 40 seconds.

            NOTE

            If the leakage is around the locally made plug in the fixture, it is possible to control the leakage if you slightly increase the pressure on the plug.

         5. If the rate of pressure decrease is more than 0.5 psig (3.4 kPa) for 40 seconds use CoMat 10-045 LEAK CHECK FLUID, BUBBLES-TYPE to find the source of the leak. The leaks must be repaired to get accurate blade airflow results.

         6. 

            WARNING

            RELEASE ALL PRESSURE REMAINING AT THE END OF THE TEST OR BEFORE YOU DO REPAIRS. INJURY TO THE OPERATOR CAN OCCUR IF THE PRESSURE IS NOT RELEASED.

            Release the pressure in the system upstream of the shutoff valves.

         7. Remove the locally made plug from the fixture.

      8. Do an airflow restriction test on the airflow fixture each time the fixture is installed:

         1. Set the P1 equal to the pressure related with the one largest individual blade flow parameter (Refer to Figure for the calculations of the P1 pressure) without the blade assembly in the fixture.

         2. Look at the P3 gage for a pressure increase.

         3. The maximum P3 indication of 0.5 psig (3.4 kPa) is acceptable, but you should try to minimize the restriction for more accurate airflow results.

         4. A P3 indication of more than 0.5 psig (3.4 kPa) restriction is not acceptable.

         5. Correct the cause of the restriction and do the check again.

            NOTE

            The two primary errors caused when you do the airflow check are:

            1. The air will leak at the interface between the engine part that is tested and the rubber grommets or the gaskets that seal the engine part to the airflow fixture.

            2. The allowance for atmospheric pressure changes that are not made in the calculated gage pressure.

   3. Do the airflow check on the blade assembly. Refer to the four sets of airflow limits and tests in the Engine Manual TASK 72-45-14-200-000 (INSPECTION-000) and Figure.

      1. Do this procedure for each of the tests given in the figure. Use the applicable airflow master for each test.

         1. Install the airflow insert in the contoured cavity of the airflow fixture.

         2. Install the applicable airflow master on the insert. Install the insert and master in the fixture with the concave side of the master pointed to the vertical clamp. Attach with the horizontal and vertical clamps.

         3. Look for air leakage at the connections and seals on the fixture, the insert and the master. No leakage is permitted.

         4. Set up the test bench to do the airflow check. Refer to limits and locations given in the Engine Manual TASK 72-45-14-200-000 (INSPECTION-000) and Figure.

         5. Do a one-point test bench calibration by the procedure given in SUBTASK 70-72-01-710-004.

         6. Remove the airflow master.

         7. Block and seal the applicable airflow passages and cooling air holes, refer to Figure and the Engine Manual TASK 72-45-14-200-000 (INSPECTION-000), for each test by one of these methods:

            1. Use melted CoMat 02-021 MASKING WAX COMPOUND, applied with an artist's soft bristle brush.

               NOTE

               The blade assembly can be sealed at room temperature. If the blade is lightly warmed, the wax seal will be better.

            2. Use CoMat 02-047 TAPE, HEAT REFLECTIVEor CoMat 02-030 MASKING TAPE (CLOTH BACKING).

         8. Install the blade assembly on the insert. Install the insert and blade on the fixture with the concave side of the blade pointed to the vertical clamp. Attach with the horizontal and vertical clamps.

         9. Look for air leakage at the connections and seals on the fixture, the insert and the blade. No leakage is permitted.

         10. Do the airflow check. Refer to the limits given in the Engine Manual TASK 72-45-14-200-000 (INSPECTION-000). No leakage is permitted at the sealed airflow passages or cooling air holes.

         11. Accept the airflow on each test of the blade airflow passage if the flow is within the limits given in Step 9. of Figure.

         12. Remove the blade assembly from the fixture.

             NOTE

             Go to Step (2) if you have done the airflow operation for 15 minutes.

         13. Do the procedure again on the blade assembly for each of the airflow tests given in the Engine Manual TASK 72-45-14-200-000 (INSPECTION-000) and Figure.

         14. Do the airflow check again for any remaining blade assembly.

      2. Fifteen minutes after you start the blade assembly airflow operation, do the checks that follow:

         1. Check the barometer to find if any change in the atmospheric pressure has occurred since it was written on the worksheet.

         2. If the atmospheric pressure has changed less than 0.1 psia (0.7 kPa) or less than 0.2 inch Hg (5.2 mm Hg), go to step (d).

         3. If the atmospheric pressure has changed more than 0.1 psia (0.7 kPa) or more than 0.2 inch Hg (5.2 mm Hg), stop the test on the blades. Do a one-point test bench calibration and calculate the new gage pressure by the procedure given in Step. Use the new limits when you check the blade assembly.

         4. Remove the blade assembly and the insert from the fixture.

         5. Install a locally made plug into the airflow fixture and check for air leakage.

         6. If there is no leakage, remove the locally made plug from the fixture and install the blade and insert and start the airflow check again.

         7. If there is leakage, repair the leaks as necessary and do Step (e) again.

            NOTE

            The continuous 15-minute cycle, when you check the change in the atmospheric pressure, must be done to make sure that the gage pressures that are used as limits, are accurate. An atmospheric pressure change, without a change in the pre-calculated gage pressure, makes an error in the airflow test results. For example, in the equation PR x Pa = P3, if the blade assembly PR is 2.470 psia (17.0 kPa), then a 0.1 psia (0.7 kPa) or 0.2 inch Hg (5.2 mm Hg) change in the atmospheric pressure becomes a 0.247 psia (1.7 kPa) error in the P3 pressure. This is approximately a 0.7 percent error. The continuous 15-minute cycle, when you install the locally made plug, is necessary to monitor the condition of the airflow insert on the airflow fixture. If three of four blades, one after the other, are rejected for high flow, do not wait the full 15 minutes to do the checks.

         8. After each 15 minutes of the airflow operation, do these checks again.

      3. Airflow the blade assembly that shows more airflow than the limits. Refer to the worksheet Step 9. for the blades marked plus (+). (Refer to Figure).

         1. Do the airflow check again. Find if the high airflow was caused by the blade or by air leakage in the test set up.

         2. If the blade assembly has high airflow, do the airflow check procedure again.

         3. Reject the blade assembly that has airflow more than the limits given on the worksheet Step 9.

      4. Do the subsequent procedure on the blade assembly that has less airflow than the limits. Refer to the worksheet Step 9. for the blades marked minus (-). (Refer to Figure).

         1. Ultrasonic clean the blade assembly by the procedure given in the SPM TASK 70-13-01-100-501 but flush the inside of the blades with hot water. Flush and air dry fully. If necessary, use 0.009 inch (0.229 mm) diameter wire or equivalent to put into the trailing edge cooling air slots to clean the air passage.

         2. Do the airflow check procedure again.

         3. Reject the blade assembly that has less airflow than the limits given on the worksheet Step 9.

      5. Clean the blade assembly by the procedure given in the Engine Manual TASK 72-45-14-100-003-A00 (CLEANING-003).

         1. Remove the wax compound and tape residue from the blade airflow passages and cooling air holes.

      6. Two hours after you start the airflow operation, do a one-point test bench calibration for each airflow parameter by the procedure given in Step. Refer to Figure and the Engine Manual TASK 72-45-14-200-000 (INSPECTION-000).

9. SUBTASK 70-72-01-720-009 Airflow Testing the Stage 2 HPT Ring Segment and Vane Clusters

   NOTE

   1. Do all the inspections and repairs on the vane cluster assembly or vane assembly before you do the airflow check.

   2. Do the procedure in the sequences given for accurate airflow data. Make sure you do all the steps.

   3. This procedure is for the A1/A5/D5 models.

   1. Refer to: Figure, Figure and Figure

      NOTE

      To get accurate airflow results, you must leak check and calibrate the test bench. The vane performance and engine efficiency are directly related to the correct airflow procedure.

      If the test bench has absolute pressure gages, add the psig value given in the procedure to the ambient atmospheric pressure to get the psia value.

   2. Set up and leak check the vane airflow fixture and the test bench.

      1. Select the sonic nozzle with the correct throat diameter. Use the mathematical method of nozzle selection given in the SPM TASK 70-72-02-720-501, SUBTASK 70-72-02-720-007.

      2. Set up the IAE 6P16080 Test bench 1 off (Refer to Figure).

         1. Install and clamp the flange of the airflow base to the test bench.

         2. Install and attach the airflow fixture on the base with the four cap screws.

         3. Connect and tighten the test bench pressure sense line to the small boss on the side of the base.

            NOTE

            The airflow path must be from the shop air supply, through the sonic nozzle on the test bench, into the airflow fixture and out through the vane.

         4. Connect and tighten the test bench air line to the large boss on the side of the base.

      3. Set up the test bench to do the airflow check on the vane cluster. Make sure the P1 gage is connected to the sonic nozzle inlet pressure and the P3 gage is connected to read the vane cluster inlet pressure.

      4. If the test bench has absolute P1 and P3 pressure gages with adjustable dials, adjust the gages to indicate the ambient atmospheric pressure, or set the gages to zero if the gages indicate psig (at zero air pressure).

         NOTE

         A different worksheet is necessary for each airflow parameter.

      5. Calculate the values for the pressure ratio method of airflow check. Use the applicable airflow test limit table in the Engine Manual TASK 72-45-24-200-000 (INSPECTION-000) and Figure.

      6. Do a shutoff valve leak check on the test bench.

         1. Install a locally made plug into the airflow fixture. Attach the plug to the fixture with the two toggle clamps.

         2. Close all the shutoff valves on the test bench.

         3. Pressurize the system upstream of the shutoff valves when you set the P1 to the maximum bench capacity.

         4. Look at the P3 gage for a pressure increase.

         5. The shutoff valve leakage will cause a pressure increase on the P3 gage.

         6. The maximum pressure increase is 0 psig (0 kPa) for one minute.

         7. 

            WARNING

            RELEASE ALL PRESSURE REMAINING AT THE END OF THE TEST OR BEFORE YOU DO REPAIRS. INJURY TO THE OPERATOR CAN OCCUR IF THE PRESSURE IS NOT RELEASED.

            Release the pressure in the system upstream of the shutoff valves.

         8. If the P3 indication is unsatisfactory, repair as necessary and do the leak check again.

            NOTE

            Do the leak check each day, before the airflow check is done or the test bench is repaired.

      7. Do a leak check on the airflow fixture.

         1. If the test bench has absolute P1 and P3 pressure gages with adjustable dials, adjust the dials to indicate atmospheric pressure or zero the gages if the gages indicate psig (at zero air pressure).

         2. Slowly open the air supply line and pressurize the system to 9 psig (62.1 kPa) on the P3 pressure gage. Close the valve to isolate the system.

         3. Look at the P3 gage for a pressure decrease.

         4. The maximum acceptable rate of pressure decrease in the isolated system is 1.0 psig (6.9 kPa) in 30 seconds.

            NOTE

            If the leakage is around the locally made plug in the fixture, it is possible to control the leakage if you slightly increase the pressure on the plug.

         5. If the rate of pressure decrease is more than 0.5 psig (3.4 kPa) for one minute, use CoMat 10-045 LEAK CHECK FLUID, BUBBLES-TYPE to find the source of the leak. The leaks must be repaired to get an accurate vane airflow result.

         6. 

            WARNING

            RELEASE ALL PRESSURE REMAINING AT THE END OF THE TEST OR BEFORE YOU DO REPAIRS. INJURY TO THE OPERATOR CAN OCCUR IF THE PRESSURE IS NOT RELEASED.

            Release the pressure in the system upstream of the shutoff valves.

         7. Remove the locally made plug from the fixture.

      8. Do an airflow restriction check on the airflow fixture.

         1. Set the P1 equal to the pressure related with the one largest individual vane flow parameter (Refer to the applicable airflow limits table in the Engine Manual TASK 72-45-24-200-000 (INSPECTION-000) and Figure for the calculations of the P1 pressure) without the vane cluster in the fixture.

         2. Look at the P3 indication.

         3. The maximum P3 indication of 0.5 psig (3.4 kPa) is acceptable, but you should try to minimize the restriction for more accurate airflow results.

         4. A P3 indication of more than 0.5 psig (3.4 kPa) restriction is not acceptable.

         5. Correct the cause of the restriction and do the check again. The cause of the restriction can be:

            1. An insert with damage.

            2. Grease.

            3. Kinked hoses.

            4. Unwanted objects.

         6. Do the check again.

            NOTE

            The vane cluster or an individual vane with or without the borescope hole can be airflow tested in the airflow fixture. Only one passage in one vane of the cluster can be airflow tested at a time.

            NOTE

            The two primary errors caused when you do the airflow check are:

            1. The air will leak at the interface between the engine part that is tested and the rubber grommets or the gaskets that seal the engine part to the airflow fixture.

            2. The allowance for atmospheric pressure changes that are not made in the calculated gage pressure.

   3. Do the airflow check on the vane cluster assembly and if applicable on an individual vane.

      1. Do the airflow check on the vane rear air passage. (Refer to Figure).

         1. Install the airflow insert on the airflow fixture.

         2. Install the airflow master on the insert and attach to the fixture with the two toggle clamps.

         3. Look for air leakage at the connections and the seals on the fixture, the insert and the master. No leakage is permitted.

         4. Set up the test bench to do the airflow check by the applicable limits and locations. (Refer to the Engine Manual TASK 72-45-24-200-000 (INSPECTION/CHECK-000) and Figure).

         5. Do a one-point test bench calibration by the procedure given in Step. (Refer to the Engine Manual TASK 72-45-24-200-000 (INSPECTION-000) and Figure).

         6. Remove the airflow master.

         7. Install the vane cluster on the airflow insert and attach to the fixture with the two toggle clamps.

         8. Look for air leakage at the vane cannon hole (if present), the connections and the seals on the fixture, the insert and the master. No leakage is permitted.

            NOTE

            The vane assembly can be sealed at room temperature. If the vane is lightly warmed, the wax seal will be better.

         9. If applicable, when you have air leakage from the vane assembly cannon hole, remove the vane assembly from the insert and seal the front passage and install a locally made plug in the cannon hole. Use masking wax compound or heat reflective tape. Install the vane assembly in the insert and do step (h) again. (Refer to Figure).

         10. Do the airflow check by the limits given. Refer to the Engine Manual TASK 72-45-24-200-000 (INSPECTION-000) and Figure.

         11. Accept the airflow on the vane rear air passage if the flow is within the limits given in Step 9. of Figure.

         12. Do the airflow check again for the other vane in the cluster.

             NOTE

             Go to step (4) if you have done the airflow operation for 15 minutes.

         13. Remove the vane cluster and the insert from the fixture.

      2. Do the airflow check on the vane front air passage - leading edge cooling hole. (Refer to Figure).

         1. Install the airflow insert on the airflow fixture.

         2. Install the airflow master on the insert and attach to the fixture with the two toggle clamps.

         3. Look for air leakage at the connections and the seals on the fixture, the insert and the master. No leakage is permitted.

         4. Set up the test bench to do the airflow check by the applicable limits and locations given. Refer to the Engine Manual TASK 72-45-24-200-000 (INSPECTION-000) and Figure.

         5. Do a one-point test bench calibration by the procedure given in Step. Refer to Engine Manual TASK 72-45-24-200-000 (INSPECTION-000) and Figure.

         6. Remove the airflow master.

         7. Block the front flange cooling holes with CoMat 02-021 MASKING WAX COMPOUND or CoMat 02-047 TAPE, HEAT REFLECTIVE.

         8. Install the vane cluster on the airflow insert and attach to the fixture with the two toggle clamps.

         9. Look for air leakage at the trailing edge cooling air slots, the connections, the insert and the master. No leakage is permitted.

            NOTE

            The vane assembly can be sealed at room temperature. If the vane is lightly warmed, the wax seal will be better.

         10. If applicable, when you have air leakage from the vane assembly trailing edge cooling air slots, remove the vane assembly from the insert. Seal the vane passage D and the trailing edge cooling air slots. Use masking wax compound or heat reflective tape. Install the vane assembly in the insert and do step (h) again. (Refer to Figure).

         11. Do the airflow check by the limits given. Refer to the Engine Manual TASK 72-45-24-200-000 (INSPECTION-000) and Figure.

         12. Accept the airflow on the vane rear air passage if the flow is within the limits given in Step 9. of Figure.

         13. Do the airflow check again for the other vane in the cluster.

         14. Remove the vane cluster and the insert from the fixture.

             NOTE

             Go to Step (4) if you have done the airflow operation for 15 minutes.

         15. Do the airflow check again on all remaining vanes or vane cluster assemblies.

      3. Do the airflow check on the vane front air passage - inner flange cooling hole(s). (Refer to Figure).

         1. Install the airflow insert on the air flow fixture.

         2. Install the airflow master on the airflow insert and attach to the fixture with the two toggle clamps.

         3. Look for air leakage at the connections and the seals on the fixture, the insert and the master. No leakage is permitted.

         4. Set up the test bench to do the air flow check by the applicable limits and locations given. Refer to Engine Manual TASK 72-45-24-200-000 (INSPECTION/CHECK-000) and Figure.

         5. Do a one-point test bench calibration by the procedure given in Step. Refer to Engine Manual TASK 72-45-24-200-000 (INSPECTION-000) and Figure.

         6. Remove the airflow master.

         7. Block the leading edge cooling holes with CoMat 02-021 MASKING WAX COMPOUND or CoMat 02-047 TAPE, HEAT REFLECTIVE.

         8. Install the vane cluster on the airflow insert and attach to the fixture with the two toggle clamps.

         9. Look for air leakage at the trailing edge cooling air air slots, the connections, the insert, and the master. No leakage is permitted.

            NOTE

            The vane assembly can be sealed at room temperature. If the vane is lightly warmed, the wax seal will be better.

         10. If applicable, when you have air leakage from the vane assembly trailing edge cooling air slots, remove the vane assembly from the insert. Seal the vane passage D and the trailing edge cooling air slots. Use CoMat 02-021 MASKING WAX COMPOUND or CoMat 02-047 TAPE, HEAT REFLECTIVE. Install the vane assembly in the insert and do step (h) again. (Refer to Figure).

         11. Do the airflow check by the limits given. Refer to the Engine Manual TASK 72-45-24-200-000 (INSPECTION-000) and Figure.

         12. Accept the airflow on the vane rear air passage if the flow is within the limits given in Step 9. of Figure.

         13. Do the airflow check again for the other vanes in the cluster.

         14. Remove the vane cluster and the insert from the fixture.

             NOTE

             Go to step (4) if you have done the airflow operation for 15 minutes.

         15. Do the airflow check again on all remaining vanes or vane cluster assemblies.

      4. Fifteen minutes after you start the vane airflow operation do the checks that follow:

         1. Check the barometer to find if any change in the atmospheric pressure has occurred since it was written on the worksheet.

         2. If the atmospheric pressure has changed less than 0.1 psia (0.7 kPa) or less than 0.2 inch Hg (5.2 mm Hg or 0.7 kPa), go to Step (d).

         3. If the atmospheric pressure has changed more than 0.1 psia (0.7 kPa) or more than 0.2 inch Hg (5.2 mm Hg or 0.7 kPa), stop the test on the vanes. Do a one-point test bench calibration and calculate the new gage pressure by the procedure given in Step. Use the new limits when you check the vanes.

         4. Remove the vane or vane cluster from the fixture.

         5. Install a locally made plug into the airflow fixture and check for air leakage.

         6. If there is no leakage, remove the locally made plug from the fixture, install the vane or the vane cluster and the insert in the fixture. Start the airflow check again.

         7. If there is leakage, repair or replace the insert or repair the test bench as necessary and do Step (e) again.

            NOTE

            The continuous 15-minute cycle, when you check the change in the atmospheric pressure, must be done to make sure that the gage pressures that are used as limits are accurate. An atmospheric pressure change, without a change in the pre-calculated gage pressure, makes an error in the airflow test results. For example, in the equation PR x Pa = P3, if the vane PR is 2.470 psia (17.0 kPa) then a 0.1 psia (0.7 kPa) or 0.2 inch Hg (5.2 mm Hg) change in the atmospheric pressure becomes a 0.247 psia (1.7 kPa) error in the P3 pressure. This is approximately a 0.7 percent error. The continuous 15-minute cycle, when you install the locally made plug, is necessary to monitor the condition of the airflow insert on the airflow fixture. If three or four vanes, one after the other, are rejected for high flow, do not wait the full 15 minutes to do the checks.

         8. After each 15 minutes of the airflow operation, do these checks again.

      5. Airflow the vane or the vane cluster that shows more airflow than the limits. Refer to the worksheet Step 9, for the vanes marked plus (+). (Refer to Figure.).

         1. Do the airflow check again. Find if the high airflow was caused by the vane or by air leakage in the test set up.

         2. If the vane or the vane cluster has high airflow, do the airflow check procedure again.

         3. Reject all the vanes that have airflow more than the limits given on the worksheet Step 9. of Figure.

      6. Do the procedure that follows on the vane or the vane cluster that has less airflow than the limits. Refer to the worksheet Step 9. for the vanes marked minus (-). (Refer to Figure.).

         1. Ultrasonic clean the vanes by the procedure given in the SPM TASK 70-13-01-100-501 but flush fully the inside of the vanes with hot water. Flush and air dry fully. If necessary, use 0.017 inch (0.43 mm) diameter wire or equivalent to put into the trailing edge cooling air slots to clean the air passage.

         2. Do the airflow check procedure again.

         3. Reject all the vanes that have less airflow than the limits given on the worksheet Step 9. of Figure.

      7. Clean the vane assembly by the procedure given in TASK 72-45-24-100-002 (CLEANING-002).

         1. Remove the CoMat 02-021 MASKING WAX COMPOUND and the CoMat 02-047 TAPE, HEAT REFLECTIVE from the vane assembly airflow passages and cooling air holes.

         2. Two hours after you start the airflow operation, do a one-point test bench calibration for each airflow parameter by the procedure given in Step. Refer to Figure and the Engine Manual TASK 72-45-24-200-000 (INSPECTION-000).

10. SUBTASK 70-72-01-720-010 Testing the Stage 2 HPT Blade Assembly

    NOTE

    1. Do all the inspections and repairs on the vane cluster assembly or vane assembly before you do the airflow check.

    2. Do the procedure in the sequences given for accurate airflow data. Make sure you do all the steps.

    3. This procedure is for the A1/A5/D5 models.

    1. Refer to: Figure, Figure and Figure

       NOTE

       To get accurate results, you must leak check and calibrate the test bench. The blade performance and engine efficiency are directly related to the correct airflow procedure.

       If the test bench has absolute pressure gages, add the psig value given in the procedure to the ambient atmospheric pressure to get the psia value.

    2. Set up and leak check the blade airflow fixture and the test bench.

       1. Select the sonic nozzle with the correct throat diameter. Use the mathematical method of nozzle selection given in the SPM TASK 70-72-02-720-501, SUBTASK 70-72-02-720-007.

       2. Set up the IAE 6P16080 Test bench 1 off. Refer to Figure.

          1. Install and clamp the flange of the airflow base to the test bench.

          2. Retract the two clamps on the fixture to a fully retracted position.

          3. Install the fixture on the base and align the two open holes in the base with the holes in the fixture. Move the horizontal clamp block on the fixture until the holes in the block align with the holes in the base. Install and tighten the four bolts.

          4. Connect and tighten the test bench pressure sense line to the small boss on the side of the base.

             NOTE

             The airflow path must be from the shop air supply, through the sonic nozzle on the test bench, into the airflow fixture and out through the blade.

          5. Connect and tighten the test bench air line to the large boss on the side of the base.

       3. Set up the test bench to do the airflow check on the blade assembly. Make sure the P1 gage is connected to the sonic nozzle inlet pressure and the P3 gage is connected to read the blade inlet pressure.

       4. If the test bench has absolute P1 and P3 pressure gages with adjustable dials, adjust the gages to indicate the ambient atmospheric pressure, or set the gages to zero if the gages indicate psig (at zero air pressure).

          NOTE

          A different worksheet is necessary for each airflow parameter.

       5. Calculate the values for the pressure ratio method of airflow check. Refer to the airflow limits table in the Engine Manual TASK 72-45-32-200-000 (INSPECTION-000) and use the pressure ratio method worksheet procedure in Figure.

       6. Do a shutoff valve leak check on the test bench.

          1. Install a locally made plug into the airflow fixture.

          2. Close all the shutoff valves on the test bench.

          3. Pressurize the system upstream of the shutoff valves when you set the P1 to the maximum bench capacity.

          4. Look at the P3 gage for a pressure increase.

          5. The shutoff valve leakage will cause a pressure increase on the P3 gage.

          6. The maximum pressure increase is 0 psig (0 kPa) for one minute.

          7. 

             WARNING

             RELEASE ALL PRESSURE REMAINING AT THE END OF THE TEST OR BEFORE YOU DO REPAIRS. INJURY TO THE OPERATOR CAN OCCUR IF THE PRESSURE IS NOT RELEASED.

             Release the pressure in the system upstream of the shutoff valves.

          8. If the P3 indication is unsatisfactory, repair as necessary and do the leak check again.

             NOTE

             Do the leak check each day, before the airflow check is done or the test bench is repaired.

       7. Do a leak check on the airflow fixture.

          1. If the test bench has absolute P1 and P3 pressure gages with adjustable dials, adjust the dials to indicate atmospheric pressure or zero the gages if the gages indicate psig (at zero air pressure).

             NOTE

             If the test bench has absolute pressure gages, add 9 psig (62.1 kPa) to the atmospheric pressure (in psia) to find the leak check pressure.

          2. Slowly open the air supply line and pressurize the system to 9 psig (62.1 kPa) on the P3 pressure gage. Close the valve to isolate the system.

          3. Look at the P3 gage for a pressure decrease.

          4. The maximum acceptable rate of the pressure decrease in the isolated system is 1.0 psig (6.9 kPa) in 40 seconds.

             NOTE

             If the leakage is around the locally made plug in the fixture, it is possible to control the leakage if you slightly increase the pressure on the plug.

          5. If the rate of pressure decrease is more than 0.5 psig (3.4 kPa) for 40 seconds, use CoMat 10-045 LEAK CHECK FLUID, BUBBLES-TYPE to find the source of the leak. The leaks must be repaired to get accurate blade airflow results.

          6. 

             WARNING

             RELEASE ALL PRESSURE REMAINING AT THE END OF THE TEST OR BEFORE YOU DO REPAIRS. INJURY TO THE OPERATOR CAN OCCUR IF THE PRESSURE IS NOT RELEASED.

             Release the pressure in the system upstream of the shutoff valves.

          7. Remove the locally made plug from the fixture.

       8. Do an airflow restriction check on the airflow fixture each time the fixture is installed.

          1. Set the P1 equal to the pressure related with the one largest individual blade flow parameter (refer to Figure) for the calculations of the P1 pressure) without the blade assembly in the fixture.

          2. Look at the P3 gage for a pressure increase.

          3. The maximum P3 indication of 0.5 psig (3.4 kPa) is acceptable, but you should try to minimize the restriction for a more accurate airflow result.

          4. A P3 indication of more than 0.5 psig (3.4 kPa) restriction is not acceptable.

          5. Correct the cause of the restriction and do the check again.

             NOTE

             The two primary errors caused when you do the airflow check are:

             1. The air will leak at the interface between the engine part that is tested and the rubber grommets or the gaskets that seal the engine part to the airflow fixture.

             2. The allowance for atmospheric pressure changes that are not made in the calculated gage pressure.

    3. Do the airflow check on the blade assembly. Refer to the airflow limits given in the Engine Manual TASK 72-45-32-200-000 (INSPECTION-000).

       1. Do this procedure for each one of the tests given. Refer to the Engine Manual TASK 72-45-32-200-000 (INSPECTION-000). Use the applicable airflow master for each test.

          1. Install the airflow insert in the contoured cavity of the airflow fixture.

          2. Install the airflow master on the insert with the concave side of the master pointed to the vertical clamp. Attach the insert and the master to the fixture with the horizontal and vertical clamps.

          3. Look for air leakage at the connections and the seals on the fixture, the insert and the master. No leakage is permitted.

          4. Set up the test bench to do the airflow check by the application limits and locations given. Refer to the Engine Manual TASK 72-45-32-200-000 (INSPECTION-000), Figure and Figure.

          5. Do a one-point test bench calibration by the procedure given in Step.

          6. Remove the airflow master.

          7. Install the blade assembly on the insert with the concave side of the blade pointed to the vertical clamp. Attach the insert and the blade to the fixture with the horizontal and vertical clamps.

          8. Look for air leakage at the connections and the seals on the fixture, the insert and the master. No leakage is permitted.

          9. Do the airflow check by the limits given. Refer to the Engine Manual TASK 72-45-32-200-000 (INSPECTION-000) and Figure.

          10. Accept the airflow on each test of the blade airflow passage if the flow is within the limits given in Step 9. of Figure.

              NOTE

              Go to Step (2) if you have done the airflow operation for 15 minutes.

          11. Remove the blade assembly from the fixture.

          12. Do the airflow check again for any blade assembly that remains.

       2. Fifteen minutes after you start the blade assembly airflow operation, do these checks:

          1. Check the barometer to find if any change in the atmospheric pressure occurred since it was written on the worksheet.

          2. If the atmospheric pressure changed less than 0.1 psia (0.7 kPa) or less than 0.2 inch Hg (5.2 mm Hg), go to Step (d).

          3. If the atmospheric pressure changed more than 0.1 psia (0.7 kPa) or more than 0.2 inch Hg (5.2 mm Hg or 0.7 kPa), stop the test on the blades. Do a one-point test bench calibration and calculate the new gage pressure by the procedure given in Step. Use the new limits when you check the blade assembly.

          4. Remove the blade assembly and the insert from the fixture.

          5. Install a locally made plug into the airflow fixture and do a check for air leakage.

          6. If there is no leakage, remove the locally made plug from the fixture and install the blade assembly and the insert and start the airflow check again.

          7. If there is leakage, repair the leaks as necessary and do Step (f) again.

             NOTE

             The continuous 15-minute cycle, when you check the change in the atmospheric pressure, must be done to make sure that the gage pressures that are used as limits are accurate. An atmospheric pressure change, without a change in the pre-calculated gage pressure, makes an error in the airflow test results. For example, in the equation PR x Pa = P3, if the blade assembly PR is 2.470 psia (17.0 kPa), then a 0.1 psia (0.7 kPa) or 0.2 inch Hg (5.2 mm Hg) change in the atmospheric pressure becomes a 0.247 psia (1.7 kPa) error in the P3 pressure. This is approximately a 0.7 percent error. The continuous 15-minutes cycle, when you install the locally made plug, is necessary to monitor the condition of the airflow insert on the airflow fixture. If three or four blades, one after the other, are rejected for high flow, do not wait the full 15 minutes to do the checks.

          8. After each 15 minutes of the airflow operation, do these checks again.

       3. Airflow the blade assembly that shows more airflow than the limits. Refer to the worksheet Step 9. for the blades marked plus (+). (Refer to Figure).

          1. Do the airflow check again. Find if the high airflow was caused by the blade or by air leakage in the test set up.

          2. If the blade assembly has high airflow, do the airflow check procedure again.

          3. Reject the blade assembly that has airflow more than the limits given on the worksheet Step 9. of Figure.

       4. Do the procedure that follows on the blade assembly that has less airflow than the limits. Refer to the worksheet Step 9. for the blades marked minus (-). (Refer to Figure).

          1. Ultrasonic clean the blade assembly by the procedure given in the SPM TASK 70-13-01-100-501 but flush the inside of the blades with hot water. Flush and air dry fully. If necessary, use 0.010 inch (0.254 mm) diameter wire or equivalent to put into the trailing edge cooling air slots to clean the air passage.

          2. Do the airflow check procedure again.

          3. Reject the blade assembly that has less airflow than the limits given on the worksheet Step 9. of Figure.

       5. Two hours after you start the airflow operation, do a one-point test bench calibration for each airflow parameter by the procedure given in Step. Refer to the Engine Manual TASK 72-45-32-200-000 (INSPECTION-000) and Figure.

11. SUBTASK 70-72-01-720-011 Troubleshooting

    1. Refer to: Figure and Figure

    2. General.

       1. One of the more usual problems in the airflow test is that the shop air system cannot supply the test bench with a sufficient volume of air for a sufficient period of time to test a high airflow part.

       2. The subsequent paragraphs give procedures to make an analysis of the airflow test problem plus steps for its solution.

          NOTE

          Measurements to calculate the shop air system operation are important only after you bleed down the shop air system for the period of time necessary to test a high airflow part. The subsequent check is an equivalent to test an engine part.

    3. Calculate the volume of air available at the test bench.

       1. Set up the test bench for an airflow test of a high airflow part but which does not include the items that follow:

          1. Do not install an engine part or a correlation master tool on the airflow test fixture.

          2. If a non integral cylindrical damper, open at the top, is used to decrease the noise, place the damper around the airflow test fixture in the normal position.

          3. If an integral acoustic chamber is used, which fully contains the engine part, leave one door open.

       2. Record the nozzle throat diameter and K factor in PPS.

          Example: A 1.00 inch (25.40 mm) nozzle and a value for K of 0.41365 will be used during the example.

       3. Record the temperature and atmospheric pressures. Change the temperature to Rankine and the atmospheric pressure to psia. Refer to Step.

          Example: 70 deg F (530 deg R) and 29.92 inches Hg (14.696 psia) will be used during the example.

       4. Calculate the airflow in PPS and P1 (nozzle inlet) pressure necessary to test the highest flow engine part. Refer to Figure.

          NOTE

          If the time necessary to test the part is not known from other tests, use 20 seconds. During the time air flows continuously, increase the flow control valve opening to keep pressure on the P1 gage as constant as possible as the shop air system bleeds down. If the shop air system is defective, at some point in this procedure the flow control valve will be fully open. After which, more adjustment is not possible and pressure on the P1 gage will start to drop. The P1 pressure, which is important to this check, is that supplied by the shop air system at the end of the time period.

       5. Turn the air on and adjust the airflow to set the P1 gage to the pressure calculated in step (4). Let the air flow for the period of time necessary to test the part. Record the P1 gage pressure at the end of the time period. Turn the air off.

       6. Change the P1 gage pressure recorded at the end of the time period into airflow in PPS. Refer to Figure.

       7. Change the shop air system operation into a percentage.

          	Example: 1.600 PPS necessary by the engine part
          	1.348 PPS available at test bench = 84 percent
          	0.252 PPS short = 16 percent
          To make sure there is no problem in operation, the shop air system must supply at least 105 percent of the air necessary by the highest flow engine part in the fleet.

    4. To stop a problem in the shop air system operation, these steps are recommended:

       1. Check that the pipe which supplies air to the test bench has an ID of at least 3.0 inches (76.20 mm) and a minimum of turns. Where turns are necessary, use a large radius. That is, bend the pipe as an alternative to the use of pre-threaded, usual elbows whose radius is very small.

       2. Check that the pipe or hose in the test bench has an ID of at least 3.00 inches (76.20 mm) and large radius bends.

          NOTE

          The time necessary to test an engine part is the time to set one gage, check the setting and then read the other gage.

       3. Replace the manually-operated flow control valves with a pilot-operated pressure regulator. This device will automatically and continuously adjust the airflow to keep a stable pressure. With a stable gage pressure, the time necessary to test an engine part will be kept to a minimum.

       4. Install a sonic nozzle whose throat diameter is as large as it is possible to use, when testing the lowest flow of the high flow parts. Refer to the SPM TASK 70-72-02-720-501.

       5. The available air can be used satisfactorily with the use of steps (1) thru (4). If these steps are not sufficient to stop the problem, then a reservoir (accumulator) or more air compressors must be added to the shop air system.

          NOTE

          1. To add a reservoir is an alternative to air compressors, in that an increased volume of air is made available which can be expanded during the airflow test of an engine part.

          2. A reservoir must be added only in relation with, or subsequent to, a pilot-operated pressure regulator.

          3. A reservoir does not make pressure; it just extends the period of time during which the shop air system can supply a specified pressure.

    5. Calculate the size of a reservoir or accumulator.

       1. Change the airflow test limits for the highest flow part to airflow in PSS. Refer to Figure.

          NOTE

          The factor 800.75 is from 60 seconds for each minute divided by 0.07493 which is the density of air at standard pressure (29.92in. Hg) and standard temperature 70 deg F (21 deg C).

       2. Change PPS to a standard cubic feet per minute or standard cubic feet/minute (SCFM) with the equation that follows:

          SCFM = PSS x 800.75.

          Example 1: 1.606 PPS x 800.75 = 1286.0 SCFM.

          Example 2: 1.600 PPS x 800.75 = 1281.2 SCFM.

          NOTE

          The time necessary to test the engines part is the time to adjust the airflow, to set the pressure on one gage, check the pressure setting is stable and then read the other gage.

       3. Calculate the volume of air which will be used during the time necessary to test the engine part. Refer to step (a) below. If the actual time necessary to test an engine part is not known, use 20 seconds.

          1. Example volume of air calculations: 20 seconds (one-third of a minute) will be used in the example.

             Example 1: 1286.0 SCFM/3 = 428.6 cu ft*.

             Example 2: 1281.2 SCFM/3 = 427.1 cu ft*.

             * Volume at one atmospheric pressure.

       4. Calculate the P1 (nozzle inlet) pressure necessary to drive the nozzle used to test the engine part.

          Example 1:

          P1 = (FP x P3)/KT = (2.013 x 18.37)/0.41365 = 89.4 psia (6.08 atmospheres).

          Example 2:

          P1 = (FP x Pa)/KT = (2.506 x 14.696)/0.41365 = 89.0 psia (6.06 atmospheres).

       5. Change the volume of air necessary to test the engine part from one atmospheric pressure to P1 (nozzle inlet) pressure.

          Example 1: 428.6 cu ft/6.08 atmospheres = 70.5 cu ft.

          Example 2: 427.1 cu ft/6.06 atmospheres = 70.5 cu ft.

       6. Use the percentage calculated in Step paragraph B. Give the volume of air as the P1 pressure which must come from the reservoir.

          Example: In the example used with Step paragraph B.(7), the shop air system was calculated to be 16 percent defective.

          NOTE

          With a pressure regulator installed to control the airflow, it would be possible, in theory, to dimension the reservoir to the volume calculated in step D.(6). In practice, the factor of five is used to take into consideration:

          Engine growth.

          Inaccuracies in the evaluation of the shop air system capability.

          Increased operation of the shop air system by other functions in the shop.

          16 percent of 70.5 cu ft = 11.28 cu ft from reservoir.

       7. Dimension the reservoir at five times the volume calculated in step (6).

          Example: 5 x 11.28 cu ft = 56.4 cu ft.

          To compare, a cylindrical reservoir 4 feet in diameter by 4.5 feet high contains 56.5 cu ft.

Figure: Acoustic damper

Acoustic damper



Figure: Pressure tap in chamber wall

Pressure tap in chamber wall



Figure: One-point test bench calibration. Master tool calibration by pressure ratio procedure. Sample worksheet 1 (Sheet 1)

One-point test bench calibration. Master tool calibration by pressure ratio procedure. Sample worksheet 1 (Sheet 1)



Figure: One-point test bench calibration. Master tool calibration by pressure ratio procedure. Sample worksheet 1 (Sheet 2)

One-point test bench calibration. Master tool calibration by pressure ratio procedure. Sample worksheet 1 (Sheet 2)



Figure: One-point test bench calibration. Master tool calibration by flow parameter procedure. Sample worksheet 2 (Sheet 1)

One-point test bench calibration. Master tool calibration by flow parameter procedure. Sample worksheet 2 (Sheet 1)



Figure: One-point test bench calibration. Master tool calibration by flow parameter procedure. Sample worksheet 2 (Sheet 2)

One-point test bench calibration. Master tool calibration by flow parameter procedure. Sample worksheet 2 (Sheet 2)



Figure: Coordinates used for the sample five-point calibration curve flow parameter procedure

Coordinates used for the sample five-point calibration curve flow parameter procedure



Figure: Sample five-point calibration curve flow parameter procedure

Sample five-point calibration curve flow parameter procedure



Figure: Coordinates used for the five-point calibration curve pressure ratio procedure

Coordinates used for the five-point calibration curve pressure ratio procedure



Figure: Sample five-point calibration curve pressure ratio procedure

Sample five-point calibration curve pressure ratio procedure



Figure: Pressure ratio procedure of testing. Sample worksheet 3 (Sheet 1)

Pressure ratio procedure of testing. Sample worksheet 3 (Sheet 1)



Figure: Pressure ratio procedure of testing. Sample worksheet 3 (Sheet 2)

Pressure ratio procedure of testing. Sample worksheet 3 (Sheet 2)



Figure: Flow parameter procedure of testing. Sample worksheet 4 (Sheet 1)

Flow parameter procedure of testing. Sample worksheet 4 (Sheet 1)



Figure: Flow parameter procedure of testing. Sample worksheet 4 (Sheet 2)

Flow parameter procedure of testing. Sample worksheet 4 (Sheet 2)



Figure: Stage 1 HPT vane cluster assembly or vane assembly airflow check tools (typical)

Stage 1 HPT vane cluster assembly or vane assembly airflow check tools (typical)



Figure: Airflow check - pressure ratio method worksheet (typical)

Airflow check - pressure ratio method worksheet (typical)



Figure: Airflow check - pressure ratio method worksheet (typical)

Airflow check - pressure ratio method worksheet (typical)



Figure: Stage 1 HPT vane cluster assembly and vane assembly airflow passages

Stage 1 HPT vane cluster assembly and vane assembly airflow passages



Figure: Stage 1 HPT vane cluster assembly and vane assembly airflow passages

Stage 1 HPT vane cluster assembly and vane assembly airflow passages



Figure: Stage 1 or 2 HPT blade assembly airflow check tools (typical)

Stage 1 or 2 HPT blade assembly airflow check tools (typical)



Figure: Stage 1 HPT blade assembly airflow passages and cooling holes

Stage 1 HPT blade assembly airflow passages and cooling holes



Figure: Stage 2 HPT ring segment and vane cluster airflow check tools (typical)

Stage 2 HPT ring segment and vane cluster airflow check tools (typical)



Figure: Stage 2 HPT ring segment and vane cluster airflow passages

Stage 2 HPT ring segment and vane cluster airflow passages



Figure: Stage 2 HPT ring segment and vane cluster airflow passages

Stage 2 HPT ring segment and vane cluster airflow passages



Figure: Stage 2 HPT blade assembly airflow passages and cooling hole

Stage 2 HPT blade assembly airflow passages and cooling hole



Figure: Calculation necessary to test the highest flow engine part

Calculation necessary to test the highest flow engine part



Figure: Conversion of P1 gage pressure into airflow in PPS

Conversion of P1 gage pressure into airflow in PPS



Figure: Conversion of airflow test limits to airflow in PPS

Conversion of airflow test limits to airflow in PPS