TASK 72-00-00-200-011 Engine General - Do An Ultrasonic Inspection For Root Debond On The LPC Fan Blades, Inspection-011

DMC:V2500-A0-72-00-0000-00A-355A-B|Issue No:001.00|Issue Date:2014-05-01

Export Control

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

Copyright

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

Applicability

All

Common Information

TASK 72-00-00-200-011 Engine General - Do An Ultrasonic Inspection For Root Debond On The LPC Fan Blades, Inspection-011

General

The TASK gives the procedure for the ultrasonic inspection of the LP Compressor fan blades. For the inspection of the other parts of the engine, refer to TASK 72-00-00-200-000 (INSPECTION/CHECK-000).

NOTE

Disassembly is included in TASK 72-31-00-030-001. ASSEMBLY is included in TASK 72-31-00-430-001.

Any blade rejected should be returned to the address that follows for further investigation:

Rolls Royce plc
NDT Laboratory
Sinfin 'A' Site
Victory Rd
Derby DE24 8BJ
England
ATTN: Product Support Manager - V2500
Normal procedures in accordance with TASK 72-31-11-200-002-B00 (INSPECTION/CHECK-002) must be followed prior to each blade.
After each inspection, the information that follows should be recorded and sent to IAE:
Engine number in which the blade had been installed.
Fan blade part number, serial number and life achieved since new in hours/cycles.
The inspection record can be copied for recording and reporting purposes and, as a T.A.P. test inspection is required in TASK 72-00-00-200-010 (INSPECTION/CHECK - 010) the reading obtained can be added to the inspection record, Figure.
NOTE
To identify the consumable materials refer to the PCI.
NOTE
Special tools are identified in the procedure by the tool primary number.
Preliminary Requirements
Pre-Conditions
NONE
Support Equipment
NameManufacturerPart Number / IdentificationQuantityRemark
Ultrasonic flaw detectorLOCALUltrasonic Flaw Detector
IAE 2R18937 Shear wave ultrasonicprobe, type 45-4-FB0AM53IAE 2R18937
IAE 2R18938 Compressionwave ultrasonic probe, type 0-5-FB0AM53IAE 2R18938
IAE 2R18939 Ultrasonic calibration block0AM53IAE 2R18939
IAE 2R18940 Perspexoverlay0AM53IAE 2R18940
IAE 2R18941 Perspexoverlay0AM53IAE 2R18941
Consumables, Materials and Expendables
NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 06-148 ULTRASONIC COUPLANTLOCALCoMat 06-148
CoMat 02-121 TEMPORARY MARKER PENCIL/CRAYONIE304CoMat 02-121
Spares
NONE
Safety Requirements
NONE
Procedure
    1. SUBTASK 72-00-00-490-051 Calibrate the Ultrasonic Equipment for the Airfoil Inspection
    1. Refer to Figure.
    3. Set the instrument to pulse echo mode, set the frequency at 5 MHz and switch off any reject or signal filtration and alarms.  Turn the timebase delay to zero.
    4. Apply CoMat 06-148 ULTRASONIC COUPLANT and put the probe on the IAE 2R18939 Ultrasonic calibration block 1 off and adjust gain to identify the signals produced by two side slots.
    5. Move the probe left and right until the centre line of the probe is over the edge of the slot and the two slot signals are of equal amplitude.
    6. Adjust the range control to position the first signal from the top slot at 1.0 division of the time base 0.394 in. (10.0 mm.) and the first signal from the bottom slot should be at 1.8 division of the time base 0.709 in. (18.0 mm).  Adjust the gain to bring the amplitude of both signals to 50 percent screen height.
    2. SUBTASK 72-00-00-270-051 Examine the Airfoil of the LP Compressor Fan Blades
    1. Refer to Figure and Figure.
    2. Apply CoMat 06-148 ULTRASONIC COUPLANT to the area of the lower concave airfoil.
    3. Put the probe on the airfoil approximately 3.543 in. (90.0 mm) up the blade and 1.575 in. (40.0 mm) in from the leading edge.  A backwall signal from the solid section should appear between 1.0 and 1.5 on the time base.
    4. Slide the probe in towards the centre of the airfoil to monitor the backwall signal.  When the probe passes over the end of the solid section and onto the hollow section, the signal between 1.0 and 1.5 will reduce and the hollow backwall signal at approximately 0.8 will rise.
    5. NOTE
      1. It may be necessary to increase the gain to clearly see both backwall signals.
      NOTE
      1. If there is a gap between the solid backwall disappearing from the screen and the hollow backwall appearing after increasing the gain, move the probe out towards the leading edge until the solid backwall appears.
      Move the probe left and right to equalize the two signals from the hollow and solid backwalls, the probe is now set exactly over the edge of the hollow section.
    6. Carefully remove the probe from the blade.  Leave an impression of the probe in the gel and mark the centre of the impression with a cross.
      7. Move the probe 0.197 in. (5 mm) towards the root and repeat Step to Step. Repeat every 0.197 in. (5 mm) down the bottom of the blade.
      1. V2500-A1 On the fan blade the base of the cavity is under the root block and cannot be detected.
      2. V2500-A5 On the fan blade continue to check and mark across the base of the cavity.
    8. Repeat steps B. to G. for the trailing edge.
    9. Connect the crosses together and observe the shape of the cavity.
    10. Put the IAE 2R18940 Perspexoverlay 1 off (V2500-A1) or the IAE 2R18941 Perspexoverlay 1 off (V2500-A5) on the airfoil.  Compare the shape of the blade cavity with the cavity marked on the overlay. The cavity shape may not align fully with the cavity line marked on the overlay, but it must be the same shape. Movement of the blade cavity parallel to the overlay cavity line is acceptable. Refer to Figure and Figure for acceptable and unacceptable deviations. Because the relative position of the cavity and the external shape is not constant, a positional mismatch of 0.156 in. (4.00 mm) maximum is acceptable.
    3. Figure: Fan blade airfoil ultrasonic inspection, calibration of equipment
    Fan blade airfoil ultrasonic inspection, calibration of equipment
    Figure: Fan blade airfoil ultrasonic inspection
    Sheet 1
    Legend
    Fan blade airfoil ultrasonic inspection 
    Sheet 1
    Close
    Figure: Fan blade airfoil ultrasonic inspection
    Sheet 2
    Legend
    Fan blade airfoil ultrasonic inspection 
    Sheet 2
    Close
    Figure: Ultrasonic inspection record sheet
    Ultrasonic inspection record sheet
Requirements After Job Completion
Follow-On Conditions
NONE
Manufacturer Code:0AM53
Enterprise Name:IAE INTERNATIONAL AERO ENGINES AG
BU Name:NULL
Building:SUITE 400
Street:628 HEBRON AVENUE
City:GLASTONBURY
State:CT
Zip Code:06033
Country:USA
Manufacturer Code:IE304
Enterprise Name:DELETED
BU Name:DELETED,SEE CAGE CODE 0V6W9
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:IE304
Supply Number:CoMat 02-121
Type:sp01
Supply Short Name:CoMat 02-121 TEMPORARY MARKER PENCIL/CRAYON
Supply Name:CoMat 02-121 TEMPORARY MARKER PENCIL/CRAYON
Specification Groups:
Doc NumberType
OMAT: 261BEROL VERITHIN (HARD TYPE)
Suppliers:
ManufacturerRemarks
IE304
K5720
K6835
LOCAL
Manufacturer Code:LOCAL
Supply Number:CoMat 06-148
Type:sp01
Supply Short Name:CoMat 06-148 ULTRASONIC COUPLANT
Supply Name:CoMat 06-148 ULTRASONIC COUPLANT
Specification Groups:
Doc NumberType
OMAT: 655SOUNDSAFE
Suppliers:
ManufacturerRemarks
LOCAL
57869
K6835
U3319
Manufacturer Code:0AM53
Tool Number:IAE 2R18937
Tool Name:IAE 2R18937 Shear wave ultrasonicprobe, type 45-4-FB
Manufacturer Code:0AM53
Tool Number:IAE 2R18938
Tool Name:IAE 2R18938 Compressionwave ultrasonic probe, type 0-5-FB
Manufacturer Code:0AM53
Tool Number:IAE 2R18939
Tool Name:IAE 2R18939 Ultrasonic calibration block
Manufacturer Code:0AM53
Tool Number:IAE 2R18940
Tool Name:IAE 2R18940 Perspexoverlay
Manufacturer Code:0AM53
Tool Number:IAE 2R18941
Tool Name:IAE 2R18941 Perspexoverlay
Manufacturer Code:LOCAL
Tool Number:Ultrasonic Flaw Detector
Tool Name:Ultrasonic flaw detector