TASK 72-00-41-300-003 HPC Assembly - HPC Stage 3 To 6 Stator Vane(s) And/or Variable Inlet Guide Vane - Blend Repair The Leading Or Trailing Edge, Repair-003 (VRS6522)

DMC:V2500-A0-72-00-4100-00A-649A-B|Issue No:002.00|Issue Date:2019-08-01

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 72-00-41-300-003 HPC Assembly - HPC Stage 3 To 6 Stator Vane(s) And/or Variable Inlet Guide Vane - Blend Repair The Leading Or Trailing Edge, Repair-003 (VRS6522)

Material of component

PART IDENT

MATERIAL

HP compressor stator vane(s) stage 3 to stage 6

Corrosion resistant steel or nickel alloy

HP compressor variable inlet guide vane (VIGV)

Titanium alloy

General

This repair must only be done when the instruction to do so is given in the related Inspection/Check.

This TASK gives the procedure to repair aerofoil leading or trailing edge damage only on HP compressor stage 3 to stage 6 stator vane(s) and/or variable inlet guide vane (VIGV), by material removal while installed in the case.

Material removal from the HP compressor vane aerofoil suction and pressure faces/platform fillet radius is not permitted.

NOTE

Equipment and materials necessary to do this repair are in the SPM TASKS given below:
SPM TASK 70-11-03-300-503
SPM TASK 70-11-08-300-503
SPM TASK 70-11-39-300-503
SPM TASK 70-23-05-230-501

NOTE

It is possible that some materials in the consumable materials chart cannot be used for some or all of the necessary applications. Before you use the materials, make sure the types, quantities and applications of the materials necessary are legally permitted in your location. All persons must obey all applicable federal, state, local and provincial laws and regulations when it is necessary to work with these materials.
To identify the consumable materials, refer to the Overhaul Processes and Consumables Index (PCI).
Other necessary consumable materials are referred to in the SPM TASKs.

NOTE

This repair scheme is a Special Procedure and does not replace or is equivalent to individual vane blending piece part repair.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Chemical Cleaning EquipmentLOCALChemical Cleaning Equipment
Penetrant Crack Test EquipmentLOCALPenetrant Crack Test Equipment
Portable Dressing EquipmentLOCALPortable Dressing Equipment
Vacuum cleaning equipmentLOCALVacuum cleaning equipment
Workshop inspection equipmentLOCALWorkshop inspection equipment

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-459 AQUEOUS WIPE CLEANER71410CoMat 01-459
CoMat 02-001 ADHESIVE TAPE (MASKING)LOCALCoMat 02-001
CoMat 02-005 ADHESIVE TAPE (MASKING)LOCALCoMat 02-005
CoMat 02-121 TEMPORARY MARKER PENCIL/CRAYONIE304CoMat 02-121
CoMat 05-075 WATERPROOF SILICON CARBIDE1E1X8CoMat 05-075
CoMat 05-076 WATERPROOF SILICON CARBIDE1E1X8CoMat 05-076
CoMat 05-077 WATERPROOF SILICON CARBIDE1E1X8CoMat 05-077
CoMat 05-079 WATERPROOF SILICON CARBIDE1E1X8CoMat 05-079
CoMat 05-082 WATERPROOF SILICON CARBIDE1E1X8CoMat 05-082
CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)X222XCoMat 06-063

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-00-41-220-057 Examine the Assembly

    1. CAUTION

      MAKE SURE THAT REPAIR AREA IS NOT NEAR TO THE EXCLUSION ZONE (ZONE B).

    2. NOTE

      The adjacent components that can prevent the access during the repair or the components that can be damaged during the repair must be removed using related disassembly TASKs.
      When you estimate whether the vane is applicable for repair, make sure that the total material to be removed from the stage (cumulative blend limit) is not more than the limits. This includes all the blends that are done before.
      While doing this repair on a compressor stage, make sure that all damaged vanes in the compressor stage are blended. This includes damage that has been accepted as given in the related inspection TASK.
      Only one blend on the leading or trailing edge is permitted for each vane. This includes all the blends.
      If the area to be blended is near to the vane tip, make sure that the blend will not produce hook feature.

      3. Examine the damaged vane.

      1. Measure the maximum depth of material to be removed.

        Examine the vane for previous application of a blend repair. Only one blend or previous blend indication for each vane is permitted.

        The vane, after repair, must be in the individual repair limits given.

      4. Examine the stator vane assembly.

      1. Visually and dimensionally examine other vanes in the repair stage for blending that was done before. Make sure the total area after blending will be in cumulative blend limits for each stage.

        Use workshop inspection equipment.

      5. Identify the repair location.

      1. Make sure all repair locations can be accessed.

        Mark all the repair areas.

    2. SUBTASK 72-00-41-350-012 Mask the Assembly

    1. Refer to Figure, Figure, Figure, Figure and Figure.

    2. NOTE

      The abradable linings are porous and can have contamination during this repair. Make sure that the abradable linings are properly masked before you continue with the repair.

      3. Mask repair area.

      1. Mask areas of the vane other than repair area. Mask adjacent areas that can have contamination during the repair.

      4. Prevent adjacent vanes or blades.

    3. SUBTASK 72-00-41-110-007 Chemically Clean

      1. Locally degrease the repair area.

      1. Refer to SPM TASK 70-11-03-300-503, SUBTASK 70-11-03-300-003.

    4. SUBTASK 72-00-41-110-008 Do a Swab Etch

    1. WARNING

      WHEN USING DANGEROUS MATERIALS, MAKE SURE THAT THE SPM MANUAL AND MANUFACTURER'S MATERIAL SAFETY DATA SHEET SAFETY PRECAUTIONS ARE FOLLOWED.

      CAUTION

      MAKE SURE THAT THE ETCH SOLUTION DOES NOT TOUCH THE AREAS OTHER THAN THE INTENDED REPAIR AREA. MAKE SURE THAT ALL THE ETCH SOLUTION IS REMOVED AFTER OPERATION.

      CAUTION

      IF ETCHING SOLUTION DOES TOUCH THE UNINTENDED AREAS, MAKE SURE THE ETCHING SOLUTION IS FULLY REMOVED, DISASSEMBLE THE ASSEMBLY IF NECESSARY.

      Refer to Figure and Figure.

      2. Swab etch the repaired area.

      1. For VIGV (titanium alloy part), refer to SPM TASK 70-11-08-300-503.

        For stage 3 to 6 vanes (corrosion resistant steel or nickel alloy), refer to SPM TASK 70-11-39-300-503 SUBTASK 70-11-39-300-001.

    5. SUBTASK 72-00-41-230-004 Do a Crack Test

      1. Do a local penetrant crack test.

    6. SUBTASK 72-00-41-350-013 Remove the Damage from HP Compressor Vane(s)

    1. CAUTION

      USE GLOVES AND SAFETY EQUIPMENT OR MASKING DURING REPAIR. SHARP EDGES OF BLADES AND VANES CAN CAUSE PERSONAL INJURY.

      CAUTION

      TITANIUM COMPONENT - YOU MUST USE SILICON CARBIDE TYPE ABRASIVE WHEELS, STONES AND PAPERS TO DRESS BLEND AND POLISH THIS COMPONENT.

      CAUTION

      TITANIUM COMPONENT - PREVENT BUILD UP OF HEAT BY CAREFULLY APPLYING THE PRESSURE AND KEEPING THE TOOL SPEED AS LOW AS POSSIBLE.

      CAUTION

      TITANIUM COMPONENT - MAXIMUM SPEED FOR MECHANICAL TOOLS MUST NOT BE MORE THAN 1000 REVOLUTIONS PER MINUTE.

      CAUTION

      TITANIUM COMPONENT - YOU MUST MAKE SURE THAT WHEN YOU DRESS MATERIAL, BLEND AND POLISH, TO MAKE SMOOTH, NO SPARKS ARE PRODUCED.

      CAUTION

      TITANIUM COMPONENT - IF THE MATERIAL SHOWS A CHANGE IN COLOR, TO DARKER THAN A LIGHT STRAW COLOR, THE COMPONENT IS TO BE REJECTED.

      CAUTION

      MAKE SURE THAT REPAIR AREA IS NOT NEAR THE EXCLUSION ZONE (ZONE B).

      CAUTION

      THE USE OF TOO MUCH FORCE WHILE REMOVING THE MATERIAL IS NOT ALLOWED. APPLY THE PRESSURE CAREFULLY AND SUFFICIENT SUPPORT OF THE VANE AEROFOIL MUST BE USED TO PREVENT THE VANE ROOT BEING SUBJECTED TO ADDITIONAL STRESSES.

      2. NOTE

        While doing this repair on a compressor stage, make sure that all damaged vanes in the compressor stage are blended. This includes damage that has been accepted as applicable in the related inspection TASK.
        Only one blend on the leading or trailing edge is permitted for each vane. This includes all the blends.
        If the area to be blended is near to the vane tip, make sure that the blend will not produce hook feature.

        Remove damage on the leading or trailing edges by material removal.

      1. The maximum depth of removed material must not be more than the limits specified.

        The repaired area length must be 8X the depth of the material removed.

        Use portable dressing equipment.

      3. Make smooth the repair area.

      1. Make sure all the damage marks are completely removed and the area is made smooth into the adjacent material.

      4. Polish the repair area.

      1. Polish the repaired area to remove scratches and to give a surface finish the same as the adjacent material.

    5. NOTE

      The last polish is to be in a radial direction.

    7. SUBTASK 72-00-41-110-009 Clean the Repair Area

      1. Locally clean the repair area.

      1. Locally clean the repair area to remove the debris.

        Use vacuum cleaning equipment.

      2. Locally degrease the repair area.

      1. Refer to SPM TASK 70-11-03-300-503, SUBTASK 70-11-03-300-003.

    8. SUBTASK 72-00-41-110-013 Do a Swab Etch

    1. WARNING

      WHEN USING DANGEROUS MATERIALS, MAKE SURE THAT THE SPM MANUAL AND MANUFACTURER'S MATERIAL SAFETY DATA SHEET SAFETY PRECAUTIONS ARE FOLLOWED.

      CAUTION

      MAKE SURE THAT THE ETCH SOLUTION DOES NOT TOUCH THE AREAS OTHER THAN THE INTENDED REPAIR AREA. MAKE SURE THAT ALL THE ETCH SOLUTION IS REMOVED AFTER OPERATION.

      CAUTION

      IF ETCHING SOLUTION DOES TOUCH THE UNINTENDED AREAS, MAKE SURE THE ETCHING SOLUTION IS FULLY REMOVED, DISASSEMBLE THE ASSEMBLY IF NECESSARY.

      Refer to Figure and Figure.

      2. Swab etch the repaired area.

      1. For VIGV (titanium alloy part), refer to SPM TASK 70-11-08-300-503.

        For stage 3 to 6 vanes (corrosion resistant steel or nickel alloy), refer to SPM TASK 70-11-39-300-503, SUBTASK 70-11-39-300-001.

    9. SUBTASK 72-00-41-230-007 Do a Crack Test

      1. Do a local penetrant crack test.

    10. SUBTASK 72-00-41-220-058 Examine the Repair Area

      2. NOTE

        1. While doing this repair on a compressor stage, make sure that all damaged vanes in the compressor stage are blended. This includes damage that has been accepted, refer to the related inspection TASK.

        2. When you estimate whether the vane is permitted after repair, make sure that the total material removed from the stage (cumulative blend limit) is not more than the limit given. This includes all the blends that were done before.

        Visually examine the repair area.

      1. Make sure the damage is removed completely and there is no undressed damage on vanes in the stage.

        Make sure all debris are removed.

      3. Dimensionally examine the repair area.

      1. Make sure the blended area is in the individual and cumulative repair limits. If not, reject the vane.

    11. SUBTASK 72-00-41-350-015 Remove the Masking

    1. Refer to Figure, Figure, Figure, Figure and Figure.

      2. Remove the masking.

      1. Remove all the masking done in Step.

    12. SUBTASK 72-00-41-350-016 Record the Repair

      1. Record the repair.

      1. Record VRS6522 and the repair dimensions for each stage in the engine log book.

    13. Figure: Repair Details and Dimensions - A1 Model

    Repair Details and Dimensions - A1 Model

    Figure: Repair Details and Dimensions - A5 Model

    Repair Details and Dimensions - A5 Model

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Editorial Update to correct SPM reference (CAS-44884-F9X4LS)

Manufacturer Code:1E1X8
Enterprise Name:SAINT-GOBAIN CERAMICS AND PLASTICS, INC
BU Name:SAINT-GOBAIN CERAMICS AND PLASTICS, INC
Street:1 NEW BOND ST
City:WORCESTER
State:MA
Zip Code:01606
Country:UNITED STATES OF AMERICA
Phone Number:1-508-795-5000, 1-800-243-0028
Fax Number:1-508-795-2380
Internet:www.saint-gobain-northamerica.com
Manufacturer Code:71410
Enterprise Name:HENKEL CORPORATION (WAS: TURCO PRODUCTS, INC)
BU Name:HENKEL CORPORATION (WAS: TURCO PRODUCTS, INC)
Street:32100 STEPHENSON HIGHWAY
City:MADISON HEIGHTS
State:MI
Zip Code:48071
Country:USA
Phone Number:1-248-583-9300
Fax Number:1-248-583-2976
Internet:www.aerospace.henkel.com
Manufacturer Code:IE304
Enterprise Name:DELETED
BU Name:DELETED,SEE CAGE CODE 0V6W9
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X222X
Enterprise Name:N/A – REFER TO APPLICABLE COMAT SUFFIX
Manufacturer Code:71410
Supply Number:CoMat 01-459
Type:sp01
Supply Short Name:CoMat 01-459 AQUEOUS WIPE CLEANER
Supply Name:CoMat 01-459 AQUEOUS WIPE CLEANER
Specification Groups:
Doc NumberType
SPMC 148-1TURCO 6780
Suppliers:
ManufacturerRemarks
71410
Manufacturer Code:LOCAL
Supply Number:CoMat 02-001
Type:sp01
Supply Short Name:CoMat 02-001 ADHESIVE TAPE (MASKING)
Supply Name:CoMat 02-001 ADHESIVE TAPE (MASKING)
Specification Groups:
Doc NumberType
OMAT: 230 (RR REF)ZINC OXIDE AT142
JCR-197 (JAEC REF)ZINC OXIDE AT142
Suppliers:
ManufacturerRemarks
LOCAL
K6835
U0415
Manufacturer Code:LOCAL
Supply Number:CoMat 02-005
Type:sp01
Supply Short Name:CoMat 02-005 ADHESIVE TAPE (MASKING)
Supply Name:CoMat 02-005 ADHESIVE TAPE (MASKING)
Specification Groups:
Doc NumberType
OMAT: 2/94 (RR REF)AT 7 BLACK, WATERPROOF
Suppliers:
ManufacturerRemarks
LOCAL
U0415
K6835
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:1E1X8
Supply Number:CoMat 05-075
Type:sp01
Supply Short Name:CoMat 05-075 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-075 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/28 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 800
JCR-181 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
K1905
K6835
LOCAL
Manufacturer Code:1E1X8
Supply Number:CoMat 05-076
Type:sp01
Supply Short Name:CoMat 05-076 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-076 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/30 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 500
JCR-183 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
K6835
LOCAL
Manufacturer Code:1E1X8
Supply Number:CoMat 05-077
Type:sp01
Supply Short Name:CoMat 05-077 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-077 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/32 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 360
JCR-185 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
K6835
LOCAL
Manufacturer Code:1E1X8
Supply Number:CoMat 05-079
Type:sp01
Supply Short Name:CoMat 05-079 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-079 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/36 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 220 (ANSI B74.18)
JCR-189 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
K6835
LOCAL
Manufacturer Code:1E1X8
Supply Number:CoMat 05-082
Type:sp01
Supply Short Name:CoMat 05-082 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-082 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/39 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 120 (ANSI B74.18)
JCR-192 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
K6835
LOCAL
Manufacturer Code:X222X
Supply Number:CoMat 06-063
Type:sp01
Supply Short Name:CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)
Supply Name:CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)
Specification Groups:
Doc NumberType
It is not permitted to mix the selected CoMat 06‐063 letter suffix material with other CoMat 06‐063 letter suffix materials. Where CoMat 06‐063 is specified with no suffix, use one of the CoMat 06‐063 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Portable Dressing Equipment
Tool Name:Portable Dressing Equipment
Manufacturer Code:LOCAL
Tool Number:Vacuum cleaning equipment
Tool Name:Vacuum cleaning equipment
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment