TASK 72-00-41-300-004 HPC Assembly - HPC Stage 3 To 5 And Stage 7 To 12 Rotor Blade(s) - Blend Repair The Leading Or Trailing Edge, Repair-004 (VRS6524)

DMC:V2500-A0-72-00-4100-01A-649A-B|Issue No:002.00|Issue Date:2016-05-01

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 72-00-41-300-004 HPC Assembly - HPC Stage 3 To 5 And Stage 7 To 12 Rotor Blade(s) - Blend Repair The Leading Or Trailing Edge, Repair-004 (VRS6524)

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 leading or trailing edge damage only on HP compressor stage 3 to stage 5 and stage 7 to stage 12 rotor blade(s), by material removal while installed on the rotor drum.

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

Material of Components

PART IDENT

MATERIAL

HP compressor rotor blade(s) stage 3 to stage 8

Titanium alloy

HP compressor rotor blade(s) stage 9 to stage 12

Nickel alloy

TASKS identified by SPM TASK are in the Standard Practices and Processes Manual (SPM).

Price and Availability: Refer to International Aero Engines

Related Repairs: None

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 Consumable 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 blade 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
Portablegrinding equipmentLOCALPortable grinding 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 CARBIDEIE241CoMat 05-075
CoMat 05-076 WATERPROOF SILICON CARBIDEK3895CoMat 05-076
CoMat 05-077 WATERPROOF SILICON CARBIDEK6835CoMat 05-077
CoMat 05-079 WATERPROOF SILICON CARBIDEK3895CoMat 05-079
CoMat 05-082 WATERPROOF SILICON CARBIDE44197CoMat 05-082
CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)LOCALCoMat 06-022

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-00-41-220-056 Examine the Assembly

    1. CAUTION

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

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

    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 blade 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 blades that have been blended.
      When you do this repair on a rotor stage, make sure that all damaged blades are blended. This includes damage that has been accepted, refer to the applicable inspection TASK.
      Only one blend on the leading or trailing edge is permitted for each blade. This includes all the blends.
      If the area to be blended is near to the blade tip, make sure that the blend will not produce hook feature.
      The HP compressor stage 6 blade is not to be blended using this repair.

      3. Examine the damaged blade.

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

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

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

      4. Examine the rotor assembly.

      1. Visually and dimensionally examine other blades 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. Examine and identify the repair location.

      1. Make sure all repair locations can be accessed.

        Mark all the reapir area.

    2. SUBTASK 72-00-41-350-014 Mask the Assembly

    1. Refer to 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 all areas other than repair location.

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

      4. Prevent adjacent vanes or blades.

    3. SUBTASK 72-00-41-110-011 Chemically Clean

      1. Locally degrease the repair area.

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

    4. SUBTASK 72-00-41-110-012 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 THAT THE ETCHING SOLUTION IS FULLY REMOVED, DISASSEMBLE THE ASSEMBLY IF NECESSARY.

      Refer to Figure.

      2. Swab etch the repaired area.

      1. For stage 3 to 8 blades (titanium alloy parts), refer to the SPM TASK 70-11-08-300-503.

        For stage 9 to 12 blades (nickel alloy), refer to the SPM TASK 70-11-39-300-503, SUBTASK 70-11-39-300-001

        Use Chemical Cleaning Equipment 1 off.

    5. SUBTASK 72-00-41-230-006 Do a Crack Test

      1. Do a local penetrant crack test.

    6. SUBTASK 72-00-41-350-005 Remove the Damage from HPC Rotor Blades(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 THE REPAIR AREA IS NOT NEAR THE EXCLUSION ZONE (ZONE B).

      2. NOTE

        While doing this repair on a compressor stage, make sure that all damaged blades 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 blade. This includes all the blends.
        If the area to be blended is near to the blade tip, make sure that the blend will not produce hook feature.
        The HP compressor stage 6 blade is not to be blended using this repair.

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

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

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

      3. CAUTION

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

        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 72-00-41-110-014 Chemically Clean

      1. Locally clean the repair area.

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

      2. Locally degrease the repair area.

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

    8. SUBTASK 72-00-41-110-015 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 THAT THE ETCHING SOLUTION IS FULLY REMOVED, DISASSEMBLE THE ASSEMBLY IF NECESSARY.

      Refer to Figure.

      2. Swab etch the repaired area.

      1. For stage 3 to 8 blades (titanium alloy parts), refer to the SPM TASK 70-11-39-300-503, SUBTASK 70-11-39-300-001.

        For stage 9 to 12 blades (nickel alloy), refer to the SPM TASK 70-11-08-300-503.

    9. SUBTASK 72-00-41-230-008 Do a Crack Test

      1. Do a local penetrant crack test.

    10. SUBTASK 72-00-41-220-059 Examine the Repair Area

    2. NOTE

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

      2. When you estimate whether a blade is acceptable 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 blades that were blended before.

      3. Visually examine the repair area.

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

        Make sure that all the debris are removed.

      4. Dimensionally examine the repair area.

      1. Make sure that the blended area is in the repair limits. If not, reject the blade.

    11. SUBTASK 72-00-41-350-062 Remove the Masking

    1. Refer to Figure, Figure and Figure.

      2. Remove the masking.

      1. Remove all the masking done in Step.

    12. SUBTASK 72-00-41-350-021 Record the Repair

      1. Record the repair.

      1. Record VRS6524 and the repair dimensions for each stage in the engine log book.

    13. Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    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:

SPM reference update (16VC133)

Change Type:

Added link to Support Equipment

Manufacturer Code:44197
Enterprise Name:SAINT-GOBAIN INDUSTRIAL CERAMICS INC.
BU Name:SAINT-GOBAIN ABRASIVES, INC
Street:ONE NEW BOND STREET
P.O. Box:PO BOX 15008
City:WORCESTER
State:MA
Zip Code:01615-0008
Country:USA
Phone Number:1-508-795-5000
Fax Number:1-508-795-2828
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:IE241
Enterprise Name:DELETED. Was ANGLO ABRASIVES.
Manufacturer Code:IE304
Enterprise Name:DELETED
BU Name:DELETED,SEE CAGE CODE 0V6W9
Manufacturer Code:K3895
Enterprise Name:DELETED. REFER TO VENDOR CODE KC1D9.
Manufacturer Code:K6835
Enterprise Name:MED-LAB LTD
BU Name:MED-LAB LTD
Street:COPELAND ST
City:DERBY
Zip Code:DE1 2PU
Country:GREAT BRITAIN
Phone Number:44-1332-349094
Fax Number:44-1332-371237
Email:sales@med-lab.co.uk
Internet:www.med-lab.co.uk
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
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 06-022
Type:sp01
Supply Short Name:CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)
Supply Name:CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)
Specification Groups:
Doc NumberType
ARDROX 985-P14 OMAT: 652 (CHEMETALL OAKITE 985-P14)It is not permitted to mix the selected CoMat 06‐022 letter suffix material with other CoMat 06‐022 letter suffix materials. Where CoMat 06‐022 is specified with no suffix, use one of the CoMat 06‐ 022 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Portable grinding equipment
Tool Name:Portablegrinding equipment
Manufacturer Code:LOCAL
Tool Number:Vacuum cleaning equipment
Tool Name:Vacuum cleaning equipment
Link not Found