TASK 72-41-12-300-015 HPC Stage 9 - 12 Drum Disk - Repair The Stage 8 to 11 Linings By Replacement, Repair-015 (VRS6008)

DMC:V2500-A0-72-41-1201-00A-920A-C|Issue No:004.00|Issue Date:2020-02-01

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 72-41-12-300-015 HPC Stage 9 - 12 Drum Disk - Repair The Stage 8 to 11 Linings By Replacement, Repair-015 (VRS6008)

Effectivity

FIG/ITEM

PART NO.

ASSEMBLY

01-600

6A7545

A

01-600

6A7546

B

01-600

6A7547

B

01-600

6A7574

A

Material of component

PART IDENT

SYMBOL

MATERIAL

HP compressor stage 9-12 disk

shaft assembly

QZD

Inconel 718 nickel base alloy

General

This repair must only be done when the instruction to do so is given in 72-41-12 Inspection (INSPECTION). This repair replaces the stage 8 to 11 linings on the HP compressor stage 9 to 12 disks shaft assembly.

If the Stage 8 to 11 linings are to be replaced, on Pre SBE 72-0347 parts, you must do SBE 72-0347 in full and re-number accordingly in accordance with SBE 72-0347.

The practices and processes referred to in the procedure by the TASK/SUBTASK numbers are in the SPM. This is a Source Demonstration Repair that can only be done by approved vendors.

Price and availability

Refer to International Aero Engines.

NOTE

Equipment and materials necessary to do this repair are in the SPM TASKS given below:
SPM TASK 70-12-02-120-501
SPM TASK 70-09-00-400-501
SPM TASK 70-23-04-230-501
SPM TASK 70-33-59-300-503
SPM TASK 70-34-01-340-501

NOTE

To identify the consumable materials refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NONE

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADELOCALCoMat 01-025
CoMat 02-198 ADHESIVE TAPE (MASKING METAL SPRAY)LOCALCoMat 02-198
CoMat 03-037 METAL SPRAYING POWDER,Ni Al08662CoMat 03-037
CoMat 03-043 METAL SPRAYING POWDER,Al OXIDELOCALCoMat 03-043
CoMat 03-416 METAL SPRAYING POWDERNi, Al (95/5)LOCALCoMat 03-416
CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADELOCALCoMat 05-001

Spares

NONE

Safety Requirements

NONE

Procedure

    1. Repair Facilities

      1. The Source Demonstration requirements of this repair means that any facility not authorised to accomplish this repair, either utilise the Authorised Repair Vendors listed below or contact the IAE Repair Services Group to determine if a qualification program can be initiated at their facility

        IAE International Aero Engines AG

        400 Main Street

        M/S 121-10

        East Hartford CT 06118

        USA

        Attn: Manager Technical Services

        1. Authorised repair vendors for Repair VRS6008 are listed below:

          GENERAL PLASMA INC.

          12 THOMPSON ROAD,

          EAST WINDSOR, CT 06088

          ATTN. DIRECTOR, QUALITY ASSURANCE

          MTU MAINTENANCE GMBH

          FLUGHAFEN HANNOVER

          MUNCHNER STRASSE 31

          POSTFACH 1720

          D3012 LANGENHAGEN

          GERMANY

          ATTN. MANAGER, QUALITY ASSURANCE

          ROLLS-ROYCE PLC

          AERO, REPAIR AND OVERHAUL

          MAVOR AVENUE

          NERSTON

          EAST KILBRIDE

          GLASGOW

          G74 4PY

          SCOTLAND

          ATTN. BUSINESS MANAGER, COMPONENT REFURBISHMENT

          MTU MAINTENANCE ZHUHAI CO. LTD

          NO. 1 TIANKE ROAD

          FREE TRADE ZONE

          ZHUHAI, GUANGDONG

          PC: 519030 P.R.CHINA

          ATTN. MANAGER, PARTS REPAIR

          CHRISTCHURCH ENGINE CENTRE-CHCEC

          634 MEMORIAL AVENUE

          CHRISTCHURCH INTERNATIONAL AIRPORT

          CHRISTCHURCH

          NEW ZEALAND

          IHI Corporation

          229 Tonogaya, Mizuho-Machi

          Nishitama-gun

          Tokyo 190-1297

          JAPAN

          Lufthansa Technik AG

          HAM WR 420

          PO Box 63 03 00

          D-22313 Hamburg-Airport

          Germany

          Rolls-Royce Inchinnan

          Inchinnan Drive

          Inchinnan Business Park

          Inchinnan, PA4 9AF

          Scotland

        1. The designation by IAE of an authorised repair vendor indicates that the repair vendor has demonstrated the necessary capability to enable it to carry out the listed repair work.However, IAE makes no warranties or representations concerning the qualification or quality standards of the repair vendors to carry out the repair work and accepts no responsibility whatsoever for any work that may be carried out by a repair vendor other than when IAE is listed as the repair vendor. Authorised repair vendors do not act as agents or representatives of IAE.

    2. SUBTASK 72-41-12-110-061 Clean the Assembly

      1. Chemically clean.

      1. Refer to TASK 72-41-12-100-000 (CLEANING-000).

      2. Use chemical cleaning equipment.

    3. SUBTASK 72-41-12-120-053-A00 Loosen the Top Coat Lining at Each Stage, Assembly A

    1. CAUTION

      REMOVE THE TOP COAT ONLY. THE BLAST OPERATION MUST STOP WHEN THE WHITE TOP COAT IS REMOVED. FAILURE TO STOP THE BLAST OPERATION AS SPECIFIED CAN RESULT IN SUBSEQUENT ENGINE FAILURE.

      NOTE

      It is permitted to loosen the top coat lining in part, to allow the Nitric Acid by capillary action, to release both top and bond coats at each stage.

      Refer to Figure.

      2. Seal all surfaces not to be blasted.

      1. Use CoMat 02-198 ADHESIVE TAPE (MASKING METAL SPRAY) or equivalent masking listed in the SPM TASK 70-34-18-380-501 or refer to Step. Repair Facilities for approved vendor tools.

      3. Lightly dry blast to loosen the top coat lining at each stage.

      1. Refer to the SPM TASK 70-12-02-120-501.

    4. Remove the masks.

    4. SUBTASK 72-41-12-120-053-B00 Loosen the Top Coat Lining at Each Stage, Assembly B

    1. CAUTION

      REMOVE THE TOP COAT ONLY. THE BLAST OPERATION MUST STOP WHEN THE WHITE TOP COAT IS REMOVED. FAILURE TO STOP THE BLAST OPERATION AS SPECIFIED MAY RESULT IN SUBSEQUENT ENGINE FAILURE.

      NOTE

      It is permitted to loosen the top coat lining in part, to allow the Nitric Acid by capillary action, to release both top and bond coats at each stage for chemical strip step. This step is optional when using water jet to remove linings.

      Refer to Figure.

      2. Seal all surfaces not to be blasted.

      1. Use CoMat 02-198 ADHESIVE TAPE (MASKING METAL SPRAY) or equivalent masking listed in the SPM TASK 70-34-18-380-501 or refer to Step. Repair facilities for approved vendor tools.

      3. Lightly dry blast to loosen top coat lining at each stage.

      1. Refer to the SPM TASK 70-12-02-120-501.

    4. Remove the masks.

    5. SUBTASK 72-41-12-330-052-A00 Chemically Remove the Linings at Each Stage, Assembly A

    1. Refer to Figure and Figure.

      2. Remove the lining at each stage.

      1. Refer to the SPM TASK 70-33-59-300-503.

      2. Use CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADE. Put the assembly into nitric acid solution and keep below surface until bubbles stop.

    6. SUBTASK 72-41-12-350-178-B00-001 Remove the Linings at Each Stage by Water Jet, Assembly B (PN 6A7546 only)

    1. Refer to Figure, Figure and Figure.

      2. Remove the lining at each stage by high pressure water blasting.

        NOTE

        This is a source demonstration processes which can only be done by approved vendors.

        NOTE

        This method is applicable to PNs 6A7546 only.

        NOTE

        This step is an alternative to Step.

      1. Waterjet blasting permitted in areas labeled AZ only.

      2. Blasting outside of repair area is not allowed.

      3. Hard mask required in areas labeled AG.

        4. Remove the abradable lining.

        1. Refer to SPM TASK 70-15-01-160-501.

        2. Make sure the liner is completely removed.

        3. 0.0005 in. (0.0127 mm) maximum erosion from waterjet allowed.

        4. Overspray permitted in areas labeled AJ.

    7. SUBTASK 72-41-12-330-052-B00-002 Chemically Remove the Linings at Each Stage, Assembly B

    1. Refer to Figure and Figure.

      2. Remove the lining at each stage.

      1. Refer to the SPM TASK 70-33-59-300-503.

      2. Use CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADE. Put the assembly into nitric acid solution and keep below surface until bubbles stop.

    8. SUBTASK 72-41-12-220-086-A00 Visually Examine Surfaces for Repair, Assembly A

    1. Refer to Figure and Figure.

      2. Visually examine.

      1. Make sure all the lining material has been removed. If not do Step and Step again as necessary.

    9. SUBTASK 72-41-12-220-086-B00 Visually Examine Surfaces for Repair, Assembly B

    1. Refer to Figure and Figure.

      2. Visually examine.

      1. Make sure all the lining material has been removed. If not do Step and Step or Step again as necessary.

    10. SUBTASK 72-41-12-230-061 Do a Crack Test

      1. Do a penetrant crack test.

      1. Refer to the SPM TASK 70-23-04-230-501.

      2. No cracks allowed, reject part if found.

    11. SUBTASK 72-41-12-220-087 Dimensionally Examine Surfaces for Repair

    1. CAUTION

      ASSEMBLIES WHICH ARE NOT ACCEPTED AND CANNOT BE REPAIRED ARE TO BE DISCARDED.

      Refer to Figure and Figure.

      2. Dimensionally examine the radial depth of the groove for the lining at each stage.

      1. The depth of the groove must not be more than 0.016 in. (0.40 mm).

    12. SUBTASK 72-41-12-350-064-A00 Seal all Surfaces not to be Repaired, Assembly A

    1. Refer to Figure.

      2. Seal applicable surfaces.

      1. NOTE

        The adhesive tape (metal masking spray) permits the blasting and sprayed coating to be done in one operation.

        Use CoMat 02-198 ADHESIVE TAPE (MASKING METAL SPRAY) or equivalent tape listed in the SPM TASK 70-34-18-380-501.

      2. Alternatively refer to step 4. Repair Facilities for approved vendor tools.

    13. SUBTASK 72-41-12-350-064-B00 Seal all Surfaces not to be Repaired, Assembly B

    1. Refer to Figure.

      2. Seal applicable surfaces.

      1. NOTE

        The adhesive tape (metal masking spray) permits the blasting and sprayed coating to be done in one operation.

        Use CoMat 02-198 ADHESIVE TAPE (MASKING METAL SPRAY) or equivalent masking in the SPM TASK 70-34-18-380-501.

      2. Alternatively refer to 4. Repair Facilities for approved vendor tools.

    14. SUBTASK 72-41-12-120-054 Prepare Surfaces for Repair

      1. CAUTION

        DO NOT TOUCH SURFACE(S) TO BE REPAIRED AFTER THEY ARE CLEANED.

        CAUTION

        TOO MUCH ABRASIVE BLAST CAN CAUSE DETERIORATION OF THE PREPARED SURFACE CONDITION AND MUST BE PREVENTED.

        Lightly dry blast to prepare surfaces for the lining.

      1. Refer to the SPM TASK 70-12-02-120-501.

    15. SUBTASK 72-41-12-340-054-A00 Apply the New Linings, Assembly A

    1. Refer to Figure, Figure and Figure.

      2. NOTE

        Pre SBE 72-0347.
        If the stage 8 to 11 linings are to be replaced, on Pre SBE 72-0347 parts, you must do SBE 72-0347 in full and re-number accordingly in accordance with SBE 72-0347.

        Apply the bond coat at each stage.

      1. Refer to SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-007 or SUBTASK 70-34-01-340-025.

      3. Apply a thickness of 0.0080 to 0.0100 in. (0.203 to 0.254 mm).

      3. Apply the top coat at each stage.

      1. Refer to TASK SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-013.

      3. Apply a layer of sufficient thickness to get the correct dimensions after assembly is machined.

    4. Remove the masks.

    16. SUBTASK 72-41-12-340-054-B00 Apply the new Linings, Assembly B

    1. Refer to Figure, Figure and Figure.

      2. NOTE

        Pre SBE 72-0347.
        If the stage 8 to 11 linings are to be replaced, on Pre SBE 72-0347 parts, you must do SBE 72-0347 in full and re-number accordingly in accordance with SBE 72-0347.

        Apply the bond coat at each stage.

      1. Refer to the SPM TASK 70-34-01-340-501 SUBTASK 70-34-01-340-007 or SUBTASK 70-34-01-340-025.

      3. Apply a thickness of 0.008 to 0.010 in. (0.203 to 0.254 mm).

      3. Apply the top coat at each stage.

      1. Refer to the SPM TASK 70-34-01-340-501 SUBTASK 70-34-01-340-013.

      3. Apply a layer of sufficient thickness to get the correct dimensions after assembly is machined.

    4. Remove the masks.

    17. SUBTASK 72-41-12-220-088 Visually Examine

      1. Visually examine the new linings.

      1. Refer to the SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-002.

    18. SUBTASK 72-41-12-325-051-A00 Machine the Linings, Assembly A

      2. Set up the disk assembly to be machined.

      1. Refer to Step. Repair Facilities for approved vendor tools.

      3. Machine the linings.

      2. Machine at 200 feet/min (60 meters per min.).

      4. NOTE

        Operators have the option to include the spiral groove as necessary.

        Machine the spiral grooves. The operation to machine the spiral groove is not mandatory.

      1. See Figure, Figure and Figure.

      2. Refer to step 4. Repair Facilities for approved vendor tools.

      3. Use spindle speed 40 revs/minute.

    19. SUBTASK 72-41-12-325-051-B00 Machine the Linings, Assembly B

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

      2. Set up the disk assembly to be machined.

      1. Refer to Step. Repair Facilities for approved vendor tools.

      3. Machine the linings.

      1. Machine at 200 feet/min (60 meters per min.).

    20. SUBTASK 72-41-12-220-089-A00 Visually and Dimensionally Examine the Repair, Assembly A

      2. Visually examine repaired area.

      1. Refer to the SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-002.

    3. Dimensionally examine the repaired linings at each stage.

    21. SUBTASK 72-41-12-220-089-B00 Visually and Dimensionally Examine the Repair, Assembly B

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

      2. Visually examine repaired area.

      1. Refer to the SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-002.

    3. Dimensionally examine the repaired linings at each stage.

    22. SUBTASK 72-41-12-110-062 Clean the Assembly

      1. Chemically clean.

    23. SUBTASK 72-41-12-350-066 Identify the Repair

    1. Refer to Figure.

      2. NOTE

        Pre SBE 72-0347.
        If the stage 8 to 11 linings are to be replaced, on Pre SBE 72-0347 parts, you must do SBE 72-0347 in full and re-number accordingly in accordance with SBE 72-0347.

        Vibro-engrave VRS6008 adjacent to the part number.

      1. Refer to the SPM TASK 70-09-00-400-501, SUBTASK 70-09-00-400-001.

    24. Figure: Repair details and dimensions - Assy A

    Repair details and dimensions - Assy A

    Figure: Repair details and dimensions Assy B

    Repair details and dimensions Assy B

    Figure: Repair details and dimensions - Assy A and Assy B

    Repair details and dimensions - Assy A and Assy B

    Figure: Repair details and dimensions - Assy A and Assy B

    Repair details and dimensions - Assy A and Assy B

    Figure: Repair details and dimensions - Assy A

    Repair details and dimensions - Assy A

    Figure: Repair details and dimensions - Assy B

    Repair details and dimensions - Assy B

    Figure: Repair details and dimensions - Assy A

    Repair details and dimensions - Assy A

    Figure: Repair details and dimensions - Assy B

    Repair details and dimensions - Assy B

    Figure: Repair details and dimensions - Assy A and Assy B

    Repair details and dimensions - Assy A and Assy B

    Figure: Repair details and dimensions - Assy A

    Repair details and dimensions - Assy A

    Figure: Repair details and dimensions - Assy A

    Repair details and dimensions - Assy A

    Figure: Repair details and dimensions - Assy A

    Repair details and dimensions - Assy A

    Figure: Repair details and dimensions - Assy A and Assy B

    Repair details and dimensions - Assy A and Assy B

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedure to use high pressure water and figures. (18VG169)

Manufacturer Code:08662
Enterprise Name:PRAXAIR CORPORATE OFFICE
BU Name:PRAXAIR CORPORATE OFFICE
Department:formerly Miller Thermal Technologies Inc
Street:1500 POLCO STREET
City:INDIANAPOLIS
State:IN
Zip Code:46222
Country:USA
Phone Number:1-603-224-9585, 1-317-240-2500
Fax Number:1-317-240-2426
Internet:www.praxairthermalspray.com
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:5FCA4
Supply Number:CoMat 01-025
Type:sp01
Supply Short Name:CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADE
Supply Name:CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADE
Specification Groups:
Doc NumberType
orTECHNICAL GRADE SP.GR. 1.42 NITRIC ACID
orTECHNICAL GRADE 42 BAUME NITRIC ACID
TECHNICAL GRADE 67.5 WT% NITRIC ACID
Suppliers:
ManufacturerRemarks
5FCA4
K6835
LOCAL
U0PR4
U0SV8
U6726
V272V
Manufacturer Code:07512
Supply Number:CoMat 02-198
Type:sp01
Supply Short Name:CoMat 02-198 ADHESIVE TAPE (MASKING METAL SPRAY)
Supply Name:CoMat 02-198 ADHESIVE TAPE (MASKING METAL SPRAY)
Specification Groups:
Doc NumberType
OMAT: 2/96 (RR REF)CHR 23816 TAPE
Suppliers:
ManufacturerRemarks
07512
K6835
K1369
KC622
Manufacturer Code:08662
Supply Number:CoMat 03-037
Type:sp01
Supply Short Name:CoMat 03-037 METAL SPRAYING POWDER, Ni Al
Supply Name:CoMat 03-037 METAL SPRAYING POWDER,Ni Al
Specification Groups:
Doc NumberType
PWA1321AI-1404
Suppliers:
ManufacturerRemarks
08662
Manufacturer Code:LOCAL
Supply Number:CoMat 03-043
Type:sp01
Supply Short Name:CoMat 03-043 METAL SPRAYING POWDER, Al OXIDE
Supply Name:CoMat 03-043 METAL SPRAYING POWDER,Al OXIDE
Specification Groups:
Doc NumberType
MSRR9507/9METCO 105 NS MIL-P-85856/10
OMAT:3/94METCO 105 NS MIL-P-85856/10
Suppliers:
ManufacturerRemarks
LOCAL
39918
IE103
IE195
IE200
K1030
K6835
Manufacturer Code:LOCAL
Supply Number:CoMat 03-416
Type:sp01
Supply Short Name:CoMat 03-416 METAL SPRAYING POWDERNi, Al (95/5)
Supply Name:CoMat 03-416 METAL SPRAYING POWDERNi, Al (95/5)
Specification Groups:
Doc NumberType
MSRR9507/5AMDRY 956 MIL-P-85856/10
OMAT:3/188A
Suppliers:
ManufacturerRemarks
LOCAL
K6835
53654
IE200
K1030
Manufacturer Code:LOCAL
Supply Number:CoMat 05-001
Type:sp01
Supply Short Name:CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADE
Supply Name:CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADE
Specification Groups:
Doc NumberType
Use one of the CoMat 05-001 letter suffix alternatives.
Suppliers:
ManufacturerRemarks
LOCAL