Preliminary Requirements

Procedure

1. Repair Facilities

   1. The Source Demonstration requirements of this repair means that any facility not authorized to accomplish this repair either, utilize the Authorized 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

      U.S.A.

      Attn: Manager Technical Services

   2. Authorized Repair Vendors for Repair VRS6151 are listed below:

      ROLLS-ROYCE AERO ENGINE SERVICES LTD.

      COMPONENT REFURBISHMENT

      MAVOR AVENUE

      NERSTON

      EAST KILBRIDE

      GLASGOW

      G74 4PY

      SCOTLAND

      ATTN: Business Manager, Component Refurbishment

      Stage 3 Blades Only

      MTU MAINTENANCE GMBH

      FLUGHAFEN HANNOVER

      MUNCHNER STRASSE 31

      30855 LANGENHAGEN

      GERMANY

      ATTN: Manager, Quality Assurance

      Stages 4 to 6 Blades Only

      AIRFOIL SERVICES SDN BHD (ASSB)

      NO. 12 JALAN TEKNOLOGI

      TAMAN SAINS SELANGOR 1

      KOTA DAMANSARA PJU5

      47810 PETAILING JAYA

      SELANGOR DARUL EHSAN

      MALAYSIA

      ATTN: Managing Director

      ISHIKAWAJIMA-HARIMA HEAVY INDUSTRIES CO. LTD

      229 TONOGAYA, MIZUHO-MACHI

      NISHITAMA-GUN

      TOKYO 190-12

      JAPAN

      ATTN: Manager, Repair Engineering Group

      TURBINE OVERHAUL SERVICES PTE, LTD. (TOS)

      5 TUAS DRIVE TWO - MAIL STOP 107-58

      SINGAPORE 638639

      TEL: 65-6860-2260

      FAX: 65-6862-1068

      Rolls-Royce Inchinnan

      Inchinnan Drive

      Inchinnan Business Park

      Inchinnan, PA4 9AF

      Scotland

   3. The designation by IAE of an Authorized 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 qualifications 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. Authorized Repair Vendors do not act as agents or representatives of IAE.

2. SUBTASK 72-41-15-110-114 Clean the HP Compressor Rotor Blades, Stage 3 to 6

   1. Chemically clean the blades.

      1. Refer to TASK 72-41-15-100-000.

      2. Use Chemical cleaning equipment.

3. SUBTASK 72-41-15-230-096 Do a Crack Test

   1. Do a penetrant crack test.

      1. Refer to TASK 72-41-15-200-000.

      2. Use Penetrant Crack Test Equipment.

4. SUBTASK 72-41-15-220-264-A00 Make Sure the HP Compressor Rotor Blades, Stage 3 can be Repaired, Assembly A

   1. Refer to Figure.

   2. Visually examine the roots of the HP Compressor Rotor Blades, Stage 3, Assembly A, to tell you if shot-peening has been done before, (look for the Repair identification symbol).

      1. If the repair identification symbol and /4 is engraved adjacent to the part number, then the blade cannot be shot-peened.

5. SUBTASK 72-41-15-220-264-B00 Make Sure the HP Compressor Rotor Blades, Stage 4, can be Repaired, Assembly B

   1. Refer to Figure.

   2. Visually examine the roots of the HP Compressor Rotor Blades, Stage 4, Assembly B, to tell you if the shot-peening has been done before, (look for the Repair identification symbol).

      1. If the Repair identification symbol and /4 is engraved adjacent to the part number, then the blade cannot be shot-peened.

6. SUBTASK 72-41-15-220-264-C00 Make Sure the HP Compressor Rotor Blades, Stage 5, can be Repaired, Assembly C

   1. Refer to Figure.

   2. Visually examine the roots of the HP Compressor Rotor Blades, Stage 5, Assembly C, to tell you if the shot-peening has been done before, (look for the Repair identification symbol).

      1. If the Repair identification symbol and /4 is engraved adjacent to the part number, then the blade cannot be shot-peened.

7. SUBTASK 72-41-15-220-264-D00 Make Sure the HP Compressor Rotor Baldes, Stage 6, can be Repaired, Assembly D

   1. Refer to Figure.

   2. Visually examine the roots of the HP Compressor Rotor Blades, Stage 6, Assembly D, to tell you if the shot-peening has been done before, (look for the Repair identification symbol).

      1. If the Repair identification symbol and /4 is engraved adjacent to the part number, then the blade cannot be shot-peened.

8. SUBTASK 72-41-15-220-264-E00 Make Sure the HP Compressor Rotor Blades, Stage 6, can be Repaired, Assembly E

   1. Refer to Figure.

   2. Visually examine the roots of the HP Compressor Rotor Blades, Stage 6, Assembly E, to tell you if the shot-peening has been done before, (look for the Repair identification symbol).

      1. If the Repair identification symbol and /2 is engraved adjacent to the part number, then the blade cannot be shot-peened.

9. SUBTASK 72-41-15-380-100 Shot-Peen the Dovetail Root of the HP Compressor Rotor Blades, Stage 3 to 6, Assembly A, Assembly B, Assembly C, Assembly D, Assembly E

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

   2. Seal the areas of the blades not to be shot-peened.

      1. Use CoMat 02-003 ADHESIVE TAPE BLACK WATERPROOF or a locally made mechanical mask.

      2. Patch mask all identification marks and symbols.

   3. Install the sealed blades onto the table of the shot-peening equipment.

      1. Use Shot peening equipment.

   4. Shot-peen the dovetail root of the HP Compressor Rotor Blades, Stage 3 to 6, as necessary.

      1. Refer to SPM TASK 70-38-04-300-503, SUBTASK 70-38-04-300-002.

      2. Use CoMat 05-028 METALLIC SHOT (CAST STEEL), S230 to get an Almen intensity of 0.006 in. to 0.010 in. (0.15 mm to 0.25 mm) on A type test strip.

      3. A coverage of 200 percent must be applied.

      4. Use Shot peening equipment.

         Shot-Peening Data
         Machine type	Metal shot-peen
         Process type/mode	Dry/auto
         Shot type	CoMat 05-028 METALLIC SHOT (CAST STEEL), S230
         Shot size	0.024 in. to 0.04 in. (0.6 mm to 1.0 mm) diameter
         Shot hardness	450 HV to 600 HV
         Coverage	200 percent
         Table speed	5.900 in. (150.00 mm) per minute
         Oscillation speed	30 cycles per minute
         Oscillation height	1.970 in. (50.00 mm)
         Oscillation type	Pneumatic
         Air pressure	54 psi - 56 psi (372 KPa to 386 KPa)
         Nozzle type/diameter	Y type 36 CFM/0.375 in. (9.52 mm)
         Nozzle/Work distance	3.540 in. (90 mm)
         Number of nozzles	8
         Almen intensity	0.006 in. to 0.010 in. (0.15 mm to 0.25 mm) using "A" type test strip
         NOTE For information, the table speed, oscillation speed, height, type, air pressure, nozzle type/diameter and work distance may change if different equipment is being used. You must achieve the coverage and almen intensity as given in the Shot-Peening data.

   5. Make sure all loose unwanted cast steel shot is removed.

   6. Remove iron contamination after you have shot-peened, as necessary.

      1. Refer to Approved Vendors in Step. Repair Facilities, Para. B and/or refer to SPM TASK 70-38-04-300-503, SUBTASK 70-38-04-300-002.

      2. Use wet or dry glass beads with Glass bead peening equipment.

   7. Remove the mechanical masks and/or seal tape.

10. SUBTASK 72-41-15-220-265 Examine the Shot-Peened Areas of the HP Compressor, Rotor Blades, Stage 3 to 6, Assembly A, Assembly B, Assembly C, Assembly D and Assembly E

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

    2. Make a visual inspection of the shot-peened dovetails roots.

       1. Refer to SPM TASK 70-38-04-300-503, SUBTASK 70-38-04-300-002.

11. SUBTASK 72-41-15-350-129-A00 Identify the Repair, Assembly A, Assembly B, Assembly C and Assembly D

    1. Refer to Figure.

    2. Make a mark adjacent to the part number.

    3. If the HP Compressor Rotor Blades have been shot-peened once, mark a code symbol adjacent to the part number.

       1. NOTE

          The HP Compressor Rotor Blades, Assembly A, Assembly B, Assembly C and Assembly D, can only be shot-peened five times to this repair.

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

          1. If this is the second repair to this scheme, then vibro-engrave /1 adjacent to the code symbol.

          2. If this is the third repair to this scheme, then vibro-engrave /2 adjacent to the code symbol.

          3. If this is the fourth repair to this scheme, then vibro-engrave /3 adjacent to the code symbol.

          4. If this is the fifth repair to this scheme, then vibro-engrave /4 adjacent to the code symbol.

          5. Use vibro-engraving equipment.

12. SUBTASK 72-41-15-350-129-E00 Identify the Repair, Assembly E

    1. Refer to Figure.

    2. Make a mark adjacent to the part number.

    3. NOTE

       The HP Compressor Rotor Blades, Assembly E, can only be shot-peened three times to this repair.

       If the HP Compressor Rotor Blades, Assembly E, have been shot-peened once, mark a code symbol adjacent to the part number.

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

       2. If this is the second repair to this scheme, then vibro-engrave /1 adjacent to the code symbol.

       3. If this is the third repair to this scheme then vibro-engrave /2 adjacent to the code symbol.

       4. Use Vibrating marking pencil.

Figure: Repair details and dimensions - Assembly A

Repair details and dimensions - Assembly A



Figure: Repair details and dimensions - Assembly B

Repair details and dimensions - Assembly B



Figure: Repair details and dimensions - Assembly C

Repair details and dimensions - Assembly C



Figure: Repair details and dimensions - Assembly D

Repair details and dimensions - Assembly D



Figure: Repair details and dimensions - Assembly E

Repair details and dimensions - Assembly E



Figure: Repair details and dimensions

Repair details and dimensions



Figure: Repair details and dimensions

Repair details and dimensions