TASK 72-41-23-300-025 Replace the Worn Linings on the HP Compressor Rear Outer Case Assembly, Repair 025 (VRS6538)

DMC:V2500-A0-72-41-2302-01A-920A-C|Issue No:001.00|Issue Date:2016-08-01

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 72-41-23-300-025 Replace the Worn Linings on the HP Compressor Rear Outer Case Assembly, Repair 025 (VRS6538)

Effectivity

FIG/ITEM

PART NO.

02-400

6B1427

Material of component

DESCRIPTION

MATERIAL

HP Compressor Rear Outer Case

Corrosion Resistant Steel

General

This repair must only be done when the instruction to do so is given in the relevant inspection procedures (identified by the applicable part number) located in section 72-41-23.

This TASK gives the procedure to repair the HP Compressor Rear Outer Case Assembly, by the replacement of the lining.

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

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 70-09-00-400-501
SPM TASK 70-11-01-300-503
SPM TASK 70-12-02-120-501
SPM TASK 70-23-05-230-501
SPM TASK 70-33-59-300-503
SPM TASK 70-34-03-340-501
SPM TASK 70-34-01-340-501

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.

NOTE

To identify the consumable materials refer to the Overhaul Processes and Consumables Index (PCI).

NOTE

Other necessary consumable materials are referred to in the SPM TASKS.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Abrasive blast equipmentLOCALAbrasive blast equipment
Chemical cleaning equipmentLOCALChemical cleaning equipment
Cotton gloves or polythene glovesLOCALCotton gloves or polythene gloves
Dial test indicatorLOCALDial test indicator
Grinding MachineLOCALGrinding Machine
LatheLOCALLathe
Metal spray equipmentLOCALMetal spray equipment
Penetrant crack test equipmentLOCALPenetrant Crack Test Equipment
Standard Workshop EquipmentLOCALStandard Workshop Equipment
Standard workshop toolsLOCALStandard workshop tools
Vacuum Assisted BrushLOCALVacuum Assisted Brush
Vibrating Marking PencilLOCALVibrating Marking Pencil
Workshop inspection equipmentLOCALWorkshop inspection equipment
IAE 3R18658 Turn/Grind fixture0AM53IAE 3R186581 Off
Locally manufactured tooling/maskingLOCALN/AAs required

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-001 ADHESIVE TAPE (MASKING)LOCALCoMat 02-001
CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOILK0993CoMat 02-006
CoMat 03-096 PLASMA SPRAY POWDERLOCALCoMat 03-096
CoMat 03-239 METAL SPRAYING POWDER, CHROMIUM CARBIDE/NICHROME 75/25, FINELOCALCoMat 03-239
CoMat 03-240 METAL SPRAYING POWDER, CHROMIUM CARBIDE/NICHROME 75/25, FINELOCALCoMat 03-240
CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADELOCALCoMat 05-001
CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)LOCALCoMat 06-064

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-23-110-083 Remove the Surface Protection as necessary from the Area to be Repaired

      1. Remove the surface protection.

      1. Refer to TASK 72-41-23-100-003, SUBTASK 72-41-23-110-058.

    2. SUBTASK 72-41-23-330-002 Remove the Lining(s)

      CAUTION

      SURFACES FOR REPAIR MUST BE FULLY CLEANED AND NOT TOUCHED BY HAND. CLEAN COTTON OR POLYTHENE GLOVES MUST BE WORN.

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

      NOTE

      This SUBTASK is an alternative to Step.

      2. Chemically degrade the lining at area(s) identified AD.

      1. Refer to SPM TASK 70-33-59-300-503, SUBTASK 70-33-59-300-007.

      3. Abrasive blast area(s) identified AD.

      1. Refer to SPM TASK 70-33-59-300-503, SUBTASK 70-33-59-300-008.

    3. SUBTASK 72-41-23-325-053 Remove the Lining(s)

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

      NOTE

      This SUBTASK is an alternative to Step.

      2. Install the turn/grind fixture on to the machine and set to run true.

      3. Install the HP Compressor Rear Outer Case on the fixture.

      1. Make sure that datum 'A' is set to turn correctly.

      4. Turn to remove the lining from the area(s) Identified AD.

      1. You must not remove any metal from the rear outer case. Use a Lathe with Standard Workshop Equipment.

    4. SUBTASK 72-41-23-220-135 Examine the Rear Outer Case Assembly

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

      2. Visually examine and measure the dimensions of the rear outer case at repair area(s).

      1. Make sure all the lining material and corrosion has been removed.

      2. Make sure the dimensions are within the limits.

      3. If dimensions are outside limits.

      1. Reject.

    5. SUBTASK 72-41-23-230-081 Do a Crack Test

      1. Do a penetrant crack test on the repaired area(s).

      1. Refer to SPM TASK 70-23-05-230-501.

      4. Cracks are not permitted.

    6. SUBTASK 72-41-23-120-062 Chemically Clean

      1. Chemically clean the rear outer case.

      1. Refer to SPM TASK 70-11-01-300-503.

    7. SUBTASK 72-41-23-120-063 Abrasive Blast the Rear Outer Case

      CAUTION

      SURFACES FOR REPAIR MUST BE FULLY CLEANED AND NOT TOUCHED BY HAND. CLEAN COTTON OR POLYTHENE GLOVES MUST BE WORN.

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

      2. Seal the areas not to be repaired.

      3. Abrasive blast the rear outer case on area 'AD' as required.

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

    4. Remove masking tape and/or masks.

      5. Clean the blasted area(s).

      1. Use a dry air blast or a Vacuum Assisted Brush.

      2. Make sure that all the abrasive grit has been removed.

    8. SUBTASK 72-41-23-220-136 Examine the Rear Outer Case Assembly

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

      2. Measure the diameter in VIEW AC to calculate the repair area.

      1. If the diameter is less than or equal to 23.2580 in. (590.762 mm), continue the repair from Step

      2. If the diameter is more than 23.2580 in. (590.762 mm) but less than 23.2860 in. (591.464 mm), continue the repair.

      3. Measure the diameter in View AF to calculate the repair area.

      1. If the diameter is less than or equal to 23.1808 in. (588.792 mm), continue the repair from Step

      2. If the diameter is more than 23.1808 in. (588.792 mm) but less than 23.2078 in. (589.478 mm), continue the repair.

    9. SUBTASK 72-41-23-340-056 Apply the Plasma Spray (Bond Coat) to the H.P. Compressor Rear Outer Case Assembly

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

      3. Apply the plasma spray to area(s) 'AD'.

      1. Refer to SPM TASK 70-34-03-340-501.

      3. Apply a bond coat of sufficient thickness to get the correct dimensions after the top coat is applied.

        NOTE

        Top coat thickness should be 0.0032 in. to 0.0098 in. (0.08 mm to 0.250 mm) after final machining and remaining thickness should be build by bond coat.

    4. Remove masking tape and/or tooling/masks.

    10. SUBTASK 72-41-23-220-137 Examine the Repair Area(s)

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

      2. Examine and measure the dimensions at the repair area(s).

      1. Examine the coated area for chips, cracks; lifted material coating that is not attached to the base metal and surfaces that show heat cracks.

      2. Make sure the dimensions are within the limits.

    11. SUBTASK 72-41-23-340-057 Apply the Lining to the H.P. Compressor Rear Outer Case Assembly

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

      3. Apply the lining to area(s) 'AD'.

      1. Refer to SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-026.

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

    4. Remove masking tape and/or tooling/masks.

    12. SUBTASK 72-41-23-220-138 Examine the Lining

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

      2. Visually examine and measure the dimensions of the new lining.

      1. Examine the coated area for chips, cracks, lifted material coating that is not attached to the base metal and surface that show heat cracks.

      2. Make sure the dimensions are within the limits.

    13. SUBTASK 72-41-23-324-055 Machine the Lining

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

      2. Install the turn/grind fixture on a grinding machine and set to turn correctly.

      3. Install the HP compressor rear outer case onto the fixture.

      1. Make sure that datum A is set to turn correctly.

    4. Fully grind the lining at area(s) 'AD' to the dimensions shown.

    5. Remove burrs.

    14. SUBTASK 72-41-23-220-139 Examine the Repair Area(s)

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

      2. Visually examine and measure the dimensions at area(s) 'AD'.

      1. Examine the coated area for chips, cracks, lifted material coating that is not attached to the base metal and surface that show heat cracks.

      3. If dimensions are outside limits.

      1. Reject.

    15. SUBTASK 72-41-23-110-084 Chemically Clean

      1. Chemically clean the rear outer case.

      1. Refer to SPM TASK 70-11-01-300-503.

    16. SUBTASK 72-41-23-350-132 Identify the Repair

    1. Refer to Figure.

      2. Mark VRS6538 adjacent to the part number.

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

    17. SUBTASK 72-41-23-380-061 Re-apply the Surface Protection

      1. Apply the surface protection again.

      1. Refer to repair, VRS6178 TASK 72-41-23-300-003 (REPAIR 003).

    18. 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:

Added new repair for VRS6538. (15VR816)

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:K0993
Enterprise Name:3M (UK) PLC
BU Name:3M (UK) PLC
Street:3M CENTRE, CAIN ROAD
City:BRACKNELL
Zip Code:RG12 8HT
Country:UNITED KINGDOM
Phone Number:44-161-236-8500
Fax Number:44-161-237-6136
Internet:www.mmm.co.uk
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
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:K6835
Supply Number:CoMat 02-006
Type:sp01
Supply Short Name:CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOIL
Supply Name:CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOIL
Specification Groups:
Doc NumberType
OMAT: 298 (RR REF)SCOTCH 425
Suppliers:
ManufacturerRemarks
K6835
52152
76381
LOCAL
Manufacturer Code:LOCAL
Supply Number:CoMat 03-096
Type:sp01
Supply Short Name:CoMat 03-096 PLASMA SPRAY POWDER
Supply Name:CoMat 03-096 PLASMA SPRAY POWDER
Specification Groups:
Doc NumberType
AMPERIT 298.442 OR AMPERIT 299.442
Suppliers:
ManufacturerRemarks
LOCAL
IAE15
IE252
Manufacturer Code:00BB6
Supply Number:CoMat 03-239
Type:sp01
Supply Short Name:CoMat 03-239 METAL SPRAYING POWDER, CHROMIUM CARBIDE/NICHROME 75/25, FINE
Supply Name:CoMat 03-239 METAL SPRAYING POWDER, CHROMIUM CARBIDE/NICHROME 75/25, FINE
Specification Groups:
Doc NumberType
MSRR 9507/17 (RR REF)METCO 81VF-NS
OMAT:3/190 (RR REF)
Suppliers:
ManufacturerRemarks
00BB6
01FK3
C1840
IE103
K0455
K6835
Manufacturer Code:X111X
Supply Number:CoMat 03-240
Type:sp01
Supply Short Name:CoMat 03-240 METAL SPRAYING POWDER, CHROMIUM CARBIDE/NICHROME 75/25, FINE
Supply Name:CoMat 03-240 METAL SPRAYING POWDER, CHROMIUM CARBIDE/NICHROME 75/25, FINE
Specification Groups:
Doc NumberType
DELETED. USE COMAT 03-239
Suppliers:
ManufacturerRemarks
X111X
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
Manufacturer Code:X222X
Supply Number:CoMat 06-064
Type:sp01
Supply Short Name:CoMat 06-064FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)
Supply Name:CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)
Specification Groups:
Doc NumberType
It is not permitted to mix the selected CoMat 06‐064 letter suffix material with other CoMat 06‐064 letter suffix materials.Where CoMat 06‐064 is specified with no suffix, use one of the CoMat 06‐064 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Link not Found
Manufacturer Code:LOCAL
Tool Number:Chemical cleaning equipment
Tool Name:Chemical cleaning equipment
Manufacturer Code:LOCAL
Tool Number:Cotton gloves or polythene gloves
Tool Name:Cotton gloves or polythene gloves
Manufacturer Code:LOCAL
Tool Number:Dial test indicator
Tool Name:Dial test indicator
Manufacturer Code:LOCAL
Tool Number:Grinding Machine
Tool Name:Grinding Machine
Manufacturer Code:0AM53
Tool Number:IAE 3R18658
Tool Name:IAE 3R18658 Turn/Grind fixture
Manufacturer Code:LOCAL
Tool Number:Lathe
Tool Name:Lathe
Manufacturer Code:LOCAL
Tool Number:Metal spray equipment
Tool Name:Metal spray equipment
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Standard Workshop Equipment
Tool Name:Standard Workshop Equipment
Manufacturer Code:LOCAL
Tool Number:Standard workshop tools
Tool Name:Standard workshop tools
Link not Found
Manufacturer Code:LOCAL
Tool Number:Vibrating Marking Pencil
Tool Name:Vibrating Marking Pencil
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment