TASK 72-41-31-300-027 HPC Front Cases - Weld Repair The Stage 6 VSV Gas Washed Surface And Stage 6 VSV Counterbore Recesses, Repair-027 (VRS6629)

DMC:V2500-A0-72-41-3101-00A-627A-C|Issue No:001.00|Issue Date:2013-11-01

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 72-41-31-300-027 HPC Front Cases - Weld Repair The Stage 6 VSV Gas Washed Surface And Stage 6 VSV Counterbore Recesses, Repair-027 (VRS6629)

Effectivity

FIG/ITEM

PART NO.

01-400

6A3462

01-400

6A3675

01-400

6A5470

General

This repair must only be done when the instruction to do so is given in 72-41-31 Inspection.

This repair gives the instruction to repair damage to the HP Compressor Front Case Assembly Stage 6 VSV Gas Washed Surface and Stage 6 VSV Counterbore Recesses by Welding.

This is a source demonstrated repair which can only be done by approved vendors.

Repair Facilities

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
ROLLS-ROYCE PLC
P.O. BOX 31 
DERBY DE24 8BJ 
ENGLAND
ATTN: Manager Technical Services
Authorized Repair Vendors for repair VRS6629 are listed below:
ROLLS-ROYCE PLC
AERO REPAIR AND OVERHAUL
MAVOR AVENUE
NERSTON
EAST KILBRIDE
GLASGOW G74 4PY
SCOTLAND
PRATT AND WHITNEY PSD INC
275 E. ROBINSON
SPRINGDALE
ARKANSAS 72764
U.S.A.
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.
NOTE
More equipment and materials necessary to do this repair are in the SPM TASKS given below:
Refer to the SPM TASK 70-09-00-400-501
Refer to the SPM TASK 70-11-08-300-503
Refer to the SPM TASK 70-11-26-300-503
Refer to the SPM TASK 70-23-05-230-501
Refer to the SPM TASK 70-35-03-300-501
NOTE
To identify the consumable materials, refer to the PCI.
Preliminary Requirements
Pre-Conditions
NONE
Support Equipment
NameManufacturerPart Number / IdentificationQuantityRemark
Standard workshop equipmentLOCALStandard workshop equipment
Chemical cleaning equipmentLOCALChemical cleaning equipment
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Workshop inspection equipmentLOCALWorkshop inspection equipment
Vibrating marking pencilLOCALVibrating marking pencil
IAE 3R19420 Retaining Ring0AM53IAE 3R194201
IAE 3R19421 Location Pin0AM53IAE 3R1942110
Consumables, Materials and Expendables
NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-001 ADHESIVE TAPE (MASKING)LOCALCoMat 02-001
CoMat 05-021 WATERPROOF SILICON CARBIDE44197CoMat 05-021
CoMat 05-075 WATERPROOF SILICON CARBIDEIE241CoMat 05-075
CoMat 05-106 ABRASIVE STONEK6835CoMat 05-106
CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)LOCALCoMat 06-064
Spares
NONE
Safety Requirements
NONE
Procedure
    1. SUBTASK 72-41-31-350-100 Remove the Damage
    1. CAUTION
      TITANIUM COMPONENT - YOU MUST USE SILICON CARBIDE TYPE ABRASIVE WHEELS, STONES AND PAPERS TO DRESS, BLEND AND POLISH THIS COMPONENT.
      CAUTION
      TITANIUM COMPONENT - DO NOT USE FORCE WITH MECHANICAL CUTTERS OR THE MATERIAL WILL BECOME TOO HOT.
      CAUTION
      TITANIUM COMPONENT - MAXIMUM SPEED FOR MECHANICAL TOOLS MUST NOT EXCEED 1000 REVOLUTIONS PER MINUTE.
      CAUTION
      TITANIUM COMPONENT - YOU MUST MAKE SURE THAT DURING DRESSING, BLENDING AND POLISHING NO SPARKS ARE PRODUCED. MASK ADJACENT AREAS OF THE COMPONENT.
      CAUTION
      TITANIUM COMPONENT - IF THE MATERIAL SHOWS A CHANGE IN COLOR, TO DARKER THAN A LIGHT STRAW COLOR, THE COMPONENT IS TO BE REJECTED.
      Refer to Figure, Figure and Figure.
      2. Remove the area(s) of damage as necessary.
      1. Refer to the SPM TASK 70-35-03-300-501.
        Remove highspots and damage to depth.
        Remove no more material than is necessary.
        Use standard workshop equipment.
    2. SUBTASK 72-41-31-110-117 Do a Swab Etch
      1. Chemically clean the repair area(s).
      1. Refer to the SPM TASK 70-11-08-300-503, SUBTASK 70-11-08-300-001.
        Use chemical cleaning equipment.
      2. Swab etch the repair area(s).
      1. Refer to the SPM TASK 70-11-08-300-503, SUBTASK 70-11-08-300-002.
        Use chemical cleaning equipment.
    3. SUBTASK 72-41-31-230-112 Do a Local Crack Test
      1. Do a local penetrant crack test on the repair area(s).
    4. SUBTASK 72-41-31-110-118 Chemically Clean
      1. CAUTION
        TO PREVENT CONTAMINATION, DO NOT TOUCH THE SURFACE WHICH IS CLEANED FOR REPAIR.
        Chemically clean the HP Compressor Front Case Assembly.
      1. Refer to the SPM TASK 70-11-26-300-503.
        Use chemical cleaning equipment.
    5. SUBTASK 72-41-31-350-101 Assemble the Front Case Half Cases
    1. Refer to Figure and Figure.
      2. Assemble together, both correlated half casings of the HP Compressor Front Case Assembly.
      1. Bolt together with seven slave bolts, nuts and washers, to each side.
      3. Install the retaining ring on to the HPC Front Case Assembly rear flange, (Datum C).
    4. NOTE
      You can do operations 9. B. and 9. C. in any sequence as long as all items are assembled correctly.
    6. SUBTASK 71-41-31-110-001 Chemically Clean
      1. CAUTION
        TO PREVENT CONTAMINATION, DO NOT TOUCH THE SURFACE WHICH IS CLEANED FOR REPAIR.
        Chemically clean the HP Compressor Front Case Assembly.
      1. Refer to the SPM TASK 70-11-26-300-503.
        Use chemical cleaning equipment.
    7. SUBTASK 72-41-31-310-001 Weld the Area(s) of Damage
    1. CAUTION
      YOU MUST PREVENT TOO MUCH HEAT TO BE APPLIED DURING THE WELDING OPERATION.
      Refer to Figure, Figure and Figure.
      2. Weld the area of damage as necessary.
      1. Refer to approved vendor process.
    8. SUBTASK 71-41-31-220-001 Examine the HP Compressor Front Case Assembly
    1. CAUTION
      TITANIUM COMPONENT - IF THE WELD BEAD SHOWS A CHANGE IN COLOR, TO DARKER THAN A LIGHT STRAW COLOR, THE COMPONENT IS TO BE REJECTED.
      Refer to Figure, Figure and Figure.
      2. Visually examine the welded area(s) of the HP Compressor Front Case Assembly.
      1. If the weld bead shows a change in color to a darker than light straw color the component is to be rejected.
    9. SUBTASK 72-41-31-230-113 Dress Surface AH of the HP Compressor Front Case Assembly
    1. CAUTION
      TITANIUM COMPONENT - YOU MUST USE SILICON CARBIDE TYPE ABRASIVE WHEELS, STONES AND PAPERS TO DRESS, BLEND AND POLISH THIS COMPONENT.
      CAUTION
      TITANIUM COMPONENT - DO NOT USE FORCE WITH MECHANICAL CUTTERS OR THE MATERIAL WILL BECOME TOO HOT.
      CAUTION
      TITANIUM COMPONENT - MAXIMUM SPEED FOR MECHANICAL TOOLS MUST NOT EXCEED 1000 REVOLUTIONS PER MINUTE.
      CAUTION
      TITANIUM COMPONENT - YOU MUST MAKE SURE THAT DURING DRESSING, BLENDING AND POLISHING NO SPARKS ARE PRODUCED.MASK ADJACENT AREAS OF THE COMPONENT.
      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
      YOU MUST ENSURE THAT DURING THE DRESSING OPERATION THE MINIMUM AMOUNT OF PARENT MATERIAL IS REMOVED FROM SURFACE AH.
      CAUTION
      YOU MUST ONLY REMOVE MATERIAL FROM AREA(S) THAT HAVE BEEN WELDED ON SURFACE AH.
      Refer to Figure, Figure, Figure and Figure.
      2. Dress the area(s) of weld on surface AH only.
    3. NOTE
      1. The dressing of the weld bead must be flush to underflush, refer to the limits given in Figure.
      2. During dressing removal of parent material is allowed but must be contained locally, refer to Figure and 
        be within the limits given in Figure.
      3. It is mandatory that during operation 13 the retaining fixture and location pins remain installed.
    10. SUBTASK 72-41-31-230-114 Disassemble the HP Compressor Front Case Assembly
    1. Refer to Figure and Figure.
      2. Disassemble the HPC Front Case Assembly.
      1. Remove the seven slave bolts, nuts and washers and the retaining ring and location pins from the HPC Front Case Assembly.
    11. SUBTASK 72-41-31-230-115 Machine the HP Compressor Front Case Stage 6 VSV Counterbore Recesses
    1. CAUTION
      TITANIUM COMPONENT - YOU MUST USE SILICON CARBIDE TYPE ABRASIVE WHEELS, STONES AND PAPERS TO DRESS, BLEND AND POLISH THIS COMPONENT.
      CAUTION
      TITANIUM COMPONENT - DO NOT USE FORCE WITH MECHANICAL CUTTERS OR THE MATERIAL WILL BECOME TOO HOT.
      CAUTION
      TITANIUM COMPONENT - MAXIMUM SPEED FOR MECHANICAL TOOLS MUST NOT EXCEED 1000 REVOLUTIONS PER MINUTE.
      CAUTION
      TITANIUM COMPONENT - YOU MUST MAKE SURE THAT DURING DRESSING, BLENDING AND POLISHING NO SPARKS ARE PRODUCED.MASK ADJACENT AREAS OF THE COMPONENT.
      CAUTION
      TITANIUM COMPONENT - IF THE MATERIAL SHOWS A CHANGE IN COLOR, TO DARKER THAN A LIGHT STRAW COLOR, THE COMPONENT IS TO BE REJECTED.
      Refer to Figure, Figure, Figure, Figure and Figure.
      2. Machine the HP Compressor Front Case Stage 6 VSV Counterbore Recesses.
      1. Machine the counterbore recesses, where necessary, to the dimensions given.
        Use standard workshop equipment.
      3. Machine the HP Compressor Front Case Stage 6 VSV Tower Slots.
      1. Machine the tower slots, where necessary, to the dimensions given.
        Use standard workshop equipment.
      4. Remove sharp edges from the HP Compressor Stage 6 VSV Counterbore Recesses.
      1. Use standard workshop equipment.
    12. SUBTASK 72-41-31-110-119 Do a Swab Etch
      1. Chemically clean.
      1. Refer to the SPM TASK 70-11-08-300-503, SUBTASK 70-11-08-300-001.
        Use chemical cleaning equipment.
      2. Swab etch the repaired area(s).
      1. Refer to the SPM TASK 70-11-08-300-503, SUBTASK 70-11-08-300-002.
        Use chemical cleaning equipment.
    13. SUBTASK 72-41-31-230-116 Do a Crack Test
      1. Do a local penetrant crack test on the repaired area(s).
      1. Refer to the SPM TASK 70-23-05-230-501.
        Cracks are not permitted.
    14. SUBTASK 72-41-31-110-120 Chemically Clean
      1. Chemically clean the HP Compressor Front Case Assembly to remove fluorescent penetrant.
      1. Refer to the SPM TASK 70-11-26-300-503.
        Use Chemical cleaning equipment.
    15. SUBTASK 72-41-31-220-242 Examine the HP Compressor Front Case Assembly
    1. Refer to Figure, Figure, Figure, Figure and Figure.
      2. Visually examine and measure the dimensions of the HP Compressor Front Case Assembly.
      1. Make sure the surface finish is the same as the adjacent material.
        Make sure that dimensions given are achieved.
        Use workshop inspection equipment.
    16. SUBTASK 72-41-31-350-102 Identify the Repair
      1. Make a mark VRS6629 adjacent to the part number.
      1. Refer to the SPM TASK 70-09-00-400-501, SUBTASK 70-09-00-400-501.
        Use vibro-engraving equipment.
    17. 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
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: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:IE241
Enterprise Name:DELETED. Was ANGLO ABRASIVES.
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: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:1E1X8
Supply Number:CoMat 05-021
Type:sp01
Supply Short Name:CoMat 05-021 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-021 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/35 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 240 (ANSI B74.18 )
JCR-188 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
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:K6835
Supply Number:CoMat 05-106
Type:sp01
Supply Short Name:CoMat 05-106 ABRASIVE STONE
Supply Name:CoMat 05-106 ABRASIVE STONE
Specification Groups:
Doc NumberType
(SS-S-736/2/26) (A-A-3068/2-26)SQUARE FINE SS-S-736 TYPE II CLASS A1
Suppliers:
ManufacturerRemarks
K6835
KC1D9
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
Manufacturer Code:LOCAL
Tool Number:Chemical cleaning equipment
Tool Name:Chemical cleaning equipment
Manufacturer Code:0AM53
Tool Number:IAE 3R19420
Tool Name:IAE 3R19420 Retaining Ring
Manufacturer Code:0AM53
Tool Number:IAE 3R19421
Tool Name:IAE 3R19421 Location Pin
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment