TASK 72-41-32-300-005 HPC Stage 4 Variable Stator Vane - Repair Surface Damage By Material Removal, Repair-005 (VRS6035)

DMC:V2500-A0-72-41-3204-00A-649A-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 72-41-32-300-005 HPC Stage 4 Variable Stator Vane - Repair Surface Damage By Material Removal, Repair-005 (VRS6035)

Effectivity

FIG/ITEM

PART NO

ASSEMBLY

03-500

6A3816

A

03-500

6A3880

A

03-500

6A4370

B

03-500

6A5679

B

03-500

6A7478

B

03-500

6A7558

B

03-500

6A8064

A

03-500

6A8069

A

03-500

6A8731

C

03-500

6B1274

C

03-600

6B1275

C

Material of component

DESCRIPTION

MATERIAL

Stage 4

HP compressor variable stator vane

Corrosion resistant steel

General

This repair must only be done when the instruction to do so is given in TASK 72-41-32Inspection/Check (Inspection/Check).

This repair gives the instruction to remove damage on the HP compressor variable stator vane, stage 4 by material removal.

Not more than ten percent of variable stator vanes dressed to the maximum limit of this repair should be included in any one stator stage.

Variable stator vanes must be repaired as soon as damage or wear is monitored, to get back HP compressor efficiency and extend the variable stator vane life.

Material removal from the HP compressor variable stator vane airfoil fillet radius is not permitted.

The practices and processes referred to in the procedure by the TASK/SUBTASK numbers are in the SPM.

Price and availability

Refer to International Aero Engines

Related repairs

None

NOTE

More equipment and materials necessary to do this repair are given in SPM TASK given below:
SPM TASK 70-09-00-400-501
SPM TASK 70-11-39-300-503
SPM TASK 70-23-04-230-501
SPM TASK 70-23-05-230-501

NOTE

To identify the consumable materials, refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Portablegrinding equipmentLOCALPortable grinding equipment
Dimensional inspection equipmentLOCALDimensional inspection equipment
Chemical cleaning equipmentLOCALChemical cleaning equipment
Vibrating marking pencilLOCALVibrating marking pencil

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
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 72-41-32-230-095 Do a Crack Test

      1. Do a penetrant crack test.

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

        Do a full crack test to identify all areas for dressing.

        Use penetrant crack test equipment.

        Cracks are not permitted.

    2. SUBTASK 72-41-32-220-227 Visually Examine

      1. Visually examine the vane.

      1. Indications of defects on the vane are not permitted and must be removed.

    3. SUBTASK 72-41-32-350-053-A00 Remove Damage from the HP Compressor Variable Stator Vane, Stage 4, Assembly A

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

      2. Remove damage on the leading and trailing edges by material removal.

      1. Use portable grinding equipment.

        Continue to remove material until all the damage is removed.

        Refer to the material removal limits shown below:

        AD 0.950 in. (24.13 mm).

        AE 2.300 in. (58.42 mm).

        AF 0.360 in. (9.14 mm).

        AG 1.370 in. (34.80 mm).

        AH 2.790 in. (70.87 mm).

        AJ 1.505 in. (38.23 mm).

        AK 1.505 in. (38.23 mm).

        AL 1.476 in. (37.49 mm).

        AN 0.900 in. (22.86 mm).

      3. Remove damage on the airfoil surfaces by material removal.

      1. Use portable grinding equipment.

        Continue to remove material until all the damage is removed.

        The maximum depth to remove the damage must not be more than 0.005 in. (0.13 mm).

        The diameter of the repaired area is to be 50 times the depth.

      4. Make smooth the repaired area.

      1. Make sure all the damage marks are completely removed and the area is made smooth into the adjacent material.

      5. Polish the repaired area.

      1. Polish the repaired area to remove scratches and to give a surface finish the same as the adjacent material.

        NOTE

        The last polish is to be in a radial direction.

    4. SUBTASK 72-41-32-350-053-B00 Remove Damage from the HP Compressor Variable Stator Vane, Stage 4, Assembly B

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

      2. Remove damage on the leading and trailing edges by material removal.

      1. Use portable grinding equipment.

        Continue to remove material until all the damage is removed.

        Refer to the material removal limits shown below:

        AD 0.950 in. (24.13 mm).

        AE 2.300 in. (58.42 mm).

        AF 0.320 in. (8.13 mm).

        AG 1.350 in. (34.29 mm).

        AH 2.720 in. (69.09 mm).

        AJ 1.708 in. (43.38 mm).

        AK 1.640 in. (41.66 mm).

        AL 1.592 in. (40.44 mm).

        AN 0.900 in. (22.86 mm).

      3. Remove damage on the airfoil surfaces by material removal.

      1. Use portable grinding equipment.

        Continue to remove material until all the damage is removed.

        The maximum depth to remove the damage must not be more than 0.005 in. (0.13 mm).

        The diameter of the repaired area is to be 50 times the depth.

      4. Make smooth the repaired area.

      1. Make sure all the damage marks are completely removed and the area is made smooth into the adjacent material.

      5. Polish the repaired area.

      1. Polish the repaired area to remove scratches and to give a surface finish the same as the adjacent material.

        NOTE

        The last polish is to be in a radial direction.

    5. SUBTASK 72-41-32-350-053-C00 Remove Damage from the HP Compressor Variable Stator Vane, Stage 4, Assembly C

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

      2. Remove damage on the leading and trailing edges by material removal.

      1. Use portable grinding equipment.

        Continue to remove material until all the damage is removed.

        Refer to the material removal limits shown below:

        AD 0.950 in. (24.13 mm).

        AE 2.300 in. (58.42 mm).

        AF 0.320 in. (8.13 mm).

        AG 1.350 in. (34.29 mm).

        AH 2.720 in. (69.09 mm).

        AJ 1.742 in. (44.25 mm).

        AK 1.633 in. (41.48 mm).

        AL 1.602 in. (40.70 mm).

        AN 0.900 in. (22.86 mm).

      3. Remove damage on the airfoil surfaces by material removal.

      1. Use portable grinding equipment.

        Continue to remove material until all the damage is removed.

        The maximum depth to remove the damage must not be more than 0.005 in. (0.13 mm).

        The diameter of the repaired area is to be 50 times the depth.

      4. Make smooth the repaired area.

      1. Make sure all the damage marks are completely removed and the area is made smooth into the adjacent material.

      5. Polish the repaired area.

      1. Polish the repaired area to remove scratches and to give a surface finish the same as the adjacent material.

        NOTE

        The last polish is to be in a radial direction.

    6. SUBTASK 72-41-32-220-098-A00 Examine the Repair of the HP Compressor Variable Stator Vane, Stage 4, Assembly A

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

      2. Visually examine and measure the dimensions of the leading, trailing edges and airfoil surfaces.

      1. Make sure the maximum depth of the repair on the airfoil surface(s) is not more than 0.005 in. (0.13 mm).

        Use dimensional inspection equipment.

        Discard the vanes, if more than the limits specified.

    7. SUBTASK 72-41-32-220-098-B00 Examine the Repair of the HP Compressor Variable Stator Vane, Stage 4, Assembly B

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

      2. Visually examine and measure the dimensions of the leading, trailing edges and airfoil surfaces.

      1. Make sure the maximum depth of the repair on the airfoil surface(s) is not more than 0.005 in. (0.13 mm).

        Use dimensional inspection equipment.

        Discard the vanes, if more than the limits specified.

    8. SUBTASK 72-41-32-220-098-C00 Examine the Repair of the HP Compressor Variable Stator Vane, Stage 4, Assembly C

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

      2. Visually examine and measure the dimensions of the leading, trailing edges and airfoil surfaces.

      1. Make sure the maximum depth of the repair on the airfoil surface(s) is not more than 0.005 in. (0.13 mm).

        Use dimensional inspection equipment.

        Discard the vanes, if more than the limits specified.

    9. SUBTASK 72-41-32-110-068 Cold Ferric Chloride Etch

      1. Swab etch the repaired area(s).

      1. Refer to the SPM TASK 70-11-39-300-503, SUBTASK 70-11-39-300-001.

        Use chemical cleaning equipment.

    10. SUBTASK 72-41-32-230-058 Do a Local Crack Test

      1. Do a local penetrant crack test on the repaired areas.

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

        Use penetrant crack test equipment.

        No cracks are permitted.

    11. SUBTASK 72-41-32-350-054 Identify the Repair

    1. Refer to Figure.

      2. Mark a code symbol adjacent to the assembly number.

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

        Use vibro-engraving equipment.

    12. Figure: Repair Details and Dimensions - Assembly A, Assembly B and Assembly C

    Repair Details and Dimensions - Assembly A, Assembly B and Assembly C

    Figure: Repair Details and Dimensions - Assembly A, Assembly B and Assembly C

    Repair Details and Dimensions - Assembly A, Assembly B and Assembly C

    Figure: Repair Details and Dimensions - Assembly A, Assembly B and Assembly C

    Repair Details and Dimensions - Assembly A, Assembly B and Assembly C

    Figure: Repair Details and Dimensions - Assembly A, Assembly B and Assembly C

    Repair Details and Dimensions - Assembly A, Assembly B and Assembly C

Requirements After Job Completion

Follow-On Conditions

NONE
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: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: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
Manufacturer Code:LOCAL
Tool Number:Chemical cleaning equipment
Tool Name:Chemical cleaning equipment
Manufacturer Code:LOCAL
Tool Number:Dimensional inspection equipment
Tool Name:Dimensional inspection equipment
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Manufacturer Code:LOCAL
Tool Number:Portable grinding equipment
Tool Name:Portablegrinding equipment
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