TASK 72-41-32-300-014 HP Compressor Variable Stator Vane, Stage 4 - Repair Worn/Damaged Inner And/or Outer Pivot Journal, by Metal Spray, Repair-014 (VRS6183)

DMC:V2500-A0-72-41-3204-01A-609A-C|Issue No:002.00|Issue Date:2018-05-01

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 72-41-32-300-014 HP Compressor Variable Stator Vane, Stage 4 - Repair Worn/Damaged Inner And/or Outer Pivot Journal, by Metal Spray, Repair-014 (VRS6183)

Effectivity

ENGINE MARK

FIG/ITEM

PART NO.

SERVICE BULLETIN

ASSEMBLY

V2500 A1

03-500

6A3816

-

A

V2500 A1

03-500

6A3880

70-0092

B

V2500 A5

03-500

6A4370

-

B

V2500 A5

03-500

6A5679

70-0726/72-0186

C

V2500 A1

03-500

6A8064

72-0422

D

V2500 A1

03-500

6A8069

72-0422

E

V2500 A5

03-500

6A7478

70-0714

B

V2500 A5

03-500

6A7558

72-0410

F

V2500 A5

03-500

6A8731

72-0560

F

V2500 A5

03-500

6A8837

72-0564

G

V2500 A5

03-500

6B1274

72-0571

H

V2500 A5

03-600

6A8838

72-0564

J

V2500 A5

03-600

6B1275

72-0571

K

Material of component

PART IDENT

SYMBOL

MATERIAL

HP Compressor Stage 4 Variable Stator Vane

ECP

Corrosion Resistant Steel

Or

QMP

Heat Resisting Alloy

Or

EYG

Heat Resisting AIIoy

General

CAUTION

DO NOT DO THIS REPAIR TO BOTH THE INNER JOURNAL AND OUTER JOURNAL AT THE SAME TIME. IF BOTH JOURNALS ARE DAMAGED, DO NOT REPAIR THE INNER JOURNAL UNTIL THE OUTER JOURNAL HAS BEEN FULLY REPAIRED.

This TASK gives the procedure to repair worn or damaged inner and/or outer pivot journal on the HP Compressor Variable Stator Vane, Stage 4, by metal spray.

TASKs identified by SPM TASK are in the Standard Practices and Processes Manual.

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 70-11-03-300-503
SPM TASK 70-11-39-300-503
SPM TASK 70-12-02-120-501
SPM TASK 70-23-01-230-501
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 Consumable Index (PCI).

NOTE

Other necessary consumable materials are referred to in the SPM TASKs in this TASK.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Abrasive Blast EquipmentLOCAL
Chemical Cleaning EquipmentLOCAL
Dial test indicatorLOCAL
External grinding equipmentLOCAL
LatheLOCAL
Metal spray equipmentLOCAL
Penetrant Crack Test EquipmentLOCAL
Standard equipmentLOCAL
Vibro-engraving equipmentLOCAL
Workshop inspection equipmentLOCAL

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-198 ADHESIVE TAPE (MASKING METAL SPRAY)LOCALCoMat 02-198
CoMat 03-320 METAL SPRAYING POWDER,WC/CoLOCALCoMat 03-320
CoMat 03-456 METAL SPRAY POWDER WC-17CO39918CoMat 03-456
CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADELOCALCoMat 05-001
CoMat 05-002 ABRASIVE MEDIUM, ALUMINUM OXIDELOCALCoMat 05-002
CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)X222XCoMat 06-063
DELETEDLOCALDELETED

Spares

NONE

Safety Requirements

CAUTION

DO NOT DO THIS REPAIR TO BOTH THE INNER JOURNAL AND OUTER JOURNAL AT THE SAME TIME.

Procedure

    1. SUBTASK 72-41-32-220-137 Examine the HP Compressor Variable Stator Vane, Stage 4

    1. For Assembly A and B, refer to Figure and Figure.

    2. For Assembly C, refer to Figure and Figure.

    3. For Assembly D and E, refer to Figure and Figure.

    4. For Assembly F, refer to Figure and Figure.

    5. For Assembly G and J, refer to Figure and Figure.

    6. For Assembly H and K, refer to Figure and Figure.

      7. Examine the HP Compressor Variable Stator Vane, Stage 4, inner and/or outer pivot journal.

      1. The minimum worn or damaged diameter of the inner pivot and outer pivot journal that can be repaired is 0.2619 in. (6.653 mm) and 0.4595 in. (11.672 mm) respectively.

      2. If dimensions are within the limits, continue with this repair.

      3. If dimensions are not within the limits, reject the vane.

    2. SUBTASK 72-41-32-325-053 Remove Damage from the HP Compressor Variable Stator Vane, Stage 4

      CAUTION

      DO NOT REMOVE MATERIAL FROM THE HP COMPRESSOR VARIABLE STATOR VANE, STAGE 4, INNER AND OUTER RADII.

    1. For Assembly A and B, refer to Figure and Figure.

    2. For Assembly C, refer to Figure and Figure.

    3. For Assembly D and E, refer to Figure and Figure.

    4. For Assembly F, refer to Figure and Figure.

    5. For Assembly G and J, refer to Figure and Figure.

    6. For Assembly H and K, refer to Figure and Figure.

      7. Set up the HP Compressor Variable Stator Vane, Stage 4, to run true.

      8. Turn to remove damage and/or wear from the inner and/or outer pivot journal.

      1. Remove the minimum quantity of material that is necessary to remove the damage. Make sure that all the damage is removed and the area is made smooth into the adjacent material.

      2. Use a Lathe.

        NOTE

        The minimum diameter of the inner pivot journal after removal of wear and/or damage must be 0.2609 in. (6.627 mm).

        NOTE

        The minimum diameter of the outer pivot journal after removal of wear and/or damage must be 0.4585 in. (11.646 mm).

    3. SUBTASK 72-41-32-220-138 Examine the HP Compressor Variable Stator Vane, Stage 4

    1. For Assembly A and B, refer to Figure and Figure.

    2. For Assembly C, refer to Figure and Figure.

    3. For Assembly D and E, refer to Figure and Figure.

    4. For Assembly F, refer to Figure and Figure.

    5. For Assembly G and J, refer to Figure and Figure.

    6. For Assembly H and K, refer to Figure and Figure.

      7. Measure the dimensions of the HP Compressor Variable Stator Vane, Stage 4.

      1. Make sure that, after machining the dimensions are in the given limits.

      2. If dimensions are within the limits, continue with this repair.

      3. If dimensions exceed the limits, reject the vane.

    4. SUBTASK 72-41-32-110-081 Chemically Clean

      1. Chemically clean.

      1. Refer to SPM TASK 70-11-03-300-503.

    5. SUBTASK 72-41-32-110-082 Do Swab Etch

      1. Swab etch the repaired area.

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

    6. SUBTASK 72-41-32-230-076 Do a crack test

      1. Do a penetrant crack test on the repaired area.

      1. Refer to SPM TASK 70-23-01-230-501.

      3. Cracks are not permitted.

    7. SUBTASK 72-41-32-120-055 Prepare the Surfaces for Repair

      CAUTION

      DO NOT TOUCH SURFACES TO BE REPAIRED AFTER THEY ARE CLEANED.

      CAUTION

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

    1. For Assembly A and B, refer to Figure and Figure.

    2. For Assembly C, refer to Figure and Figure.

    3. For Assembly D and E, refer to Figure and Figure.

    4. For Assembly F, refer to Figure and Figure.

    5. For Assembly G and J, refer to Figure and Figure.

    6. For Assembly H and K, refer to Figure and Figure.

      7. Mask the surfaces not to be repaired.

      1. NOTE

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

    8. SUBTASK 72-41-32-340-053 Apply the Metal Spray Coat

    1. For Assembly A, refer to Figure, Figure, Figure, Figure and Figure.

    2. For Assembly B, refer to Figure, Figure, Figure, Figure and Figure.

    3. For Assembly C, refer to Figure, Figure, Figure, Figure and Figure.

    4. For Assembly D, refer to Figure, Figure, Figure, Figure and Figure.

    5. For Assembly E, refer to Figure, Figure, Figure, Figure and Figure.

    6. For Assembly F, refer to Figure, Figure, Figure, Figure and Figure.

    7. For Assembly G, refer to Figure, Figure, Figure, Figure and Figure.

    8. For Assembly H, refer to Figure, Figure, Figure, Figure and Figure.

    9. For Assembly J, refer to Figure, Figure, Figure, Figure and Figure.

    10. For Assembly K, refer to Figure, Figure, Figure, Figure and Figure.

      11. Apply the metal spray to the HP Compressor Variable Stator Vane, Stage 4, inner and/or outer pivot journal.

      1. Refer to SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-014.

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

    12. Remove the masking tape.

    9. SUBTASK 72-41-32-340-055 Examine the HP Compressor Variable Stator Vane, Stage 4

    1. For Assembly A, refer to Figure, Figure, Figure, Figure and Figure.

    2. For Assembly B, refer to Figure, Figure, Figure, Figure and Figure.

    3. For Assembly C, refer to Figure, Figure, Figure, Figure and Figure.

    4. For Assembly D, refer to Figure, Figure, Figure, Figure and Figure.

    5. For Assembly E, refer to Figure, Figure, Figure, Figure and Figure.

    6. For Assembly F, refer to Figure, Figure, Figure, Figure and Figure.

    7. For Assembly G, refer to Figure, Figure, Figure, Figure and Figure.

    8. For Assembly H, refer to Figure, Figure, Figure, Figure and Figure.

    9. For Assembly J, refer to Figure, Figure, Figure, Figure and Figure.

    10. For Assembly K, refer to Figure, Figure, Figure, Figure and Figure.

      11. Visually examine and measure the dimensions of the sprayed coating.

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

      2. Make sure there is a layer of sufficient thickness to get the correct dimensions after the component is machined.

    10. SUBTASK 72-41-32-324-054 Grind the HP Compressor Variable Stator Vane, Stage 4, Inner and/or Outer Pivot Journal

    1. For Assembly A, refer to Figure, Figure, Figure, Figure and Figure.

    2. For Assembly B, refer to Figure, Figure, Figure, Figure and Figure.

    3. For Assembly C, refer to Figure, Figure, Figure, Figure and Figure.

    4. For Assembly D, refer to Figure, Figure, Figure, Figure and Figure.

    5. For Assembly E, refer to Figure, Figure, Figure, Figure and Figure.

    6. For Assembly F, refer to Figure, Figure, Figure, Figure and Figure.

    7. For Assembly G, refer to Figure, Figure, Figure, Figure and Figure.

    8. For Assembly H, refer to Figure, Figure, Figure, Figure and Figure.

    9. For Assembly J, refer to Figure, Figure, Figure, Figure and Figure.

    10. For Assembly K, refer to Figure, Figure, Figure, Figure and Figure.

      11. Set up the HP Compressor Variable Stator Vane, Stage 4, to run true.

      1. Use an External grinding equipment and a dial test indication.

      12. Grind the inner and/or outer pivot journal to the dimensions given.

        NOTE

        Put back the radii as necessary.

      1. Make sure that dimensions of the vane are restored to Its original dimensions.

      13. Remove unwanted metal spray from all other surfaces to the dimensions given.

    11. SUBTASK 72-41-32-110-083 Chemically Clean

      1. Chemically clean.

      1. Refer to SPM TASK 70-11-03-300-503.

    12. SUBTASK 72-41-32-220-139 Examine the HP Compressor Variable Stator Vane, Stage 4

    1. For Assembly A, refer to Figure, Figure, Figure, Figure and Figure.

    2. For Assembly B, refer to Figure, Figure, Figure, Figure and Figure.

    3. For Assembly C, refer to Figure, Figure, Figure, Figure and Figure.

    4. For Assembly D, refer to Figure, Figure, Figure, Figure and Figure.

    5. For Assembly E, refer to Figure, Figure, Figure, Figure and Figure.

    6. For Assembly F, refer to Figure, Figure, Figure, Figure and Figure.

    7. For Assembly G, refer to Figure, Figure, Figure, Figure and Figure.

    8. For Assembly H, refer to Figure, Figure, Figure, Figure and Figure.

    9. For Assembly J, refer to Figure, Figure, Figure, Figure and Figure.

    10. For Assembly K, refer to Figure, Figure, Figure, Figure and Figure.

      11. Measure the dimensions of the repaired area.

      1. Make sure that the dimensions are within the limits.

      2. If dimensions exceed the limits, reject the vane.

    13. SUBTASK 72-41-32-350-085 Identify the Repair

      NOTE

      If the HP Compressor Variable Stator Vanes, Stage 4 are already identified with the Repair Scheme number "VRS6183" by vibro peen process from the previous repair application, further identification is not required.

    1. For Assembly A and B, refer to Figure.

    2. For Assembly C, refer to Figure.

    3. For Assembly D and E, refer to Figure.

    4. For Assembly F, refer to Figure.

    5. For Assembly G and J, refer to Figure.

    6. For Assembly H and K, refer to Figure.

      7. Vibro-engrave VRS6183, adjacent to the assembly number.

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

    14. Figure: Repair Details and Dimensions - Assembly A and B

    Repair Details and Dimensions - Assembly A and B

    Figure: Repair Details and Dimensions - Assembly C

    Repair Details and Dimensions - Assembly C

    Figure: Repair Details and Dimensions - Assembly D and E

    Repair Details and Dimensions - Assembly D and E

    Figure: Repair Details and Dimensions - Assembly F

    Repair Details and Dimensions - Assembly F

    Figure: Repair Details and Dimensions - Assembly G and J

    Repair Details and Dimensions - Assembly G and J

    Figure: Repair Details and Dimensions - Assembly H and K

    Repair Details and Dimensions - Assembly H and K

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

    Repair Details and Dimensions - Assembly A, B and C

    Figure: Repair Details and Dimensions - Assembly D, E and F

    Repair Details and Dimensions - Assembly D, E and F

    Figure: Repair Details and Dimensions - Assembly G, H, J and K

    Repair Details and Dimensions - Assembly G, H, J and K

    Figure: Repair Details and Dimensions - Assembly A and B

    Repair Details and Dimensions - Assembly A and B

    Figure: Repair Details and Dimensions - Assembly C

    Repair Details and Dimensions - Assembly C

    Figure: Repair Details and Dimensions - Assembly D and E

    Repair Details and Dimensions - Assembly D and E

    Figure: Repair Details and Dimensions - Assembly F

    Repair Details and Dimensions - Assembly F

    Figure: Repair Details and Dimensions - Assembly G and J

    Repair Details and Dimensions - Assembly G and J

    Figure: Repair Details and Dimensions- Assembly H and K

    Repair Details and Dimensions- Assembly H and K

    Figure: Repair Details and Dimensions - Assembly A and E

    Repair Details and Dimensions - Assembly A and E

    Figure: Repair Details and Dimensions - Assembly B and D

    Repair Details and Dimensions - Assembly B and D

    Figure: Repair Details and Dimensions - Assembly C and F

    Repair Details and Dimensions - Assembly C and F

    Figure: Repair Details and Dimensions - Assembly G

    Repair Details and Dimensions - Assembly G

    Figure: Repair Details and Dimensions - Assembly H

    Repair Details and Dimensions - Assembly H

    Figure: Repair Details and Dimensions - Assembly J

    Repair Details and Dimensions - Assembly J

    Figure: Repair Details and Dimensions - Assembly K

    Repair Details and Dimensions - Assembly K

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

    Repair Details and Dimensions- Assembly A, B, C, D, E and F

    Figure: Repair Details and Dimensions - Assembly G and H

    Repair Details and Dimensions - Assembly G and H

    Figure: Repair Details and Dimensions - Assembly J

    Repair Details and Dimensions - Assembly J

    Figure: Repair Details and Dimensions - Assembly K

    Repair Details and Dimensions - Assembly K

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedure in its entirety. (00VR784B)

Change Type:

Deleted CoMat 06-022. (00VR784B)

Manufacturer Code:39918
Enterprise Name:SULZER METCO (US) INC, SEE SUPPLIER CODE 01FK3
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X222X
Enterprise Name:N/A – REFER TO APPLICABLE COMAT SUFFIX
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:LOCAL
Supply Number:CoMat 03-320
Type:sp01
Supply Short Name:CoMat 03-320 METAL SPRAYING POWDER, WC/Co
Supply Name:CoMat 03-320 METAL SPRAYING POWDER,WC/Co
Specification Groups:
Doc NumberType
MSRR9507/1METCO 73F-NS-2
OMAT:3/114C
Suppliers:
ManufacturerRemarks
LOCAL
39918
56923
IE103
IE195
IE200
K1030
K6835
Manufacturer Code:39918
Supply Number:CoMat 03-456
Type:sp01
Supply Short Name:CoMat 03-456 METAL SPRAY POWDER WC-17CO
Supply Name:CoMat 03-456 METAL SPRAY POWDER WC-17CO
Specification Groups:
Doc NumberType
METCO 73F-NS-1
Suppliers:
ManufacturerRemarks
39918
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 05-002
Type:sp01
Supply Short Name:CoMat 05-002 ABRASIVE MEDIUM, ALUMINUM OXIDE
Supply Name:CoMat 05-002 ABRASIVE MEDIUM, ALUMINUM OXIDE
Specification Groups:
Doc NumberType
Where CoMat 05-002 is specified with no letter suffix, use one of the CoMat 05-002 letter suffix alternatives.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:X222X
Supply Number:CoMat 06-063
Type:sp01
Supply Short Name:CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)
Supply Name:CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)
Specification Groups:
Doc NumberType
It is not permitted to mix the selected CoMat 06‐063 letter suffix material with other CoMat 06‐063 letter suffix materials. Where CoMat 06‐063 is specified with no suffix, use one of the CoMat 06‐063 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:LOCAL
Supply Number:DELETED
Type:sp01
Supply Short Name:DELETED
Supply Name:DELETED
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
LOCAL
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