TASK 72-41-33-300-004 HPC Stage 5 Variable Stator Vane Shroud - Replace The Lining, Repair-004 (VRS6040)

DMC:V2500-A0-72-41-3315-00A-920A-C|Issue No:003.00|Issue Date:2018-11-01

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 72-41-33-300-004 HPC Stage 5 Variable Stator Vane Shroud - Replace The Lining, Repair-004 (VRS6040)

Effectivity

FIG/ITEM

PART NO.

ASSEMBLY

04-200

6A3471

A

04-200

6A7563

B

04-200

6B1158

B

Material of component

PART IDENT

MATERIAL

HP compressor stage 5 half shroud assembly

Corrosion resistant steel

General

This repair must only be done when the instruction to do so is given in 72-41-33 Inspection/Check.

This repair has been issued for the HP compressor stage 5 half shroud assembly lining.

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

Price and Availability.

Refer to International Aero Engines.

Related Repairs.

None.

NOTE

  1. More equipment and materials necessary to do this repair are in the SPM TASKS given below.

NOTE

To identify the consumable materials refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Air grinderLOCAL
Chemical strip equipmentLOCAL
Hardness TesterLOCAL
LatheLOCAL
Metal spray equipmentLOCAL
Penetrant Crack Test EquipmentLOCAL
Rotary burrLOCAL
Vibrating Marking PencilLOCAL
Workshop inspection equipmentLOCAL

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-001 ADHESIVE TAPE (MASKING)LOCALCoMat 02-001
CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOIL76381CoMat 02-006
CoMat 03-036 METAL SPRAYING WIRE, Ni,AlLOCALCoMat 03-036
CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5)00BB6CoMat 03-038
CoMat 03-057 ALUMINIUM ALLOY/POLYESTERCOMPOSITELOCALCoMat 03-057
CoMat 03-089 METAL SPRAYING POWDER Ni/Al (95/5)33870CoMat 03-089
CoMat 03-090 METAL SPRAYING POWDER Ni/Al (95/5)0AM53CoMat 03-090
CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADELOCALCoMat 05-001
CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADELOCALCoMat 05-003
CoMat 06-018 FLUORESCENT PENETRANT (POST-EMULSIFIED HIGH SENSITIVITY)X222XCoMat 06-018

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-33-350-059 Identify the Correlation Marks

    1. Refer to Figure for Assembly A and Figure for Assembly B.

      2. Identify the locations of the correlation marks.

        1. Make sure the assembly can be correctly assembled.

        1. Find the locations of the correlation marks identified by *.

    3. Disassemble the stage 5 half shroud assembly.

    2. SUBTASK 72-41-33-325-052 Remove the Stage 5 Half Shroud Assembly Lining

    1. Refer to Figure, Figure and Figure for Assembly A and Figure, Figure and Figure for Assembly B.

      2. Install the stage 5 half shroud assembly in the machine.

        1. Use a lathe.

        1. Set the assembly to turn correctly.

      3. Remove the stage 5 half shroud assembly lining.

        1. Turn to remove the lining.

        1. Do not remove any metal from the stage 5 half shroud assembly.

    3. SUBTASK 72-41-33-350-060 Remove the Bond Coat

    1. Refer to Figure, Figure and Figure for Assembly A and Figure, Figure and Figure for Assembly B.

      NOTE

      This is an alternative procedure to Step.

      2. Remove the remaining bond coat.

        1. Remove the remaining lining by hand.

        1. Use an air operated grinder with a rotary burr or a suitable alternative.

        2. Do not remove any metal from the stage 5 half shroud assembly.

    4. SUBTASK 72-41-33-330-051 Remove the Remaining Bond Coat

    1. Refer to Figure, Figure and Figure for Assembly A and Figure, Figure and Figure for Assembly B.

      NOTE

      This is an alternative procedure to Step.

    2. Chemically remove the remaining bond coat.

    3. Refer to SPM TASK 70-33-59-300-503, SUBTASK 70-33-59-300-003 and SUBTASK 70-33-59-300-002.

    4. Abrasive blast the stage 5 half shroud assembly.

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

    5. SUBTASK 72-41-33-220-116 Examine the Stage 5 Half Shroud Assembly

    1. Refer to Figure, Figure and Figure for Assembly A and Figure, Figure and Figure for Assembly B.

      2. Visually/dimensionally examine the stage 5 half shroud assembly.

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

        1. Make sure that the lining and bond coat has been completely removed.

        2. Make sure there is no damage to the parent material.

        3. Make sure all the dimensions are in the limits shown.

    6. SUBTASK 72-41-33-230-066 Examine the Stage 5 Half Shroud Assembly for Cracks

      1. Do the penetrant crack test.

        1. Refer to SPM TASK 70-23-03-230-501.

        1. Use CoMat 06-018 FLUORESCENT PENETRANT (POST-EMULSIFIED HIGH SENSITIVITY) fluorescent penetrant with the penetrant crack test equipment.

        2. Cracks are not permitted.

    7. SUBTASK 72-41-33-110-056 Remove the Grease

      1. Remove the grease.

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

    8. SUBTASK 72-41-33-350-061 Apply Adhesive Tape to the Areas not to be Sprayed

      1. Mask the areas not to be sprayed.

      1. Use CoMat 02-001 ADHESIVE TAPE (MASKING) or a locally manufactured mask.

    9. SUBTASK 72-41-33-120-051 Clean the Areas to be Sprayed

      1. Abrasive blast the areas to be sprayed.

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

        2. Remove the adhesive tape or masks when the component has been cleaned.

        3. Do not touch the areas which have been cleaned.

    10. SUBTASK 72-41-33-350-062 Apply Adhesive Tape to the Areas not to be Sprayed

      1. Mask the areas not to be sprayed.

      1. Use CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOIL or a locally manufactured fixture.

    11. SUBTASK 72-41-33-340-052 Apply the Lining to the Stage 5 Half Shroud Assembly

    1. Refer to Figure, Figure and Figure for Assembly A and Figure, Figure and Figure for Assembly B.

      2. Apply the bond coat.

        1. Refer to SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-025 and SUBTASK 70-34-01-340-010.

        2. For the wire feed combustion spray use CoMat 03-036 METAL SPRAYING WIRE, Ni,Al.

        3. Heat the shroud assembly to a temperature of 221 deg F to 257 deg F (105 deg C to 125 deg C).

        4. Use the spray gun with the powder feed off. Apply a thickness of 0.0030 in. to 0.0050 in. (0.076 mm to 0.127 mm).

      3. Apply the lining to the stage 5 half shroud assembly.

        1. Refer to SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-020.

        2. Apply sufficient thickness to allow for machining.

        3. Also spray a test piece to examine for hardness.

        4. Remove the adhesive tape when the lining has been applied.

    12. SUBTASK 72-41-33-220-117 Examine the Stage 5 Half Shroud Assembly Lining

    1. Refer to Figure, Figure and Figure for Assembly A and Figure, Figure and Figure for Assembly B.

      2. Visually examine the lining on the stage 5 half shroud assembly.

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

      3. Do a hardness test on the test spray sample.

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

        1. The average hardness must be 55 R15Y to 85 R15Y with the outer limits of 50 minimum and 90 maximum.

    13. SUBTASK 72-41-33-325-054 Machine the Lining

    1. Refer to Figure, Figure and Figure for Assembly A and Figure, Figure and Figure for Assembly B.

      2. Install the part on the machine.

        1. Use a lathe.

        1. Set the part to turn correctly.

      3. Machine the lining.

        1. Turn to machine the lining.

        1. Do not remove any metal from the half shroud assembly.

    14. SUBTASK 72-41-33-350-063 Remove the Overspray

      1. Remove the overspray.

      1. Use a hand scraper.

    15. SUBTASK 72-41-33-220-118 Examine the Stage 5 Half Shroud Assembly Lining

    1. Refer to Figure, Figure and Figure for Assembly A and Figure, Figure and Figure for Assembly B.

      2. Visually and dimensionally examine the stage 5 half shroud assembly lining.

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

    16. SUBTASK 72-41-33-350-064 Assemble the Stage 5 Half Shroud Assembly

    1. Refer to Figure for Assembly A and Figure for Assembly B.

      2. Assemble the stage 5 half shroud assembly.

      1. Align the correlation marks identified by *.

    17. SUBTASK 72-41-33-350-065 Identify the Repair on the Stage 5 Half Shroud Assembly

      1. Vibro-engrave VRS6040 adjacent to the part number on the stage 5 half shroud assembly.

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

        1. Use vibro-engraving equipment.

    18. Figure: Details to Machine the Stage 5 Half Shroud Assembly - Assembly A

    Details to Machine the Stage 5 Half Shroud Assembly - Assembly A

    Figure: Details to Apply the Lining to the Stage 5 half Shroud Assembly - Assembly A

    Sheet 1

    Legend
    Details to Apply the Lining to the Stage 5 half Shroud Assembly

    Sheet 1

    Close

    Figure: Details to Apply the Lining to the Stage 5 Half Shroud Assembly - Assembly A

    Sheet 2

    Legend
    Details to Apply the Lining to the Stage 5 Half Shroud Assembly

    Sheet 2

    Close

    Figure: Details to Machine the Stage 5 Half Shroud Assembly - Assembly B

    Details to Machine the Stage 5 Half Shroud Assembly - Assembly B

    Figure: Details to Apply the Lining to the Stage 5 Half Shroud Assembly - Assembly B

    Details to Apply the Lining to the Stage 5 Half Shroud Assembly - Assembly B

    Figure: Details to Apply the Lining to the Stage 5 Half Shroud Assembly - Assembly B

    Details to Apply the Lining to the Stage 5 Half Shroud Assembly - Assembly B

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Update graphics with correct conversions (CAS-25081-L1K2K8 and CAS-25930-T4X6B8)

Manufacturer Code:00BB6
Enterprise Name:INDESTRUCTIBLE PAINT INC
BU Name:INDESTRUCTIBLE PAINT INC
Street:1 INDEPENDENCE DRIVE
City:MONROE
State:CT
Zip Code:06468
Country:USA
Phone Number:1-203-880-9130
Fax Number:1-203-880-9133
Email:dave@indestructiblepaint.com
Internet:www.indestructiblepaint.com
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:33870
Enterprise Name:PRAXAIR SURFACE TECHNOLOGIES INC.
BU Name:PRAXAIR SURFACE TECHNOLOGIES INC.
Street:1500 POLCO STREET
City:INDIANAPOLIS
State:IN
Zip Code:46222
Country:USA
Manufacturer Code:76381
Enterprise Name:3M COMPANY
BU Name:3M COMPANY
Department:3M CENTER
City:ST PAUL
State:MN
Zip Code:55144-1000
Country:USA
Phone Number:1-651-733-1110
Fax Number:1-651-733-9973
Internet:www.mmm.com
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X222X
Enterprise Name:N/A – REFER TO APPLICABLE COMAT SUFFIX
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 03-036
Type:sp01
Supply Short Name:CoMat 03-036 METAL SPRAYING WIRE, Ni, Al
Supply Name:CoMat 03-036 METAL SPRAYING WIRE, Ni,Al
Specification Groups:
Doc NumberType
MSRR 9507/101METCO 405 NS
OMAT:3/90MIL-W-6712 NI80
JCR-019
Suppliers:
ManufacturerRemarks
LOCAL
IE103
IE195
IE200
K1030
K6835
39918
Manufacturer Code:00BB6
Supply Number:CoMat 03-038
Type:sp01
Supply Short Name:CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5)
Supply Name:CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5)
Specification Groups:
Doc NumberType
OMAT: 3/188 (RR REF)METCO 450NS
JCR-020 (JAEC REF)
Suppliers:
ManufacturerRemarks
00BB6
01FK3
0Y7E4
C1840
IE103
K0455
K6835
Manufacturer Code:LOCAL
Supply Number:CoMat 03-057
Type:sp01
Supply Short Name:CoMat 03-057 ALUMINIUM ALLOY/POLYESTERCOMPOSITE
Supply Name:CoMat 03-057 ALUMINIUM ALLOY/POLYESTERCOMPOSITE
Specification Groups:
Doc NumberType
MSRR9507/15METCO 601NS
OMAT:3/143MIL-P-85856/22
JCR-022MIL-P-85856/22
Suppliers:
ManufacturerRemarks
LOCAL
39918
IE103
IE195
IE200
K1030
K6835
Manufacturer Code:33870
Supply Number:CoMat 03-089
Type:sp01
Supply Short Name:CoMat 03-089 METAL SPRAYING POWDER Ni/Al (95/5)
Supply Name:CoMat 03-089 METAL SPRAYING POWDER Ni/Al (95/5)
Specification Groups:
Doc NumberType
PWA 1337 (PW REF)NI-109 or NI-970 or AI 1037
Suppliers:
ManufacturerRemarks
33870
Manufacturer Code:X111X
Supply Number:CoMat 03-090
Type:sp01
Supply Short Name:CoMat 03-090 METAL SPRAYING POWDER Ni/Al(95/5)
Supply Name:CoMat 03-090 METAL SPRAYING POWDER Ni/Al (95/5)
Specification Groups:
Doc NumberType
DELETED Use CoMat 03-089
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 05-003
Type:sp01
Supply Short Name:CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE
Supply Name:CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE
Specification Groups:
Doc NumberType
Use one of the CoMat 05-003 letter suffix alternatives.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:X222X
Supply Number:CoMat 06-018
Type:sp01
Supply Short Name:CoMat 06-018FLUORESCENT PENETRANT (POST-EMULSIFIED HIGH SENSITIVITY)
Supply Name:CoMat 06-018 FLUORESCENT PENETRANT (POST-EMULSIFIED HIGH SENSITIVITY)
Specification Groups:
Doc NumberType
It is not permitted to mix the selected CoMat 06‐018 letter suffix material with other CoMat 06‐018 letter suffix materials. Where CoMat 06‐018 is specified with no suffix, use one of the CoMat 06‐018 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
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