TASK 72-42-40-300-005 HPC Exit Guide Vane Stator - Repair Damaged Vane(s) By Replacement, Repair-005 (VRS6619)

DMC:V2500-A0-72-42-4000-00A-920A-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 72-42-40-300-005 HPC Exit Guide Vane Stator - Repair Damaged Vane(s) By Replacement, Repair-005 (VRS6619)

Effectivity

FIG/ITEM

PART NO.

01-200

6A3332

Material of component

PART IDENT

SYMBOL

MATERIAL

HP Compressor OGV Assembly -

Stage 12

QNP or

QTB

Nickel base alloy

Vane, Outlet Guide -

HP Compressor Stage 12 Front

QNP or

QTB

Nickel base alloy

Vane, Outlet Guide -

HP Compressor Stage 12 Rear

QNP or

QTB

Nickel base alloy

General

This Repair must only be done when the instruction to do so is given in 72-42-40 Inspection/Check.

This Repair repairs damaged HP Compressor OGV Assemblies - Stage 12, by Vane replacement, with new and/or serviceable vane(s) made from a donor HP Compressor OGV Assembly.

To keep the HP Compressor efficiency, Stage 12 OGV Assemblies are repaired as near to the new OGV condition as possible.

This Repair will permit a limit of 50 percent vane replacement on airfoil AB and airfoil AC, refer to Figure.

This is a Source Demonstration Repair which can only be done by approved vendors.

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

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 cntact the IAE Repair Services Group to determine if a qualification program can be initiated at their facility.

IAE - INTERNATIONAL AERO ENGINES AG,
C/O ROLLS-ROYCE COMMERCIAL AERO ENGINES LTD.,
P.O. BOX 31,
DERBY DE24 8BJ,
ENGLAND
ATTN: Manager Technical Services
Authoirized Repair Vendors for Repair VRS6619 are listed below:
Chromalloy Connecticut,
601 Marshall Phelps Road,
Windsor,
Connecticut 06095,
USA
ATTN: Technical Director
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 qualification 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
  1. DELETED
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
Nickel plate equipmentLOCALNickel plate equipment
Lint free white cotton glovesLOCALLint free white cotton gloves
Argonarc welding equipmentLOCALArgonarc welding equipment
Wire brushLOCALWire brush
Stainless steel
Furnace brazing equipmentLOCALFurnace brazing equipment
Heat treatment equipmentLOCALHeat treatment equipment
Hardness testerLOCALHardness tester
Workshop inspection equipmentLOCALWorkshop inspection equipment
Vibro-engraving equipmentLOCALVibro-engraving equipment
Consumables, Materials and Expendables
NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-001 ADHESIVE TAPE (MASKING)LOCALCoMat 02-001
CoMat 03-150 DELETED0AM53CoMat 03-150
CoMat 03-250 BRAZING FILLER MATERIAL,Ni-BASE01FK3CoMat 03-250
CoMat 03-284 WELDING FILLER WIRE, NiBASELOCALCoMat 03-284
CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADELOCALCoMat 05-003
CoMat 05-109 SILICON CARBIDE ABRASIVETAPE44197CoMat 05-109
CoMat 05-110 EMERY POLISHING PAPER0AM53CoMat 05-110
Spares
NameManufacturerPart Number / IdentificationQuantityRemark
Vane, Outlet Guide - HP Compressor6A7390
Vane, Outlet Guide - HP Compressor6A7391
Safety Requirements
NONE
Procedure
    1. SUBTASK 72-42-40-220-062 Examine the HP Compressor OGV Assembly, Stage 12
    1. Refer to: Figure, Figure and Figure
      2. Visually eaxmine the HP Compressor OGV Assembly, Stage 12.
      1. Mark the damaged vane(s) to be replaced.
        Use standard workshop equipment.
      3. Measure the dimensions of the HP Compressor OGV Assembly, Stage 12, prior to the removal of the damaged vane(s).
      1. Refer to TASK 72-42-40-200-000 (72-42-40 (INSPECTION-000)).
        Make a record of all dimensions, to allow dimensions before and after repair, to be checked.
    2. SUBTASK 72-42-40-320-051 Remove Damaged Vane(s), from the HP Compressor OGV Assembly, Stage 12
      2. Remove damaged vane(s), from the HP Compressor OGV Assembly, Stage 12.
      1. Refer to 4. Repair Facilities, Para B., for approved vendor tools.
    3. SUBTASK 72-42-40-350-058 Remove any Rough Material
      1. Remove any rough material on the platform surfaces after vane removal and make smooth.
      1. Make sure all the rough material is removed and the area is made smooth into the adjacent gas path surfaces.
        Use standard workshop equipment.
    4. SUBTASK 72-42-40-220-063 Examine the Outer and Inner Platform Surfaces, for Vane Fit
    1. Refer to: Figure, Figure, Figure, Figure and Figure
      2. Visually inspect the fit of the replacement vane(s).
      1. Use 6A7390  Stage 12 Front, 01-220 and/or 6A7391  Stage 12 Rear, 01-221 and/or serviceable vane(s) made from a donor HP Compressor OGV Assembly.
        Make sure the vane(s) can be located correctly in the outer and inner platform surfaces.
        Make sure there is sufficient clearance, for brazing, up to a maximum of 0.010in. (0.254 mm).
    5. SUBTASK 72-42-40-110-061 Chemically Clean
      1. Chemically clean.
      1. Refer to the SPM TASK 70-11-03-300-503, SUBTASK 70-11-03-300-001-001.
        Use chemical cleaning equipment.
    6. SUBTASK 72-42-40-120-052 Abrasive Blast the HP Compressor OGV Assembly, Stage 12
      1. Mask areas of the HP Compressor OGV Assembly, Stage 12 not to be repaired.
      1. Refer to 4. Repair Facilities, Para B., for approved vendor masks or use CoMat 02-001 ADHESIVE TAPE (MASKING).
      2. Abrasive blast areas of the HP Compressor OGV Assembly, Stage 12 to be repaired and the replacement vanes.
      1. Refer to the SPM TASK 70-12-09-120-501.
        Use 6A7390  Stage 12 Front, 01-220, 74 off and/or 6A7391  Stage 12 Rear, 01-221, 74 off and/or serviceable vane(s) made from the donor HP Compressor OGV Assembly, as necessary.
    3. Remove the masking tape.
    7. SUBTASK 72-42-40-330-051 Nickel Plate the HP Compressor OGV Assembly, Stage 12 and the Replacement Vane(s)
      1. Nickel plate the HP Compressor OGV Assembly, Stage 12 and the replacement vane(s).
      1. Refer to the SPM TASK 70-31-16-310-501, SUBTASK 70-31-16-310-004.
        Use 6A7390  Stage 12 Front, 01-220, 74 off and/or 6A7391  12 Rear, 01-221, 74 off and/or serviceable vane(s) made from the donor HP Compressor OGV Assembly, as necessary.
        Nickel plate must be 0.0001 in. to 0.0006 in. (0.003 mm to 0.015 mm) thick.
        Use nickel plate equipment.
    8. SUBTASK 72-42-40-350-059 Install Replacement Vane(s) in the HP Compressor OGV Assembly, Stage 12
      CAUTION
      WEAR LINT FREE WHITE COTTON GLOVES WHEN YOU DO THIS PROCEDURE.
      2. Place the HP Compressor OGV Assembly, Stage 12 in to the assembly fixture, with the trailing edge up.
      1. Refer to 4. Repair Facilities, Para B., for approved vendor tools.
        Use a locally made fixture.
      3. Install the new vane(s) as necessary.
      1. Use 6A7390  Stage 12 Front, 01-220, 74 off and/or 6A7391  Stage 12 Rear, 01-221, 74 off and/or serviceable vane(s) made from the donor HP Compressor OGV Assembly.
        Place tang end first through the outer platform and seat it in to the pocket on the inner platform.
        Make sure the tang portion of the vane(s) is completely through the inner platform and located correctly.
        Repeat for all vane(s), both rows, as necessary.
      4. Secure all vane(s) in each row, with suitable clamps.
      1. Refer to 4. Repair Facilities, Para B., for approved vendor tools.
    9. SUBTASK 72-42-40-220-064 Examine the Position of the Replacement Vane(s)
    1. Refer to: Figure, Figure, Figure, Figure and Figure
      2. Visually examine and check the position of the replacement vane(s).
      1. Make sure the replacement vane(s) is/are located and positioned correctly in relation to the outer and inner platform and the assembly fixture.
    10. SUBTASK 72-42-40-310-051 Safety the Replacement Vane(s) in Position
    1. Refer to: Figure, Figure, Figure and Figure
      2. Strap weld the replacement vane(s) to the non-gas-path side of the inner and outer platform at the mid chord position.
      1. Refer to the SPM TASK 70-31-02-310-501-001.
        Use CoMat 03-284 WELDING FILLER WIRE, NiBASE with argonarc welding equipment.
      3. Fusion weld the trailing edge only of the replacement vane(s) AC, to the outer platform.
      1. Refer to the SPM TASK 70-31-02-310-501-001.
        Use CoMat 03-284 WELDING FILLER WIRE, NiBASE, with argonarc welding equipment.
        Weld Data
        Refer to approved vendor in 4. Repair Facilities, Para B., for weld parameters.
        NOTE
        This weld is to prevent the trailing edge thin wall from cracking due to expansion and contraction during the braze cycle.
      4. Remove weld discoloration.
      1. Lightly wire brush the strap weld, with a stainless steel wire brush.
    11. SUBTASK 72-42-40-220-065 Examine the Replacement Vane(s)
    1. Refer to: Figure, Figure, Figure, Figure and Figure
      2. Visually examine and measure the replacement vane angle(s) for correct location and position.
      1. Refer to 4. Repair Facilities, Para B., for approved vendor tools.
    12. SUBTASK 72-42-40-310-052 Braze the Replacement Vane(s) in Position
    1. Refer to: Figure and Figure
      2. Apply braze alloy paste to the vane joint(s) on both the inner and outer platform.
      1. Refer to the SPM TASK 70-31-16-310-501.
        Use an applicable needle to apply the brazing filler powder.
      3. Fill wide gaps, as necessary.
      1. Refer to the SPM TASK 70-31-16-310-501.
        When you use the wide gap filler material, apply the filler to the joint, then trim any excess material smooth with the adjacent outer and/or inner platform surface.
        On completion apply CoMat 03-150 DELETED to cover the joint completely.
      4. Assemble the HP Compressor OGV Assembly, Stage 12 on to the brazing fixture.
      1. Refer to 4. Repair Facilities, Para B., for approved vendor tools.
        Use a locally made fixture.
      5. Furnace braze the HP Compressor OGV Assembly, Stage 12.
      1. Refer to the SPM TASK 70-31-16-310-501.
        Use furnace brazing equipment.
        Braze data
        Refer to approved vendor in 4. Repair Facilities, Para B., for braze parameters.
    13. SUBTASK 72-42-40-220-066 Examine the Brazed Joint(s)
    1. Refer to: Figure, Figure and Figure
      2. Visually examine the brazed joint(s) of the replacement vane(s).
      1. Refer to the SPM TASK 70-31-16-310-501.
        The brazed joint must show the presence of a fillet and must show no recess or through voids.
    14. SUBTASK 72-42-40-350-060 Remove Excess Weld Material from Vanes AC
    1. Refer to: Figure and Figure
      2. Remove excess weld material from the trailing edge on vane(s) AC only.
      1. Blend smooth and continuous with the original contour.
        Use standard workshop equipment.
    15. SUBTASK 72-42-40-370-051 Heat-Treat the HP Compressor OGV Assembly, Stage 12
      1. Position the HP Compressor OGV Assembly, Stage 12 in the heat treatment fixture.
      1. Refer to 4. Repair Facilities, Para B., for approved vendor tools.
        Use a locally made fixture.
      2. Heat-treat the HP Compressor OGV Assembly, Stage 12 in a vacuum or controlled atmosphere.
      1. Refer to 4. Repair Facilities, Para B., for approved vendor tools.
        Heat-Treat Data
        Heat to a temperature of 1400 deg F (760 deg C) and hold for 2 hours in a vacuum or argon.
        Furnace cool at a rate of 100 deg F (56 deg C) per hour to 1150 deg F (621 deg C) and hold for 4 hours.
        Cool down to room temperature in air.
    16. SUBTASK 72-42-40-220-066 Do a Hardness Check
      1. Do a hardness check on a sample of HP Compressor OGV Assembly, Stage 12.
      1. Use a sample piece of OGV.
        The hardness check must be within RC34 to RC43, with RC32 minimum.
        This ia a guide for quality control and is not an absolute limit.
        Use a hardness tester.
        NOTE
        If the sample OGV piece is outside the hardness variation limits, additional OGV's must be sampled, if more than 10 percent variation in hardness is experienced, then the cause must be investigated.
    17. SUBTASK 72-42-40-220-067 Examine
      2. Visually examine and measure the vane angle(s).
      1. Refer to 4. Repair Facilities, Para B., for approved vendor tools.
        Make sure the vane(s) are still brazed in position.
        Make sure the vane angle(s) is/are to the dimensions given, adjust the vane(s), as necessary.
        Compare before and after repair dimensions, refer to Step.
        Use workshop inspection equipment.
    18. SUBTASK 72-42-40-230-057 Do a Crack Test
      1. Do a penetrant crack test on the repaired area(s).
      1. Refer to the SPM TASK 70-23-02-230-501.
        Use penetrant crack test equipment.
        Cracks are not permitted.
    19. SUBTASK 72-42-40-110-064 Chemically Clean
      1. Chemically clean.
      1. Refer to the SPM TASK 70-11-03-300-503, SUBTASK 70-11-03-300-001-001.
        Use chemical cleaning equipment.
    20. SUBTASK 72-42-40-350-061 Identify the Repair
      1. Make a mark VRS6619 adjacent to the part number.
      1. Refer to the SPM TASK 70-09-00-400-501, SUBTASK 70-09-00-400-001.
        Use vibro-engraving equipment.
    21. 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
    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
Link not Found
Manufacturer Code:01FK3
Enterprise Name:OERLIKON METCO (US), INC
BU Name:SULZER METCO (US), INC
Street:1101 PROSPECT AVE
City:WESTBURY, NY 11590
Country:USA
Phone Number:1-888-COAT-544, 1-516-338-2301
Fax Number:1-516-338-2342, 1-516-338-2414
Internet:www.sulzermetco.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: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:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Link not Found
Link not Found
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:0AM53
Supply Number:CoMat 03-150
Type:sp01
Supply Short Name:CoMat 03-150 DELETED
Supply Name:CoMat 03-150 DELETED
Specification Groups:
Doc NumberType
See CoMat CoMat 03-249
Suppliers:
ManufacturerRemarks
0AM53
Manufacturer Code:01FK3
Supply Number:CoMat 03-250
Type:sp01
Supply Short Name:CoMat 03-250 BRAZING FILLER MATERIAL, Ni-BASE
Supply Name:CoMat 03-250 BRAZING FILLER MATERIAL,Ni-BASE
Specification Groups:
Doc NumberType
AMDRY 915 PASTE PWA 996-1S-PASTE
Suppliers:
ManufacturerRemarks
01FK3
Manufacturer Code:LOCAL
Supply Number:CoMat 03-284
Type:sp01
Supply Short Name:CoMat 03-284 WELDING FILLER WIRE, Ni BASE
Supply Name:CoMat 03-284 WELDING FILLER WIRE, NiBASE
Specification Groups:
Doc NumberType
INCONEL 718 AMS 5832 AWS 5.14 MSRR9500/220
INCONEL 718 AMS 5832 AWS 5.14CLASS ER NI FE Cr-2 OMAT:3/206
INCONEL 718 AMS 5832 AWS 5.14CLASS ER NI FE Cr-2
Suppliers:
ManufacturerRemarks
LOCAL
28553
IE137
08489
IE508
0ZDB5
2R602
55596
58401
80357
K6835
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:44197
Supply Number:CoMat 05-109
Type:sp01
Supply Short Name:CoMat 05-109 SILICON CARBIDE ABRASIVE TAPE
Supply Name:CoMat 05-109 SILICON CARBIDE ABRASIVETAPE
Specification Groups:
Doc NumberType
GRIT SIZE 150
Suppliers:
ManufacturerRemarks
44197
IE441
K3895
K6835
LOCAL
Manufacturer Code:X111X
Supply Number:CoMat 05-110
Type:sp01
Supply Short Name:CoMat 05-110 EMERY POLISHING PAPER
Supply Name:CoMat 05-110 EMERY POLISHING PAPER
Specification Groups:
Doc NumberType
DISCONTINUED
Suppliers:
ManufacturerRemarks
X111X
Link not Found
Manufacturer Code:LOCAL
Tool Number:Chemical cleaning equipment
Tool Name:Chemical cleaning equipment
Manufacturer Code:LOCAL
Tool Number:Furnace brazing equipment
Tool Name:Furnace brazing equipment
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Lint free white cotton gloves
Tool Name:Lint free white cotton gloves
Link not Found
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Link not Found
Manufacturer Code:LOCAL
Tool Number:Vibro-engraving equipment
Tool Name:Vibro-engraving equipment
Manufacturer Code:LOCAL
Tool Number:Wire brush
Tool Name:Wire brush
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment