TASK 72-42-50-300-002 HPC Rear Static Seal - Replace The Inner Seal Carrier, Repair-002 (VRS6203)

DMC:V2500-A0-72-42-5001-01A-920A-C|Issue No:004.00|Issue Date:2017-11-01

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 72-42-50-300-002 HPC Rear Static Seal - Replace The Inner Seal Carrier, Repair-002 (VRS6203)

Effectivity

FIG/ITEM

PART NO.

01-100

6A3306

01-100

6A3932

01-100

6A4806

01-100

6A4447

01-100

6B1412

Material of component

RR

DESCRIPTION

SYMBOL

MATERIAL

Support cone

QAW or

Nimonic 80A

QAL

Inner seal carrier

QAH or

C263

QAU

Rivets

QBE

Nimonic 75

General

This repair must only be done when the instruction to do so is given in TASK 72-42-50 Inspection.

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 in the SPM TASKS given below:
SPM TASK 70-09-00-400-501
SPM TASK 70-23-05-230-501
SPM TASK 70-39-02-390-501
SPM TASK 70-39-03-390-501

NOTE

To identify the consumable materials, refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Hand grinderLOCALHand grinder
Vertical drilling machineLOCALVertical drilling machine
Standard workshop equipmentLOCALStandard workshop equipment
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Special container for liquid nitrogenLOCALSpecial container for liquid nitrogen
Heat protection glovesLOCALHeat protection gloves
Hot squeeze riveting electrodesLOCALHot squeeze riveting electrodes
Resistance welding machineLOCALResistance welding machine
LatheLOCALLathe
Dial indicatorLOCALDial indicator
Dimensional inspection equipmentLOCALDimensional inspection equipment
Vibro-engraving equipmentLOCALVibro-engraving equipment
IAE 3R18736 Turning fixture0AM53IAE 3R187361
IAE 3R18749 Tool holder0AM53IAE 3R187491
IAE 3R18750 Insert use with0AM53IAE 3R187501

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-026 LIQUID NITROGENLOCALCoMat 03-026
CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)LOCALCoMat 06-022

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
Seal, assembly of inner carrier (Assembly A and Assembly B)6A41431
Rivet, solid, universal head (Assembly A and Assembly B)AS1628936AR
Rivet, solid, universal head (Assembly A and Assembly B)AS1633036AR
Seal, assembly of inner carrier (Assembly C)6A59431
Rivet, solid, universal head (Assembly C)AS1628930AR
Rivet, solid, universal head (Assembly C)AS1633030AR

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-42-50-350-055-A00 Disassemble the Static Air Seal Assembly, Assembly A

    1. Refer to Figure and Figure

      2. Grind off the rivets which hold the inner seal carrier to the support cone.

      1. Use a hand grinder.

    3. Remove the inner seal carrier.

    2. SUBTASK 72-42-50-350-055-B00 Disassemble the Static Air Seal Assembly, Assembly B

    1. Refer to Figure and Figure

      2. Grind off the rivets which hold the inner seal carrier to the support cone.

      1. Use a hand grinder.

    3. Remove the inner seal carrier.

    3. SUBTASK 72-42-50-350-055-C00 Disassemble the Static Air Seal Assembly, Assembly C

    1. Refer to Figure and Figure

      2. Grind off the rivets which hold the inner seal carrier to the support cone.

      1. Use a hand grinder.

    3. Remove the inner seal.

    4. SUBTASK 72-42-50-220-065-A00 Examine the Rivet Holes, Assembly A

    1. Refer to Figure and Figure

      2. Measure the diameter of rivet holes in the support cone.

      1. Make a note of which rivet holes are oversize in the support cone flange.

    5. SUBTASK 72-42-50-220-065-B00 Examine the Rivet Holes, Assembly B

    1. Refer to Figure and Figure

      2. Measure the diameter of rivet holes in the support cone.

      1. Make a note of which rivet holes are oversize in the support cone flange.

    6. SUBTASK 72-42-50-220-065-C00 Examine the Rivet Holes, Assembly C

    1. Refer to Figure and Figure

      2. Measure the diameter of rivet holes in the support cone.

      1. Make a note of which rivet holes are oversize in the support cone flange.

    7. SUBTASK 72-42-50-323-051-A00 Drill Damaged Rivet Holes, Assembly A and Assembly B

    1. Refer to Figure

      2. Drill damaged rivet holes in the support cone for the larger rivet(s), as necessary.

      1. Use a vertical drilling machine.

      3. Remove sharp edges.

      1. Use standard workshop equipment.

    8. SUBTASK 72-42-50-323-051-B00 Drill Damaged Rivet Holes, Assembly C

    1. Refer to Figure

      2. Drill damaged rivet holes in the support cone for the larger rivet(s), as necessary.

      1. Use a vertical drilling machine.

      3. Remove sharp edges.

      1. Use standard workshop equipment.

    9. SUBTASK 72-42-50-230-060 Do a Crack Test

      1. Do a local penetrant crack test of the drilled hole(s).

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

      3. Cracks are not permitted.

    10. SUBTASK 72-42-50-350-056-A00 Drill the Rivet Holes in the Inner Seal Carrier, Assembly A

    1. Refer to Figure and Figure

      2. Freeze the inner seal carrier.

      1. Use, seal, assembly of, inner carrier 1 off, 01-160, with CoMat 03-026 LIQUID NITROGEN put in a suitable container for liquid nitrogen.

      2. Use protective gloves.

      3. Install the inner seal carrier on to the support cone.

      1. Make sure the inner seal carrier is correctly installed.

      4. Drill the rivet holes in the inner seal carrier.

      1. Use a vertical drilling machine.

      2. Drill through the holes in the support cone, to the correct diameter, as necessary.

      3. Use standard workshop equipment.

      5. Remove sharp edges.

      1. Use standard workshop equipment.

    11. SUBTASK 72-42-50-350-056-B00 Drill the Rivet Holes in the Inner Seal Carrier, Assembly B

    1. Refer to Figure and Figure

      2. Freeze the inner seal carrier.

      1. Use seal, assembly of, inner carrier 1 off, 01-160, with CoMat 03-026 LIQUID NITROGEN put in a suitable container for liquid nitrogen.

      2. Use protective gloves.

      3. Install the inner seal carrier on to the support cone.

      1. Make sure the inner seal carrier is correctly installed.

      4. Drill the rivet holes in the inner seal carrier.

      1. Use a vertical drilling machine.

      2. Drill through the holes in the support cone, to the correct diameter, as necessary.

      3. Use standard workshop equipment.

      5. Remove sharp edges.

      1. Use standard workshop equipment.

    12. SUBTASK 72-42-50-350-056-C00 Drill the Rivet Holes in the Inner Seal Carrier, Assembly C

    1. Refer to Figure and Figure

      2. Freeze the inner seal carrier.

      1. Use seal, assembly of, inner carrier 1 off, 01-160, with CoMat 03-026 LIQUID NITROGEN put in a suitable container for liquid nitrogen.

      2. Use protective gloves.

      3. Install the inner seal carrier on to the support cone.

      1. Make sure the inner seal carrier is correctly installed.

      4. Drill the rivet holes in the inner seal carrier.

      1. Use a vertical drilling machine.

      2. Drill through the holes in the support cone, to the correct diameter, as necessary.

      3. Use standard workshop equipment.

      5. Remove sharp edges.

      1. Use standard workshop equipment.

    13. SUBTASK 72-42-50-350-067 Repair or Replace the Inner Seal Carrier

      1. Repair inner seal feltmetal.

      1. Repair, VRS9205 TASK 72-42-50-300-008 (REPAIR-008).

      2. Replace inner seal carrier.

      1. Use replacement part 6A4447 or 6B1412.

    14. SUBTASK 72-42-50-350-066-A00 Attach the Inner Seal Carrier to the Support Cone, Assembly A and Assembly B

    1. Refer to Figure and Figure

      2. Put the rivets in the rivet holes, as necessary and cut to length.

      1. Use rivet solid, universal head, 36 off, 01-123 and/or rivet solid, universal head, 36 off, 01-124, as necessary.

      2. Use standard workshop equipment.

      3. Cut the rivets to dimension AB.

    15. SUBTASK 72-42-50-350-066-B00 Attach the Inner Seal Carrier to the Support Cone, Assembly C

    1. Refer to Figure and Figure

      2. Put the rivets in the rivet holes, as necessary and cut to length.

      1. Use rivet solid, universal head, 36 off, 01-123 and/or rivet solid, universal head, 36 off, 01-124, as necessary.

      2. Use standard workshop equipment.

      3. Cut the rivets to dimension AG.

    16. SUBTASK 72-42-50-390-051-001-A00 Secure the Inner Seal Carrier, Assembly A and Assembly B

    1. Refer to Figure

      2. Hot squeeze the rivets.

      1. Refer to SPM TASK 70-39-02-390-501.

      2. Use hot squeeze riveting electrodes, with resistance welding machine.

        NOTE

        The machine settings must be established by trial using suitable test pieces. Use a low voltage setting and the minimum amount of heat required to make the rivet force over.

    17. SUBTASK 72-42-50-390-051-001-B00 Secure the Inner Seal Carrier, Assembly C

    1. Refer to Figure

      2. Hot squeeze the rivets.

      1. Refer to SPM TASK 70-39-02-390-501.

      2. Use hot squeeze riveting electrodes, with resistance welding machine.

        NOTE

        The machine settings must be established by trial using suitable test pieces. Use a low voltage setting and the minimum amount of heat required to make the rivet force over.

    18. SUBTASK 72-42-50-390-051-002-A00 Secure the Inner Seal Carrier, Assembly A and Assembly B

    1. Refer to Figure

      2. Cold squeeze the rivets.

      1. Refer to SPM TASK 70-39-03-390-501.

      2. Use standard workshop equipment.

    19. SUBTASK 72-42-50-390-051-002-B00 Secure the Inner Seal Carrier, Assembly C

    1. Refer to Figure

      2. Cold squeeze the rivets.

      1. Refer to SPM TASK 70-39-03-390-501.

      2. Use standard workshop equipment.

    20. SUBTASK 72-42-50-220-066 Examine the Assembly

      1. Visually examine the rivet(s).

      1. Reject damaged rivet(s).

    21. SUBTASK 72-42-50-325-052-A00 Machine the Seals in the Inner Carrier Ring, Assembly A and Assembly B

    1. Refer to Figure

      2. Set up the turning fixture on the lathe and set to run true.

      1. Use IAE 3R18736 Turning fixture 1 off, with a lathe and dial test indicator.

      3. Install the static air seal assembly on to the turning fixture correctly.

      1. Hold the clamps.

      4. Machine the three seals.

      1. Machine data:

        Speed

        470 surface feet (143 metres) per minute.

        Feed

        0.005 in. (0.127 mm) per rev.

        Depth of cut:

        Rough

        0.010 in. to 0.030 in. (0.25 mm to 0.75 mm).

        Finish

        0.001 in. to 0.010 in. (0.025 mm to 0.25mm)

        NOTE

        Use a higher feed rate and a higher cutting speed for finishing cuts. Machine dry, and keep a sharp cutting tool.

      5. Remove the burrs.

      1. Use standard workshop equipment.

    6. Remove the assembly from the machine.

    22. SUBTASK 72-42-50-325-002-B00 Machine the Seals in the Inner Carrier Ring, Assembly C

    1. Refer to Figure

      2. Set up the turning fixture on the lathe and set to run true.

      1. Use IAE 3R18736 Turning fixture 1 off, with a lathe and dial test indicator.

      3. Install the static air seal assembly on to the turning fixture correctly.

      1. Hold with clamps.

      4. Machine the four seals.

      1. Machine data:

        Speed

        470 surface feet (143 metres) per minute.

        Feed

        0.005 in. (0.127 mm) per rev.

        Depth of cut:

        Rough

        0.010 in. to 0.030 in. (0.25 mm to 0.75 mm).

        Finish

        0.001 in. to 0.010 in. (0.025 mm to 0.25 mm)

        NOTE

        Use a higher feed rate and a higher cutting speed for finishing cuts. Machine dry, and keep a sharp cutting tool.

      5. Remove the burrs.

      1. Use standard workshop equipment.

    6. Remove the assembly from the machine.

    23. SUBTASK 72-42-50-220-067-A00 Examine the Assembly, Assembly A and Assembly B

    1. Refer to Figure

      2. Visually examine and measure the dimensions of the inner carrier.

      1. Use dimensional inspection equipment.

    24. SUBTASK 72-42-50-220-067-B00 Examine the Assembly, Assembly C

    1. Refer to Figure

      2. Visually examine and measure the dimensions of the inner carrier seals.

      1. Use dimensional inspection equipment.

    25. SUBTASK 72-42-50-350-057 Identify the Repair

      1. Make a mark VRS6203 adjacent to the part number on the support cone.

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

      2. Use vibro-engraving equipment.

    26. Figure: Repair Details and Dimensions - Assembly A

    Repair Details and Dimensions - Assembly A

    Figure: Repair Details and Dimensions - Assembly B

    Repair Details and Dimensions - Assembly B

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

    Repair Details and Dimensions - Assembly A and Assembly B

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

    Repair Details and Dimensions - Assembly A and Assembly B

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

    Repair Details and Dimensions - Assembly A and Assembly B

    Figure: Repair Details and Dimensions - Assembly C

    Repair Details and Dimensions - Assembly C

    Figure: Repair Details and Dimensions - Assembly C

    Repair Details and Dimensions - Assembly C

    Figure: Repair Details and Dimensions - Assembly C

    Repair Details and Dimensions - Assembly C

    Figure: Repair Details and Dimensions - Assembly C

    Repair Details and Dimensions - Assembly C

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedure to add the inner seal carrier repair procedure. (16VC319)

Link not Found
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:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Link not Found
Link not Found
Link not Found
Link not Found
Manufacturer Code:LOCAL
Supply Number:CoMat 03-026
Type:sp01
Supply Short Name:CoMat 03-026 LIQUID NITROGEN
Supply Name:CoMat 03-026 LIQUID NITROGEN
Specification Groups:
Doc NumberType
OMAT:220BB-N-411 T2GBC1
JCR-135BB-N-411 T2GBC1
Suppliers:
ManufacturerRemarks
LOCAL
U2046
U2096
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:Dial indicator
Tool Name:Dial indicator
Manufacturer Code:LOCAL
Tool Number:Dimensional inspection equipment
Tool Name:Dimensional inspection equipment
Link not Found
Manufacturer Code:LOCAL
Tool Number:Heat protection gloves
Tool Name:Heat protection gloves
Manufacturer Code:LOCAL
Tool Number:Hot squeeze riveting electrodes
Tool Name:Hot squeeze riveting electrodes
Manufacturer Code:0AM53
Tool Number:IAE 3R18736
Tool Name:IAE 3R18736 Turning fixture
Manufacturer Code:0AM53
Tool Number:IAE 3R18749
Tool Name:IAE 3R18749 Tool holder
Manufacturer Code:0AM53
Tool Number:IAE 3R18750
Tool Name:IAE 3R18750 Insert use with
Manufacturer Code:LOCAL
Tool Number:Lathe
Tool Name:Lathe
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Manufacturer Code:LOCAL
Tool Number:Resistance welding machine
Tool Name:Resistance welding machine
Manufacturer Code:LOCAL
Tool Number:Special container for liquid nitrogen
Tool Name:Special container for liquid nitrogen
Link not Found
Manufacturer Code:LOCAL
Tool Number:Vertical drilling machine
Tool Name:Vertical drilling machine
Manufacturer Code:LOCAL
Tool Number:Vibro-engraving equipment
Tool Name:Vibro-engraving equipment