TASK 72-44-20-300-021 HPT Stage 1 Vane - Repair Plugged Airfoil And Platform Cooling Air Holes, Repair-021 (VRS3498)

DMC:V2500-A0-72-44-2000-00A-252A-C|Issue No:002.00|Issue Date:2015-05-01

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 72-44-20-300-021 HPT Stage 1 Vane - Repair Plugged Airfoil And Platform Cooling Air Holes, Repair-021 (VRS3498)

Effectivity

FIG/ITEM

PART NO.

01-250

2A0091CL21

01-251

2A0091CL22

01-252

2A0091CL23

01-253

2A0091CL24

01-254

2A0091CL25

01-255

2A0091CL26

01-256

2A0091CL27

01-257

2A0091CL28

01-258

2A0091CL29

01-259

2A0091CL30

01-260

2A0091CL31

01-261

2A0091CL32

01-262

2A0091CL33

01-263

2A0091CL34

01-264

2A0091CL35

01-265

2A0091CL36

01-266

2A0091CL37

01-267

2A0091CL38

01-268

2A0091CL39

01-269

2A0091CL40

01-270

2A0091CL41

01-271

2A0091CL42

01-272

2A0091CL43

01-273

2A0091CL44

01-274

2A0091CL45

01-275

2A0091CL46

01-276

2A0091CL47

01-277

2A0091CL48

01-278

2A0091CL48-5

01-279

2A0091CL49

01-280

2A0091CL49-5

01-240

2A0561

01-250

2A2591CL21

01-251

2A2591CL22

01-252

2A2591CL23

01-253

2A2591CL24

01-254

2A2591CL25

01-255

2A2591CL26

01-256

2A2591CL27

01-257

2A2591CL28

01-258

2A2591CL29

01-259

2A2591CL30

01-260

2A2591CL31

01-261

2A2591CL32

01-262

2A2591CL33

01-263

2A2591CL34

01-264

2A2591CL35

01-265

2A2591CL36

01-266

2A2591CL37

01-267

2A2591CL38

01-268

2A2591CL39

01-269

2A2591CL40

01-270

2A2591CL41

01-271

2A2591CL42

01-272

2A2591CL43

01-273

2A2591CL44

01-274

2A2591CL45

01-275

2A2591CL46

01-276

2A2591CL47

01-277

2A2591CL48

01-279

2A2591CL49

01-284

2A2591CL50

01-286

2A2591CL51

01-240

2A2761

01-240

2A4201

01-240

2A4271

Material of component

RR

DESCRIPTION

SYMBOL

MATERIAL

Stage 1 HPT vane cluster

-

Cast cobalt alloy

assembly

Stage 1 HPT vane cover

-

Nickel alloy

Baffle assembly

-

Nickel alloy

Cover

-

Nickel alloy

General

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

Price and availability - not applicable

NOTE

To identify consumable materials refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Pin viseLOCALPin vise
Pencil blasterLOCALPencil blaster
ReamersLOCALReamers
Spring wireLOCALSpring wire
Workshop inspection equipmentLOCALWorkshop inspection equipment
Ultrasonic cleaning equipmentLOCALUltrasonic cleaning equipment

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 05-155 ALUMUNUM OXIDE ABRASIVE,27 MICRONLOCALCoMat 05-155
CoMat 10-058 PENETRATING OIL0AM53CoMat 10-058
CoMat 01-339 ALKALI CLEANER (GENERAL PURPOSE)LOCALCoMat 01-339

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
Cover, HPT stage 12A0033AR

(V2500-A1)

Baffle assembly2A0024-01AR

(V2500-A1)

Baffle assembly2A0027-01AR

(V2500-A1)

Cover2A0030AR

(V2500-A1)

Cover2A0031AR

(V2500-A1)

Cover2A0032AR

(V2500-A1)

Baffle assembly2A0534-01AR

(V2500-A5)

Cover2A0536AR

(V2500-A5)

Cover2A0537AR

(V2500-A5)

Cover2A0538AR

(V2500-A5) (PN 2A0561)

Cover2A2765AR

(V2500-A5) (PN 2A2761)

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-44-20-350-058-A00 V2500-A1 Prepare the Vane Cluster for Unplugging the Cooling Air Holes

    1. Refer to Figure.

      2. If necessary, clean the vane assembly.

      1. Do the procedure given in TASK 72-44-20-100-000 (CLEANING-000).

      3. If necessary, remove the vane covers.

      1. Do the procedure given in TASK 72-44-20-300-005 (VRS3152) (REPAIR-005).

      4. If necessary, remove the vane baffle assemblies.

      1. Do the procedure given in TASK 72-44-20-300-014 (VRS3153) (REPAIR-014).

    2. SUBTASK 72-44-20-350-058-B00 V2500-A5 Prepare the Vane for Unplugging the Cooling Air Holes

    1. Refer to Figure.

      2. If necessary, clean the vane assembly.

      1. Do the procedure given in TASK 72-44-20-100-000 (CLEANING-000).

      3. If necessary, remove the vane covers.

      1. Do the procedure given in TASK 72-44-20-300-023 (VRS3542) (REPAIR-023).

      4. If necessary, remove the vane baffle assemblies.

      1. Do the procedure given in TASK 72-44-20-300-022 (VRS3541) (REPAIR-022).

    3. SUBTASK 72-44-20-350-059-001 Unplug the Vane Airfoils and Platforms Cooling Air Holes (Hand Probe)

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

      2. If necessary, apply CoMat 10-058 PENETRATING OIL to vane cooling air hole areas.

      1. Permit the oil to soak into any material that blocks the holes.

    3. Unplug the cooling air holes in the vane airfoils and platforms.

      4. Hand probe the cooling air holes with reamers and/or spring wire to remove the foreign material or blockage.

        1. Do not damage the coating when you hand probe the holes.

        1. Use a reamer or spring wire with the correct diameter for each of the holes given in the figure.

        2. If the covers and baffles are removed, be careful not to force debris in the interior of the vane.

        3. The use of spring wire with a pin vise can be used between the airfoils if a longer range is necessary.

        4. Cut the end of the spring wire at an angle.

        5. Hand probe the holes and use a rotary motion. Move the reamer or wire slowly into the hole while probing. Remove the tool intermittently and hold the vane with the cooling air holes down to permit the debris to fall out.

      5. Continue to hand probe the airfoil and platform holes to the diameter given in the figure.

      1. Finish the probing with the spring wire. This will minimize the hole taper.

    4. SUBTASK 72-44-20-350-059-002 Unplug the Vane Airfoils and Platforms Cooling Air Holes (Grit Blast)

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

      2. If necessary, apply CoMat 10-058 PENETRATING OIL to vane cooling air hole areas.

      1. Permit the oil to soak into any material that blocks the holes.

      3. If necessary, clean the vane assembly to remove the penetrating oil.

        1. Do the procedure given in TASK 72-44-20-100-000 (CLEANING-000).

        1. If the covers and baffles are not removed, the internal vane surfaces must be dry before you do the grit blast procedure.

    4. Unplug the cooling air holes in the vane airfoils and platforms.

      5. Grit blast the cooling air holes to remove the foreign material or blockage.

      1. Be careful not to damage the coating or make the holes oversize when you grit blast the holes.

      2. Use a Pencil blaster with a 0.011 in. (0.28 mm) nozzle to blast the blockage.

      4. If the covers and baffles are removed, be careful not to force debris in the interior of the vane.

      6. If necessary, hand probe the airfoil and platform holes to the diameter given in the figure.

      1. Use a reamer or spring wire with the correct diameter for each of the holes given in the figure.

      2. The use of Spring wire with a Pin vise can be used between the airfoils if a longer range is necessary.

      3. Cut the end of the spring wire at an angle.

      4. Hand probe the holes and use a rotary motion. Move the reamer or wire slowly into the hole while probing. Remove the tool intermittently and hold the vane with the cooling air holes down to permit the debris to fall out.

    5. SUBTASK 72-44-20-130-055 Clean the Internal Passages on the Vane Assembly

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

      2. NOTE

        The ultrasonics will increase the temperature of the solution.

        Ultrasonic clean the internal vane passages to remove the debris.

      1. Do the procedure given in the SPM TASK 70-13-02-300-503 at a maximum of 150 deg F (65.6 deg C). Use CoMat 01-339 ALKALI CLEANER (GENERAL PURPOSE). Mix the solution by the procedure given in the SPM TASK 70-11-48-110-501.

      2. Position the vane assembly at different angles when you clean the vane to flush out the unwanted material located inside the internal cavities.

    3. Power flush the vane assembly internally and externally with hot water and air dry.

    6. SUBTASK 72-44-20-220-067 Examine the Repair

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

    2. Visual examine all the airfoil and platform cooling air holes for blockage.

    3. If any airfoil or platform cooling air holes are plugged, do the procedure given in Step or Step and Step.

    7. SUBTASK 72-44-20-220-068 V2500-A1 Examine the Vane Cluster Assembly by Heat Tint

    1. Refer to Figure.

      2. Do a heat tint check on the airfoils and platforms. This is an optional procedure.

      1. Do the procedure given in the SPM TASK 70-28-01-280-501.

      2. The ceramic platform coating cannot be seen by the heat tint check.

    8. SUBTASK 72-44-20-350-060-A00 V2500-A1 Touch-up the Airfoils and Platforms Coating

    1. Refer to Figure.

      2. If necessary, touch-up the coating on the airfoils.

      1. Do the procedure given in TASK 72-44-20-300-007 (VRS3165) (REPAIR-007).

      2. Try to prevent the coating from going into the cooling air holes when you do the touch-up. If necessary, after the coating is baked, pierce the thin coating over the holes with spring wire.

      3. If necessary, touch-up the coating on the platforms.

      1. Do the procedure given in TASK 72-44-20-300-015 (VRS3164) (REPAIR-015).

    9. SUBTASK 72-44-20-350-060-B00 V2500-A5 Touch-up the Platforms Coating

    1. Refer to Figure.

      2. If necessary, touch-up the coating on the platforms.

      1. Do the procedure given in TASK 72-44-20-300-015 (VRS3164) (REPAIR-015).

    10. SUBTASK 72-44-20-350-061-A00 V2500-A1 Install the Vane Cluster Covers and Baffles

    1. Refer to Figure.

      2. If necessary, install the vane covers.

      1. Do the procedure given in TASK 72-44-20-300-005 (VRS3152) (REPAIR-005).

      3. If necessary, install the vane baffle assemblies.

      1. Do the procedure given in TASK 72-44-20-300-014 (VRS3153) (REPAIR-014).

    11. SUBTASK 72-44-20-350-061-B00 V2500-A5 Install the Vane Covers and Baffles

    1. Refer to Figure.

      2. If necessary, install the vane covers.

      1. Do the procedure given in TASK 72-44-20-300-023 (VRS3542) (REPAIR-023).

      3. If necessary, install the vane baffle assemblies.

      1. Do the procedure given in TASK 72-44-20-300-022 (VRS3541) (REPAIR-022).

    12. SUBTASK 72-44-20-220-069 Examine the Vane Cluster Assembly by the Airflow Check

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

      2. Do an airflow check on the airfoil cooling air holes.

      1. Do the procedure given in TASK 72-44-20-200-000 (INSPECTION/CHECK-000) except you can correct the airflow that is under the limits by hand probing or grit blasting. Increase the hole size in small increments. Do not hand probe or grit blast all the holes at one time or you can create an airflow that is over the limits.

      2. Any vane airflow that is higher than the limit given is not acceptable.

    3. The airflow check on the inner and outer platform cooling air holes is not required.

    13. SUBTASK 72-44-20-350-062 Mark the Repair

    1. Refer to Figure or Figure.

      2. Mark VRS3498 adjacent to the part number or on one of the alternate marking areas.

      1. Mark a permanent mark by the procedure given in the SPM TASK 70-09-00-400-501.

      2. Use the vibration peen method.

    14. Figure: Repair Details and Dimensions (V2500-A1)

    Repair Details and Dimensions (V2500-A1)

    Figure: Repair Details and Dimensions (V2500-A5)

    Repair Details and Dimensions (V2500-A5)

    Figure: Repair Details and Dimensions (V2500-A1)

    Sheet 1

    Legend
    Repair Details and Dimensions (V2500-A1)

    Sheet 1

    Close

    Figure: Repair Details and Dimensions (PN 2A0091) (V2500-A1)

    Sheet 2

    Legend
    Repair Details and Dimensions (PN 2A0091) (V2500-A1)

    Sheet 2

    Close

    Figure: Repair Details and Dimensions (PN 2A2591) (V2500-A1)

    Sheet 3

    Legend
    Repair Details and Dimensions (PN 2A2591) (V2500-A1)

    Sheet 3

    Close

    Figure: Repair Details and Dimensions (V2500-A5)

    Sheet 1

    Legend
    Repair Details and Dimensions (V2500-A5)

    Sheet 1

    Close

    Figure: Repair Details and Dimensions (V2500-A5)

    Sheet 2

    Legend
    Repair Details and Dimensions (V2500-A5)

    Sheet 2

    Close

    Figure: Repair Details and Dimensions (PN 2A4271) (V2500-A5)

    Repair Details and Dimensions (PN 2A4271) (V2500-A5)

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised SPM 70-11-48 task reference link. (editorial)

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
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Link not Found
Manufacturer Code:LOCAL
Supply Number:CoMat 01-339
Type:sp01
Supply Short Name:CoMat 01-339 ALKALI CLEANER (GENERAL PURPOSE)
Supply Name:CoMat 01-339 ALKALI CLEANER (GENERAL PURPOSE)
Specification Groups:
Doc NumberType
CEE-BEE A-7X7SPMC 104 (PW REF)
SPMC 104CEE-BEE A-7X7
Suppliers:
ManufacturerRemarks
LOCAL
3MCT7
U5702
Manufacturer Code:LOCAL
Supply Number:CoMat 05-155
Type:sp01
Supply Short Name:CoMat 05-155 ALUMUNUM OXIDE ABRASIVE,27 MICRON
Supply Name:CoMat 05-155 ALUMUNUM OXIDE ABRASIVE,27 MICRON
Specification Groups:
Doc NumberType
PMC 3194Aluminium Oxide Abrasive Powder, 27 micron
Suppliers:
ManufacturerRemarks
LOCAL
4TG15
1E1X8
Manufacturer Code:X222X
Supply Number:CoMat 10-058
Type:sp01
Supply Short Name:CoMat 10-058 PENETRATING OIL
Supply Name:CoMat 10-058 PENETRATING OIL
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:LOCAL
Tool Number:Pencil blaster
Tool Name:Pencil blaster
Manufacturer Code:LOCAL
Tool Number:Pin vise
Tool Name:Pin vise
Manufacturer Code:LOCAL
Tool Number:Reamers
Tool Name:Reamers
Manufacturer Code:LOCAL
Tool Number:Spring wire
Tool Name:Spring wire
Manufacturer Code:LOCAL
Tool Number:Ultrasonic cleaning equipment
Tool Name:Ultrasonic cleaning equipment
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment