TASK 72-44-20-300-005 HPT Stage 1 Vane - Replace The Covers Repair, Repair-005 (VRS3152)

DMC:V2500-A0-72-44-2000-00A-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 72-44-20-300-005 HPT Stage 1 Vane - Replace The Covers Repair, Repair-005 (VRS3152)

Effectivity

FIG/ITEM

PART NO.

01-250

2A0091CL21

01-250

2A2591CL21

01-251

2A0091CL22

01-251

2A2591CL22

01-252

2A0091CL23

01-252

2A2591CL23

01-253

2A0091CL24

01-253

2A2591CL24

01-254

2A0091CL25

01-254

2A2591CL25

01-255

2A0091CL26

01-255

2A2591CL26

01-256

2A0091CL27

01-256

2A2591CL27

01-257

2A0091CL28

01-257

2A2591CL28

01-258

2A0091CL29

01-258

2A2591CL29

01-259

2A0091CL30

01-259

2A2591CL30

01-260

2A0091CL31

01-260

2A2591CL31

01-261

2A0091CL32

01-261

2A2591CL32

01-262

2A0091CL33

01-262

2A2591CL33

01-263

2A0091CL34

01-263

2A2591CL34

01-264

2A0091CL35

01-264

2A2591CL35

01-265

2A0091CL36

01-265

2A2591CL36

01-266

2A0091CL37

01-266

2A2591CL37

01-267

2A0091CL38

01-267

2A2591CL38

01-268

2A0091CL39

01-268

2A2591CL39

01-269

2A0091CL40

01-269

2A2591CL40

01-270

2A0091CL41

01-270

2A2591CL41

01-271

2A0091CL42

01-271

2A2591CL42

01-272

2A0091CL43

01-272

2A2591CL43

01-273

2A0091CL44

01-273

2A2591CL44

01-274

2A0091CL45

01-274

2A2591CL45

01-275

2A0091CL46

01-275

2A2591CL46

01-276

2A0091CL47

01-276

2A2591CL47

01-277

2A0091CL48

01-277

2A2591CL48

01-278

2A0091CL48-5

01-279

2A0091CL49

01-279

2A2591CL49

01-280

2A0091CL49-5

01-284

2A2591CL50

01-286

2A2591CL51

Material of component

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

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 contact IAE Repair Development Group to determine if a qualification program can be initiated at their facility.

IAE - INTERNATIONAL AERO ENGINES AG
400 Main Street
East Hartford CT 06108
U.S.A.

ATTN: Manager Repair Development

Authorized Repair Vendors for Repair VRS3152 are listed below:

Pratt and Whitney Overhaul Repair Center
Airfoil Repair Technology
415 Washington Avenue
North Haven
CT 06473 USA

Chromalloy Research and Technology
Chromalloy American Corporation
Blaisdell Road
Orangeburg, NY 10962 USA

PWES - TULSA AIRFOIL REPAIR OPERATIONS
2201 E.L. Anderson Boulevard
Claremore, OK 74017
USA

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 qualifications 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

To identify the consumable materials refer to PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Airflow check equipmentLOCALAirflow check equipment
Electro-discharge metal removal (EDMR) equipmentLOCALElectro-discharge metal removal (EDMR) equipment
Portablegrinding equipmentLOCALPortable grinding equipment
Penetrant inspection equipmentLOCALPenetrant inspection equipment
Fusion welding equipmentLOCALFusion welding equipment

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-243 WELDING FILLER WIRELOCALCoMat 03-243
CoMat 03-287 WELDING FILLER WIRELOCALCoMat 03-287

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
Cover, HPT stage 12A0033AR
Cover2A0030AR
Cover2A0031AR
Cover2A0032AR

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-44-20-350-054-001 Remove the Covers from the Vane Assembly (EDMR Method)

      1. Remove the vane covers by the Electro-discharge metal removal (EDMR) method.

      1. Refer to Figure.

      2. Do the procedure given in the SPM TASK 70-32-03-320-501.

      3. The maximum material to be removed is 0.010 in. (0.254 mm).

      4. Make sure all the unwanted material is removed.

    2. SUBTASK 72-44-20-350-054-002 Remove the Covers from the Vane Assembly (Blend Method)

      1. Remove the vane covers by blending the welds.

      1. Refer to Figure.

      2. The maximum material to be removed is 0.010 in. (0.254 mm).

      3. Use the grinding equipment.

      4. Make sure all the unwanted material is removed.

    3. SUBTASK 72-44-20-350-054-003 Remove the Covers from the Vane Assembly (Grind Method)

      1. Remove the vane covers by grinding the welds.

      1. Refer to Figure.

      2. Do not grind below the minimum limits given in Figure.

      3. Use the grinding equipment.

      4. Make sure all the unwanted material is removed.

    4. SUBTASK 72-44-20-110-051 Clean the Vane Assembly

      1. Clean the vane assembly.

      1. Do the procedure given in TASK.

      2. TASK 72-44-20-100-001 (CLEANING-000).

    5. SUBTASK 72-44-20-310-051 Weld the Covers on the Vane Assembly

      1. Install the cover(s) as necessary for welding.

      1. Refer to Figure.

      2. The covers must be completely over the vane openings.

      3. No gaps permitted around the outer edges of the covers.

      4. Tack weld to hold the cover(s) in position for welding by the procedure given in the SPM TASK 70-31-13-310-501.

      2. Weld all around the cover(s).

      1. Refer to Figure.

      2. Do the procedure given in the SPM TASK 70-31-13-310-501.

      4. It is acceptable to see the tack welds.

    6. SUBTASK 72-44-20-220-083 Examine the Repair

      1. NOTE

        This SUBTASK is an alternate to Step.

        Visually inspect the repair.

      1. Damage that is 0.015 in. (0.381 mm) or less is permitted if the damage areas are not in a straight line.

      2. A maximum of six damaged areas that are 0.0313 in. (0.794 mm) are permitted in each joint if they are separated by a minimum of 0.125 in. (3.175 mm).

      3. Cracks in the weld or braze material of each joint that are 0.125 in. (3.175 mm) or less and separated by a minimum of 0.125 in. (3.175 mm) are acceptable.

      4. Cracks can go into the cast material as shown in Figure.

      5. On all other joints, cracks can go into the cast material 0.015 in. (0.381 mm) maximum.

    7. SUBTASK 72-44-20-230-052 Examine the Repair

      1. NOTE

        This SUBTASK is an alternate to Step.

        Fluorescent penetrant the welded areas.

      1. Refer to Figure.

      2. Do the procedure given in the SPM TASK 70-23-02-230-501.

      3. Use the crack limits given in TASK 72-44-20-200-000 (INSPECTION-000).

    8. SUBTASK 72-44-20-220-062 Examine the Vane Cluster Assembly by the Airflow Check

      1. Do an airflow check on the airfoil and platform cooling air holes.

      1. Refer to Figure.

      2. Do the procedure given in TASK 72-44-20-200-000 (INSPECTION-000).

    9. Figure: Stage 1 HPT vane cluster assembly cover replacement repair areas

    Sheet 1

    Legend
    Stage 1 HPT vane cluster assembly cover replacement repair areas

    Sheet 1

    Close

    Figure: Stage 1 HPT vane cluster assembly cover replacement repair areas

    Sheet 2

    Legend
    Stage 1 HPT vane cluster assembly cover replacement repair areas

    Sheet 2

    Close

    Figure: Stage 1 HPT vane cluster assembly cover removal by grinding

    Stage 1 HPT vane cluster assembly cover removal by grinding

    Figure: Stage 1 HPT vane cluster assembly visual inspection areas

    Stage 1 HPT vane cluster assembly visual inspection areas

    Figure: Stage 1 HPT vane outside diameter grind limits

    Sheet 1

    Legend
    Stage 1 HPT vane outside diameter grind limits

    Sheet 1

    Close

    Figure: Stage 1 HPT vane outside diameter grind limits

    Sheet 2

    Legend
    Stage 1 HPT vane outside diameter grind limits

    Sheet 2

    Close

Requirements After Job Completion

Follow-On Conditions

NONE
Link not Found
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 03-243
Type:sp01
Supply Short Name:CoMat 03-243 WELDING FILLER WIRE
Supply Name:CoMat 03-243 WELDING FILLER WIRE
Specification Groups:
Doc NumberType
HAYNES 188AMS 5801
Suppliers:
ManufacturerRemarks
LOCAL
IE508
0ZDB5
2R602
07098
36346
55596
57965
58401
80357
Manufacturer Code:LOCAL
Supply Number:CoMat 03-287
Type:sp01
Supply Short Name:CoMat 03-287 WELDING FILLER WIRE
Supply Name:CoMat 03-287 WELDING FILLER WIRE
Specification Groups:
Doc NumberType
INCONEL 625 AMS 5837 AMS 5837
Suppliers:
ManufacturerRemarks
LOCAL
2R602
55596
58401
Manufacturer Code:LOCAL
Tool Number:Airflow check equipment
Tool Name:Airflow check equipment
Manufacturer Code:LOCAL
Tool Number:Electro-discharge metal removal (EDMR) equipment
Tool Name:Electro-discharge metal removal (EDMR) equipment
Manufacturer Code:LOCAL
Tool Number:Fusion welding equipment
Tool Name:Fusion welding equipment
Manufacturer Code:LOCAL
Tool Number:Penetrant inspection equipment
Tool Name:Penetrant inspection equipment
Manufacturer Code:LOCAL
Tool Number:Portable grinding equipment
Tool Name:Portablegrinding equipment