TASK 72-44-20-200-001-B01 HPT Stage 1 Vane - Examine, Inspection-001

DMC:V2500-A0-72-44-2000-00B-310A-C|Issue No:004.00|Issue Date:2021-05-01

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 72-44-20-200-001-B01 HPT Stage 1 Vane - Examine, Inspection-001

Effectivity

FIG/ITEM

PART NO.

01-240

2A0561

01-240

2A2761

01-240

2A4201

01-240

2A5591

General

This TASK gives the procedure for the inspection of the stage 1 HPT vane assembly. For the other stage 1 HPT vane cluster assembly parts refer to TASK 72-44-20-200-000 (INSPECTION-000).

Fig/item numbers in parentheses in the procedure agree with those used in the IPC.

The policy that is necessary for inspection is given in the SPM TASK 70-20-00-200-501.

All the parts must be cleaned before any part is examined. Refer to the SPM TASK 70-10-00-100-501.

All parts must be visually examined for damage, corrosion and wear. Any defects that are not identified in the procedure must be referred to IAE.

A ** following repair reference in this inspection indicates that the repair is not yet published in the current revision of the manual and the part must be rejected. Contact IAE for additional information concerning FAA approved repair date.

The procedure for those parts which must have a crack test is given in SUBTASK 72-44-20-230-054. Do the test before the part is visually examined.

Do not discard any part until you are sure there are no repairs available. Refer to the instructions in Repair before a discarded part is used again or oversize parts are installed.

Parts which should be discarded can be held although no repair available. The repair of a discarded part could be shown to be necessary at a later date.

All parts must be examined to make sure that all the repairs have been completed satisfactorily.

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

References

Refer to the SPM for data on these items.

Definition of Damages, SPM TASK 70-02-02-350-501

Cleaning, SPM TASK 70-12-09-120-501

Air flow - Turbine Blades and Vanes, SPM TASK 70-72-01-720-501

Ultrasonic Clean all Metal (But not Magnesium), SPM TASK 70-13-01-100-501

Inspection of Parts, SPM TASK 70-20-00-200-501

NOTE

To identify the consumable materials refer to the PCI.

NOTE

Special tools are identified in the procedure by the tool primary number.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
OvenLOCALOven

(air furnace)

IAE 2P16407 Airflow test fixture0AM53IAE 2P164071
IAE 2P16401 Airflow test master (platform)0AM53IAE 2P164011
IAE 2P16402 Airflow test master (front)0AM53IAE 2P164021
IAE 2P16403 Airflow test master (rear)0AM53IAE 2P164031
IAE 2P16404 Airflow test insert (platform)0AM53IAE 2P164041
IAE 2P16405 Airflow test insert (front)0AM53IAE 2P164051
IAE 2P16406 Airflow test insert (rear)0AM53IAE 2P164061

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-029 MASKING TAPE (CLOTH BACKING)0AM53CoMat 02-029
CoMat 02-030 MASKING TAPE (CLOTH BACKING)IE479CoMat 02-030

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-44-20-230-054-002 Examine the Stage 1 HPT Vane Assembly (01-240) for Cracks

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

    2. Clean the part. Refer toTASK 72-44-20-100-000 (CLEANING-000).

    3. Do the test for cracks on the part that is given below. Use the applicable penetrant inspection procedure.

      PART IDENT

      TASK/SUBTASK

      Stage 1 HPT vane assembly

      (Spray)

      4. Examine the vane assembly airfoil surfaces (concave and convex sides) for axial and radial cracks, Figure.

        1. NOTE

          Example of a closed loop crack is shown at location 1 and a radial crack at location 2.

          Axial cracks that go through radial cracks when no closed loops are made or material lift-up occurs at location 3

        1. Accept

        2. Radial cracks not more than 1.200 in. (30.48 mm) in length. A radial crack must not go into a different radial crack.

        1. Accept

        3. NOTE

          Example of axial cracks are shown at locations 4 and 5.

          Any amount of axial cracks not more than 1.200 in. (30.48 mm) in length between the cooling air holes at location 3.

        1. Accept

        4. Other than Step, Step and Step

        1. Repair, VRS3034 TASK 72-44-20-300-024 (REPAIR-024) or Repair, VRS3638 TASK 72-44-20-300-038 (REPAIR-038)

      5. Examine the vane assembly trailing edge convex sides for cracks. Cracks are only permitted at locations 1 and 2, Figure.

        1. Cracks that extend in the convex fillet radii from the trailing edge to the rear cooling air holes or 0.500 in. (12.7 mm) maximum from the trailing edge fillet. The cracks must be tight and show no sign of burns.

        1. Accept

        2. Other than Step.

        1. Repair, VRS3034 TASK 72-44-20-300-024 (REPAIR-024), or Repair, VRS3638 TASK 72-44-20-300-038 (REPAIR-038, PAGE-901).

      6. Examine the vane assembly leading edge for cracks at location 2, Figure.

        1. Cracks on vane if each crack extends between two adjacent cooling air holes, no more than one crack on each hole and no closed loop cracks are made.

        1. Accept

        2. Other than Step.

        1. Repair, VRS3034 TASK 72-44-20-300-024 (REPAIR-024), or Repair, VRS3638 TASK 72-44-20-300-038 (REPAIR-038).

      7. Examine the vane assembly leading edge platform fillet area at location 1, Figure.

        1. Cracks on vane not more than 0.250 in. (6.37 mm) in length at the inner and outer platform fillets when the cracks do not go across each other, make a closed loop crack or run along the fillet parallel to the platform.

        1. Accept

        2. Other than Step.

        1. Repair, VRS3034 TASK 72-44-20-300-024 (REPAIR-024) or, Repair, VRS3638 TASK 72-44-20-300-038 (REPAIR-038)

      8. Examine the vane assembly inner and outer platforms for cracks, Figure.

        1. No cracks at locations 1, 3 and 4.

        1. Accept

        2. NOTE

          Example of a crack is shown at location 2.

          Cracks on the vane assembly when the cracks start at the feather seal slot and extends on to the platform a maximum of 0.150 in. (3.81 mm) in length. The cracks must not go across each other, make a close loop crack and be tight with no sign of burn.

        1. Accept

        3. Other than Stepor Step.

        1. Repair, VRS3034 TASK 72-44-20-300-024 (REPAIR-024) or, Repair, VRS3638 TASK 72-44-20-300-038 (REPAIR-038).

      9. Examine the vane assembly insert and impingement covers for cracks at locations 1, 2, 3 and 4, Figure.

        1. Cracks.

          1. Cracks

          1. Repair, VRS3541 TASK 72-44-20-300-022 (REPAIR-022) or, Repair, VRS3610 TASK 72-44-20-300-036 (REPAIR-036).

          2. Cracks in the outer diameter platform insert weld if the cracks extend into the insert less than 0.200 in. (5.08 mm).

          1. Accept

          3. Other than Step and Step.

          1. Repair, VRS3541 TASK 72-44-20-300-022 (REPAIR-022) or, Repair, VRS3610 TASK 72-44-20-300-036 (REPAIR-036)

      10. Examine the vane assembly for cracks in the feather seal slot plug welds at locations 1, 2 and 3, Figure.

        1. Cracks.

          1. Any amount when the cracks do not go out of the weld and make no closed loop cracks.

          1. Accept

          2. Other than Step.

          1. Repair, VRS3034 TASK 72-44-20-300-024 (REPAIR-024) or, Repair, VRS3638 TASK 72-44-20-300-038 (REPAIR-038).

    2. SUBTASK 72-44-20-220-072 Examine the Stage 1 HPT Vane Assembly (01-240) Airfoils and Platforms

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

      2. Examine the vane assembly at locations 3, 7 and 11 Figure. for burn-through or material that is not there on the airfoil and platforms.

        1. Burn-through and material that is not there.

        1. Reject

      3. Examine the vane assembly for chipped coating on the airfoil Figure, Figure and Figure.

        1. Chipped coating or coating that is not there around the cooling holes to the limits and areas specified in Figure, Figure and Figure.

        1. Accept

        2. NOTE

          Metallic coating must be on vane but minimum thickness is not necessary.

          Part or all of coating that is not there but there is undercoating on the coated areas of the vanes that you can see visually. Burns, erosion and cracks are within the applicable limits.

        1. Accept

        3. Other than Step or Step.

        1. Repair, VRS3164 TASK 72-44-20-300-015 (REPAIR-015) or Repair, VRS3607 TASK 72-44-20-300-037 (REPAIR-037)**.

      4. Examine the vane assembly at locations 4, 10 and 11 Figure.or burns and erosion on the airfoil, leading and trailing edges.

        1. Burns and erosion.

          1. Base metal does not show.

          1. Accept

          2. Other than Step.

          1. Repair, VRS3154 TASK 72-44-20-300-011 (REPAIR-011).

      5. Examine the vane assembly at locations 3 and 7 Figure for burns and erosion on the inner and outer platforms.

        1. Burns and erosion.

        1. Repair, VRS3154 TASK 72-44-20-300-011 (REPAIR-011).

      6. Examine the vane assembly for dents and nicks on the airfoil, platforms, leading and trailing edges Figure.

        1. Nicks at locations 3, 4, 7, 10 and 11.

        1. Repair, VRS3154 TASK 72-44-20-300-011 (REPAIR-011).

        2. Dents

          1. Dents with a rounded bottom up to 0.010 in. (0.254 mm) in depth and no base metal is shown at locations 4 and 10. The dent must not block a cooling air hole by more than 50 percent.

          1. Accept

          2. Other than Step.

          1. Repair, VRS3154 TASK 72-44-20-300-011 (REPAIR-011).

    3. SUBTASK 72-44-20-220-073 Examine the Stage 1 HPT Vane Assembly (01-240) Airfoil and Platform Cooling Air Holes/Slots for Plugging

    1. Refer to Figure.

      2. NOTE

        Repair VRS3498 is a vendor repair only to unplug holes/slots.

        Examine the vane assembly airfoil at location 8 (each side, all around), cooling air holes and the trailing edge at location 1 cooling air slots for plugging.

        1. Plugging

        1. Repair, VRS3145 TASK 72-44-20-300-013 (REPAIR-013) or, Repair, VRS3606 TASK 72-44-20-300-031 (REPAIR-031) and Repair, VRS3498 TASK 72-44-20-300-021 (REPAIR-021) or, Repair, VRS3609 TASK 72-44-20-300-032 (REPAIR-032).

          NOTE

          Repair VRS3498 is a vendor repair only to unplug holes/slots.

      3. Examine the vane assembly platforms cooling air holes for plugging at locations 6 and 7. Do not examine the holes at locations 2, 3, 4 and 5.

        1. Plugging

          1. Each hole must be a minimum of 0.013 in. (0.33 mm) in diameter.

          1. Accept

          2. Other than Step.

          1. Repair, VRS3145 TASK 72-44-20-300-013 (REPAIR-013) or, Repair, VRS3606 TASK 72-44-20-300-031 (REPAIR-031) and Repair, VRS3498 TASK 72-44-20-300-021 (REPAIR-021) or, Repair, VRS3609 TASK 72-44-20-300-032 (REPAIR-032).

    4. SUBTASK 72-44-20-220-074 Examine the Stage 1 HPT Vane Assembly (01-240) for Unwanted Material and Plugging on the Front and Rear Inserts and Platform Impingement Covers

    1. Refer to Figure.

      2. Examine the vane assembly for unwanted material and plugged cooling air holes on all the inserts and impingement covers at locations 1, 2, 3 and 4.

        1. Plugging and unwanted material.

        1. Repair, VRS3541 TASK 72-44-20-300-022 (REPAIR-022) or, Repair, VRS3610 TASK 72-44-20-300-036 (REPAIR-036).

    5. SUBTASK 72-44-20-220-075 Examine the Stage 1 HPT Vane Assembly (01-240) for Chipped Coating on the Platforms

    1. Refer to Figure.

      2. Examine the vane assembly platforms for chipped coating.

        1. Chipped coating in areas A, B and C on the inner and outer platforms.

        1. Accept

        2. Other than Step.

        1. Repair, VRS3164 TASK 72-44-20-300-015 (REPAIR-015) or, Repair, VRS3607 TASK 72-44-20-300-037 (REPAIR-037)** and VRS3034 TASK 72-44-20-300-024 (REPAIR-024) or, Repair, VRS3638 TASK 72-44-20-300-038 (REPAIR-038).

    6. SUBTASK 72-44-20-220-076 Examine the Stage 1 HPT Vane Assembly (01-240) for Local Damage on the Trailing Edge

    1. Refer to Figure.

      2. Examine the vane assembly at location 5 for local damage on the trailing edge.

        1. Damage

          1. Bowed for three slots 0.300 in. (7.62 mm) in length at one position at location 4 and up to 0.020 in. (0.508 mm) out of plane at location 3 in a local area.

          1. Accept

          2. Other than Step.

          1. Reject

    7. SUBTASK 72-44-20-220-077 Examine the Stage 1 HPT Vane Assembly (01-240) for Wear and Chipped Plasma Spray Coat on the Rear Foot

    1. Refer to Figure.

      2. Examine the vane assembly at location 2 for wear and chipped plasma spray coat.

        1. Wear

          1. Base metal does not show.

          1. Accept

          2. Other than Step.

          1. Repair, VRS3158 TASK 72-44-20-300-018 (REPAIR-018) or, Repair, VRS3592 TASK 72-44-20-300-034 (REPAIR-034) or, Repair, VRS3608 TASK 72-44-20-300-035 (REPAIR-035).

        2. Chipped coat.

        1. Reject

    8. SUBTASK 72-44-20-220-078 Examine the Stage 1 HPT Vane Assembly (01-240) for the Outer Diameter Rear Foot Thickness

    1. Refer to Figure.

      2. Examine the vane assembly at location 1 for thickness of the outer diameter rear foot.

        1. Thickness

          1. If the dimension is between 0.200 in. and 0.206 in. (5.080 mm and 5.232 mm) for PN 2A0561 or between 0.170 in. and 0.179 in. (4.318 mm and 4.547 mm) for PNs 2A2761, 2A4201, and 2A5591.

          1. Accept.

          2. If the dimension is less than 0.170 in. (4.318 mm) for PNs 2A2761, 2A4201, and 2A5591, then measure Dimension 6. If the Dimension 6 is more than 0.585 in. (14.859 mm).

          1. Accept.

          3. Other than Step and Step.

          1. Repair, VRS3158 TASK 72-44-20-300-018 (REPAIR-018) or, Repair VRS3592 TASK 72-44-20-300-034 (REPAIR-034) or, Repair, VRS3608 TASK 72-44-20-300-035 (REPAIR-035).

    9. SUBTASK 72-44-20-220-079 Examine the Stage 1 HPT Vane Assembly (01-240) for the Axial Dimension between the Inner Diameter Platform Leading Edge and the Front Edge of the Inner Diameter Rear Foot

    1. Refer to Figure.

      2. Examine the vane assembly at location 2004 for axial dimension.

        1. Axial dimension.

          1. If the dimension is between 0.837 and 0.857 in. (21.26 and 21.77 mm).

          1. Accept

          2. Other than Step.

          1. Repair, VRS3034 TASK 72-44-20-300-024 (REPAIR-024).

    10. SUBTASK 72-44-20-220-080 Examine the Stage 1 HPT Vane Assembly (01-240) for the Wear on the Platform Front Faces and Two Sides on the Rear Inner Diameter Flange Surfaces

    1. Refer to Figure.

      2. Examine the vane assembly at locations 1 and 2 and two sides at location 3 for wear on the contact surface.

        1. Wear

          1. Fretting and rub up to 0.015 in. (0.381 mm) in depth.

          1. Accept

          2. Other than Step.

          1. Reject

    11. SUBTASK 72-44-20-220-081 Examine the Stage 1 HPT Vane Assembly (01-240) for Burned Areas and Unwanted Material on all the Feather Seal Slots

    1. Refer to Figure.

      2. Examine the vane assembly at locations 4 and 5 (two ends) for burned areas and unwanted material in the feather seal slots.

        1. Burned areas and unwanted material.

        1. Reject

    12. SUBTASK 72-44-20-220-092 Examine the Stage 1 HPT Vane Assembly (01-240) for Wear on the Forward Outer Mounting Lug Anti-Rotation Slot

    1. Refer to Figure.

      2. Examine the vane at location 6 for wear on the anti-rotation slot.

        1. Wear.

          1. If the slot is a maximum of 0.372 in. (9.449 mm).

          1. Accept

          2. If the slot is a maximum of 0.422 in. (10.719 mm).

          1. Repair, VRS3562 TASK 72-44-20-300-025 (REPAIR-025) or Repair, VRS3612 TASK 72-44-20-300-029 (REPAIR-029).

            NOTE

            Wear can be on one or both sides of the mounting lug anti-rotation slot.

    13. SUBTASK 72-44-20-280-054 Examine the Stage 1 HPT Vane Assembly (01-240) by the Airflow Check

    1. NOTE

      Do all the inspections and repairs on the vane cluster before you do the airflow check.

      Refer to Figure and Figure.

    2. Do the airflow procedure for the stage 1 HPT vane assembly by the procedures given in the SPM TASK 70-72-01-720-501.

    3. Refer to Figure and Figure.or the specific airflow check tools and limits.

    14. Figure: Stage 1 HPT Vane Assembly Axial and Radial Cracks Inspection Locations

    Stage 1 HPT Vane Assembly Axial and Radial Cracks Inspection Locations

    Figure: Stage 1 HPT Vane Assembly Trailing Edge Cracks (Convex Side) Inspection Locations

    Stage 1 HPT Vane Assembly Trailing Edge Cracks (Convex Side) Inspection Locations

    Figure: Stage 1 HPT Vane Assembly Leading Edge Cracks Inspection Locations

    Stage 1 HPT Vane Assembly Leading Edge Cracks Inspection Locations

    Figure: Stage 1 HPT Vane Assembly Inner and Outer Platform Cracks Inspection Location

    Stage 1 HPT Vane Assembly Inner and Outer Platform Cracks Inspection Location

    Figure: Stage 1 HPT Vane Assembly Platforms, Inserts and Impingement Cover Cracks Inspection Location

    Stage 1 HPT Vane Assembly Platforms, Inserts and Impingement Cover Cracks Inspection Location

    Figure: Stage 1 HPT Vane Assembly Inspection Locations

    Stage 1 HPT Vane Assembly Inspection Locations

    Figure: Stage 1 HPT Vane Assembly Coating Inspection

    Sheet 1

    Legend
    Stage 1 HPT Vane Assembly Coating Inspection

    Sheet 1

    Close

    Figure: Stage 1 HPT Vane Assembly Coating Inspection

    Sheet 2

    Legend
    Stage 1 HPT Vane Assembly Coating Inspection

    Sheet 2

    Close

    Figure: Stage 1 HPT Vane Assembly Coating Inspection

    Sheet 3

    Legend
    Stage 1 HPT Vane Assembly Coating Inspection

    Sheet 3

    Close

    Figure: Stage 1 HPT Vane Assembly Cooling Air Holes Inspection Locations

    Stage 1 HPT Vane Assembly Cooling Air Holes Inspection Locations

    Figure: Stage 1 HPT Vane Assembly Platform Coating Inspection Locations

    Stage 1 HPT Vane Assembly Platform Coating Inspection Locations

    Figure: Stage 1 HPT Vane Assembly Inspection Locations

    Stage 1 HPT Vane Assembly Inspection Locations

    Figure: Stage 1 HPT Vane Assembly Inspection Locations

    Stage 1 HPT Vane Assembly Inspection Locations

    Figure: Stage 1 HPT Vane Assembly Airflow Limits Table

    Stage 1 HPT Vane Assembly Airflow Limits Table

    Figure: Stage 1 HPT Vane Assembly Airflow Check Tools

    Stage 1 HPT Vane Assembly Airflow Check Tools

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added and revised procedural steps, figure. (20VC328)

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:IE479
Enterprise Name:DELETED,SEE CAGE CODE 4L0S0
BU Name:DELETED,SEE CAGE CODE 4L0S0
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:0AM53
Supply Number:CoMat 02-029
Type:sp01
Supply Short Name:CoMat 02-029 MASKING TAPE (CLOTH BACKING)
Supply Name:CoMat 02-029 MASKING TAPE (CLOTH BACKING)
Suppliers:
ManufacturerRemarks
0AM53
Manufacturer Code:IE479
Supply Number:CoMat 02-030
Type:sp01
Supply Short Name:CoMat 02-030 MASKING TAPE (CLOTH BACKING)
Supply Name:CoMat 02-030 MASKING TAPE (CLOTH BACKING)
Specification Groups:
Doc NumberType
PMC 4001SHURTAPE PC-622
Suppliers:
ManufacturerRemarks
IE479
Manufacturer Code:0AM53
Tool Number:IAE 2P16401
Tool Name:IAE 2P16401 Airflow test master (platform)
Manufacturer Code:0AM53
Tool Number:IAE 2P16402
Tool Name:IAE 2P16402 Airflow test master (front)
Manufacturer Code:0AM53
Tool Number:IAE 2P16403
Tool Name:IAE 2P16403 Airflow test master (rear)
Manufacturer Code:0AM53
Tool Number:IAE 2P16404
Tool Name:IAE 2P16404 Airflow test insert (platform)
Manufacturer Code:0AM53
Tool Number:IAE 2P16405
Tool Name:IAE 2P16405 Airflow test insert (front)
Manufacturer Code:0AM53
Tool Number:IAE 2P16406
Tool Name:IAE 2P16406 Airflow test insert (rear)
Manufacturer Code:0AM53
Tool Number:IAE 2P16407
Tool Name:IAE 2P16407 Airflow test fixture
Manufacturer Code:LOCAL
Tool Number:Oven
Tool Name:Oven