TASK 72-45-11-200-003 HPT Stage 1 Hub - Eddy Current Inspect The Blade Slot Pressure Face (Dimensional), Inspection-003

DMC:V2500-A0-72-45-1100-00A-353A-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 72-45-11-200-003 HPT Stage 1 Hub - Eddy Current Inspect The Blade Slot Pressure Face (Dimensional), Inspection-003

Effectivity

FIG/ITEM PART NO.

01-010

2A1121

01-010

2A2021

01-010

2A2221

01-011

2A1101

01-011

2A1801

01-011

2A1901

01-011

2A2201

01-011

2A2801

01-011

2A5001

General

This TASK gives the procedure for the inspection of the stage 1 turbine hub blade slot pressure face contact surfaces.

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 SPM TASK 70-20-00-200-501.

All the parts must be cleaned before you examine the parts. Refer to the SPM TASK 70-10-00-100-501.

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

References

Refer to the SPM for data on these items.

Record and Control of the Lives of Parts, SPM TASK 70-05-00-220-501

Marking of parts, SPM TASK 70-09-00-400-501

Inspection of Parts, SPM TASK 70-20-01-200-501

Wipe with Solvent, SPM TASK 70-11-26-300-503

UniWest US-454A Eddy Current Instrument User Manual.

Qualifications

Only qualified operators specially designated, trained and approved can do this inspection. Inspectors must be fully trained NDI (Non-Destructive Inspection) specialists who can examine the indications correctly and make decisions on whether parts are serviceable, or must be rejected. Qualification of personnel must obey with one of the standards that follow:

  1. ATA 105

  2. MIL-STD-410

  3. NAS 410/DIN EN4179

  4. SNT-TC-1A

Operators must be able to calibrate the equipment, do the inspection and interpret the results before they accept or reject a part.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
IAE 2P16593 UniWest US-454A digital eddy current instrument0AM53IAE 2P16593
IAE 2P16592 US-MPX-32 Multiplexer0AM53IAE 2P16592
IAE 2P16594 Dell Optiplex desktop computer system0AM53IAE 2P16594
IAE 2P16585 Dimensional eddy current probe0AM53IAE 2P16585
IAE 2P16595 Pneumatic Controller, UniWest PN 997900AM53IAE 2P16595
IAE 2P16588 Plastic Shims0AM53IAE 2P16588
IAE 2P16586 Calibration standard0AM53IAE 2P16586

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 05-125 ABRASIVE PAD, SILICON CARBIDE, ULTRA-FINELOCALCoMat 05-125
CoMat 05-126 ABRASIVE PAD, ALUMINUM OXIDE, VERY FINELOCALCoMat 05-126

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-45-11-350-070 Prepare the Stage 1 Turbine Hub

      NOTE

      It is recommended that this inspection be conducted in a temperature controlled environment, with temperature ranging between 65 and 85 degrees Fahrenheit (18.3 and 29.4 degrees Celsius). Failure will cause unwanted effect in the inspection results due to the necessary accuracy of the measurements and inspection equipment.

      1. Make sure the part is disassembled

      1. Refer to TASK 72-45-10-040-001-A00 (DISASSEMBLY-001, CONFIG-001) or TASK 72-45-10-040-001-C00 (DISASSEMBLY-001, CONFIG-003)

      2. Make sure the part is fully cleaned

      1. Refer to TASK 72-45-11-100-001 (CLEANING-001)

      2. Visually examine the blade slots. Make sure that there is no significant unwanted material.

      3. Locate the serial number of the Stage 1 turbine hub.

      3. NOTE

        You can find the serial number on one of the front or rear hub blade slot faces.

        Use a temporary marker to mark the blade slot directly to the right of the serial number on the front side of the hub blade slot face as Blade Slot Number 1. Continue in a counterclockwise direction and mark each blade slot that remains

      1. Refer to the SPM TASK 70-09-00-400-501

      2. Make sure the hub has the forward face laying in the upward facing direction.

    2. SUBTASK 72-45-11-250-001 Prepare the Eddy Current Tools

    1. NOTE

      Warm up is recommended due to the accuracy of measurement needed during this inspection.

      Turn on the power for the IAE 2P16593 UniWest US-454A digital eddy current instrument US-454A eddy current instrument, IAE 2P16592 US-MPX-32 Multiplexer multiplexer and IAE 2P16594 Dell Optiplex desktop computer system computer. Let the instrument warm up for a minimum of ten minutes.

    3. SUBTASK 72-45-11-250-002 Assemble the Eddy Current Equipment

      CAUTION

      IT IS NOT PERMITTED TO BE MORE THAN 80 PSI (551,6 KPA) WHEN YOU ARE ACTUATING THE PROBE. TOO MUCH PRESSURE CAN CAUSE DAMAGE TO THE PROBE, DAMAGE TO THE PART OR INSPECTION RESULTS WILL NOT BE ACCURATE.

    1. Refer to Figure, Fig-72-45-11-990-032, Figure, Figure, Figure, Figure and Figure.

      2. Connect the Ethernet cable from the computer to the IAE 2P16593 UniWest US-454A digital eddy current instrument US-454A eddy current instrument Ethernet input

      1. Refer to Figure, Index 1

      3. Connect the IAE 2P16592 US-MPX-32 Multiplexer Multiplexer to the IAE 2P16593 UniWest US-454A digital eddy current instrument US-454A AUX I/O input with Cable 71141

      1. Refer to Figure, Index 2 and Figure, Index 3

      4. NOTE

        The four cable connectors from the probe are labeled with the correct sensor input numbers (1-4).

        Connect the IAE 2P16585 Dimensional eddy current probe to the multiplexer.

        1. Plug the proper connector into the multiplexer input

        1. Refer to Figure, Index 4

      5. Connect the Probe input to the multiplexer probe input with the 71142 cable.

      1. Refer to Figure, Index 5 and Figure, Index 6

    6. Make sure that the actuator switch is set to the "UNLOCKED" position.

    7. Connect the air tube from the IAE 2P16595 Pneumatic Controller, UniWest PN 99790 to the input on the probe.

    8. Connect the air supply to a shop air input.

      9. Use the dial regulator to set the pressure on the gauge display to 80 psi (551.6 kPa). Pull the knob outwards to adjust

      1. Refer to Figure

    4. SUBTASK 72-45-11-250-003 Prepare the Eddy Current Software

    1. Refer to Figure.

    2. NOTE

      Each IAE 2P16585 Dimensional eddy current probe has a unique software CD. You must use the correct CD with the proper probe during inspection. If you do not use this unique CD then inspection results will not be accurate.

      Load the applicable probe software CD into the disk drive for the correct Serial Number probe.

      3. Open the program named "ECI Dimensional 2012".

        1. The main menu will appear

        1. Refer to Figure

    5. SUBTASK 72-45-11-250-004 Pre-Inspection Calibration of the Eddy Current Equipment

      NOTE

      1. Display screen will show inspection options for the number of blade slots that will be examined. Refer to Figure.

      2. Only 16 of the 64 blade slots on the hub will be examined.

    1. NOTE

      "File Setup" option on the display screen gives the directory information of different result files.

      2. On the display screen, pick the "Probe Setup" option on the display screen

      1. Refer to Figure

    3. Make sure the correct probe model number and serial number are shown in the top two drop down boxes.

    4. On the display screen, pick "Exit" to return to the main menu.

      5. On the display screen, pick "Part setup" from the main menu.

      1. Refer to Figure.

      6. Pick the correct part number from the current part number drop down box.

      1. Refer to Figure

      2. On the display screen, pick "Exit" option to return to the main menu.

      7. On the display screen, pick the "Inspect" option from the main menu.

      1. Refer to Figure.

    8. NOTE

      Two IAE 2P16588 Plastic Shims that you use during the pre-inspection and post-inspection calibration of the IAE 2P16585 Dimensional eddy current probe surfaces. The shims are made in matched pairs. Refer to Figure.
      You can use shims for a total of one full inspection and then discard them. Shim thickness values and serial numbers are printed on a sticker attached to the top of each shim surface.

      Input the inspector ID, the serial number of the inspected part, the number of cycles on the part, and the thickness of the two IAE 2P16588 Plastic Shims that you use.

      NOTE

      Display screen will show inspection options for the number of blade slots that will be examined. Refer to Figure.
      Only 16 of the 64 blade slots on the hub will be examined.

      9. On the display screen, pick the "Next >" option

      1. Refer to Figure.

    10. On the display screen, pick "Partial or re-inspection".

    11. Pick the following blade slots. Refer to Figure.

      Blade Slot No. 1, 5, 9, 13, 17, 21, 25, 29, 33, 37, 41, 45, 49, 53, 57, 61.

    12. Make sure the IAE 2P16595 Pneumatic Controller, UniWest PN 99790 is initially switched to the "UNLOCKED" position.

      NOTE

      1. The blade slots of the IAE 2P16586 Calibration standard calibration standard are numbered corresponding to the probe inspection Surface to be calibrated.

      2. You can use Blade slot No. 1 to calibrate the inboard pressure face group 1 surfaces (Surfaces 1 and 5).

      3. You can use Blade slot No. 2 to calibrate the second pressure face group 2 surfaces (Surfaces 2 and 6).

      4. You can use Blade slot No. 3 to calibrate the third pressure face group 3 surfaces (Surfaces 3 and 7).

      5. You can use Blade slot No. 4 to calibrate the outboard pressure face group 4 surfaces (Surfaces 4 and 8).

    13. Make sure the probe can be easily inserted into the blade slots of the IAE 2P16586 Calibration standard calibration standard. Refer to Figure.

      14. Insert the probe into the blade slot No. 1 of the calibration standard. Refer to Figure.

        NOTE

        This will actuate the pneumatic cylinder and lock the probe into position in the calibration blade slot.

      1. Flip the actuator switch on the pneumatic controller to the "LOCKED" position.

      2. On the display screen, pick the "Start" option. Refer to Figure.

        NOTE

        Data will be sent from the probe to the eddy current instrument to null the group 1 sensors.

      3. On the display screen, pick the "Acquire" option. Refer to Figure.

      4. After the group 1 sensors are nulled, flip the actuator switch on the pneumatic controller to the "UNLOCKED" position.

      5. Pick the correct matched pair of the IAE 2P16588 Plastic Shims.

        NOTE

        The plastic shims must be inserted so that the shims are above and below the eddy current probe.

      6. Insert the plastic shims between the calibration standard pressure face, and Surface No. 1 and Surface No. 5 on the probe. Refer to Figure and Figure.

      15. Flip the actuator switch on the pneumatic controller to the "LOCKED" position, to lock probe into the position in calibration Blade Slot No. 1.

        NOTE

        1. Group 1 sensors will be calibrated. Gain and phase values will be set automatically on the US-454A instrument for each sensor.

        2. If an error is made during calibration of Surface, picking the "Repeat" option from the display screen will return the inspector to the previous steps.

        3. The software will request a secondary null of the group 1 sensors.

      1. On the display screen, pick the "Acquire" option. Refer to Figure.

      2. Flip the actuator switch on the pneumatic controller to the "UNLOCKED" position.

      16. Do a Null of the probe again.

      1. Remove the plastic shims from the Surfaces of the calibration standard.

      2. Keep the plastic shims that you use for pre-inspection calibration and that you can use during post-inspection calibration.

      3. CAUTION

        YOU MUST KEEP THE PLASTIC SHIMS THAT YOU USE DURING PRE-INSPECTION CALIBRATION OF THE PROBE. IF YOU DO NOT DO THIS IT WILL CAUSE NOT ACCURATE INSPECTION RESULTS.

        Flip the actuator switch on the pneumatic controller to the "LOCKED" position.

      4. On the display screen, pick the "Acquire" action.

      5. After null is done, flip the actuator switch on the pneumatic controller to the "UNLOCKED" position.

        NOTE

        You can use this slot to calibrate the group 2 sensors.

      17. Insert the probe in Blade Slot No. 2 of the calibration standard. Refer to Figure.

      1. Do steps 8.F. thru 8.J. again for calibration of the group 2 sensors.

        NOTE

        This slot will be used to calibrate the group 3 sensors.

      18. Insert the probe in the Blade Slot No. 3 of the calibration standard. Refer to Figure.

      1. Do steps 8.F. thru 8.J. again for calibration of the group 3 sensors.

        NOTE

        You can use this blade slot to calibrate the group 4 sensors.

      19. Insert the probe in the Blade Slot No. 4 of the calibration standard. Refer to Figure.

      1. Do steps 8.F. thru 8.J. again for calibration of the group 4 sensors.

    20. On the display screen, pick the "Finish" followed by the "Next >" option.

    6. SUBTASK 72-45-11-250-005 Examine the Stage 1 Turbine Hub Blade Slot

    1. NOTE

      Each blade slot that is examined will take approximately two minutes to collect the necessary data.

      Refer to Figure, Figure, Figure and Figure.

    2. Insert the IAE 2P16585 Dimensional eddy current probe probe into Blade Slot No. 1. Refer to Figure.

    3. Flip the switch on the IAE 2P16595 Pneumatic Controller, UniWest PN 99790 Pneumatic Controller to the "LOCKED" position to actuate the probe. Refer to Figure.

    4. On the display screen, pick the "Start" option. Refer to Figure.

      NOTE

      Group 1 will remain in the group box during the inspection.

    5. On the display screen, pick the "Acquire" option. Refer to Figure.

    6. After data collection is done, flip the switch on the pneuamtic controller to the "UNLOCKED" position.

    7. Remove the probe from the slot.

    8. Do steps 11.A. thru 11.F. again for Blade Slot No. 5, 9, 13, 17, 21, 25, 29, 33, 37, 41, 45, 49, 53, 57 and 61.

    9. Pick "Finish" followed by the "Next >" options.

    7. SUBTASK 72-45-11-250-006 Post-Inspection Calibration of the Eddy Current Equipment

    1. Refer to Figure and Figure.

    2. Insert the IAE 2P16585 Dimensional eddy current probe into the blade slot No. 1 on the IAE 2P16586 Calibration standard calibration standard.

    3. Insert the IAE 2P16588 Plastic Shims that you use during pre-inspection calibration between the calibration standard pressure face, and group 1 sensors on the probe.

    4. Flip the actuator switch on the IAE 2P16595 Pneumatic Controller, UniWest PN 99790 to the "LOCKED" position.

    5. On the display screen, pick the "Start" option. Refer to Figure.

      NOTE

      If post calibration is out of tolerance an error message will be displayed on the screen. Make sure that you use the correct blade slot for the correct probe surface, the shims are in position and not damaged, or that there is no dirt or debris on the face of the probe or calibration standard. The operator will have three attempts to register an acceptable post calibration of each probe Surface. After three attempts, if post calibration is not done successfully, the software will return the operator to the main menu and the inspection must be done again.

    6. On the display screen, pick the "Acquire" action. Refer to Figure.

      NOTE

      A printable version of the inspection report is located in the directory folder "C:/Pratt and Whitney/".

    7. After all four blade slots passed the post-inspection calibration successfully, pick "Finish", followed by the "Next" option.

    8. SUBTASK 72-45-11-250-007 Examine the Stage 1 Turbine Hub Blade Slot Inspection Report for Failed Blade Slots

      NOTE

      A report table will be generated that shows inspection results. All Acceptance/Rejection Criteria is internally programmed in the software.

    1. Refer to Figure and Figure.

      2. Review inspection report for "Failed" blade slots.

        1. Make a temporary mark on all the blade slots that are defective

        1. Refer to the SPM TASK 70-09-01-440-501

    9. SUBTASK 72-45-11-250-008 Examine the Defective Stage 1 Turbine Hub Blade Slots for False Positive

    1. NOTE

      You can examine the rejected blade slots only one more time after initial inspection.

      2. For blade slots that fail inspection:

        1. Scrub the blade slots

        1. Use CoMat 05-126 ABRASIVE PAD, ALUMINUM OXIDE, VERY FINE or CoMats 05-125 ultra fine scrub pads. Refer to the SPM TASK 70-10-00-100-501.

        2. Wipe the blade slots

        1. Refer to the SPM TASK 70-11-26-300-503.

          NOTE

          You can use a new pair of IAE 2P16588 Plastic Shims during the inspection again on the defective blade slots.

    3. Examine the defective blade slots by steps 10 thru 13.

    4. If you find one or more blade slots are defective during inspection again, reject the Stage 1 Turbine Hub.

    10. Figure: Inspection Equipment

    Inspection Equipment

    Figure: IAE 2P16585 Eddy Current Probe

    IAE 2P16585 Eddy Current Probe

    Figure: IAE 2P16586 Calibration Standard

    IAE 2P16586 Calibration Standard

    Figure: IAE 2P16593 US-454A Connections to IAE 2P16594 Computer and IAE 2P16592 Multiplexer

    IAE 2P16593 US-454A Connections to IAE 2P16594 Computer and IAE 2P16592 Multiplexer

    Figure: IAE 2P16592 Multiplexer Connection to IAE 2P16593 US-454A

    IAE 2P16592 Multiplexer Connection to IAE 2P16593 US-454A

    Figure: IAE 2P16585 Probe Connections and IAE 2P16593 US-454A Connections to IAE 2P16592 Multiplexer

    IAE 2P16585 Probe Connections and IAE 2P16593 US-454A Connections to IAE 2P16592 Multiplexer

    Figure: IAE 2P16593 PUS-454A Connection to IAE 2P16592 Multiplexer

    IAE 2P16593 PUS-454A Connection to IAE 2P16592 Multiplexer

    Figure: IAE 2P16595 Pneumatic Controller Set to 80 psi (551,6 kPa) and in the "UNLOCKED" Position

    IAE 2P16595 Pneumatic Controller Set to 80 psi (551,6 kPa) and in the "UNLOCKED" Position

    Figure: Main Display Screen for Inspection Software

    Main Display Screen for Inspection Software

    Figure: Probe Setup Window

    Probe Setup Window

    Figure: Part Setup Window

    Part Setup Window

    Figure: Hub Inspection Information Window

    Hub Inspection Information Window

    Figure: Blade Slots Selected to be Examined

    Blade Slots Selected to be Examined

    Figure: Group Numbers Assigned for Each Probe

    Group Numbers Assigned for Each Probe

    Figure: Display for Start-up of Inspection Pre-Calibration

    Display for Start-up of Inspection Pre-Calibration

    Figure: Display for NULL Operation of Surface No. 1 and No. 5

    Display for NULL Operation of Surface No. 1 and No. 5

    Figure: IAE 2P16588 Plastic Shims Inserted for Surface Calibration

    IAE 2P16588 Plastic Shims Inserted for Surface Calibration

    Figure: Display for 10 mil Lift-off Calibration

    Display for 10 mil Lift-off Calibration

    Figure: Probe Inserted in Blade Slot to be Examined

    Probe Inserted in Blade Slot to be Examined

    Figure: Probe Actuated in Blade Slot

    Probe Actuated in Blade Slot

    Figure: Start-up Screen for Inspection

    Start-up Screen for Inspection

    Figure: Inspection Screen on the Software

    Inspection Screen on the Software

    Figure: Example of Inspection Report for Failed Part Inspection

    Example of Inspection Report for Failed Part Inspection

    Figure: Example of Inspection Report for Acceptable Part Inspection

    Example of Inspection Report for Acceptable Part Inspection

    Figure: Start-up Screen for Post-Calibration

    Start-up Screen for Post-Calibration

    Figure: Display for 10 Mil Lift-off Post-Calibration

    Display for 10 Mil Lift-off Post-Calibration

Requirements After Job Completion

Follow-On Conditions

NONE
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
Manufacturer Code:LOCAL
Supply Number:CoMat 05-125
Type:sp01
Supply Short Name:CoMat 05-125 ABRASIVE PAD, SILICON CARBIDE, ULTRA-FINE
Supply Name:CoMat 05-125 ABRASIVE PAD, SILICON CARBIDE, ULTRA-FINE
Specification Groups:
Doc NumberType
OMAT: 582 (RR REF)SCOTCH BRITE TYPE S.7448 SCOTCH BRITE No.7448 MIL-A-9962A TYPE III GRADE AAA
JCR-255 (JAEC REF)SCOTCH BRITE TYPE S.7448 SCOTCH BRITE No.7448 MIL-A-9962A TYPE III GRADE AAA
PMC 4435 (PW REF)SCOTCH BRITE TYPE S.7448 SCOTCH BRITE No.7448 MIL-A-9962A TYPE III GRADE AAA
Suppliers:
ManufacturerRemarks
LOCAL
K0993
K6835
28124
Manufacturer Code:LOCAL
Supply Number:CoMat 05-126
Type:sp01
Supply Short Name:CoMat 05-126 ABRASIVE PAD, ALUMINUM OXIDE, VERY FINE
Supply Name:CoMat 05-126 ABRASIVE PAD, ALUMINUM OXIDE, VERY FINE
Specification Groups:
Doc NumberType
OMAT: 583 (RR REF)SCOTCH BRITE TYPE A.7447 SCOTCH BRITE No. 7447 MIL-A-9962A TYPE I GRADE A
JCR-256 (JAEC REF)
PMC 4095 (PW REF)
Suppliers:
ManufacturerRemarks
LOCAL
K0993
K6835
28124
Manufacturer Code:0AM53
Tool Number:IAE 2P16585
Tool Name:IAE 2P16585 Dimensional eddy current probe
Manufacturer Code:0AM53
Tool Number:IAE 2P16586
Tool Name:IAE 2P16586 Calibration standard
Manufacturer Code:0AM53
Tool Number:IAE 2P16588
Tool Name:IAE 2P16588 Plastic Shims
Manufacturer Code:0AM53
Tool Number:IAE 2P16592
Tool Name:IAE 2P16592 US-MPX-32 Multiplexer
Manufacturer Code:0AM53
Tool Number:IAE 2P16593
Tool Name:IAE 2P16593 UniWest US-454A digital eddy current instrument
Manufacturer Code:0AM53
Tool Number:IAE 2P16594
Tool Name:IAE 2P16594 Dell Optiplex desktop computer system
Manufacturer Code:0AM53
Tool Number:IAE 2P16595
Tool Name:IAE 2P16595 Pneumatic Controller, UniWest PN 99790