TASK 72-45-23-200-004-D00 HPT Stage 1 Duct Segment - Examine, Inspection-004

DMC:V2500-A0-72-45-2301-00C-300A-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 72-45-23-200-004-D00 HPT Stage 1 Duct Segment - Examine, Inspection-004

Effectivity

FIG/ITEM

PART NO.

01-060

2A3886-01

General

This TASK gives the procedure for the inspection of the stage 1 HPT duct segment assembly.

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 TASK 72-45-23-100-000 (CLEANING-000).

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.

The procedure for those parts which must have a crack test is given in Step or Step. Do the test before the part is visually inspected.

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 is 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.

Definitions of Damage, SPM TASK 70-02-02-350-501

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

Some data on these items is contained in this TASK. For more data on these items refer to the SPM.

Methods of Testing for Crack Indications

Chemical Processes

Surface Protection

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NONE

Consumables, Materials and Expendables

NONE

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-45-23-230-065-001 Examine the Stage 1 HPT Duct Segments (01-060) for Cracks

    1. Refer to Figure, Figure and Figure.

    2. Clean the part. Refer to TASK 72-45-23-100-000 (CLEANING-000).

      3. Do the test for cracks on the part that is given below. Examine the metal surfaces at location 8. Do not examine the ceramic coated areas at location 4. Look carefully at the metering cover at location 7 and the attachment slot and shiplap surfaces at locations 3, 6, 9, 11 and 12. Use the applicable penetrant procedure.

        PART IDENT

        TASK/SUBTASK

        Stage 1 HPT duct segment

        1. Cracks at location 3

        1. Repair, VRS3717 TASK 72-45-23-300-016 (REPAIR-016) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

        2. Base metal cracks, all other areas

        1. Repair, VRS3717 TASK 72-45-23-300-016 (REPAIR-016) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

          2. Cracks on the duct segment shiplap edges at location 14 and 15.

            1. NOTE

              Depth measurement must be taken at the edge of the segment.

              A maximum of four cracks on each edge, not more than 0.200 in. (5.08 mm) in length (circumferentially) and 0.050 in. (1.27 mm) in depth (radially). Cracks must not break into the cooling holes and must be separated by a minimum of 0.075 in. (1.91 mm) (axially)

            1. Repair, VRS3717 TASK 72-45-23-300-016 (REPAIR-016) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

    2. SUBTASK 72-45-23-230-065-002 Examine the Stage 1 HPT Duct Segments (01-060) for Cracks

    1. Refer to Figure, Figure and Figure.

    2. Clean the part. Refer to TASK 72-45-23-100-000 (CLEANING-000).

      3. Do the test for cracks on the part that is given below. Examine the metal surfaces at location 8. Do not examine the ceramic coated areas at location 4. Look carefully at the metering cover at location 7 and the attachment slot and shiplap surfaces at locations 3, 6, 9, 11 and 12. Use the applicable penetrant procedure.

        PART IDENT

        TASK/SUBTASK

        Stage 1 HPT duct segment

        1. Cracks at location 3

        1. Repair, VRS3717 TASK 72-45-23-300-016 (REPAIR-016) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

        2. Base metal cracks, all other areas

        1. Repair, VRS3717 TASK 72-45-23-300-016 (REPAIR-016) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

          2. Cracks on the duct segment shiplap edges at location 14 and 15.

            1. NOTE

              Depth measurement must be taken at the edge of the segment.

              A maximum of four cracks on each edge, not more than 0.200 in. (5.08 mm) in length (circumferentially) and 0.050 in. (1.27 mm) in depth (radially). Cracks must not break into the cooling holes and must be separated by a minimum of 0.075 in. (1.91 mm) (axially)

            1. Repair, VRS3717 TASK 72-45-23-300-016 (REPAIR-016) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

    3. SUBTASK 72-45-23-220-095 Examine the Stage 1 HPT Duct Segments (01-060) for Bent, Part Missing, Wear and Unwanted Material on the Attachment and Shiplap Surfaces

    1. Refer to Figure and Figure.

      2. Examine the duct segment assembly for bends, part missing, wear and unwanted material on the attachment and shiplap surfaces.

        1. Wear.

          1. Not more than 0.005 in. (0.13 mm) at locations 2, 9, 10, 11 and 12

          1. Accept

          2. Other than (a)

          1. Repair, VRS3717 TASK 72-45-23-300-016 (REPAIR-016) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

        2. Bent or part missing at locations 3, 6, 9, 11 and 12

        1. Reject

        3. All quantities of unwanted material at location 1 (four positions) between the shiplap lug surfaces

        1. Accept

        4. Axial bowing at location 11 and 12 not more than 0.010 in. (0.01 mm)

        1. Accept

        5. Other than (4)

        1. Repair, VRS3717 TASK 72-45-23-300-016 (REPAIR-016) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

    4. SUBTASK 72-45-23-220-096 Examine the Stage 1 HPT Duct Segments (01-060) for the Seal Groove Width

    1. Refer to Figure.

      2. Examine the duct segments at location 16 for the width of the seal groove.

        1. The seal groove width is 0.025 to 0.031 in. (0.64 to 0.79 mm)

        1. Accept

        2. The seal groove width is less than 0.016 in. (0.41 mm) and the tab is bent inward

        1. Repair, VRS3640 TASK 72-45-23-300-015 (REPAIR-015) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

        3. The seal groove width is less than 0.016 in. (0.41 mm) or the tab is bent outward

        1. Repair, VRS3760 TASK 72-45-23-300-021 (Repair-021)

    5. SUBTASK 72-45-23-220-097 Examine the Stage 1 HPT Duct Segment Assembly (01-060) Ceramic Coated Surfaces for Unwanted Material in the Cooling Holes

    1. Refer to Figure and Figure.

      2. Examine the duct segment at location 13 for unwanted material in the cooling holes.

        1. Unwanted material

        1. Repair, VRS3071 TASK 72-45-23-300-007 (REPAIR-007) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

    6. SUBTASK 72-45-23-220-098 Examine the Stage 1 HPT Duct Segment Assembly (01-060) for Corrosion, Dents, Erosion, Nicks and Pits on the Base Metal Surfaces

    1. Refer to Figure, Figure and Figure.

      2. Examine the duct segment assembly at location 8, 11, 12, 18 and 19 for corrosion, dents, nicks and pits on all the base metal surfaces.

        1. Corrosion, dents, erosion, nicks and pits.

          1. Sealing surfaces (location 17 and 18), nicks, dents, gouges and similar surface imperfections are permitted to 0.005 in. (0.13 mm) depth, if the imperfections are round bottomed

          1. Accept

          2. Hooks (location 19), nicks, dents, gouges and similar surface imperfections are permitted to 0.005 in. (0.13 mm) depth, if they are smooth bottomed and not in the fillet radii under the hooks. Outside of the fillet radii and ID surfaces, isolated surface imperfections are permitted to 0.040 in. (1.02 mm) depth, if they are smooth bottomed and no two adjacent hooks are affected. The total affected area on each hook is less than 0.016 sq in. (10.32 sq mm) and no imperfection spans more than 0.100 in. (2.54 mm) circumferentially. For hooks with multiple surface imperfections only one can be more than 0.005 in. (0.13 mm) depth

          1. Accept

          3. Shiplap surfaces (location 11 and 12), nicks, dents, gouges and similar surface imperfections are permitted to 0.005 in. (0.13 mm) depth, if they are smooth bottomed and not in the fillet radii, isolated surface imperfections are permitted to 0.040 in. (1.016 mm) depth, if they are smooth bottomed, the total affected area is less than 0.016 in. (0.406 mm) and no imperfection spans more than 0.100 in. (2.54 mm) axially. For multiple surface imperfections, only one can be more than 0.005 in. (0.13 mm) deep

          1. Accept

          4. All other surfaces, nicks, dents, gouges and similar surface imperfections are permitted to 0.005 in. (0.13 mm) depth, if they are smooth bottomed. Isolated surface imperfections are permitted to 0.040 in. (1.02 mm) depth, if fillet radii, metering cover, cooling holes and hook web are not affected, the imperfection is smooth bottomed and total affected area is less than 0.050 sq in. (32.26 sq mm). All imperfections more than 0.005 in. (0.13 mm) in depth must be separated by 0.010 in. (0.25 mm) minimum. Imperfections on axial and circumferential faces spanning more than half of the face width are not permitted. At location 20 the imperfection may span the entire radial width

          1. Accept

          5. Other than (a), (b), (c) and (d)

          1. Repair, VRS3721 TASK 72-45-23-300-017 (REPAIR-017) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

      3. Examine the duct segment at locations 14 and 15 for erosion on the shiplap edges.

        1. Erosion on the shiplap edges.

          1. Erosion on the edges not more 0.050 in. (1.27 mm) measured circumferentially from the shiplap edge, along the entire length

          1. Repair, VRS3721 TASK 72-45-23-300-017 (REPAIR-017) or Repair, VRS3717 TASK 72-45-23-300-016 (REPAIR-016) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

          2. More than in (a)

          1. Repair, VRS3717 TASK 72-45-23-300-016 (REPAIR-016) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

          3. Erosion on the shiplap edge at location 14 not more than 0.200 in. (5.08 mm) from the shiplap edge (circumferentially) by not more than 50 per cent of the edge (axially)

          1. Repair, VRS3717 TASK 72-45-23-300-016 (REPAIR-016) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

    7. SUBTASK 72-45-23-220-099 Examine the Stage 1 HPT Duct Segment Assembly (01-060) for Chips and Spalls on the Ceramic Coating

    1. Refer to Figure and Figure.

      2. Examine the duct segment assembly at location 4 for chips and spalls on the ceramic coating in areas 1 and 2.

        1. Chips and spalls in Area 2.

          1. All quantities not more than 0.020 in. (0.51 mm) in depth

          1. Accept

          2. Other than (a)

          1. Repair, VRS3717 TASK 72-45-23-300-016 (REPAIR-016) or Repair, VRS 3760 TASK 72-45-23-300-021 (REPAIR-021)

        2. Chips and spalls in Area 1.

          1. All quantities not more than 20 per cent of the surface area and 0.020 in. (0.51 mm) in depth

          1. Accept

          2. All quantities not more than 0.125 in. (3.175 mm) in diameter and 0.020 in. (0.508 mm) in depth

          1. Accept

          3. Two areas not more than 0.250 in. (6.35 mm) in diameter and 0.020 in. (0.51 mm) in depth

          1. Accept

          4. One area between 0.250 and 0.500 in. (6.35 and 12.7 mm) in diameter and not more than 0.020 in. (0.51 mm) in depth

          1. Accept

          5. Other than (a) through (d)

          1. Repair, VRS3717 TASK 72-45-23-300-016 (REPAIR-016) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

    8. SUBTASK 72-45-23-220-100 Examine the Stage 1 HPT Duct Segment Assembly (01-060) for Bend or Wear on the Anti-Rotation Pin

    1. Refer to Figure and Figure.

      NOTE

      Cast to size segments have a cast in or integral anti-rotation feature (no pressed in pin).

      2. Examine the anti-rotation pin on the duct segment assembly at location 5 for bends or wear.

      1. Wear on the integral anti-rotation feature or anti-rotation pin not more than 0.005 in. (0.13 mm) is acceptable. Blend raised material.

        2. Bent anti-rotation pin

        1. Repair, VRS3161 TASK 72-45-23-300-009 (REPAIR-009)

    9. SUBTASK 72-45-23-220-101 Examine the Stage 1 HPT Duct Segment Assembly (01-060) for Metal Transfer, Cracks, Erosion and Rub on the Ceramic Coating

    1. Refer to Figure.

      2. Examine the duct segment assembly for metal transfer and cracks.

        1. Metal transfer at location 1

        1. Repair, VRS3543 TASK 72-45-23-300-010 (REPAIR-010)

        2. NOTE

          Example of a checkered crack pattern is shown at location 4.

          All quantities of a checkered crack pattern at location 1

        1. Accept

        3. NOTE

          Examples of the axial cracks are shown at location 3 and the circumferential cracks are shown at location 2.

          All axial and circumferential cracks that are horizontal to the top surface at location 3 (each end) and location 2 (each side)

        1. Accept

      3. Examine the duct segment assembly for erosion and rub at location 1.

        1. Erosion and rub.

          1. NOTE

            The maximum radius of the duct segment assembly is temporarily marked on the duct segment surface when the HP turbine case and vane assembly is disassembled.

            If the maximum radius that is temporarily marked on the surface is not more than 12.825 in. (325.76 mm)

          1. Accept

          2. Other than (a)

          1. Repair, VRS3717 TASK 72-45-23-300-016 (REPAIR-016) or Repair, VRS3760 TASK 72-45-23-300-021 (REPAIR-021)

    10. SUBTASK 72-45-23-280-053-A00 Examine the Stage 1 HPT Duct Segment Assembly (01-060) by the Airflow Check

      1. Do the airflow procedure for the stage 1 HPT duct segment assembly by Repair, VRS3071 TASK 72-45-23-300-007 (REPAIR-007).

        NOTE

        If you did or will do an airflow check as a requirement of Repair 011, Repair 013, Repair 016 or Repair 021, then this TASK is not necessary.

      1. Before you do the airflow check, all the inspection checks and repairs must be completed.

      2. If the airflow is not satisfactory, do one of the steps that follow:

      1. If the airflow is more than the maximum, do Repair 007, Repair 011, Repair 013, Repair 016 or Repair 021.

      2. If the airflow is less than than the minimum, do Repair 011, Repair 013, Repair 016 or Repair 021.

    11. Figure: Stage 1 HPT Duct Segment Inspection Locations

    Sheet 1

    Legend
    Stage 1 HPT Duct Segment Inspection Locations

    Sheet 1

    Close

    Figure: Stage 1 HPT Duct Segment Inspection Location

    Sheet 2

    Legend
    Stage 1 HPT Duct Segment Inspection Location

    Sheet 2

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    Figure: Stage 1 HPT Duct Inspection Locations

    Sheet 3

    Legend
    Stage 1 HPT Duct Inspection Locations

    Sheet 3

    Close

    Figure: Stage 1 HPT Duct Segment Inspection Locations

    Stage 1 HPT Duct Segment Inspection Locations

Requirements After Job Completion

Follow-On Conditions

NONE