Preliminary Requirements

Procedure

1. SUBTASK 72-45-31-350-072 Prepare the Stage 2 Turbine Hub

   1. NOTE

      It is recommended that this inspection be conducted in a temperature controlled environment, with temperature ranging between 65 and 85 deg F (18,3 and 29,4 deg C). Failure will cause unwanted effect in the inspection results due to the necessary accuracy of the measurements and inspection equipment.

      Make sure the part is disassembled.

      1. Refer to TASK 72-45-30-040-001-A00 (DISASSEMBLY-001, CONFIG-001), 72-45-30-040-001-B00 (DISASSEMBLY-001, CONFIG-002) or 72-45-30-040-001-C00 (DISASSEMBLY-001, CONFIG-003).

   2. Make sure the part is fully cleaned.

      1. Refer to TASK 72-45-31-100-001 (CLEANING-001)

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

      3. NOTE

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

         Locate the serial number of the Stage 2 turbine hub.

   3. 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 SPM TASK 70-09-00-400-501

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

2. SUBTASK 72-45-31-250-013 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 72-45-31-250-014 Assemble the Eddy Current Equipment

   1. Refer to Figure, Figure, Figure, Figure, Figure, Figure and 72-45-31-990-056.

   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.

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

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

      2. NOTE

         The three cable connectors from the probe are labeled with the correct sensor input numbers (1-3).

         Connect the IAE 2P16597 Probe Probe to the Multiplexer.

         1. Plug the proper connector into the multiplexer input.

            1. Refer to Figure Index 4.

   4. Connect the probe input to the multiplexer probe input with the 71142 Cable.

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

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

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

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

   5. 
      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.

      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 72-45-31-250-015 Prepare the Eddy Current Software

   1. Refer to Fig. 72-45-31-250-057.

   2. NOTE

      Each IAE 2P16597 Probe 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 for the correct serial number probe.

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

      1. The main menu will appear.

         1. Refer to Figure.

5. SUBTASK 72-45-31-250-016 Pre-Inspection Calibration of the Eddy Current Equipment

   1. Refer to Fig. 72-45-31-250-051, Fig. 72-45-31-250-057, Fig. 72-45-31-250-058, Fig. 72-45-31-250-059, Fig. 72-45-31-250-060, Fig. 72-45-31-250-061, Fig. 72-45-31-250-062, Fig. 72-45-31-250-063, Fig. 72-45-31-250-064, Fig. 72-45-31-250-065 and Fig. 72-45-31-250-066.

   2. NOTE

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

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

      1. Refer to Figure.

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

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

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

      1. Refer to Figure.

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

         1. Refer to Fig.72-4-31-990-059.

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

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

      1. Refer to Figure.

      2. 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 Plastic Shims that you use.

         NOTE

         Two IAE 2P16588 Plastic Shims that you use during the pre-inspection and post-inspection calibration of the IAE 2P16597 Probe. 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.

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

         1. Refer to Figure.

            NOTE

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

            2. Only 18 of the 72 blade slots on the hub will be examined.

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

   5. Pick the following blade slots. Blade slot No. 1, 5, 9, 13, 17, 21, 25, 29, 33, 37, 41, 45, 49, 53, 57, 61, 65, 69.

      1. Refer to Figure.

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

   6. Make sure the probe can be easily inserted into the blade slots of the IAE 2P16598 Calibration standard .

      1. Refer to Figure.

         NOTE

         1. The blade slots of the IAE 2P16598 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 4).

         3. You can use Blade Slot No. 2 to calibrate the second pressure face group 2 surfaces (Surfaces 2 and 5).

         4. You can use Blade Slot No. 3 to calibrate the third pressure face group 3 surfaces (Surfaces 3 and 6).

   7. Insert the probe into the Blade Slot No.1 of the calibration standard

      1. Refer to Figure.

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

         NOTE

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

      3. On the display screen, pick the "Start" option.

         1. Refer to Figure.

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

         1. Refer to Figure.

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

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

            NOTE

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

      5. Insert the plastic shims between the calibration standard pressure face, and Surface No. 1 and Surface No. 4 on the probe.

         1. Refer to Figure and Figure.

            NOTE

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

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

      7. On the display screen, pick the "Acquire" option.

         1. Refer to Figure.

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

            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.

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

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

         5. 

            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.

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

   8. Insert the probe in Blade Slot No. 2 of the calibration standard.

      1. Refer to Figure.

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

         NOTE

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

   9. Insert the probe in the Blade Slot No.3 of the calibration standard.

      1. Refer to Figure

      2. Do steps 8.F. thru 8.K. again for calibration of the group 3 sensors.

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

         NOTE

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

6. SUBTASK 72-45-31-250-017 Examine the Stage 2 Turbine Hub Blade Slot

   NOTE

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

   1. Refer to Fig. 72-45-31-250-067, Fig. 72-45-31-250-068, Fig. 72-45-31-250-069 and Fig. 72-45-31-250-070.

   2. Insert the IAE 2P16597 Probe into Blade Slot No. 1.

      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.

      1. Refer to Figure.

   4. On the display screen, pick the "Start" option.

      1. Refer to Figure.

   5. On the display screen, pick the "Acquire" option.

      1. Refer to Figure.

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

      3. Remove the probe from the slot.

      4. Do steps 11.A. thru 11.G. again for Blade Slot No. 5, 9, 13, 17, 21, 25, 29, 33, 37, 41, 45, 49, 53, 57, 61, 65 and 69.

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

         NOTE

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

7. SUBTASK 72-45-31-250-018 Post-Inspection Calibration of the Eddy Current Equipment

   1. Refer to Fig. 72-45-31-250-071 and Fig. 72-45-31-250-072.

   2. Insert the IAE 2P16597 Probe into the Blade Slot No. 1 on the IAE 2P16598 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.

      1. Refer to Figure

   6. On the display screen, pick the "Acquire" option.

      1. Refer to Figure.

         NOTE

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

      2. After all three blade slots pass the post-inspection calibration successfully, pick "Finish", followed by the "Next" option.

         NOTE

         If post calibration is out of tolerance an error messsage 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.

8. SUBTASK 72-45-31-250-019 Examine the Stage 2 Turbine Hub Blade Slot Inspection Report for Failed Blade Slots

   1. Refer to Fig. 72-45-31-250-073 and Fig. 72-45-31-250-074.

   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.

            NOTE

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

9. SUBTASK 72-45-31-250-020 Examine the Defective Stage 2 Turbine Hub Blade Slots for False Positive

   1. For blade slots that fail inspection:

      1. Scrub the blade slots. Use CoMat 05-126 ABRASIVE PAD, ALUMINUM OXIDE, VERY FINE or CoMat 05-125 ABRASIVE PAD, SILICON CARBIDE, ULTRA-FINE.

         1. Refer to the SPM TASK 70-10-00-100-501

      2. 
         CAUTION
         USE OF SOLVENTS OTHER THAN THOSE APPROVED IN THE SPM TASK 70-11-26-300-503 CAN RESULT IN DAMAGE TO THE PROBE.

         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.

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

   3. If you find one or more blade slots are defective during inspection again, reject the Stage 2 Turbine Hub.

      NOTE

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

Figure: Inspection Equipment

Inspection Equipment



Figure: IAE 2P16597 Eddy Current Probe

IAE 2P16597 Eddy Current Probe



Figure: IAE 2P16598 Calibration Standard

IAE 2P16598 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 2P16597 Probe Connections and IAE 2P16593 US-454A Connections to IAE 2P16592 Multiplexer

IAE 2P16597 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. 3

Display for NULL Operation of Surface No. 1 and No. 3



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: 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



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