TASK 72-50-23-300-067 Low Pressure (LP) Turbine Outer Static Seals - Replace The Honeycomb Seal Segments, Repair-067 (VRS4569)

DMC:V2500-A1-72-50-2304-01A-920A-C|Issue No:002.00|Issue Date:2020-05-01

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 72-50-23-300-067 Low Pressure (LP) Turbine Outer Static Seals - Replace The Honeycomb Seal Segments, Repair-067 (VRS4569)

Effectivity

FIG/ITEM

PART NO.

01-250

3A3090

Material of Component

PART IDENT

IAE SYMBOL

MATERIAL

Stage 4 shroud seal segment

-

Hastelloy X

Honeycomb seal segment

-

Hastelloy X

General

Price and availability - none

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

NOTE

For more equipment and materials necessary to do this repair refer to SPM TASK 70-09-00-400-501, SPM TASK 70-11-03-300-503, SPM TASK 70-23-02-230-501 and SPM TASK 70-31-07-310-501.
Equivalent equipment may be used.
To identify the consumable materials refer to the OPCI.
Special tools are identified in the procedure by the tool primary number.
Approved vendors for the supply of honeycomb material AMS 5536, refer to CoMat 03-469 HONEYCOMB, NICKEL ANDCOBALT ALLOYS. To locally manufacture supplied honeycomb seal segments refer to Figure and Figure.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Belt grinderLOCALBelt grinder
Grinding Machine0AM53Grinding Machine
IAE 3M14214 Grinding/turning fixture0AM53IAE 3M14214

1 off

IAE 3M14215 Spot welding fixture0AM53IAE 3M14215

1 off

IAE 3M14220 Cross slide table0AM53IAE 3M14220

1 off

IAE 3M14221 Electrode guide0AM53IAE 3M14221

1 off

IAE 3M14222 Electrode holder0AM53IAE 3M14222

1 off

IAE 3M14223 Universal joint electrode0AM53IAE 3M14223

1 off

IAE 3M14265 Spot welding fixture0AM53IAE 3M14265

1 off

Spot welding machineLOCALSpot welding machine
Turning latheLOCALTurning lathe

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-144 BONDING AGENTLOCALCoMat 02-144
CoMat 03-148 BRAZING FILLER POWDERLOCALCoMat 03-148
CoMat 03-227 WHITE STOP OFFD3309CoMat 03-227
CoMat 03-249 BRAZING FILLER MATERIAL,Ni-BASELOCALCoMat 03-249
CoMat 03-469 HONEYCOMB, NICKEL ANDCOBALT ALLOYSLOCALCoMat 03-469

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
SEAL SEGMENT - HONEYCOMB0AM533A30911

FIG/ITEM - 01-271

SEAL SEGMENT - HONEYCOMB0AM533A30921

FIG/ITEM - 01-281

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-50-23-320-001 Machine the Damaged Honeycomb Seal Segments

    1. Refer to Figure.

      2. Machine off the worn honeycomb seal segments.

      2. Keep material removal to a minimum.

      3. Remove the damaged honeycomb seal segments fully.

      4. Remaining braze thickness not more than 0.005 in. (0.127 mm) is permitted.

      3. Bend the shroud seal segments back to shape if required.

      1. Use cold work.

    2. SUBTASK 72-50-23-110-001 Clean the Stage 4 Shroud Seal Segment

      1. Aqueous cleaning.

      1. Refer to SPM TASK 70-11-03-300-503.

    3. SUBTASK 72-50-23-230-022 Examine the Stage 4 Shroud Seal Segment for Cracks

      1. Do the test for cracks.

      1. Refer to SPM TASK 70-23-02-230-501. Refer to Task TASK 72-50-23-200-003-C00 (Inspection - 003) for acceptable limits.

    4. SUBTASK 72-50-23-310-001 Prepare the Honeycomb Seal Segments for Brazing

      1. Cut the honeycomb seal segments to length.

      1. Replacement honeycombs are supplied longer than necessary.

    5. SUBTASK 72-50-23-110-002 Clean the New Honeycomb Seal Segments and the Stage 4 Shroud Seal Segment

      1. Aqueous cleaning.

      1. Refer to SPM TASK 70-11-03-300-503.

      2. Use clean gloves when you touch the clean parts.

    6. SUBTASK 72-50-23-310-002 Braze in the New Honeycomb Seal Segments

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

      NOTE

      If CoMat 03-249 BRAZING FILLER MATERIAL,Ni-BASE is used, do not perform Step and Step. If CoMat 03-148 BRAZING FILLER POWDER is used, do not perform Step.
      If you install 3A3092 SEAL SEGMENT - HONEYCOMB (72-50-23, 01-281 or detail N), do not perform Step and if you install 3A3091 SEAL SEGMENT - HONEYCOMB (72-50-23, 01-371 or detail M), do not perform Step.

      2. Install the cross slide table onto the spot welding machine.

      3. Install the electrode holder onto the spot welding machine.

      4. Install the electrode swivel onto the electrode holder.

      1. Use IAE 3M14223 Universal joint electrode 1 off. Make sure that the electrode insert with the mark "OUTER" (part of the electrode swivel) is installed.

      5. Install the electrode guide onto the cross slide table.

      6. Install the spot welding fixture onto the electrode guide.

      7. Install the spot welding fixture onto the electrode guide.

      8. Attach the shroud seal segment onto the spot welding fixture.

      1. Make sure that the shroud seal segment is installed correctly against the stop plates (parts of the spot welding fixture).

      9. Prepare the new honeycomb seal segments.

      2. Apply brazing filler tape to the shroud seal segment mating side of the honeycomb seal segment.

      3. Use a roller or equivalent to roll the tape into the honeycomb cells and remove the backing.

      10. Put the honeycomb seal segments onto the shroud seal segment.

      1. Align the honeycomb seal segments.

      11. Resistance weld the honeycomb seal segments.

      1. Use a short time and low weld amperage to safety the honeycomb seals without damage. Start to weld in the middle and continue to the outer sides.

      12. Apply brazing filler powder to the honeycomb seal segments.

      1. Use CoMat 03-148 BRAZING FILLER POWDER. Make sure that the brazing filler powder is applied equally around the honeycomb seal segments.

      13. Safety the brazing filler powder to the honeycomb cells.

      14. Apply white stop off around the edges of the shroud seal segment.

      15. Vacuum braze.

      1. Refer to SPM TASK 70-31-07-310-501. Use process 2.

    7. SUBTASK 72-50-23-110-003 Clean the Stage 4 Shroud Seal Segment

      1. Aqueous cleaning.

      1. Refer to SPM TASK 70-11-03-300-503.

    8. SUBTASK 72-50-23-210-001 Examine the Brazed Honeycomb Seal Segments

      1. Do the gravity leak test.

      1. Refer to SPM TASK 70-31-07-310-501.

      2. Acceptance limits.

        1. Refer to SPM TASK 70-31-07-310-501 except the following limits:

        1. No unbrazed honeycomb cells around the edges of the honeycomb segments are permitted.

        2. The minimum space between the unbonded areas of more than 0.063 sq. in. (40.65 sq-mm) should be 1.000 in (25.40 mm).

        3. The honeycomb wall thickness must not be increased by more than 0.001 in. (0.025 mm) in the area above the braze fillet.

    9. SUBTASK 72-50-23-320-002 Machine the Honeycomb Seal Segments

    1. Refer to Figure and Figure.

      2. Grind the honeycomb seal segments.

      1. Use IAE 3M14214 Grinding/turning fixture 1 off and grinding machine.

      3. Deburr the honeycomb seal segments.

      1. Refer to SPM TASK 70-31-07-310-501.

    10. SUBTASK 72-50-23-110-004 Clean the Stage 4 Shroud Seal Segment

      1. Aqueous cleaning.

      1. Refer to SPM TASK 70-11-03-300-503.

    11. SUBTASK 72-50-23-220-001 Do the Post Repair Inspection

    1. Refer to Figure and Figure.

    2. Examine dimensionally.

      3. Examine visually.

      1. Refer to SPM TASK 70-31-07-310-501.

    12. SUBTASK 72-50-23-350-001 Make a Mark to Identify the Repair

      1. Electrolytically etch or vibropeen VRS4569 adjacent to the part number.

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

    13. Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Local Manufacture Honeycomb Seal Segment of the Shroud Seal Segment

    Local Manufacture Honeycomb Seal Segment of the Shroud Seal Segment

    Figure: Local Manufacture Honeycomb Seal Segment of the Shroud Seal Segment

    Local Manufacture Honeycomb Seal Segment of the Shroud Seal Segment

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Correct subtask number due to duplication (CAS-62915-K9P4S0)

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:D3309
Enterprise Name:MTU MOTOREN-UND-TURBINE UNION MUNCHEN GMBH
BU Name:MTU MOTOREN-UND-TURBINE UNION MUNCHEN GMBH
Street:DACHAUERSTRASSE 665
P.O. Box:80995
City:MUNCHEN 50
Country:GERMANY
Phone Number:49-89-14890
Fax Number:49-89-1502621
Internet:www.mtu.de
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Part Number:3A3091
Part Name:SEAL SEGMENT - HONEYCOMB
Manufacturer Code:0AM53
Part Number:3A3092
Part Name:SEAL SEGMENT - HONEYCOMB
Manufacturer Code:0AM53
Manufacturer Code:LOCAL
Supply Number:CoMat 02-144
Type:sp01
Supply Short Name:CoMat 02-144 BONDING AGENT
Supply Name:CoMat 02-144 BONDING AGENT
Specification Groups:
Doc NumberType
DELETED. USE COMAT 03-290.
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:LOCAL
Supply Number:CoMat 03-148
Type:sp01
Supply Short Name:CoMat 03-148 BRAZING FILLER POWDER
Supply Name:CoMat 03-148 BRAZING FILLER POWDER
Specification Groups:
Doc NumberType
MSRR 9500/97NICROBRAZ LM NICROBRAZ LM (-150 MESH) AMS 4777 B.S.1845 HTN2
OMAT:3/181NICROBRAZ LM NICROBRAZ LM (-150 MESH) AMS 4777 B.S.1845 HTN2
JCR-214NICROBRAZ LM NICROBRAZ LM (-150 MESH) AMS 4777 B.S.1845 HTN2
Suppliers:
ManufacturerRemarks
LOCAL
63585
K6835
U0163
K5086
Manufacturer Code:D3309
Supply Number:CoMat 03-227
Type:sp01
Supply Short Name:CoMat 03-227 WHITE STOP OFF
Supply Name:CoMat 03-227 WHITE STOP OFF
Specification Groups:
Doc NumberType
MTH 316NICROBRAZE WHITE STOP OFF
Suppliers:
ManufacturerRemarks
D3309
Manufacturer Code:LOCAL
Supply Number:CoMat 03-249
Type:sp01
Supply Short Name:CoMat 03-249 BRAZING FILLER MATERIAL, Ni-BASE
Supply Name:CoMat 03-249 BRAZING FILLER MATERIAL,Ni-BASE
Specification Groups:
Doc NumberType
AMS 4777
Suppliers:
ManufacturerRemarks
LOCAL
0UEE7
0Y7E4
01FK3
63585
Manufacturer Code:LOCAL
Supply Number:CoMat 03-469
Type:sp01
Supply Short Name:CoMat 03-469 HONEYCOMB, NICKEL ANDCOBALT ALLOYS
Supply Name:CoMat 03-469 HONEYCOMB, NICKEL ANDCOBALT ALLOYS
Specification Groups:
Doc NumberType
(AMS 5536, AMS 5540) PWA 123HONEYCOMB, NICKEL AND COBALT ALLOYS
Suppliers:
ManufacturerRemarks
LOCAL
FA1X9
IE499
U0F75
0FGC3
0MRR3
0TML8
0ALH8
25632
49741
50554
Manufacturer Code:LOCAL
Tool Number:Belt grinder
Tool Name:Belt grinder
Link not Found
Manufacturer Code:0AM53
Tool Number:IAE 3M14214
Tool Name:IAE 3M14214 Grinding/turning fixture
Manufacturer Code:0AM53
Tool Number:IAE 3M14215
Tool Name:IAE 3M14215 Spot welding fixture
Manufacturer Code:0AM53
Tool Number:IAE 3M14220
Tool Name:IAE 3M14220 Cross slide table
Manufacturer Code:0AM53
Tool Number:IAE 3M14221
Tool Name:IAE 3M14221 Electrode guide
Manufacturer Code:0AM53
Tool Number:IAE 3M14222
Tool Name:IAE 3M14222 Electrode holder
Manufacturer Code:0AM53
Tool Number:IAE 3M14223
Tool Name:IAE 3M14223 Universal joint electrode
Manufacturer Code:0AM53
Tool Number:IAE 3M14265
Tool Name:IAE 3M14265 Spot welding fixture
Manufacturer Code:LOCAL
Tool Number:Spot welding machine
Tool Name:Spot welding machine
Manufacturer Code:LOCAL
Tool Number:Turning lathe
Tool Name:Turning lathe