TASK 72-00-00-300-007 HPT Module Repair - Project Visit Maintenance, Repair-007 (VRS3828)

DMC:V2500-A5-72-00-0000-02A-664A-B|Issue No:003.00|Issue Date:2021-08-01

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 72-00-00-300-007 HPT Module Repair - Project Visit Maintenance, Repair-007 (VRS3828)

General

This procedure outlines the requirements to remove one or both HPT Disks to examine for potential manufacturing defect by SBE 72-0661, SBE 72-0713 and Special Instructions (SI) 64F-20 and replace the Disks, if you find not serviceable.

This maintenance action is considered a Project Visit and does not zero time any hardware relative to maintenance requirements – including BSI inspection, and no Maintenance Planning Document (MPD) tasks are necessary. Any scheduled or planned maintenance activity should continue with the operator’s approved Aircraft Maintenance Program (AMP).

All AD Notes that are applicable and affected need to be accomplished, as well as any mandated inspections in the Engine Manual Airworthiness Limitations Section (ALS) and Maintenance Scheduling Section (MSS) of the Instructions for Continued Airworthiness (ICA), located in the Time Limits Manual (Chapter 05-10-00) of the Engine Manuals, to include mandatory enhanced inspection of selected critical life-limited parts at each piece part exposure.

This EA mandates the use of a Visual Check as defined in the Standard Practices Manual, for continued serviceability assessment for all parts, subassemblies and modules that are removed or exposed solely to gain access to the HPT module and HPT hubs. The minimum inspection requirement to return a part, subassembly or module to service is to do a Visual Check to detect obvious damage, failure or irregularity outside of normal in-service wear to make sure that the item is approved for continued in-service use. A Visual Check is made without magnification and does not need dimensional measurements. Please refer to Standard Practices Manual TASK 70-20-00-200-501 Inspection - General Information. If during Project Visit there is a finding that needs additional actions, contact CTS for further instructions.

Preliminary Requirements

Pre-Conditions

Action/ConditionData Module/Technical Publication
For the engine selection process, the pre-requisites listed below are for internal use by International Aero Engines (IAE), AG to define candidate engines for this procedure:
1. Engine must not have had any major event on wing.
2. Service Bulletin 72-0642 - Engine - High Pressure (HP) Compressor - Stage 3 to 8 Compressor Drum - Introduction of Damper Wires for Stages 6 to 8.
3. Service Bulletin 72-0673 - NMSB - Replacement of No. 3 Bearings from Suspect Population (LOT A).
Pre-Conditions (checklist):
The preconditions listed below are for internal use by IAE-AG to define candidate engines for this procedure:
1. Engine must be serviceable when removed or can be returned to serviceability through implementation of this EA or any other AMM task.
2. The engine must be preserved for each requirements in AMM TASK 71-00-00-550-010-A.
3. The engine must have more than 30% of hot section interval remaining.
4. The engine must have more than 20% LLP life remaining.
5. The engine must obey to the N1 and N2 vibration conditions below:
- N1 vibration, monitored at cruise conditions before 30 days of operation, is no higher than 1.5 aircraft units and has no upward step greater than 1.0 aircraft unit.
- N2 vibration data, monitored at cruise conditions before 30 days of operation, is no higher than 1.2 aircraft units.
6. The engine must have an EGT margin at takeoff conditions (realistic worst case EGT margin) more than the limit of 20°C (68°F).
7. The engine must have Diffuser M-Flange with less than 19,000 cycles since new.

Support Equipment

NONE

Consumables, Materials and Expendables

NONE

Spares

NONE

Safety Requirements

NONE

Procedure

  1. The proprietary nature of this repair mandates that any facility not authorized to accomplish this repair must contact IAE Repair Development Group to determine if a qualification program can be initiated at their facility.

    IAE International Aero Engines AG

    400 Main Street

    Mail Stop 121-10

    East Hartford CT 06118

    USA

    Email: gpiaerepaircouncil@iaev2500.com

    ATTN: IAE Repair Council

    2. NOTE

      Remove and install protection covers as necessary to prevent damage to the engine.

      NOTE

      Wipe clean all parts and tools as necessary to remove debris and prevent damage to the parts and engine. No other cleaning is necessary for Visual Check.

      1. Task A: Removal of LPT/TEC and HPT modules and inspection conditions:

      1. Do a Visual Check TASK 70-20-00-200-501 Step (3) (b) of the engine assembly for foreign objects, damage, and correct assembly. Photograph front, rear, left side, right side, top, and bottom of the engine to record the full inspection. Contact CTS with any damage that is considered to be abnormal.

        2. Disassemble to remove LPT/TEC and HPT modules to expose the HPT hubs:

        1. Do a Visual Check of the Fan Inlet Cone, Inlet Cone Fairing, and Fan Front Retaining Ring for obvious damage.

        2. Examine the TEC No. 4 weep tube exit location in the TEC.

        3. Before you do LPT/TEC removal, carry out No. 5 Compartment Vacuum check and record results, refer to TASK 72-00-50-420-001-C00.

        4. Before you do LPT/TEC removal, correlate the position of the LPT Shaft relative to the LPC Drive Shaft. Identify shaft positions with suitable marker.

        5. Remove the LPT/TEC Module from the Engine by TASK 72-00-50-020-002.

        3. NOTE

          It is permitted to leave the fan rotor assembly installed in the fan case after removal of LPT/TEC.

          After LPT/TEC module removal, do not do EM inspections of exposed interfaces of LPT and TEC. Do instead:

        1. A Visual Check of the LPT/TEC module by TASK 70-20-00-200-501 Step (3) (b).

        2. Photograph any findings considered to be unusual wear or damage and give to CTS.

        3. No further action is necessary.

      5. Examine the HPT module by Project Visit Maintenance TASK 72-00-45-200-003.

      6. Disassemble HPT module by Project Visit Maintenance TASK 72-00-45-200-004. Route HPT hubs to approved sources for inspection by SBE 72-0661 or SBE 72-0713.

        7. After you remove HPT module, do not do engine manual inspections for the interfaces of the HPC rear shaft, diffuser, and stage 1 nozzle assemble that you can see but do the procedure that follows:

          1. Do a Visual Check by SPM TASK 70-20-00-200-501 of the interfaces and hardware that follows:

          1. Rear of stage 1 Nozzle group.

          2. Rear of No. 4 Bearing Compartment.

          3. Section of HPC rear shaft that you can see.

          4. Visually examine the Diffuser case M-flange bolt holes.

            Photograph any findings considered to be unusual wear or damage and give to CTS.

      2. Task B: Installation of LPT and HPT modules and inspection requirements:

        1. Install again the HPT module (TASK 72-00-45-420-000 HPT Assembly – Install The HPT Assembly, Installation-000):

          1. Fits need not be measured, if you install again the same HPT module that was original to the engine.

          1. Location #2225 is not necessary for this Project Visit only.

          2. Location #2246 can be estimated if one or more parts were replaced/repaired, or if wear/distortion are visible.

        2. Install again the LPT/TEC module (TASK 72-00-50-420-000 LPT Module – Install The LPT Module, Installation-000):

        1. Fits need not be measured, if you install again the same LPT/TEC module that was orginal to the engine and the HPT hardware at LPT interface locations 5623 and 5624 is original to the engine.

        2. Install the LPT shaft, use the correlation marks with LPC stub shaft that were applied before you remove LPT/TEC module. The adjustment ring for the axial setting of the LPT module stays the same only if the identical hardware will be assembled again.

      3. Complete the installation procedure again for the external hardware removed to enable HPT disassembly.

Requirements After Job Completion

Follow-On Conditions

Action/ConditionData Module/Technical Publication
Engine performance must satisfy the limits of Engine Manual Test 8.TASK 71-00-00-700-008-B00
Engine performance must satisfy the limits of Engine Manual Test 10.TASK 71-00-00-700-010-B00
Acceptable visual check of LPC and HPC gaspath that confirms airfoils did not sustain damage during test.
Engine does not need any reduced interval inspections at re-delivery.
Upon completion of test Engine, a serviceability tag (Form 8130) is needed.
Change Type:

Revised the procedure in its entirety. (16VC106B)