TASK 72-45-00-200-002-I00 HPT Stage 2 Airseal - Examine, Inspection-002

DMC:V2500-A5-72-45-0012-00I-300A-C|Issue No:007.00|Issue Date:2020-08-01

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

V2500-A5

Common Information

TASK 72-45-00-200-002-I00 HPT Stage 2 Airseal - Examine, Inspection-002

Effectivity

FIG/ITEM

PART NO.

01-080

2A4157

General

This TASK gives the procedure for the inspection of the stage 2 HPT air seal. For the other parts of the HP turbine rotor and stator assembly, refer to TASK 72-45-00-200-000 (INSPECTION-000).

Fig/item numbers in parentheses in the procedure agree with those used in the IPC.

The policy that is necessary for the inspection is given in SPM TASK 70-20-00-200-501.

All the parts must be cleaned before any part is examined. Refer to TASK 72-45-00-100-000 (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. Do the test before the part is visually examined.

A** following repair referenced in this inspection indicates that the repair is not yet published in the current revision of the manual and the part must be rejected. Contact IAE for additional information concerning FAA approved repair date.

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 repairs have been completed satisfactorily.

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

References

Refer to SPM for data on these items.

Definitions of damage, SPM TASK 70-02-02-350-501.

Record and control of the lives of parts, SPM TASK 70-05-00-220-501.

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 SPM.

Method of testing for crack indications.

Chemical processes.

Surface protection.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Balancing fixtureLOCALBalancing fixture

Consumables, Materials and Expendables

NONE

Spares

NONE

Safety Requirements

CAUTION

DELETED.

CAUTION

PERFORM SUBTASK 72-45-00-220-196 TO EXAMINE FOR THE PRESENCE OF SOOT AND OIL.

CAUTION

CLEAN THE PART BY TASK 72-45-00-100-002.

CAUTION

FPI THE PART FOR CRACK INDICATIONS BY SUBTASK 72-45-00-230-067.

CAUTION

PERFORM THE SUBTASK 72-45-00-220-206 TO INSPECT BORE DROP DIMENSION.

CAUTION

IF THE BORE DROP DIMENSION WAS OUT OF LIMITS, PERFORM ALL THE SUBTASKS OF THIS INSPECTION AND REPORT ALL FINDINGS TO IAE TECH SERVICES.

Procedure

    1. SUBTASK 72-45-00-220-196 Examine the Stage 2 HPT Airseal (01-080) for Soot and Oil

      CAUTION

      MAKE SURE THAT YOU DO THIS INSPECTION BEFORE YOU CLEAN THE PART OR CLEANING PROCEDURE WILL REMOVE THE INDICATION OF SOOT AND OIL.

    1. Refer to Figure.

      2. Examine the airseal for soot and oil at Location 1.

        1. No soot or oil.

        1. Accept.

        2. Soot or oil.

        1. Do inspection of HPT for possible oil ignition event. Refer to TASK 72-45-00-200-801. Report all findings to IAE Technical Services.

    2. SUBTASK 72-45-00-230-067 Examine the Stage 2 HPT Airseal (01-080) for Cracks

    1. Refer to Figure and Figure.

    2. Clean the Part. Refer to TASK 72-45-00-100-000 (CLEANING-000).

      NOTE

      When you inspect the seal for cracks make sure you check the important areas. These areas are shown in Figure Location 7 and all areas identified in Figure.

      3. Do the test for cracks on the part that is given below. Carefully examine fillet radii at location 7, the knife-edge seals at location 1, the web at location 4 and the tab at location 5. Use the applicable penetrant procedure.

        PART

        TASK/SUBTASK

        Stage 2 HPT airseal

        SPM TASK 70-23-04-230-501 (Dip or spray)

        1. Cracks that go into the base metal at the knife-edges, Location 1.

        1. Repair, VRS3207 TASK 72-45-00-300-004 (REPAIR-004).

        2. Cracks found in the front filled radius.

        1. Reject. Report all findings to IAE Technical Services.

        3. Cracks that go into the base metal at locations other than the knife-edges or front filled radius.

        1. Reject.

          NOTE

          Refer to Step for cracked coating on the knife-edge seals.

    3. SUBTASK 72-45-00-220-197 Examine the Stage 2 HPT Airseal (01-080) for Scratches, Nicks, Dents and Corrosion

      1. Examine the airseal for scratches, nicks, dents and corrosion.

        1. Scratches, nicks, dents or corrosion.

        1. Repair, VRS3208 TASK 72-45-00-300-002 (REPAIR-002).

    4. SUBTASK 72-45-00-220-198 Examine the Stage 2 HPT Airseal (01-080) for Chipped or Cracked Plasma Spray Coating on the Knife-Edge Seals

    1. Refer to Figure and Figure.

      NOTE

      If 10 or more of the HPT Stage 2 cane ring inner segments HPT Stage 2 Ring Segment And Vane Cluster (72-45-24, 02-120) and/or HPT Stage 2 Ring Segment And Vane Cluster (72-45-24, 02-320) have new honeycomb, the stage 2 airseal must be new or have the knife edge coating reapplied (per VRS3209) to prevent knife-edge cracking.

      2. Examine the airseal at Location 1, for chipped or cracked plasma spray coating on the knife-edge seal (5 Locations).

        1. Chipped coating.

          1. If the base metal does not show.

          1. Accept.

          2. Other than Step.

          1. Repair, VRS3209 TASK 72-45-00-300-003 (REPAIR-003) or Repair, VRS3207 TASK 72-45-00-300-004 (REPAIR-004) or Repair, VRS3833 TASK 72-45-00-300-011 (REPAIR-011).

        2. Cracked coating.

          1. If the cracks do not look like they go into the base metal.

          1. Repair, VRS3209 TASK 72-45-00-300-003 (REPAIR-003) or Repair, VRS3207 TASK 72-45-00-300-004 (REPAIR-004) or Repair, VRS3833 TASK 72-45-00-300-011 (REPAIR-011).

          2. Cracks that go into the knife-edge base metal.

          1. Repair, VRS3207 TASK 72-45-00-300-004 (REPAIR-004).

        3. Cracks that go into the pedestal.

        1. Reject.

    5. SUBTASK 72-45-00-220-199 Examine the Stage 2 HPT Airseal (01-080) for Wear on the Rear Contact Faces

    1. Refer to Figure and Figure.

      2. Examine the airseal at Location 3, for wear on the rear contact face.

        1. Wear.

        1. Repair, VRS3208 TASK 72-45-00-300-002 (REPAIR-002).

      3. Examine the airseal at Location 2, for wear on the rear contact face.

        1. Wear not more than 0.002 in. (0.05 mm).

        1. Accept.

        2. Other than in Step.

        1. Repair, VRS3208 TASK 72-45-00-300-002 (REPAIR-002).

    6. SUBTASK 72-45-00-220-200 Examine the Stage 2 HPT Airseal (01-080) for Wear on the Sides of the Front Tabs

    1. Refer to Figure and Figure.

      2. Examine the airseal at Location 5, for wear on the sides of the front tabs.

        1. Wear.

          1. Not more than 0.005 in. (0.13 mm) in depth.

          1. Accept.

          2. Other than Step.

          1. Reject.

    7. SUBTASK 72-45-00-220-201 Examine the Stage 2 HPT Airseal (01-080) for Wear on the Front Contact Faces

    1. Refer to Figure and Figure.

      2. Examine the airseal at Location 6, for wear on the front contact faces (3 Locations).

        1. Wear.

          1. Not more than 0.002 in. (0.05 mm) in depth.

          1. Accept.

          2. Other than Step.

          1. Repair, VRS3208 TASK 72-45-00-300-002 (REPAIR-002) and/or VRS3211 TASK 72-45-00-300-006 (REPAIR-006).

    8. SUBTASK 72-45-00-220-202 Examine the Stage 2 HPT Airseal (01-080) for Wear Marks on the Bore

    1. Refer to Figure and Figure.

      2. Examine the airseal for wear marks on the bore.

        1. No wear marks.

        1. Accept.

        2. Wear marks.

        1. Do inspection of HPT for possible oil ignition event. Refer to TASK 72-45-00-200-801. Report all findings to IAE Technical Services.

    9. SUBTASK 72-45-00-220-203 Examine the Stage 2 HPT Airseal (01-080) for the Axial Length

    1. Refer to Figure.

      NOTE

      If the measured axial length in a free condition is not satisfactory, a held condition is permitted. All dimensions apply when surfaces F and G are flat by 0.002 in. (0.05 mm), diameter D maintains a clearance envelope of 17.136 in. (435.25 mm) diameter, and diameter E maintains a clearance envelope of 18.127 in. (460.43 mm) diameter in a free or held condition. Hold the airseal only on surfaces F and G and diameters D and E.

      2. Examine the airseal at Location 1, for the axial length.

        1. Axial length.

          1. If the axial length is between 2.739 in. and 2.749 in. (69.57 mm and 69.82 mm).

          1. Accept.

          2. Other than Step.

          1. Reject.

      2. Record the average dimension as AB. This recorded dimension AB will be used during assembly process.

    10. SUBTASK 72-45-00-220-204 Examine the Stage 2 HPT Airseal (01-080) for Wear on the Rear Flange Diameter, the Knife-edge Seal Diameters, and the Front Flange Diameter

    1. Refer to Figure.

      NOTE

      If the measured diameters in a free condition are not satisfactory, a held condition is permitted. All dimensions apply when surfaces F and G are flat by 0.002 in. (0.05 mm), diameters D maintains a clearance envelope of 17.136 in. (435.25 mm) diameter, and diameter E maintains a clearance envelope of 18.127 in. (460.43 mm) diameter in a free or held condition. Hold the airseal only surfaces F and G and diameters D and E.

      2. Examine the airseal at Location 1505, for wear on the rear flange diameter.

        1. If the diameter is between 17.131 in. and 17.135 in. (435.13 mm and 435.23 mm).

        1. Accept.

        2. Write down the dimension of the diameter.

        2. If the diameter is between 17.126 in. and 17.131 in. (435.00 mm and 435.13 mm) or between 17.135 in. and 17.1355 in. (435.23 mm and 435.242 mm).

        1. Accept part for select fit only.

          NOTE

          This part can be used only if the mating part has a diameter that will result in fit of reference No. 1505. Refer to TASK 72-45-00-430-001-C00 (ASSEMBLY-001) and TASK 72-45-00-430-001-D00 (ASSEMBLY-001).

        2. Write down the dimension of the diameter.

        3. Other than Step and Step.

        1. Reject.

      3. Examine the airseal at Location 1579, for wear on the knife-edge seal diameters (4 Locations).

        1. If the average diameter of the knife-edges is between 19.156 in. (486.563 mm) and 19.166 in. (486.816 mm) and the coating is not fully worn from the tips of the knife-edges.

        1. Accept.

        2. Write down the dimension of the diameters.

        2. Other than Step.

          1. If the diameter of the knife-edges is a minimum of 19.150 in. (486.410 mm) and the coating is not fully worn from the tips of the knife-edges, do one of the following.

          1. Repair, VRS3209 TASK 72-45-00-300-003 (REPAIR-003). Do this repair if the part was previously repaired by VRS3209.

          2. Repair, VRS3833 TASK 72-45-00-300-011 (REPAIR-011).

          2. If the diameter of the knife-edges is a minimum of 19.126 in. (485.801 mm) after removal of the coatings.

          1. Repair, VRS3833 TASK 72-45-00-300-011 (REPAIR-011).

          3. If the diameter of the knife-edges is less than of 19.126 in. (485.801 mm).

          1. Reject.

      4. Examine the airseal at Location 1503, for wear on the front flange diameter.

        1. If diameter is between 18.122 in. and 18.126 in. (460.30 mm and 460.40 mm).

        1. Accept.

        2. Write down the dimension of the diameter.

        2. If the diameter is between 18.117 in. and 18.122 in. (460.17 mm and 460.30 mm) or between 18.126 in. and 18.1265 in. (460.40 mm and 460.413 mm).

        1. Accept part for select fit only.

          NOTE

          This part can be used only if the mating part has a diameter that will result in fit of reference No. 1503. Refer to TASK 72-45-00-430-001-C00 (ASSEMBLY-001).

        2. Write down the dimension of the diameter.

        3. If the diameter is between 18.117 in. and 18.122 in. (460.17 mm and 460.30 mm) and fit of reference No. 1503 cannot be met.

        1. Repair, VRS3834 TASK 72-45-00-300-012 (REPAIR-012).

        4. Other than Step, Step or Step.

        1. Reject.

    11. SUBTASK 72-45-00-220-205 Examine the Stage 2 HPT Airseal (01-080) for the Engine Cycles of the Part

    1. Refer to Figure.

    2. Examine the airseal at Location 2, for the total engine cycles that was marked before (at each disassembly).

      3. Calculate the new total number of engine cycles for the airseal (You can get the new engine cycles from the operating records).

      1. Add the new engine cycles since the last inspection to the engine cycles that are marked on the airseal.

    4. Do not install the airseal if the total number of engine cycles is more than the maximum cycles given in TASK 05-10-01-200-001-B00 (GROUP A PARTS LIVES, CONFIG-002) or TASK 05-10-01-200-001-C00 (GROUP A PARTS LIVES, CONFIG-003).

      5. Mark the new total number of engine cycles on the airseal.

      1. Electrical contact is only permitted at Location 5.

      2. Mark the airseal at Location 2.

        3. Examine the airseal at Location 5, for electrical contact, burns, pitting and selective attack.

          1. Electrical contact.

          1. Accept.

          2. Burns, pitting or selective attack.

          1. Reject.

    12. SUBTASK 72-45-00-220-206 Examine the Stage 2 HPT Airseal (01-080) for the Bore Drop Dimension

    1. Refer to Figure.

      2. Examine the airseal at Location 3 for the bore drop dimension.

        1. Bore drop dimension.

          1. Between 0.742 in. and 0.782 in. (18.85 mm and 19.86 mm).

          1. Accept.

          2. Other than Step.

          1. Reject.

          2. Do inspection of HPT for possible oil ignition event. Refer to TASK 72-45-00-200-801. Report all findings to IAE Technical Services.

    13. SUBTASK 72-45-00-220-237 Examine the Stage 2 HPT Airseal (01-080) for thickness.

    1. Refer to Figure.

      2. Examine wall thickness.

        1. Wall thickness Dimension A (2 places).

          1. Greater than 0.160 in. (4.06 mm).

          1. Accept.

            NOTE

            Thickness at any distance must be uniform within 0.004 in. (0.10 mm) total throughout 360 degrees.

          2. Other than Step.

          1. Reject.

        2. Wall thickness Dimension B (1 place).

          1. Greater than 0.170 in. (4.32 mm).

          1. Accept.

            NOTE

            Thickness at any distance must be uniform within 0.004 in. (0.10 mm) total throughout 360 degrees.

          2. Other than Step.

          1. Reject.

    14. Figure: Stage 2 HPT Airseal Inspection Locations

    Stage 2 HPT Airseal Inspection Locations

    Figure: Stage 2 HPT Airseal Inspection Locations

    Stage 2 HPT Airseal Inspection Locations

    Figure: Stage 2 HPT Airseal Inspection Locations

    Stage 2 HPT Airseal Inspection Locations

    Figure: Stage 2 HPT Airseal Inspection Locations

    Stage 2 HPT Airseal Inspection Locations

    Figure: Stage 2 HPT Airseal Wall Thickness Inspection Locations

    Stage 2 HPT Airseal Wall Thickness Inspection Locations

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised inspection criteria. (20VC013)

Change Type:

Deleted caution. (19VC682)

Change Type:

Editorial to add inadvertently removed step. (17VC109)

Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Tool Number:Balancing fixture
Tool Name:Balancing fixture