GENX-1B - CLEANING,INSPECTION,AND REPAIR MANUAL

	GENX-1B CLEANING,INSPECTION,AND REPAIR MANUAL	Dated: 04/30/2019
	CIR 72-00-31 , SPECIAL PROCEDURES 001
	HIGH PRESSURE COMPRESSOR ROTOR ASSEMBLY - SPECIAL PROCEDURE - EDDY CURRENT INSPECTION OF THE COATED SEAL TEETH ON THE CDP SEAL

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TASK 72-00-31-800-801

1 .

Eddy Current Inspection.

This procedure gives instructions to do a manual eddy current inspection of the coated seal teeth on the high pressure compressor rotor (HPCR) CDP Seal for cracking at the tip of the seal teeth. Refer to Figure 201.

This procedure can be used module level, on coated seal teeth.

Personnel that will do this procedure must do the requirements that follow:

(1)

Personnel that do this inspection must be certified by one of the certifications that follow: NAS-410, American Society of Nondestructive Testing (ASNT-TC-1A), Air Transport Association Specification No. 105 (ATA 105), COSAC, or one of the equivalent certification document acknowledged by the local regulatory agencies.

(2)

Make sure that the personnel that do this inspection receive practical training to use this procedure and must demonstrate proficiency in the calibration, inspection, and evaluation routines before accept/reject authority is delegated.

NOTE:

Training personnel on this inspection does not imply that they have completed the requirements for an inspector certification or agree with the appropriate certification document.

NOTE:

Personnel that has received the practical training on other, similar inspection (i.e. CF6-80A/-C2/-E Eddy Current Inspection of the seal teeth on the HPT thermal shield or HPT rotating interstage seal), can be considered as qualified according to TASK 72-00-31-800-801 (paragraph 1.C.(2)) of this document.

2 .

Tools, Equipment, and Materials.

NOTE:

You can use equivalent alternatives for tools, equipment, and consumable materials. However, the repair source must demonstrate and document equivalency.

Tools and Equipment.

(1)

Special Tools. None.

(2)

Standard Tools and Equipment.

Description

Manufacturer

GE Aircraft Engines Inspection Kit GE FQAP-587F

GE Field Support Technology ndttooling@ge.com

Calibration Standard PN SGP-112 (part of inspection kit GE FQAP-587F)

Calibration Standard Holder PN SGP-113 (part of inspection kit GE FQAP-587F)

Eddy Current Probe PN US-2056 (part of inspection kit GE FQAP-587F)

Eddy Current Probe Holder (Spring Included) PN JO57138 (part of inspection kit GE FQAP-587F)

Probe Cable PN 94161 (part of inspection kit GE FQAP-587F)

Teflon Tape PN 5490 (part of inspection kit GE FQAP-587F)

Black Action Marker (size 33 fine) Q404 (part of inspection kit GE FQAP-587F)

Storm Case PN iM2100 (part of inspection kit GE FQAP-587F)

Label (part of inspection kit GE FQAP-587F)

NOTE:

Customers that already have the inspection kit P/N: GE-FQAP-587, do not need to order kit P/N: GE-FQAP-587F.

(3)

Locally Manufactured Tools. None.

Consumable Materials.

Code No.

Description

C04-003

Solvent, General (acetone)

C04-035

Solvent, General (isopropyl alcohol)

Tape, Teflon

Referenced Procedures. None.

Expendable Parts. None.

SPD Information. None.

Special Solutions. None.

Test Specimens. None.

3 .

Dimensional Information.

None.

4 .

Setup Information.

Subtask 72-00-31-350-001

CAUTION:

SEAL TEETH ARE EASILY DAMAGED. USE EXTREME CARE IN HANDLING THE PART.

NOTE:

Parts with blends in the seal teeth, damage or conditions that prevent the probe from moving across the seal teeth cannot be eddy current inspected and must be inspected with FPI by the engine manual.

NOTE:

Make sure that the seal teeth are in the coated condition prior to eddy current inspection.

Make sure that the part number and the serial number of the CDP seal. Refer to Figure 201 and do as follows:

Subtask 72-00-31-350-002

(1)

Put a reference mark on the aft side of the part close to the seal teeth that is radially in line with the slash symbol (/) in the serial number identification (S/N).

NOTE:

If S/N is not visible, place an arbitrary mark for the start position.

NOTE:

This will be the start and stop location for each seal tooth scan.

Subtask 72-00-31-220-081

WARNING:

REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THESE PRODUCTS.

(2)

Perform a visual inspection of the seal teeth and mark on the part the location of any nicks, dents or other anomalies, which may prevent the inspection or cause an indication during inspection. Any damage or condition that prevents the probe from moving across the tooth must be inspected with FPI by the engine manual. If necessary, lightly clean the areas using an approved solvent.

5 .

Procedure.

Subtask 72-00-31-250-001

Do the initial equipment setup as follows:

(1)

Turn the eddy current instrument on.

(2)

Let the instrument warm up. Refer to manufacturer's recommendations or at least 10 minutes before the inspection.

(3)

Adjust the instrument to the initial settings listed in the table that follows:

STAVELEY - NORTEC 19e & 19eII

CONTROL DESCRIPTION

INITIAL SETTING

MAIN

FREQUENCY

500 KHZ

ANGLE

350

H-DB

51 DB

V-DB

51 DB

PROBE DRIVE

HIGH

DISPLAY

SWEEP

OFF

V-POS

50%

H-POS

50%

SCREEN

PERSIST

OFF

DISP ERASE

AS NEEDED

FILTER

LPF

100 HZ

HPF

STAVELEY - NORTEC 24

CONTROL DESCRIPTION

INITIAL SETTING

FREQUENCY

500 KHZ

GAIN

H-DB

50 DB

V-DB

50 DB

PROBE DRIVE

HIGH

ANGLE

170

DISPLAY

SWEEP

OFF

V-POS

50%

H-POS

50%

SCREEN

PERSIST

OFF

SWP ERS

OFF

DISP ERS

AS NEEDED

FILTER

LP FILT

100 HZ

HP FILT

HPF POLE

2-POLE

STAVELEY - NORTEC 2000 Series

CONTROL DESCRIPTION

INITIAL SETTING

MAIN

FREQUENCY

500 KHZ

ANGLE

170

H-DB

50.0 DB

V-DB

50.0 DB

PROBE DRIVE

HIGH

CONT NULL

OFF

DISPLAY

SWEEP

OFF

V-POS

50%

H-POS

50%

SCREEN

PERSIST

OFF

DISP ERASE

AS NEEDED

FILTER

LPF

100 HZ

HPF

HPF POLE

2-POLE

NORTEC 500 Series

ADAPTOR P/N: 9230392

CONTROL DESCRIPTION

INITIAL SETTING

FREQ 1 SETUP

FREQ

500 KHz

ANGLE

170

GAIN - H

GAIN - V

FILTER SETUP

HiPASS

OFF

LowPASS

100

CONT NULL

OFF

PRE AMP

OFF

BALANCE

OFF

DISPLAY SCREEN SETUP

H POS

50.00%

V POS

50.00%

DOT/BOX

DOT

ERASE SETUP

PERSIST

OFF

DISP ERS

AS NEEDED

SWP ERS

OFF

GRATICUL

MAIN DSP

SCAN

SWP MODE

OFF

SETUP

INST. SETUP

PROBE DRIVE

HIGH

ANGSTEP

FRQ MODE

SINGLE

HMIX GN

0 dB

VMIX GN

0 dB

INST. PREFS

LOCK

OFF

LANG

AS NEEDED

SOFTKEY

RIGHT

AUTO ERASE

UNIWEST 454 Series; Pro and Premium Series

CONTROL DESCRIPTION

INITIAL SETTING

FREQ 1

500 KHz

F1 Gain

F1 Rot

290

FREQ 2

Off

DRIVE

High

LP FLT

100 Hz

HP FLT

Off

X Sens

.5 v/Div

Y Sens

X-Null Point

0.0 Div

Y-Null Point

0.0 Div

AUTO CLEAR

AS NEEDED

ROHMANN ELOTEST B1 V3 Series

Adapter P/N: B1-NOB 8H

CONTROL DESCRIPTION

INITIAL SETTING

FREQ

500 KHZ

AUTO

GAIN

24 DB

PREAMP

6 DB

Y AXIS SPREAD

0 DB

X AXIS SPREAD

0 DB

PHASE

290

DISP:

Y/X

FILTER U

HIGHPASS

STATIC

LOWPASS

100 HZ

DOT POSITION X and Y

ROHMANN ELOTEST B1 V4 Series

Adapter P/N: B1-NOB 8H

CONTROL DESCRIPTION

INITIAL SETTING

FREQ

500 KHZ

BWL

GAIN

28/28 DB

PREAMP

10 DB

Y AXIS SPREAD

0 DB

X AXIS SPREAD

0 DB

PHASE

240

DISP:

Y/X

FILTER

HIGHPASS

STATIC

LOWPASS

100 HZ

DOT POSITION X & Y

ROHMANN ELOTEST B300 Series

Adapter P/N: B1-NOB 8H

CONTROL DESCRIPTION

INITIAL SETTING

PARAMETER SETUP

FREQUENCY

500 KHZ

AMPLITUDE

50%

PREAMPLIFIER

10.0 DB

MAIN AMPLIFIER

16.0 DB

SPREAD Y

0.0 DB

TOTAL GAIN Y/X

26.0 DB

PHASE

FILTER

LOPASS

100 HZ

HIPASS

STATIC

DOT POSITION Y

0.00%

DOT POSITION X

0.00%

PERSISTANCE

AS NEEDED

PRB/CHAN SETUP

CHA1

INPUT A

PROBE TYPE

NOT USED

ATTENUATOR

OFF

HOCKING - PHASEC 2200

Probe Adapter P/N: 640-015-007

CONTROL DESCRIPTION

INITIAL SETTING

MODE

DIFF 1CH

DISPLAY

VIEW

CH 1

PERSIST

AS NEEDED

CH 1 FREQ

500 KHZ

CH 1 PHASE

226

CH 1 GAIN

30.0 DB

CH 1 X:Y

0.0DB

HI-PASS

LO-PASS

100 HZ

INP. GAIN

+20DB

X & Y POS

SUBMENU

GRATICULE

RECT.

PROBE

STANDARD

DRIVE

0 DB 2.0 V

HOCKING PHASEC 2s

Probe Adapter P/N: 640-015-007

CONTROL DESCRIPTION

INITIAL SETTING

GAIN DB

28.0/28.0

X DB

Y DB

PHASE

FREQUENCY

500 KHZ

HIPASS HZ

LOPASS HZ

100

BAND LOCK

OFF

PROBE

BRIDGE

LOAD μH

INPUT GAIN

LOW

DISPLAY

SPOT

SWEEP

N/A

PERSIST

AS NEEDED

GRATICULE

GRID 2

SPOT X

50%

SPOT Y

50%

HOCKING PHASEC 2d

Probe Adapter P/N: 640-015-007

CONTROL DESCRIPTION

INITIAL SETTING

GAIN XY1

28.0/28.0

PHASE1

260

FREQ1

500 KHZ

FILTER1

BP/RATIO

HP/LP1

DC/100

PROBE

BRIDGE

DISPLAY

SPOT

GRATICULE

GRID 2

SPOT XY

90/0

SPOT INFO

NONE

PERSIST

AS NEEDED

SWEEP

N/A

LOAD μH

Subtask 72-00-31-820-001

Do the calibration of the system as follows:

(1)

Insert probe P/N: US-2056 into probe holder P/N: JO57138 for the following.

(a)

Make sure the spring is placed over the cable connection side of the probe and is resting on the large diameter of the probe body. Refer to Figure 204.

(b)

Grasp the clamp on the probe holder by the two notched areas and slide it back, (open), until it stops. Refer to Figure 205.

(c)

Insert the probe, coil end first into the probe holder. Refer to Figure 206.

(d)

Make sure the flat sides of the probe body are parallel with the clamp slot and the spring is completely to the bottom of the probe holder counter bored hole. The clamp must glide easily over the top of the spring when closing to keep the probe locked into the holder.

(e)

Connect the inspection probe, P/N: US-2056, to the eddy current instrument with the probe cable, P/N: 94161.

(2)

Apply Teflon tape to the probe as follows:

(a)

Make sure the tape is correctly attached to the bottom of the groove in the probe tip. Refer to Figure 206.

(b)

An acceptable method to attach the tape into the groove is with the use of the calibration standard to push the tape into the bottom of the probe tip groove and swiping the probe along the standard.

(c)

Make sure that the tape does not inhibit movement of the probe inside the probe holder.

CAUTION:

DO NOT PUT TENSION ON THE PROBE CABLE. TENSION WILL CAUSE THE PROBE TO PULL AWAY FROM THE STANDARD SURFACE AND CAN CAUSE A LIFT-OFF EFFECT AND CHANGE IN CALIBRATION SENSITIVITY.

NOTE:

Deleted.

(3)

Put the eddy current probe and probe holder on the calibration standard until the inspection coil is away from the electro discharge machining (EDM) notch.

(4)

Make sure the probe holder is seated flat on the calibration standard holder and the probe spring compresses up when set on the calibration standard. Refer to Figure 202, Figure 203, and Figure 206.

(5)

Null the eddy current instrument.

(6)

Slowly scan the probe across the EDM notch until the notch is detected and observe the response. Scan speed must be kept relatively slow, approximately 3.0 inches (76 mm) per second or less.

NOTE:

While you scan across the EDM notch in different directions, a small difference in notch response can be observed. The highest amplitude response (regardless of scan direction) can be used to set the calibration sensitivity.

(7)

While scanning back and forth across the EDM notch, adjust the instrument phase and gain control until the EDM notch response is vertical and 6 major divisions peak to peak. Refer to Figure 208.

(8)

Null the eddy current instrument again after you do instrument adjustments. Make sure that the probe coil is away from the EDM notch.

(9)

Scan the EDM notch again to make sure that the notch response is still vertical and at 6 major divisions peak to peak.

(10)

Record all instrument settings and requested information on the appropriate inspection data sheet. Refer to Figure 210.

Subtask 72-00-31-250-002

Do the hardware inspection as follows:

NOTE:

Make sure that the seal teeth are in the coated condition prior to do the eddy current inspection.

(1)

Calibrate the equipment. Refer to Subtask 72-00-31-820-001 (paragraph 5.B).

Subtask 72-00-31-250-003

CAUTION:

DO NOT PUT TENSION ON THE PROBE CABLE. TENSION WILL CAUSE THE PROBE TO PULL AWAY FROM THE SEAL TOOTH SURFACE CAUSING A LIFT OFF EFFECT AND CHANGE IN INSPECTION SENSITIVITY.

(2)

Start at the previously marked reference point (S/N). Refer to Subtask 72-00-31-350-002 (paragraph 4.A.(1)).

(3)

Put the eddy current probe on the number one seal tooth. Refer to Figure 201.

(4)

Maintain the probe at an angle similar to the angle of the seal teeth. The bubble level is not used for this inspection. Refer to Figure 207.

(5)

When you put the coil over the seal tooth, make sure the spring applies pressure to the probe and the seal tooth is riding in the groove of both the probe and the probe holder wheels. Refer to Figure 207.

(6)

Try to keep the wheels of the probe holder on the seal teeth so the probe is not restricted while performing the inspection around the seal teeth.

(7)

With the probe properly seated over the seal tooth, null the eddy current instrument.

(8)

Scan the circumference of the part overlapping the start and stop position to make sure a 360 degree coverage of the entire seal tooth. Scan speed must be kept relatively slow, approximately 3.0 inches (76 mm) per second or less.

NOTE:

The scans do not have to be continuous for 360 degrees. The seal tooth can be divided into sections and each section inspected. If this is done, make sure that all scans overlap.

(9)

Monitor the instrument display for any indication equal to or exceeding 3.0 major divisions, regardless of scan direction.

(10)

For any indications equal to or exceeding 3.0 major divisions, perform an evaluation as described in the evaluation section of this document. Record the indication amplitude on the inspection data sheet. Refer to Figure 210.

Subtask 72-00-31-250-004

(11)

It is recommended that the tape be replaced after every tooth is inspected or as needed. A calibration check must be performed before and after every tape change to make sure that the calibration sensitivity has not changed. Refer to Subtask 72-00-31-210-001 (paragraph 5.D.) for a calibration check.

Subtask 72-00-31-250-005

(12)

Do Subtask 72-00-31-250-003 (paragraph 5.C.(2)) thru Subtask 72-00-31-250-004 (paragraph 5.C.(11)) again for the remaining seal teeth.

Subtask 72-00-31-210-001

Do a calibration check as follows:

(1)

Do a calibration check, if you are in the conditions that follow:

(a)

After each inspection.

(b)

The component is changed.

(c)

The operator is changed.

(d)

After loss of power.

(e)

When the operator suspects a change in the system.

(f)

Before and after every tape change.

(g)

At least once every hour.

(2)

Put the eddy current probe and probe holder on the calibration standard until the inspection coil is away from the EDM notch.

(3)

Make sure that the probe holder is setting flat on the calibration standard holder and that the probe spring is compressed when set on the standard.

(4)

Null the eddy current instrument.

(5)

Slowly scan the probe across the EDM notch of the calibration standard and observe the response.

NOTE:

(6)

If the calibration shows to be in a half division full screen height (FSH) (5.5 to 6.5) of the initial calibration again, the test was acceptable.

(7)

If the notch response is less than 5.5 divisions, the system must be calibrated again and all hardware inspected since the last acceptable calibration must be inspected again.

(8)

If the notch response is greater than 6.5 divisions, the system must be calibrated again prior to inspection of additional hardware and any rejected hardware must be inspected again.

Subtask 72-00-31-210-002

Do an evaluation of the indications as follows:

(1)

Indications that are equal or more than three major divisions must be evaluated as follows:

(a)

Make sure that the calibration notch response is still at 6 major divisions in amplitude.

(b)

Do a visual inspection of the seal tooth for any blends, nicks, dents, or other anomalies. Record the results on Figure 210.

WARNING:

REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THESE PRODUCTS.

CAUTION:

DO NOT USE SCOTCH-BRITE. DAMAGE TO THE PART CAN OCCUR.

(c)

If necessary, lightly clean the surface in question with C04-003 acetone or C04-035 isopropyl alcohol.

(d)

If the suspect signal remains but is reduced in amplitude repeat the cleaning process as required to reduce the amplitude to an acceptable level.

(e)

If cleaning fails to reduce the indication to acceptable amplitude (below 3.0 major divisions), document the indications on the inspection data sheet. Refer to Figure 210.

(f)

Reposition the eddy current probe over the suspect area of the seal tooth and scan again several times to make sure that the previously observed indication can be repeated. If the calibration is correct and the indication is repeatable, the indication must be considered valid.

(g)

If the indication is not repeatable or less than (3.0 major divisions), the indication is not valid and must be considered acceptable.

Subtask 72-00-31-280-001

Disposition criteria.

(1)

Any seal tooth indications that are equal or exceed 3 major divisions, must be considered rejected by this procedure.

(2)

If there is no obvious reason for a rejectable eddy current indication, mark and record the location of the seal tooth indication on Figure 210 and continue to process the part to perform the FPI of the seal teeth by the engine manual. FPI must be the only inspection used to determine the serviceability of the part once the coating has been removed.

(3)

If the rejectable eddy current indication appears to be from visual condition (damaged tooth), mark and record the location of the seal tooth indication on Figure 210 and continue to process the part to perform FPI of the seal teeth by the engine manual. FPI must be the only inspection used to determine the serviceability of the part once the coating has been removed.

Subtask 72-00-31-280-002

As a minimum, record all requested information on the inspection data sheet and forward to the local GE Aviation Product Support Engineering representative.

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