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

	GENX-1B CLEANING,INSPECTION,AND REPAIR MANUAL	Dated: 12/12/2019
	CIR 72-31-43 , REPAIR 001
	HIGH PRESSURE COMPRESSOR ROTOR STAGE 3-4 SPOOL - REPAIR - GENERAL BLEND REPAIR OF THE STAGE 3-4 SPOOL

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TASK 72-31-43-300-802

1 .

General Blend Repair of the Stage 3-4 Spool.

This procedure gives instructions to repair the high pressure compressor rotor stage 3-4 spool (HPC 3-4 spool) by blending. Refer to Figure 901.

The following maximum repairable limits apply to this repair:

NOTE:

The information below gives maximum repairable limits for the applicable Inspection sections. The paragraphs are numbered the same as the manual Inspection sections.

NOTE:

For 72-31-43, Inspection 001. Refer to TASK 72-31-43-200-801 (72-31-43, INSPECTION 001) .

(4)

Visual Inspection.

(c)

Do an inspection of the flange surfaces for:

Nicks, dents, and scratches on the forward flange forward face:

Maximum repairable limit:

• For part number 2357M34G01 : One blend is permitted with a maximum length of 1.5 inches (38 mm). The finished blend depth cannot be more than 0.015 inch (0.38 mm). Blend cannot be within 0.275 inch (6.99 mm) of a bolthole center

• For part number 2439M37G01 and part number 2439M37G02 : One blend is permitted with a maximum length of 1.5 inches (38 mm). The finished blend depth cannot be more than 0.015 inch (0.38 mm) and to a minimum of 0.429 inch (10.90 mm) in radius. Blend cannot be within 0.275 inch (6.99 mm) of a bolthole center.

Nicks, dents, and scratches on the aft flange, forward and aft face, and forward flange aft face:

Maximum repairable limit:

(d)

Do an inspection of the outer diameter surfaces for:

Nicks, dents, and scratches:

Maximum repairable limit:

Any amount, not more than 0.015 inch (0.38 mm) in depth after blending. Nicks/dents/scratches must be located to a minimum of 1.00 inch (25.4 mm) apart.

(f)

Deleted.

(g)

Do an inspection of the retainer hooks for:

Fretting or wear of forward retainer hooks:

Maximum repairable limit:

Any amount, not more than 0.005 inch (0.13 mm) in depth, after the removal of high metal.

(h)

Do an inspection of the seal teeth for:

Nicks, dents, and scratches of stage 2 seal tip:

Maximum repairable limit:

Any amount that can be removed by blending the seal tip to a maximum of 0.040 inch (1.01 mm) in depth and to a minimum of 5.00 inches (127.0 mm) in radius, if the limits in the notes are kept.

NOTE:

Maximum cumulative length of blends on the tooth must not be more than 5.00 inches (127.0 mm).

NOTE:

Total cumulative length of all blends between stages must not be more than 10.00 inches (254.0 mm).

NOTE:

Measurement must be made at the OD of the serration sections.

NOTE:

Minimum distance between blends must not be less than 1.00 inch (25.4 mm).

NOTE:

Blends on the stage of seals cannot be in line axially across more than two serrations in a row.

Nicks, dents, and scratches of stage 3 and stage 4 seal tip:

Maximum repairable limit:

Any amount that can be removed by blending the seal tip to a maximum of 0.040 inch (1.01 mm) in depth, to a minimum of 2.60 inches (66.1 mm) in radius, and to a maximum circumferential length of 1.20 inch (30.4 mm), if the limits in the notes are kept.

NOTE:

Maximum cumulative length of blends on the tooth must not be more than 5.00 inches (127.0 mm).

NOTE:

Total cumulative length of all blends between stages must not be more than 10.00 inches (254.0 mm).

NOTE:

Measurement must be made at the OD of the serration sections.

NOTE:

Minimum distance between blends must not be less than 1.00 inch (25.4 mm).

NOTE:

Blends on the stage of seals cannot be in line axially across more than two serrations in a row.

(i)

Do an inspection of the dovetail for:

Nicks, dents, and scratches on the top fillets:

Maximum repairable limit:

Any amount, not more than 0.005 inch (0.13 mm) in depth, after the removal of high metal.

(k)

Do an inspection of diameter E for:

Nicks and scratches:

Maximum repairable limit:

• For part number 2357M34G01 : Any amount, not more than 0.005 inch (0.13 mm) in depth, after the removal of high metal

• For part number 2439M37G01 and part number 2439M37G02 : Any amount, not more than 0.005 inch (0.13 mm) in depth and to a minimum of 0.143 inch (3.64 mm) in radius after the removal of high metal.

Dents:

Maximum repairable limit:

• For part number 2357M34G01 : Any amount, not more than 0.005 inch (0.13 mm) in depth, after the removal of high metal

• For part number 2439M37G01 and part number 2439M37G02 : Any amount, not more than 0.005 inch (0.13 mm) in depth and to a minimum of 0.143 inch (3.64 mm) in radius after the removal of high metal.

(l)

Do an inspection of diameter F for:

Nicks and scratches:

Maximum repairable limit:

Any amount, not more than 0.005 inch (0.13 mm) in depth after the removal of high metal.

Dents:

Maximum repairable limit:

Any amount, not more than 0.005 inch (0.13 mm) in depth after the removal of high metal.

(m)

Do an inspection of the web-rim fillets:

Nicks, dents, and scratches on stage 3 forward and stage 4 aft/forward web-rim fillets:

Maximum repairable limit:

• For part number 2357M34G01 : Any amount, not more than 0.005 inch (0.13 mm) in depth, after blending if they are a minimum of 1.00 inch (25.4 mm) apart

• For part number 2439M37G01 and part number 2439M37G02 : Any amount, not more than 0.005 inch (0.13 mm) in depth and to a minimum of 0.143 inch (3.64 mm) in radius, after blending if they are a minimum of 1.00 inch (25.4 mm) apart.

Nicks, dents, and scratches on stage 3 aft web-rim fillet:

Maximum repairable limit:

Any amount, not more than 0.005 inch (0.13 mm) in depth after blending, and to a minimum of 0.570 inch (14.48 mm) in radius if they are a minimum of 1.00 inch (25.4 mm) apart.

(n)

Do an inspection of flange scallops:

Nicks, dents, and scratches on stage 3 flange scallop:

Maximum repairable limit:

• For part number 2357M34G01 : Any amount, not more than 0.005 inch (0.13 mm) in depth, after blending if they are a minimum of 1.00 inch (25.4 mm) apart

• For part number 2439M37G01 and part number 2439M37G02 : Any amount, not more than 0.005 inch (0.13 mm) in depth and to a minimum of 0.253 inch (6.43 mm) in radius, after blending if they are a minimum of 1.00 inch (25.4 mm) apart.

Nicks, dents, and scratches on stage 4 flange scallop:

Maximum repairable limit:

Any amount, not more than 0.005 inch (0.13 mm) in depth after blending, and to a minimum of 0.570 inch (14.48 mm) in radius if they are a minimum of 1.00 inch (25.4 mm) apart.

(p)

Do an inspection of the disk bores and bore faces for:

Nicks and dents:

Maximum repairable limit:

Any amount, not more than 0.005 inch (0.13 mm) in depth after blending, and to a minimum of 0.570 inch (14.48 mm) in radius if they are a minimum of 1.00 inch (25.4 mm) apart.

Scratches:

Maximum repairable limit:

Any amount, not more than 0.005 inch (0.13 mm) in depth after blending, and to a minimum of 0.570 inch (14.48 mm) in radius if they are a minimum of 1.00 inch (25.4 mm) apart.

(q)

Do an inspection of all other surfaces for:

Nicks and dents:

Maximum repairable limit:

• For part number 2357M34G01 : Any amount, not more than 0.005 inch (0.13 mm) in depth, after blending if they are a minimum of 1.00 inch (25.4 mm) apart

Scratches:

Maximum repairable limit:

• For part number 2357M34G01 : Any amount, not more than 0.005 inch (0.13 mm) in depth, after blending if they are a minimum of 1.00 inch (25.4 mm) apart

The subsequent table gives a list of the part numbers that are applicable to this repair. All part numbers are applicable to all paragraphs unless specified differently.

Part Number(s)

2357M34G01

2439M37G01

2439M37G02

Proprietary/Complex Process Statement.

(1)

None.

2 .

Tools, Equipment, and Materials.

NOTE:

Repair sources 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. None.

(3)

Locally Manufactured Tools. None.

Consumable Materials.

Code No.

Description

C04-166

Shot, Peening, Conditioned Cut Wire (CCW14 shot)

C10-010

Abrasive Cloth

C10-205

Almen Test Strips (type N Almen strips)

Referenced Procedures.

ATA No.

Description

70-21-00

Chemical Cleaning

70-21-03

Cleaning Method No. 3 - Steam Cleaning

70-24-00

Etching Procedures for Fluorescent-Penetrant Inspection

70-24-01

Swab Etching Procedure

70-32-00

Indirect Inspection Methods

70-32-02

Fluorescent Penetrant Inspection

70-32-03

Spot-Fluorescent-Penetrant Inspection

70-42-00

Blending and Removal of High Metal Procedures

70-47-01

Shotpeening

72-31-43

Inspection 001

Expendable Parts. None.

SPD Information.

(1)

Locally Manufactured SPD. None.

Special Solutions. None.

Test Specimens. None.

3 .

Dimensional Information.

Subtask 72-31-43-220-052

Refer to Figure 901 for specified dimensions and locations.

NOTE:

The dimensional data identified within this procedure was designed using inches as the base unit of measurement for dimensional values. The conversion to millimeters is rounded to one less decimal digit than inches. For minimum dimensions, converted values are rounded up. For maximum dimensions, converted values are rounded down. To avoid conversion errors, do not reconvert from millimeters to inches.

NOTE:

Reference dimensions do not require inspection.

4 .

Setup Information.

None.

5 .

Procedure.

Subtask 72-31-43-350-009

Blend the HPC 3-4 spool. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES), paragraph 1.B., Figure 901, and as follows:

(1)

Remove the minimum quantity of material until it agrees with the maximum blend limits.

Subtask 72-31-43-160-006

Clean the repair areas of the HPC 3-4 spool. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).

Subtask 72-31-43-110-007

Etch the repair areas of the HPC 3-4 spool. Refer to TASK 70-24-00-110-033 (ETCHING PROCEDURES FOR FLUORESCENT-PENETRANT INSPECTION), TASK 70-24-01-110-034 (SWAB ETCHING PROCEDURE), and as follows:

(1)

Use Class B etchant.

Subtask 72-31-43-230-002

Alternative Procedure Available. Do an inspection of the repair areas of the HPC 3-4 spool. Refer to TASK 70-32-00-200-002 (INDIRECT INSPECTION METHODS), TASK 70-32-02-230-001 (FLUORESCENT PENETRANT INSPECTION), and as follows:

(1)

Use Class G penetrant.

(2)

Indications more than 0.015 inch (0.38 mm) are not permitted.

(3)

Linear indications are not permitted.

NOTE:

Linear indications are indications that are at least three times longer that they are wide.

Subtask 72-31-43-230-003

D.A.

Alternative Procedure. Do an inspection of the repair areas of the HPC 3-4 spool. Refer to TASK 70-32-00-200-002 (INDIRECT INSPECTION METHODS), TASK 70-32-03-230-002 (SPOT-FLUORESCENT-PENETRANT INSPECTION), and as follows:

(1)

Use Class G penetrant.

(2)

Indications more than 0.015 inch (0.38 mm) are not permitted.

(3)

Linear indications are not permitted.

NOTE:

Linear indications are indications that are at least three times longer that they are wide.

Subtask 72-31-43-140-002

WARNING:

USE EYE PROTECTION WHEN YOU POLISH MATERIAL OR PARTS. THE PARTICLES CAN CAUSE AN INJURY TO YOUR EYES. USE IN A WELL-VENTILATED AREA.

Polish the HPC 3-4 spool repair area to remove the effects of the swab etching procedure as follows:

(1)

Use C10-010 abrasive cloth.

Subtask 72-31-43-380-002

Peen the repair areas of the HPC 3-4 spool. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 902, Figure 903, and as follows:

(1)

Use C04-166 CCW14 shot.

(2)

Use C10-205 type N Almen strips.

(3)

Peen the HPC 3-4 spool to an intensity of 0.006N-0.012N.

(4)

Intensity verification is necessary at all repaired locations.

(5)

Coverage must be a minimum of 100 percent.

(6)

Ricochet peening is permitted in areas identified in Figure 903.

Subtask 72-31-43-160-007

Clean the repair areas of the HPC 3-4 spool. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).

Subtask 72-31-43-220-051

Do a final inspection of the HPC 3-4 spool blended areas.

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Figure 901 (Sheet 1 ) High Pressure Compressor Rotor Stage 3-4 Spool

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Figure 901 (Sheet 2 ) High Pressure Compressor Rotor Stage 3-4 Spool

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Figure 901 (Sheet 3 ) High Pressure Compressor Rotor Stage 3-4 Spool

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Figure 901 (Sheet 4 ) High Pressure Compressor Rotor Stage 3-4 Spool

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Figure 901 (Sheet 5 ) High Pressure Compressor Rotor Stage 3-4 Spool

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Figure 901 (Sheet 6 ) High Pressure Compressor Rotor Stage 3-4 Spool

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Figure 902 Shot Peen Intensity Verification Locations

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Figure 903 Allowable Ricochet Peening Locations

GE Designated: - CONFIDENTIAL Subject to the restrictions on the media