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TASK 72-32-01-300-806
1 . Replacement of the Stage 3 and Stage 4 Shrouds.
A.This procedure gives instructions to repair the HPC stator forward case assembly (case assembly) by removing and replacing the damaged stage 3 and/or stage 4 shrouds. Refer to Figure 901.
B.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.
(4)Visual Inspection.
(c)Do an inspection of the stage 3 shroud and stage 4 shroud flowpath surfaces for:
1Rubs and gouges:
Maximum repairable limit:
Any amount.
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount.
3Local scabs (positive metal pickup from the blades):
Maximum repairable limit:
Any amount.
C.The subsequent table gives a list of the part numbers that are applicable to this procedure. All part numbers are applicable to all paragraphs unless specified differently.
 
Part Number(s)
 
2302M67G07  
2302M67G11  
2514M80G01  
2644M01G01  
D.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.
A.Tools and Equipment.
(1)Special Tools. None.
(2)Standard Tools and Equipment. None.
(3)Locally Manufactured Tools. None.
B.Consumable Materials. None.
C.Referenced Procedures.
 
ATA No.
Description
 
70-00-03
Machining Data
 
70-16-00
Marking Practices
 
70-16-04
Vibro-Peen Marking
 
70-16-08
Dot Peen Marking for Optical Character Recognition
 
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
 
70-31-02
Acceptability Limits for Fluorescent Penetrant Inspection
 
70-32-00
Indirect Inspection Methods
 
70-32-03
Spot-Fluorescent-Penetrant Inspection
 
70-42-00
Blending and Removal of High Metal Procedures
 
72-30-00
Disassembly 002
 
72-32-01
Cleaning 001
 
72-32-01
Inspection 001
D.Expendable Parts. None.
E.SPD Information.
(1)Spares Supplied.
 
CSN
Description
 
2303M43P07
Shroud, Stage 3 (stage 3 shroud)
 
2303M43P08
Shroud, Stage 3 (stage 3 shroud)
 
2303M43P09
Shroud, Stage 3 (stage 3 shroud)
 
2303M43P10
Shroud, Stage 3 (stage 3 shroud)
 
2303M43P11
Shroud, Stage 3 (stage 3 shroud)
 
2303M44P08
Shroud, Stage 4 (stage 4 shroud)
 
2303M44P09
Shroud, Stage 4 (stage 4 shroud)
 
2303M44P10
Shroud, Stage 4 (stage 4 shroud)
 
2303M44P11
Shroud, Stage 4 (stage 4 shroud)
 
2303M44P12
Shroud, Stage 4 (stage 4 shroud)
 
2303M44P13
Shroud, Stage 4 (stage 4 shroud)
 
2327M84P01
Key, Lock (lock key)
 
2327M84P02
Key, Lock (lock key)
 
2327M84P03
Key, Lock (lock key)
 
2327M84P04
Key, Lock (lock key)
(2)Protected Spares. None.
(3)Locally Manufactured Spares. None.
F.Special Solutions. None.
G.Test Specimens. None.
3 . Dimensional Information.
Subtask 72-32-01-220-118
A.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 re-convert from millimeters to inches.
NOTE:
Reference dimensions do not require inspection.
4 . Setup Information.
Subtask 72-32-01-350-064
A.Set-up the case assembly for machining. Refer to Figure 901 and as follows:
Subtask 72-32-01-930-004
(1)If necessary, make a machining fixture to attach surface C and diameter D of the case assembly to the machine table.
Subtask 72-32-01-350-065
(2)Put the case assembly, aft end down, on the machine table and do as follows:
(a)Adjust the position of the case assembly on the machine table until the flatness of surface C is 0.001 inch (0.02 mm) or less.
(b)Adjust the position of the case assembly on the machine table until the circular runout of diameter D is 0.001 inch (0.02 mm) or less, full indicator reading (FIR).
(c)Attach the case assembly to the machine table.
Subtask 72-32-01-220-119
(3)Do a check of the forward flange dimensions as follows:
(a)Surface B must be parallel to surface C in 0.002 inch (0.05 mm).
(b)Diameter A must be concentric to diameter B in 0.003 inch (0.07 mm).
Subtask 72-32-01-350-066
(4)If necessary, do Subtask 72-32-01-930-004 (paragraph 4.A.(1)) thru Subtask 72-32-01-220-119 (paragraph 4.A.(3)) again to get the correct dimensions.
5 . Procedure.
Subtask 72-32-01-160-009
A.If necessary, clean the case assembly. Refer to TASK 72-32-01-100-801 (72-32-01, CLEANING 001).
Subtask 72-32-01-350-067
B.If necessary, disassemble the case assembly to disconnect the upper and lower case halves. Refer to Figure 901.
Subtask 72-32-01-350-068
C.If necessary, remove the stage 3 shrouds from the case assembly. Refer to Figure 901 and as follows:
(1)If there is a stage 3 spline seal, remove it from the end slot of the stage 3 shroud.
NOTE:
There are no stage 3 spline seals along the split-line between the upper and lower halves of the case assembly.
NOTE:
Spline seals are no longer necessary. It is possible that the new case assemblies have no spline seals.
(2)Smoothly move a stage 3 shroud to remove it from the rail.
(3)Remove a lock key from the related case assembly slot.
(4)Do Subtask 72-32-01-350-068 (paragraph 5.C.(1)) thru (paragraph 5.C.(3)) again until you remove all stage 3 shrouds.
(5)Discard all stage 3 shrouds, spline seals, and lock keys. Stage 3 shrouds are not repairable.
Subtask 72-32-01-350-069
D.If necessary, remove the stage 4 shrouds from the case assembly. Refer to Figure 901 and as follows:
(1)If there is a stage 4 spline seal, remove it from the end slot of the stage 4 shroud.
NOTE:
There are no stage 4 spline seals along the split-line between the upper and lower halves of the case assembly.
NOTE:
Spline seals are no longer necessary. It is possible that new case assemblies have no spline seals.
(2)Smoothly move a stage 4 shroud to remove it from the rail.
(3)Remove a lock key from the related case assembly slot.
(4)Do Subtask 72-32-01-350-069 (paragraph 5.D.(1)) thru (paragraph 5.D.(3)) again until you remove all stage 4 shrouds.
(5)Discard all stage 4 shrouds, spline seals, and lock keys. Stage 4 shrouds are not repairable.
Subtask 72-32-01-350-070
E.Get new sets of stage 3 and/or stage 4 shrouds and lock keys. Refer to Figure 902, Figure 903, paragraph 2.E., and do as follows:
(1)You must replace the shrouds with a new set for each stage as necessary and as follows:
(a)Make sure that you get the correct quantity and position for each set.
NOTE:
Stage 3 and stage 4 shroud sets have specific quantities and positions for each SPD part.
Subtask 72-32-01-350-071
(2)Alternative Procedure Available. Put clock location marks on the new stage 3 and/or stage 4 shrouds. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES), TASK 70-16-04-350-019 (VIBRO-PEEN MARKING), Figure 904, and as follows:
(a)Start with the stage 3 shroud that is at the 12 o’clock position and continue clockwise, forward looking aft, put marks of numbers from 1 to 8 on the stage 3 shrouds.
(b)Start with the stage 4 shroud that is at the 12 o’clock position and going clockwise, forward looking aft, put marks of numbers from 1 to 10 on the stage 4 shrouds.
(c)Put a mark with the serial number of the case assembly on all stage 3 and/or stage 4 shrouds.
Subtask 72-32-01-350-072
(2).A.Alternative Procedure. Put clock location marks on the new stage 3 and/or stage 4 shrouds. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES), TASK 70-16-08-350-001 (DOT PEEN MARKING FOR OPTICAL CHARACTER RECOGNITION), Figure 904, and as follows:
(a)Start with the stage 3 shroud that is at the 12 o’clock position and continue clockwise, forward looking aft, put marks of numbers from 1 to 8 on the stage 3 shrouds.
(b)Start with the stage 4 shroud that is at the 12 o’clock position and continue clockwise, forward looking aft, put marks of numbers from 1 to 10 on the stage 4 shrouds.
(c)Put a mark with the serial number of the case assembly on all stage 3 and/or stage 4 shrouds.
Subtask 72-32-01-350-073
F.If necessary, install the new stage 3 shrouds into the upper and lower case halves. Refer to Figure 902 and as follows:
(1)Install the shrouds in the upper case half as follows:
(a)Move the shroud (item 3) into the rail at the 3 o’clock position until it is fully through the lock key (item 8) position.
(b)Move the shroud (item 2) into the rail at the 3 o’clock position until it is fully through the lock key (item 7) position.
(c)Install the lock key (item 7) into the slot.
(d)Move the shroud (item 2) in the opposite direction until it engages with the lock key (item 7).
(e)Install the lock key (item 8) into the slot.
(f)Move the shroud (item 3) in the opposite direction until it engages with the lock key (item 8).
(g)Install the lock key (item 9) into the slot at the 12 o’clock position.
(h)Move the shroud (item 4) into the rail at the 9 o’clock position until it engages with the lock key (item 9).
(i)Install the lock key (item 9) into the slot at the 10:30 o’clock position.
(j)Move the shroud (item 5) into the rail at the 9 o’clock position until it engages with the lock key (item 9).
(2)Install the shrouds in the lower case half as follows:
(a)Move the shroud (item 1) into the rail at the 9 o’clock position until it is fully through the lock key (item 6) position at the 7:30 o’clock position.
(b)Move the shroud (item 1) into the rail at the 9 o’clock position until it is fully through the lock key (item 6) at the 9 o’clock position.
(c)Install the lock key (item 6) into the slot at the 9 o’clock position.
(d)Move the shroud (item 1) that you installed second in the opposite direction until it engages with the lock key (item 6) at the 9 o’clock position.
(e)Install the lock key (item 6) into the slot at the 7:30 o’clock position.
(f)Move the shroud (item 1) that you installed first in the opposite direction until it engages with the lock key (item 6) at the 7:30 o’clock position.
(g)Install the lock key (item 6) into the slot at the 6 o’clock position.
(h)Move the shroud (item 1) into the rail at the 3 o’clock position until it engages with the lock key (item 6) at the 6 o’clock position.
(i)Install the lock key (item 6) into the slot at the 4:30 o’clock position.
(j)Move the shroud (item 1) into the rail at the 3 o’clock position until it engages with the lock key (item 6) at the 4:30 o’clock position.
Subtask 72-32-01-350-074
G.If necessary, install the new stage 4 shrouds into the upper and lower case halves. Refer to Figure 903 and as follows:
(1)Install the shrouds in the upper case half as follows:
(a)Move the shroud (item 3) into the rail at the 3 o’clock position until it is fully through the lock key (item 9) position at the 2 o’clock position.
(b)Move the shroud (item 2) into the rail at the 3 o’clock position until it is fully through the lock key (item 8) position.
(c)Install the lock key (item 8) into the slot.
(d)Move the shroud (item 2) in the opposite direction until it engages with the lock key (item 8).
(e)Install the lock key (item 9) into slot at the 2 o’clock position.
(f)Move the shroud (item 3) in the opposite direction until it engages with the lock key (item 9) at the 2 o’clock position.
(g)Install the lock key (item 10) into the slot at the 12:30 o’clock position.
(h)Move the shroud (item 4) into the rail at the 9 o’clock position until it engages with the lock key (item 10) at the 12:30 o’clock position.
(i)Install the lock key (item 10) into the slot at the 11:30 o’clock position.
(j)Move the shroud (item 5) into the rail at the 9 o’clock position until it engages with the lock key (item 10) at the 11:30 o’clock position.
(k)Install the lock key (item 9) into the slot at the 10 o’clock position.
(l)Move the shroud (item 6) into the rail at the 9 o’clock position until it engages with the lock key (item 9) at the 10 o’clock position.
(2)Install the shrouds in the lower case half as follows:
(a)Move the shroud (item 1) into the rail at the 9 o’clock position until it is fully through the lock key (item 7) position at the 8 o’clock position.
(b)Move the shroud (item 1) into the rail at the 9 o’clock position until it is fully through the lock key (item 7) position at the 9 o’clock position.
(c)Install the lock key (item 7) into the slot at the 9 o’clock position.
(d)Move the shroud (item 1) that you installed second in the opposite direction until it engages with the lock key (item 7) at the 9 o’clock position.
(e)Install the lock key (item 7) into the slot at the 8 o’clock position.
(f)Move the shroud (item 1) that you installed first in the opposite direction until it engages with the lock key (item 7) at the 8 o’clock position.
(g)Install the lock key (item 7) into the slot at the 6:30 o’clock position.
(h)Move the shroud (item 1) into the rail at the 3 o’clock position until it engages with the lock key (item 7) at the 6:30 o’clock position.
(i)Install the lock key (item 7) into the slot at the 5:30 o’clock position.
(j)Move the shroud (item 1) into the rail at the 3 o’clock position until it engages with the lock key (item 7) at the 5:30 o’clock position.
(k)Install the lock key (item 7) into the slot at the 4 o’clock position.
(l)Move the shroud (item 1) into the rail at the 3 o’clock position until it engages with the lock key (item 7) at the 4 o’clock position.
Subtask 72-32-01-350-075
H.Assemble the upper and lower case halves of the case assembly. Refer to TASK 72-32-01-200-801 (72-32-01, INSPECTION 001).
Subtask 72-32-01-320-013
I.Machine the stage 3 and/or stage 4 shroud flow paths. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 905, and as follows:
(1)Set-up the case assembly for machining. Refer to Subtask 72-32-01-350-064 (paragraph 4.A.).
(2)Do not machine into the adjacent case assembly surfaces.
Subtask 72-32-01-320-014
J.Machine the lobes on the stage 3 and/or stage 4 shroud flow paths. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 904, Figure 906, Figure 907, and as follows:
(1)If necessary, machine the stage 3 shroud flow path only between point JU and point JV.
(2)If necessary, machine the stage 4 shroud flow path only between point JW and point JX.
Subtask 72-32-01-350-076
CAUTION:
REMOVE ONLY THE MINIMUM QUANTITY OF MATERIAL NECESSARY OR DAMAGE TO THE CASE ASSEMBLY CAN OCCUR.
K.Blend the stage 3 and/or stage 4 shrouds. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
(1)Blend the forward and aft edges of the stage 3 and/or stage 4 shroud flow paths to get a step of 0.004 inch (0.10 mm) or less from the stage 3 and/or stage 4 shrouds to the adjacent case assembly surfaces.
(2)Do not remove material from the case assembly surfaces.
Subtask 72-32-01-350-077
L.Disassemble the case assembly to disconnect the upper and lower case halves. Refer to TASK 72-30-00-030-803 (72-30-00, DISASSEMBLY 002).
Subtask 72-32-01-350-078
M.Remove the stage 3 and/or stage 4 shrouds from the case assembly. Refer to Subtask 72-32-01-350-068 (paragraph 5.C.) thru Subtask 72-32-01-350-069 (paragraph 5.D.).
Subtask 72-32-01-160-010
N.Clean the stage 3 and/or stage 4 shrouds and case assembly. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-32-01-110-017
O.Etch the machined areas of stage 3 and/or stage 4 shrouds. 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 C etchant.
Subtask 72-32-01-220-120
P.Do an inspection of the stage 3 and/or stage 4 shrouds machined areas. 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 D penetrant.
(2)Refer to TASK 70-31-02-220-003 (ACCEPTABILITY LIMITS FOR FLUORESCENT PENETRANT INSPECTION) and as follows:
(a)Use Class A limits.
Subtask 72-32-01-350-079
Q.Install the machined stage 3 and/or stage 4 shrouds into the upper and lower case halves. Refer to Subtask 72-32-01-350-073 (paragraph 5.F.) thru Subtask 72-32-01-350-074 (paragraph 5.G.).
Subtask 72-32-01-350-080
R.Assemble the upper and lower case halves of the case assembly. Refer to TASK 72-32-01-200-801 (72-32-01, INSPECTION 001).
Subtask 72-32-01-220-121
S.Do a dimensional inspection of the stage 3 and/or stage 4 flow paths. Refer to Figure 901, Figure 908, Figure 909, and as follows:
(1)For the lobe machined area HE (stage 3) and/or area HC (stage 4), do an inspection of the stage 3 at point HG, point HH, and point HJ, and/or do an inspection of the stage 4 at point HK, point HL, and point HM, and as follows:
(a)Do an inspection of each point at 10 degree increments, full circumference.
(b)The line profile definition gives circumferential relief for machined areas that are more than the 0.006 (0.15 mm) surface profile tolerance.
(2)For the non-lobe machined area HF (stage 3) and/or area HD (stage 4), do an inspection of the stage 3 at point HG, point HH, and point HJ, and/or do an inspection of the stage 4 at point HK, point HL, and point HM, and as follows:
(a)Do an inspection of each point at 10 degree increments, full circumference.
(b)The line profile definition gives circumferential relief for machined areas that are more than the 0.004 inch (0.10 mm) surface profile tolerance.
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Figure 901   (Sheet 1 ) High Pressure Compressor Stator Forward Case Assembly - Dimensions and Locations
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Figure 901   (Sheet 2 ) High Pressure Compressor Stator Forward Case Assembly - Dimensions and Locations
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Figure 902   High Pressure Compressor Stator Forward Case Assembly - Stage 3 Shroud Set
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Figure 903   High Pressure Compressor Stator Forward Case Assembly - Stage 4 Shroud Set
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Figure 904   Stage 3 and Stage 4 Shrouds - Marking Locations
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Figure 905   (Sheet 1 ) Stage 3 and Stage 4 Shroud - Machining Dimensions
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Figure 905   (Sheet 2 ) Stage 3 and Stage 4 Shroud - Machining Dimensions
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Figure 906   Stage 3 Shroud Lobe Machining Dimensions
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Figure 907   Stage 4 Shroud Lobe Machining Dimensions
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Figure 908   (Sheet 1 ) Stage 3 Shroud Dimensional Inspection
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Figure 908   (Sheet 2 ) Stage 3 Shroud Dimensional Inspection
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Figure 909   (Sheet 1 ) Stage 4 Shroud Dimensional Inspection
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Figure 909   (Sheet 2 ) Stage 4 Shroud Dimensional Inspection