* * * FOR ALL
TASK 72-51-01-300-812
1 . Weld Linear Indication Repair of the Inducer Outer Support Wall, Inner Support Wall, and Cross Over Tubes.
A.This procedure gives instructions to repair the high pressure turbine stage 1 nozzle support (nozzle support) by welding the linear indications in the inducer (inducer) outer support wall, inner support wall, and cross over tubes. 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.
(i)Do an inspection of the inducer surfaces for:
3Cracks:
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)
 
2303M22G03  
2303M22G04  
2303M22G05  
2303M22G06  
 
2303M22G08  
2303M22G09  
2303M22G10  
2407M46G02  
 
2407M46G04  
2407M46G06  
2407M46G08  
--  
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.
 
Code No.
Description
 
C06-039
Weld Wire (Rene 220 weld wire)
C.Referenced Procedures.
 
ATA No.
Description
 
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
 
70-33-00
Special Inspection Procedures
 
70-33-02
Capillary Inspection of Open Face Honeycomb Structures
 
70-41-00
Welding and Brazing Practices
 
70-41-03
High Temperature Furnace Braze
 
70-42-00
Blending and Removal of High Metal Procedures
 
70-44-00
Heat Treating
 
70-44-03
Furnace Heat Treatment
 
72-51-01
Cleaning 001
 
72-51-01
Inspection 001
 
72-51-01
Repair 001
 
--
GEAE Photo Standard 8311253, Class 30
D.Expendable Parts. None.
E.SPD Information.
(1)Spare Supplied. None.
(2)Protected Spares. None.
(3)Locally Manufactured Spares. None.
F.Special Solutions. None.
G.Test Specimens. None.
3 . Dimensional Information.
Subtask 72-51-01-220-115
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 72-51-01-350-121
A.Set-up the nozzle support for heat treatment as follows:
(1)Put Hastelloy X shims on top of a graphite plate as follows:
(a)Put the Hastelloy X shims on top of a graphite plate to make sure that the nozzle support will not touch the graphite plate directly during the heat treatment.
CAUTION:
MAKE SURE THAT THE NOZZLE SUPPORT DOES NOT TOUCH THE GRAPHITE PLATE DIRECTLY. IF IT TOUCHES THE GRAPHITE AT THE HEAT TREATMENT TEMPERATURES, DAMAGE TO NOZZLE SUPPORT CAN OCCUR.
(2)Put the nozzle support on the Hastelloy X shims that are equally spaced on the top surface of the graphite plate.
(3)For the quantity and location requirements of the load thermocouples, refer to TASK 70-44-03-370-004 (FURNACE HEAT TREATMENT) .
5 . Procedure.
Subtask 72-51-01-160-027
A.If necessary, clean the nozzle support. Refer to TASK 72-51-01-100-801 (72-51-01, CLEANING 001).
Subtask 72-51-01-350-122
B.Remove the shank nuts from the nozzle support. Refer to TASK 72-51-01-300-801 (72-51-01, REPAIR 001).
Subtask 72-51-01-350-123
C.Blend the linear indication in the inducer to prepare it for welding process. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and Figure 901.
NOTE:
Linear indications are indications that are at least four times longer than they are wide.
Subtask 72-51-01-160-028
CAUTION:
DO NOT USE TOO MUCH ABRASIVE BLASTING. WHEN YOU OPERATE THE EQUIPMENT, MAKE SURE THAT THE ABRASIVE JET IS NOT ON THE SAME AREA FOR TOO LONG. DO NOT STAY FOR MORE THAN 2 SECONDS IN THE SAME AREA. MAKE SURE THAT YOU DO THE ABRASIVE BLAST CLEANING PROCESS BY CLEANING OBLIQUELY ALONG THE FULL SURFACE OF THE NOZZLE SUPPORT OR DAMAGE TO THE NOZZLE SUPPORT CAN OCCUR.
D.Clean the nozzle support. Refer to TASK 72-51-01-100-801 (72-51-01, CLEANING 001).
Subtask 72-51-01-110-039
E.Etch the inducer repair areas of the nozzle support. 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 72-51-01-230-033
F.Do an inspection of the inducer repair area of the nozzle support. Refer to TASK 70-32-00-200-002 (INDIRECT INSPECTION METHODS), TASK 70-32-03-230-002 (SPOT-FLUORESCENT-PENETRANT INSPECTION). Refer to Figure 901, and as follows:
(1)Use Class A penetrant.
(2)linear indications of 0.030 inch (0.76 mm) or less are not interpretable and are permitted.
NOTE:
Linear indications are indications that are at least four times longer than they are wide.
(3)Non-linear indications of 0.060 inch (1.52 mm) or less with a minimum distance of 0.15 inch (3.9 mm) between indications are permitted.
(4)Linear indications of more than 0.030 inch (0.76 mm) are not permitted.
NOTE:
Linear indications are indications that are at least four times longer than they are wide.
(5)Through indications are not permitted.
(6)Microshrinkage must agree with GEAE Photo Standard 8311253, Class 30.
Subtask 72-51-01-370-048
G.Optional Procedure. Alternative Procedure Available. Heat-treat the nozzle support. Refer to TASK 70-44-00-800-010 (HEAT TREATING), TASK 70-44-03-370-004 (FURNACE HEAT TREATMENT) , and as follows:
(1)Set-up the nozzle support for heat treatment. Refer to Subtask 72-51-01-350-121 (paragraph 4.A.).
(2)Do a solution heat treatment of the nozzle support as follows:
(a)Use a vacuum of 1.0 micron of mercury or less.
(b)Increase the temperature of the nozzle support to a temperature range of 1835 to 1885°F (1002 to 1029°C) and keep the temperature for 20-30 minutes.
(c)Decrease the temperature of the nozzle support to 1000°F (538°C) in less than 30 minutes.
(d)Remove the nozzle support from the furnace.
Subtask 72-51-01-370-049
G.A.Optional Procedure. Alternative Procedure. Heat-treat the nozzle support. Refer to TASK 70-44-00-800-010 (HEAT TREATING), TASK 70-44-03-370-004 (FURNACE HEAT TREATMENT) , and as follows:
(1)Set-up the nozzle support for heat treatment. Refer to Subtask 72-51-01-350-121 (paragraph 4.A.).
(2)Do a solution heat treatment of the nozzle support as follows:
(a)Use a vacuum of 1.0 micron of mercury or less.
(b)Increase the temperature of the nozzle support to a range of 1700 to 1750ºF (927 to 954ºC) and as follows:
1Keep this temperature for 10-15 minutes or until the vacuum rate gets back to a vacuum pressure of 5.0 X 10-4 mm Hg or less (6.7 x 10-4 millibar).
CAUTION:
DO NOT KEEP THE TEMPERATURE OF THE NOZZLE SUPPORT AT MORE THAN 1900°F (1038°C) FOR MORE THAN 30 MINUTES (TOTAL ACCUMULATED TIME) OR DAMAGE TO THE HONEYCOMB CAN OCCUR.
(c)Increase the temperature of the nozzle support to a temperature range of 1875 to 1925ºF (1024 to 1052ºC) at a rate of 20 to 25ºF (11 to 14ºC) for each minute and as follows:
1Keep this temperature for a maximum of 3-5 minutes.
2The accumulated time more than 1900ºF must be 30 minutes or less.
(d)Decrease the temperature of the nozzle support to a temperature range of 1750 to 1800ºF (954 to 982ºC) at a minimum rate of 20ºF (11ºC) for each minute and as follows:
1Keep this temperature for 10-15 minutes.
(e)Decrease the temperature of the nozzle support to 975 to 1025ºF (524 to 552ºC) in 30 minutes or less.
NOTE:
The rate of the temperature decrease below 1000ºF (538ºC) is not important.
(f)Remove the nozzle support from the furnace.
Subtask 72-51-01-310-014
H.Weld the inducer prepared areas of the nozzle support. Refer to TASK 70-41-00-310-001 (WELDING AND BRAZING PRACTICES), Figure 901, and as follows:
(1)Use C06-039  Rene 220 weld wire.
Subtask 72-51-01-350-124
WARNING:
DO NOT BREATHE THE PARTICLES FROM BLENDING. PARTICLES FROM BLENDING CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE APPROPRIATE PERSONAL PROTECTION EQUIPMENT, INCLUDING RESPIRATORY PROTECTION, SAFETY GLASSES, AND GLOVES.
I.Blend the inducer welded areas of the nozzle support to the initial contour. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Subtask 72-51-01-160-029
J.Clean the nozzle support. Refer to TASK 72-51-01-100-801 (72-51-01, CLEANING 001).
Subtask 72-51-01-230-034
K.Optional Procedure. Alternative Procedure Available. Do an inspection of the inducer repair area of the nozzle support. 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 A penetrant.
(2)Linear indications of 0.030 inch (0.76 mm) or less are not interpretable and are permitted.
NOTE:
Linear indications are indications that are at least four times longer than they are wide.
(3)Non-linear indications 0.060 inch (1.52 mm) or less with a minimum distance of 0.15 inch (3.9 mm) between indications are permitted.
(4)Linear indications more than 0.030 inch (0.76 mm) are not permitted.
NOTE:
Linear indications are indications that are at least four times longer than they are wide.
(5)Through indications are not permitted.
(6)Microshrinkage must agree with GEAE Photo Standard 8311253, Class 30.
Subtask 72-51-01-230-035
K.A.Optional Procedure. Alternative Procedure. Do an inspection of the inducer repair area of the nozzle support. 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 A penetrant.
(2)Linear indications of 0.030 inch (0.76 mm) or less are not interpretable and are permitted.
NOTE:
Linear indications are indications that are at least four times longer than they are wide.
(3)Non-linear indications 0.060 inch (1.52 mm) or less with a minimum distance of 0.15 inch (3.9 mm) between indications are permitted.
(4)Linear indications more than 0.030 inch (0.76 mm) are not permitted.
NOTE:
Linear indications are indications that are at least four times longer than they are wide.
(5)Through indications are not permitted.
(6)Microshrinkage must agree with GEAE Photo Standard 8311253, Class 30.
Subtask 72-51-01-160-030
L.If necessary, clean the nozzle support. Refer to TASK 72-51-01-100-801 (72-51-01, CLEANING 001).
Subtask 72-51-01-370-050
M.Alternative Procedure Available. Heat-treat the nozzle support. Refer to TASK 70-44-00-800-010 (HEAT TREATING), TASK 70-44-03-370-004 (FURNACE HEAT TREATMENT), and as follows:
(1)Set-up the nozzle support for heat treatment. Refer to Subtask 72-51-01-350-121 (paragraph 4.A.).
(2)Do a solution heat treatment of the nozzle support as follows:
(a)Use a vacuum of 1.0 micron of mercury or less.
(b)Increase the temperature of the nozzle support to a temperature range of 1835 to 1885°F (1002 to 1029°C) and keep the temperature for 20-30 minutes.
(c)Decrease the temperature of the nozzle support to 1000°F (538°C) in less than 30 minutes.
(d)Remove the nozzle support from the furnace.
Subtask 72-51-01-370-051
M.A.Alternative Procedure. Heat-treat the nozzle support. Refer to TASK 70-44-00-800-010 (HEAT TREATING), TASK 70-44-03-370-004 (FURNACE HEAT TREATMENT) , and as follows:
(1)Set-up the nozzle support for heat treatment. Refer to Subtask 72-51-01-350-121 (paragraph 4.A.).
(2)Do a solution heat treatment of the nozzle support as follows:
(a)Use a vacuum of 1.0 micron of mercury or less.
(b)Increase the temperature of the nozzle support to a range of 1700 to 1750ºF (927 to 954ºC) and as follows:
1Keep this temperature for 10-15 minutes or until the vacuum rate gets back to a vacuum pressure of 5.0 x 10-4 mm Hg or less (6.7 x 10-4 millibar).
(c)Increase the temperature of the nozzle support to a temperature range of 1875 to 1925ºF (1024 to 1052ºC) at a rate of 20 to 25ºF (11 to 14ºC) for each minute and as follows:
1Keep this temperature for a maximum of 3-5 minutes.
2The accumulated time more than 1900ºF must be 30 minutes or less.
CAUTION:
DO NOT KEEP THE TEMPERATURE OF THE NOZZLE SUPPORT AT MORE THAN 1900ºF (1038ºC) FOR MORE THAN 30 MINUTES (TOTAL ACCUMULATED TIME) OR DAMAGE TO THE HONEYCOMB CAN OCCUR.
(d)Decrease the temperature of the nozzle support to a temperature range of 1750 to 1800ºF (954 to 982ºC) at a minimum rate of 20ºF (11ºC) for each minute and as follows:
1Keep this temperature for 10-15 minutes.
(e)Decrease the temperature of the nozzle support to 975 to 1025ºF (524 to 552ºC) in 30 minutes or less.
NOTE:
The rate of temperature decrease less than 1000ºF (538ºC) is not important.
(f)Remove the nozzle support from the furnace.
Subtask 72-51-01-370-052
N.For part numbers 2303M22   , heat-treat the nozzle support. Refer to TASK 70-44-00-800-010 (HEAT TREATING), TASK 70-44-03-370-004 (FURNACE HEAT TREATMENT) , and as follows:
(1)Set-up the nozzle support for heat treatment. Refer to Subtask 72-51-01-350-121 (paragraph 4.A.).
(2)Do an age heat treatment of the nozzle support as follows:
(a)Use Cycle V-13 or Cycle I-9.
(3)Remove the nozzle support from the furnace.
Subtask 72-51-01-370-053
O.For part numbers 2407M46   , heat-treat the nozzle support. Refer to TASK 70-44-00-800-010 (HEAT TREATING), TASK 70-44-03-370-004 (FURNACE HEAT TREATMENT) , and as follows:
(1)Set-up the nozzle support for heat treatment. Refer to Subtask 72-51-01-350-121 (paragraph 4.A.).
(2)Do an age heat treatment of the nozzle support as follows:
(a)Heat-treat the nozzle support at 1450 to 1500°F (788 to 816°C) for 8 hours.
(b)Decrease the temperature of the nozzle support to 1000°F (538°C) at a rate not less than 25°F (14°C) for each minute.
(c)Decrease the nozzle support temperature to room temperature.
(d)Remove the nozzle support from the furnace.
Subtask 72-51-01-310-015
P.Do a visual inspection of the inducer brazed areas. Refer to TASK 70-41-00-310-001 (WELDING AND BRAZING PRACTICES), TASK 70-41-03-310-004 (HIGH TEMPERATURE FURNACE BRAZE), and as follows:
(1)The diameter or length of one void and non-bonded areas must not be more than the 0.08 inch (2.0 mm).
(2)There must not be more than three voids or non-bonded areas in a section with a length of 1.0 inch (25 mm) of braze bond area.
(3)Irregular surface porosity is permitted. Indications of 0.015 inch (0.38 mm) or less are not interpretable.
(4)Through voids are not permitted.
Subtask 72-51-01-220-116
Q.Alternative Procedure Available. Do an inspection of the honeycomb. Refer to TASK 70-33-00-999-001 (SPECIAL INSPECTION PROCEDURES), TASK 70-33-02-220-005 (CAPILLARY INSPECTION OF OPEN FACE HONEYCOMB STRUCTURES), and as follows:
(1)You must fully bond the honeycomb core to its backing surface in 80 percent of the total contact area.
(2)Unbonded areas cannot contain more than 10 totally unbonded adjacent cells circumferentially by five totally unbonded adjacent cells axially.
(3)Honeycomb core node bond is not interpretable.
(4)Unbonded areas must have a distance of a minimum of five adjacent bonded cells.
(5)An unbonded area cannot include open cells, partial cells, or splices.
Subtask 72-51-01-220-117
Q.A.Alternative Procedure. Do an inspection of the honeycomb as follows:
(1)Use a video microscope under a minimum of 10X magnification.
(2)Use the inspection limits specified in Subtask 72-51-01-220-116 (paragraph 5.Q.).
Subtask 72-51-01-160-031
R.If necessary, clean the nozzle support. Refer to TASK 72-51-01-100-801 (72-51-01, CLEANING 001).
Subtask 72-51-01-220-118
S.Do an inspection of the nozzle support. Refer to TASK 72-51-01-200-801 (72-51-01, INSPECTION 001).
Subtask 72-51-01-350-125
T.Install the shank nuts again in the nozzle support. Refer to TASK 72-51-01-300-801 (72-51-01, REPAIR 001).
* * * FOR ALL
Figure 901   (Sheet 1 ) High Pressure Turbine Stage 1 Nozzle Support
* * * FOR ALL
Figure 901   (Sheet 2 ) High Pressure Turbine Stage 1 Nozzle Support