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TASK 72-53-42-300-804
1 . General Blend Repair.
A.This procedure gives instructions to repair the HPT rotor forward seal (seal) by blending to remove defects from different areas of the seal. 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 all seal serrations for:
2Nicks, dents, and scratches on the sides of the forward and middle teeth of the OD seal serrations and on the sides of the ID serrations:
NOTE:
Do an inspection of the parts blended before and make sure if they agree with the serviceable limits.
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
2.A.Nicks, dents, and scratches on the sides of the aft tooth of the OD seal serrations:
NOTE:
Do an inspection of the parts blended before and make sure if they agree with the serviceable limits.
Maximum repairable limit:
Not repairable.
3Nicks, dents, and scratches on the tips of the forward and middle teeth of the OD seal serrations and on the tip of the ID serrations:
NOTE:
Do an inspection of the parts blended before and make sure if they agree with the serviceable limits.
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.050 inch (1.27 mm) and with a minimum blend radius of 1.00 inch (25.4 mm). If blending only one tooth, the total blend area must be 0.059 square inch (38.06 square mm) maximum. If blending multiple teeth, the total blend area must be 0.025 square inch (16.12 square mm) maximum for each tooth.
3.A.Nicks, dents, and scratches on the tip of the aft tooth of the OD seal serrations:
NOTE:
Do an inspection of the parts blended before and make sure if they agree with the serviceable limits.
Maximum repairable limit:
Not repairable.
4Bends in the tips of the forward and middle teeth of the OD seal serrations and in the tip of the ID serrations:
NOTE:
Do an inspection of the parts blended before and make sure if they agree with the serviceable limits.
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.050 inch (1.27 mm) and with a minimum blend radius of 1.00 inch (25.4 mm). If blending only one tooth, the total blend area must be 0.059 square inch (38.06 square mm) maximum. If blending multiple teeth, the total blend area must be 0.025 square inch (16.12 square mm) maximum for each tooth.
4.A.Bends in the tip of the aft tooth of the OD seal serrations:
NOTE:
Do an inspection of the parts blended before and make sure if they agree with the serviceable limits.
Maximum repairable limit:
Not repairable.
(d)Do an inspection of the inducer air holes (62 holes) for:
1Nicks, dents, and scratches in the top surface (upper half) of the inducer air holes:
NOTE:
Do an inspection of the parts blended before and make sure if they agree with the serviceable limits.
Maximum repairable limit:
Not repairable.
2Nicks, dents, and scratches in the lower surface (lower half) of the inducer air holes:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
3Nicks, dents, and scratches all around the surface of the forward chamfer of the inducer air holes:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
4Nicks, dents, and scratches in the top surfaces (upper half) of the aft chamfer of the inducer air holes:
Maximum repairable limit:
Not repairable.
5Nicks, dents, and scratches in the lower surfaces (lower half) of the aft chamfer of the inducer air holes:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(e)Do an inspection of the blade retainer (forward and aft) for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(f)Do an inspection of the stage 1 blade interface for:
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.010 inch (0.25 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(g)Do an inspection of the OD bayonet (this does not include fillets adjacent to the bayonet) for:
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.010 inch (0.25 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(h)Do an inspection of the Spiroloc interface for:
1Wear:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(j)Do an inspection of the transition seal neck (forward and aft) for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(k)Do an inspection of the web for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(l)Do an inspection of the OD seal rack and fillet for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.010 inch (0.25 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(m)Do an inspection of the inducer pad for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(n)Do an inspection of the ID seal arm upper for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.010 inch (0.25 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(o)Do an inspection of the ID seal arm lower and fillet for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(p)Do an inspection of the bayonet bore for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(q)Do an inspection of the ID bayonet (including forward and aft surfaces) (this does not include fillets adjacent to the bayonet) for:
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.010 inch (0.25 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(r)Do an inspection of the seal wire groove for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.010 inch (0.25 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(s)Do an inspection of the stage 1 disk rim interface and fillet for:
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(t)Do an inspection of the outer air slot for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.010 inch (0.25 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(u)Do an inspection of the impeller vanes for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.010 inch (0.25 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(v)Do an inspection of the impeller vane slot for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(w)Do an inspection of the aft web transition for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(x)Do an inspection of the stage 1 disk inner interface for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(y)Do an inspection of the ID rabbet fillet for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage blending to a maximum blend depth of 0.005 inch (0.12 mm) and with a minimum blend radius of 0.250 inch (6.35 mm).
(z)Do an inspection of the inner air slot for:
1Nicks, dents, and scratches:
NOTE:
Do an inspection of the parts blended before and make sure if they agree with the serviceable limits.
Maximum repairable limit:
Not repairable.
(aa)Do an inspection of the bayonet rabbet for:
3Footprint impressions on the bayonet rabbet (caused by contact from the HPT stage 1 disk bayonet hook).
Maximum repairable limit:
0.001 inch (0.02 mm) in depth, after polishing.
C.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)
 
2352M60P01  
2417M60P01  
2417M60P02  
2417M60P03  
 
2756M01P01  
2759M04P01  
2793M25P01  
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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
 
C04-166
Shot, Peening, Conditioned Cut Wire (CCW14 steel shot)
 
C10-010
Abrasive Cloth
 
C10-021
Tape, Plastic
 
C10-205
Almen Test Strips (Type N)
C.Referenced Procedures.
 
ATA No.
Description
 
70-21-00
Chemical Cleaning
 
70-21-03
Cleaning Method 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
 
72-53-42
Inspection 001
D.Expendable Parts. None.
E.SPD Information.
(1)Locally Manufactured SPD. None.
F.Special Solutions. None.
G.Test Specimens. None.
3 . Dimensional Information.
Subtask 72-53-42-220-036
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.
None.
5 . Procedure.
Subtask 72-53-42-160-003
A.If necessary, clean the seal. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-53-42-220-037
B.Do a visual inspection of the seal areas that you will repair. Refer to TASK 72-53-42-200-801 (72-53-42, INSPECTION 001) and as follows:
(1)If there are footprint impressions on the bayonet rabbet, polish the footprint impressions to prepare them for inspection. Refer to Subtask 72-53-42-350-007 (paragraph 5.C.).
(2)If there are other damaged areas on the seal, blend the damage. Refer to Subtask 72-53-42-350-004 (paragraph 5.D.).
Subtask 72-53-42-350-007
CAUTION:
FOOTPRINT IMPRESSIONS ON THE BAYONET RABBET MUST BE POLISHED ONLY. IF YOU BLEND FOOTPRINT IMPRESSIONS ON THE BAYONET RABBET, THE FORWARD SEAL WILL BE NOT SERVICEABLE.
C.Polish the footprint impressions on the bayonet rabbet. Refer to Figure 901 and do as follows:
(1)Use C10-010  abrasive cloth to polish the footprint impressions to remove smeared or burred material.
(2)Make sure that you polish the footprint impressions and do not blend into parent metal. Refer to TASK 72-53-42-200-801 (72-53-42, INSPECTION 001) and as follows:
(a)If the footprint impression after polishing is more than the depth limit, you cannot repair the seal with this procedure.
Subtask 72-53-42-350-004
CAUTION:
DO NOT BLEND THE SEAL MORE THAN THE REPAIRABLE LIMITS. IF YOU BLEND MORE THAN THE REPAIRABLE LIMITS, THE FORWARD SEAL WILL BE NOT SERVICEABLE.
D.Blend the damaged areas of the seal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES), Figure 901, and do as follows:
(1)Blend the damaged areas of the seal to the maximum repairable limits specified in this repair procedure. Refer to TASK 72-53-42-200-801 (72-53-42, INSPECTION 001) and as follows:
(a)If you blend more than the repairable limits, you cannot repair the seal with this procedure.
Subtask 72-53-42-160-004
E.Clean the seal blended areas. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-53-42-110-008
F.Etch the seal blended areas. 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 or Class G etchant.
Subtask 72-53-42-230-003
G.Alternative Procedure Available. Do an inspection of the seal blended areas. 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)For the inspection of the polished footprint impressions on the bayonet rabbet, do as follows:
(a)Use a non-aqueous wet developer (NAWD) only.
(b)Make sure that the penetrant application process has a minimum dwell time of 50 minutes.
(3)Indications less than 0.015 inch (0.38 mm) are permitted.
(4)Linear indications are not permitted.
NOTE:
Linear indications are indications that are at least three times longer that they are wide.
(5)No other indications are permitted.
Subtask 72-53-42-230-004
G.A.Alternative Procedure. Do an inspection of the seal blended 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 G penetrant.
(2)For the inspection of the polished footprint impressions on the bayonet rabbet, do as follows:
(a)Use non-aqueous wet developer (NAWD) only.
(b)Make sure that the penetrant application process has a minimum dwell time of 50 minutes.
(3)Indications less than 0.015 inch (0.38 mm) are permitted.
(4)Linear indications are not permitted.
NOTE:
Linear indications are indications that are at least three times longer that they are wide.
(5)No other indications are permitted.
Subtask 72-53-42-350-005
H.Polish the seal to remove the effects of the swab etching procedure as follows:
(1)Use C10-010  abrasive cloth.
Subtask 72-53-42-380-002
I.Peen the seal blended and polished areas. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 901, Figure 902, Figure 903, and as follows:
(1)Apply masking with C10-021  plastic tape to the areas with thermal spray coating.
(2)Use C04-166  CCW14 steel shot.
(3)Peen the seal to an intensity of 6-12N.
(4)Ricochet peening is permitted in area N.
(5)Overspray is permitted.
(6)Coverage of the seal must be a minimum of 125 percent.
(7)Use a scrap part or simulative part fixture for intensity verification and curve generation.
(8)Do an inspection of the intensity in all the seal peened areas with C10-205  Type N and an Almen test strip holder.
(9)Remove all masking from the part.
Subtask 72-53-42-160-005
J.Clean the seal repaired areas. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-53-42-350-006
K.Complete all the necessary repairs.
Subtask 72-53-42-220-038
L.Do a final inspection of the seal. Refer to TASK 72-53-42-200-801 (72-53-42, INSPECTION 001).
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Figure 901   (Sheet 1 ) High Pressure Turbine Rotor Forward Seal
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Figure 901   (Sheet 2 ) High Pressure Turbine Rotor Forward Seal
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Figure 901   (Sheet 3 ) High Pressure Turbine Rotor Forward Seal
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Figure 901   (Sheet 4 ) High Pressure Turbine Rotor Forward Seal
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Figure 901   (Sheet 5 ) High Pressure Turbine Rotor Forward Seal
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Figure 901   (Sheet 6 ) High Pressure Turbine Rotor Forward Seal
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Figure 901   (Sheet 7 ) High Pressure Turbine Rotor Forward Seal
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Figure 902   (Sheet 1 ) High Pressure Turbine Rotor Forward Seal - Shotpeening
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Figure 902   (Sheet 2 ) High Pressure Turbine Rotor - Forward Seal - Shotpeening
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Figure 903   High Pressure Turbine Rotor Forward Seal - Shotpeen Intensity Verification