* * * FOR 1B/P/G03.1B/P/G04.1B/P1/G01
TASK 72-53-43-200-801
1 . General.
  A.This procedure gives instructions to do an inspection of the high pressure turbine (HPT) rotor interstage seal (interstage seal) (01-170 , 72-53-00) (SIN 150B3) or (01-170A , 72-53-00) (SIN 150B3).
B.There are two configurations for the interstage seal:
(1)Configuration 1 interstage seal does not have a corrosion resistant coating on the outer rim surfaces of the seal.
(2)Configuration 2 interstage seal has a corrosion resistant coating on the outer rim surfaces of the interstage seal.
(3)For both configurations refer to area CW in Figure 801.
2 . Tools, Equipment, and Materials.
NOTE:
You can use equivalent alternatives for tools, equipment, and consumable materials.
A.Tools and Equipment.
(1)Special Tools. None.
(2)Standard Tools and Equipment.
 
Description
Manufacturer
 
Eddy Current Inspection Kit (GE-FQAP-428)
GE Aircraft Engines, QTC Attention: Brenda Tenley One Neumann Way, MD:Q8 Cincinnati, Ohio 45215 Phone: (513) 552-4701 Fax: (513) 552-4892 Email: brenda.tenley@ae.ge.com
(3)Locally Manufactured Tools. None.
B.Consumable Materials.
 
Code No.
Description
 
C04-166
Shot, Peening, Conditioned Cut Wire (conditioned cut wire)
 
C10-021
Tape, Plastic (masking tape)
 
C10-205
Almen Test Strips (test strips)
C.Referenced Procedures.
 
ATA No.
Description
 
70-32-02
Fluorescent Penetrant Inspection
 
70-32-10
2 MHz Eddy Current Inspection Of Bores In Inconel Alloy Rotating Engine Hardware Using Systems Under Computer, Numeric, Or Robotic Control
 
70-42-00
Blending And Removal Of High Metal Procedures
 
70-47-01
Shotpeening
 
72-53-43
Special Procedure 001
 
72-53-43
Cleaning 001
 
72-53-43
Repair 001
 
72-53-43
Repair 003
D.Expendable Parts. None.
3 . Specific Inspection Procedure.
NOTE:
Any findings beyond manual limits that may be indicative of a possible crack and/or metallurgical defect must be reported to GE through a myGEAviation Technical Inquiry.
Subtask 72-53-43-350-004
A.Remove the coating from the seal serrations of the interstage seal. Refer to TASK 72-53-43-300-801 (72-53-43, REPAIR 001).
Subtask 72-53-43-350-017
B.For configuration 2 parts only, remove the corrosion resistant coating from area CW of the interstage seal. Refer to TASK 72-53-43-300-802 (72-53-43, REPAIR 003).
Subtask 72-53-43-230-001
C.Do a Class G fluorescent penetrant inspection of the interstage seal. Refer to TASK 70-32-02-230-001 (FLUORESCENT PENETRANT INSPECTION) and as follows:
(1)Apply non-aqueous wet developer (NAWD) to the air crossover hole to air crossover pad radii.
(2)Indications more than 0.015 inch (0.38 mm) are not permitted.
(3)Carefully examine the areas that follow because they are the most important. Refer to Figure 801.
•
Seal bore
•
Air crossover holes and pads
•
Rabbets
•
Seal serrations
•
Forward catenary arm (tip, fillets, and interfaces)
•
Aft catenary arm (fillets, air seal groove, aft rabbet/stage 2 disk interface).
* * * FOR 1B/P/G03.1B/P/G04.1B/P1/G01
Figure 801   (Sheet 1 ) Interstage Seal - Visual Inspection
* * * FOR 1B/P/G03.1B/P/G04.1B/P1/G01
Figure 801   (Sheet 2 ) Interstage Seal - Visual Inspection
Subtask 72-53-43-250-001
D.Do an eddy current inspection of the interstage seal bore as follows:
Subtask 72-53-43-160-001
CAUTION:
DO NOT USE METAL BRUSHES TO CLEAN THE DISK BORES. METAL BRUSHES CAN CAUSE SCRATCHES. SCRATCHES CAN CAUSE THE BORE SURFACES TO BE REJECTED DURING THE EDDY CURRENT INSPECTION.
(1)Make sure that the interstage seal is clean. Refer to 72-53-43-100-801 (72-53-43, Cleaning 001).
Subtask 72-53-43-250-002
(2)Do an eddy current inspection of the bore surfaces. Refer to TASK 70-32-10-250-003 (2 MHZ EDDY CURRENT INSPECTION OF BORES IN ROTATING ENGINE HARDWARE USING SYSTEMS UNDER COMPUTER, NUMERIC, OR ROBOTIC CONTROL) and Figure 802.
NOTE:
This inspection can only be done by identified and approved persons. You cannot accept or reject components until you have been approved.
(a)If you change the equipment or the procedure specified in this inspection, it can have an unwanted effect on the inspection results. Before you change the equipment or the procedure, write to:
GE Aircraft Engines, OTC
One Neumann Way, MD: Q8
Cincinnati, Ohio 45215
USA
(b)The material is Rene 88. Use correction factors for calibration as necessary. Refer to TASK 70-32-10-250-003 (2 MHZ EDDY CURRENT INSPECTION OF BORES IN ROTATING ENGINE HARDWARE USING SYSTEMS UNDER COMPUTER, NUMERIC, OR ROBOTIC CONTROL).
(c)Use the GE-FQAP-428inspection kit to do an inspection of the bore zones shown in Figure 802.
(d)Examine the inspection results. Use the limits that follow:
1The eddy current inspection limit is 1500 mV.
2If the amplitude of an indication is more than 1500 mV, the fan disk is not serviceable.
(e)Complete the eddy current data sheets.
(f)Make sure you complete all records during the eddy current inspection. Keep all records made during the inspection.
* * * FOR 1B/P/G03.1B/P/G04.1B/P1/G01
Figure 802   Interstage Seal - Eddy Current Bore Inspection
Subtask 72-53-43-220-116
E.Do a focused inspection of the air crossover holes of the interstage seal. Refer to TASK 72-53-43-800-801 (72-53-43, SPECIAL PROCEDURES 001).
4 . Visual Inspection.
Refer to Figure 801.
Subtask 72-53-43-220-001
A.Do an inspection of all areas of the interstage seal for:
(1)Cracks:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-002
B.Do an inspection of all areas (this does not include the seal serrations, inner diameter (ID) bayonet pocket, forward and aft rabbet fillets, seal wire grove, air crossover holes, web and hub faces, stages 1 and 2 disk interfaces, seal bore, forward catenary arm, and aft catenary arm) of the interstage seal for:
(1)Scratches:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-803 (72-53-43, REPAIR 002) .
Subtask 72-53-43-220-003
(2)Nicks and dents:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-803 (72-53-43, REPAIR 002) .
Subtask 72-53-43-220-004
C.Do an inspection of the seal serrations for:
(1)Wear on the tip:
Maximum serviceable limit:
Wear is permitted if the conditions that follow are applicable:
• The dimensions are within the dimensional inspection limits. Refer to Subtask 72-53-43-220-024 (paragraph 5.A.).
• There is no metal discoloration.
Repair method:
If metal discoloration is not present, repair. Refer to TASK 72-53-43-300-801 (72-53-43, REPAIR 001) . If metal discoloration is present, replace the interstage seal.
Subtask 72-53-43-220-006
(2)Nicks or dents:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-803 (72-53-43, REPAIR 002) .
Subtask 72-53-43-220-048
(3)Cracks or cracked out areas:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-007
(4)Bending:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-803 (72-53-43, REPAIR 002) .
Subtask 72-53-43-220-008
(5)Wear on diameters AW1, AW2, AW3, and AW4:
Maximum serviceable limit:
Any amount, if the outer diameter (OD) is not less than the dimensional inspection limits. Refer to Subtask 72-53-43-220-027 (paragraph 5.B.) thru Subtask 72-53-43-220-030 (paragraph 5.B.(4)) .
Repair method:
Repair. Refer to TASK 72-53-43-300-801 (72-53-43, REPAIR 001).
Subtask 72-53-43-220-009
D.Do an inspection of the ID bayonet pocket for:
(1)Nicks, dents, scratches, or other damage:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-803 (72-53-43, REPAIR 002) .
Subtask 72-53-43-220-010
E.Do an inspection of the fillets for:
(1)Nicks, dents, scratches, or other damage:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-011
F.Do an inspection of the air crossover holes (15 holes) for:
(1)Nicks, dents, scratches, or other damage:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-013
(2)Damage at the edge radius:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-014
G.Do an inspection of the web and hub faces for:
NOTE:
Small scratches, nicks, dents, or other surface conditions can be seen on the hub and web areas (not the adjacent radii). It is possible these indications were blended to remove high metal, with a depth no greater than 0.001 inch (0.03 mm) deep. This condition is from new production and will have a surface finish that shows signs of shot peen. These indications are permitted.
(1)Nicks, scratches, and fretting less than 0.250 inch (6.35 mm) from any fillet radius:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-803 (72-53-43, REPAIR 002) .
Subtask 72-53-43-220-015
(2)Nicks and scratches in other areas:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-803 (72-53-43, REPAIR 002) .
Subtask 72-53-43-220-016
(3)Dents:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-803 (72-53-43, REPAIR 002) .
Subtask 72-53-43-220-017
H.Do an inspection of the stage 1 disk interface and stage 2 disk interface for:
(1)Fretting:
Maximum serviceable limit:
Raised metal is not serviceable. Pitting 0.010 inch (0.25 mm) in depth is permitted after removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-018
(2)Nicks, dents, and scratches:
Maximum serviceable limit:
0.001 inch (0.03 mm) in depth, after removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .
Repair method:
Repair. Refer to TASK 72-53-43-300-803 (72-53-43, REPAIR 002) .
Subtask 72-53-43-220-020
I.Do an inspection of the seal bore for:
(1)Nicks and scratches:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-803 (72-53-43, REPAIR 002) .
Subtask 72-53-43-220-021
(2)Dents:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-803 (72-53-43, REPAIR 002) .
Subtask 72-53-43-220-022
(3)Damage in the edge radius:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-803 (72-53-43, REPAIR 002) .
Subtask 72-53-43-220-023
J.Do an inspection of the forward catenary arm and aft catenary arm for:
(1)Nicks, dents, scratches, or other damage:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-803 (72-53-43, REPAIR 002) .
Subtask 72-53-43-220-112
(2)Localized pitting or isolated deposited material on the inner diameter. Refer to Figure 803.
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Not more than 0.005 inch (0.12 mm) in depth, after the removal of high metal.
Repair method:
Blend with a minimum radius of 0.25 inch (6.4 mm) to remove all evidence of localized pitting and deposited material. Refer to TASK 72-53-43-300-803 (72-53-43, REPAIR 002) and as follows:
•
Blending more than the pitting depth is necessary to remove any material diffused into the base metal
•
To make sure there is no sign of unwanted metal material, perform an evaluation of replica of the blended area before etching and FPI. Refer to TASK 70-33-08-220-000 (REPLICATION TO IDENTIFY EVIDENCE OF FOREIGN MATERIAL AFTER BLENDING)
•
After replica evaluation, etch, FPI and shot peen the blended areas. Refer to TASK 72-53-43-300-803 (72-53-43, REPAIR 002).
* * * FOR 1B/P/G03.1B/P/G04.1B/P1/G01
Figure 803   Examples of Isolates/Localized Pitting and Isolated/Localized Deposited Material
5 . Dimensional Inspection.
Refer to Figure 804.
Subtask 72-53-43-220-024
A.Do an inspection of the interstage seal for:
(1)Diameter U:
Minimum serviceable limit:
22.287 inches (566.09 mm).
Maximum serviceable limit:
22.301 inches (566.44 mm).
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-025
(2)Dimension AY:
Minimum serviceable limit:
3.189 inches (81.01 mm).
Maximum serviceable limit:
3.200 inches (81.28 mm).
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-026
(3)Diameter Y:
Minimum serviceable limit:
22.597 inches (573.97 mm).
Maximum serviceable limit:
22.606 inches (574.19 mm).
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-027
B.Do an inspection of the seal serrations (AW1, AW2, AW3, AW4) as follows:
NOTE:
The minimum and maximum serviceable limits are for reference only. The diameters are applicable only after the coating is applied.
(1)Diameter AW1:
Minimum serviceable limit:
24.592 inches (624.64 mm).
Maximum serviceable limit:
24.596 inches (624.73 mm).
Repair method:
Repair. Refer to TASK 72-53-43-300-801 (72-53-43, REPAIR 001).
Subtask 72-53-43-220-028
(2)Diameter AW2:
Minimum serviceable limit:
24.472 inches (621.59 mm).
Maximum serviceable limit:
24.476 inches (621.69 mm).
Repair method:
Repair. Refer to TASK 72-53-43-300-801 (72-53-43, REPAIR 001).
Subtask 72-53-43-220-029
(3)Diameter AW3:
Minimum serviceable limit:
24.352 inches (618.55 mm).
Maximum serviceable limit:
24.356 inches (618.64 mm).
Repair method:
Repair. Refer to TASK 72-53-43-300-801 (72-53-43, REPAIR 001).
Subtask 72-53-43-220-030
(4)Diameter AW4:
Minimum serviceable limit:
24.232 inches (615.50 mm).
Maximum serviceable limit:
24.236 inches (615.59 mm).
Repair method:
Repair. Refer to TASK 72-53-43-300-801 (72-53-43, REPAIR 001).
* * * FOR 1B/P/G03.1B/P/G04.1B/P1/G01
Figure 804   Interstage Seal - Dimensional Inspection
6 . Post Inspection Procedure.
Subtask 72-53-43-380-004
A.Shot peen the surfaces in the marked zones. Refer to Figure 805, TASK 70-47-01-380-016 (SHOTPEENING), and as follows:
(1)Mask all the area that will not peen as follows:
(a)Use C10-021  masking tape or an applicable equivalent as necessary.
(2)Use C04-166  conditioned cut wire.
(3)Shot peen to an intensity of 6-12N.
(4)Use C10-205  test strips.
(5)A minimum coverage of 125 percent is necessary.
(6)Remove all the masking tape.
Subtask 72-53-43-350-002
B.Apply the coating to the seal serrations. Refer to TASK 72-53-43-300-801 (72-53-43, REPAIR 001).
Subtask 72-53-43-350-018
C.For configuration 2 parts only, apply the corrosion resistant coating to area CW. Refer to Figure 801 and TASK 72-53-43-300-802 (72-53-43, REPAIR 003).
* * * FOR 1B/P/G03.1B/P/G04.1B/P1/G01
Figure 805   HPT Mid Seal - Post Inspection Shot Peening Zones