* * * FOR ALL PIP 2
TASK 72-53-43-200-806
1 . General.
A.This procedure gives instructions to do an inspection of the HPT rotor interstage seal (interstage seal):
•
(02-170 , 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 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
 
72-53-43
Repair 005
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 72-53-43-350-024
A.Remove the coating from the seal serrations of the interstage seal (diameter AW1, diameter AW2, diameter AW3, and diameter AW4). Refer to TASK 72-53-43-300-801 (72-53-43, REPAIR 001) or TASK 72-53-43-300-805 (72-53-43, REPAIR 005).
Subtask 72-53-43-350-025
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 72-53-43-230-004
C.Do a Class G fluorescent penetrant inspection of the interstage seal. Refer to TASK 70-32-02-230-001 (FLUORESCENT PENETRANT INSPECTION) and do 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)
•
HPT stage 1 retainer interface.
* * * FOR ALL PIP 2
Figure 801   (Sheet 1 ) Interstage Seal - Visual Inspection
* * * FOR ALL PIP 2
Figure 801   (Sheet 2 ) Interstage Seal - Visual Inspection
* * * FOR ALL PIP 2
Figure 801   (Sheet 1 ) Interstage Seal - Visual Inspection
Subtask 72-53-43-250-007
D.Do an eddy current inspection of the interstage seal bore as follows:
Subtask 72-53-43-160-004
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 TASK 72-53-43-100-801 (72-53-43, REPAIR 001).
Subtask 72-53-43-250-008
(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. Unapproved personnel cannot do this inspection.
(a)Changing the equipment or the procedure specified in this inspection can have an unwanted effect on the inspection results. Before changing the equipment or the procedure, write to:
GE Aircraft Engines, OTC
One Neumann Way, MD: Q8
Cincinnati, Ohio 45215
USA
(b)The materials are Rene 88 for interstage seals (02-170B , 72-53-00) (SIN 150B3) and (02-170C , 72-53-00) (SIN 150B3) and Rene 65 for interstage seals (02-170 , 72-53-00) (SIN 150B3) and (02-170A , 72-53-00) (SIN 150B3). 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 to complete all records during the eddy current inspection. Keep all records made during the inspection.
* * * FOR ALL PIP 2
Figure 802   Interstage Seal - Eddy Current Bore Inspection
Subtask 72-53-43-220-117
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 72-53-43-220-120
A.Visual inspection serviceable limits for fretting are not applicable to HPT rotor interstage seal P/N 2383M85P04   with part serial numbers listed in GEnx-1B SB 72-0484 Table 6 and Table 7.
Subtask 72-53-43-220-121
B.Visual inspection serviceable limits for nicks, dents, scratches, fretting, are not applicable to HPT rotor interstage seal P/N 2383M85P04   with part serial numbers listed in GEnx-1B SB 72-0484 Table 8.
Subtask 72-53-43-220-081
C.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 72-53-43-220-082
D.Do an inspection of the seal bore, bore edge radius, and hub faces for:
NOTE:
Visual flaws on the hub and web area (not the adjacent radii) with the appearance of a small scratch, nick, dent, or other surface condition, with a possible blending process to remove high metal with no more than 0.001 inch (0.02 mm) in depth are permitted. Also, the surfaces that have indications of shot peening are permitted (indications of shot peening can be found from production).
(1)Scratches:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-804 (72-53-43, REPAIR 004).
Subtask 72-53-43-220-083
(2)Nicks and dents:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-804 (72-53-43, REPAIR 004).
Subtask 72-53-43-220-084
E.Do an inspection of the seal teeth region 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 72-53-43-220-105 (paragraph 5.B.)
• 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) or TASK 72-53-43-300-805 (72-53-43, REPAIR 005) . If metal discoloration is present, replace the interstage seal.
Subtask 72-53-43-220-085
(2)Nicks, scratches, or dents on 1st tooth (forward tooth):
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-804 (72-53-43, REPAIR 004).
Subtask 72-53-43-220-086
(3)Cracks or cracked out areas:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-087
(4)Bending of serrations on 1st tooth (forward tooth):
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-804 (72-53-43, REPAIR 004) .
Subtask 72-53-43-220-122
(5)Nicks, dents, or scratches on 2nd, 3rd, and 4th teeth:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-123
(6)Bending of 2nd, 3rd, and 4th teeth:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-088
(7)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 72-53-43-220-105 (paragraph 5.B.) thru Subtask 72-53-43-220-108 (paragraph 5.B.(4)) .
Repair method:
Repair. Refer to TASK 72-53-43-300-801 (72-53-43, REPAIR 001) or TASK 72-53-43-300-805 (72-53-43, REPAIR 005) .
Subtask 72-53-43-220-114
(8)Missing coating on the serration tip and on the face (after coating applied):
Minimum serviceable limit:
Missing coating is permitted if the conditions that follow are applicable:
• The dimensions agree with the dimensional limits. Refer to Subtask 72-53-43-220-105 (paragraph 5.B.(1)) thru Subtask 72-53-43-220-108 (paragraph 5.B.(4))
• Chipping or missing thermal spray coating is permitted if lack of coating/chipping on the seal teeth coating is 0.30 inch (7.6 mm) maximum with a total cumulative length of 1.50 inches (38.1 mm) maximum for each tooth and the space between lack of thermal spray coating/chipping is 1.0 inch (26 mm) minimum.
Repair method:
Repair. Refer to TASK 72-53-43-300-801 (72-53-43, REPAIR 001) or TASK 72-53-43-300-805 (72-53-43, REPAIR 005) .
Subtask 72-53-43-220-089
F.Do an inspection of the ID bayonet, for:
(1)Nicks, dents, scratches, or other damage (do not include ID bayonet groove):
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-804 (72-53-43, REPAIR 004).
Subtask 72-53-43-220-124
(2)Nicks, dents, and scratches, or other damage in ID bayonet groove (except within 0.262 inch (6.65 mm) distance from retaining wire slot assembly slot corner). Refer to Figure 801 and as follows:
Maximum serviceable limit (for interstage seal number 2383M85P04 with part serial numbers listed in GEnx-1B SB 72-0484 Table 8):
Not serviceable.
Maximum serviceable limit:
0.005 inch (0.12 mm) in depth, after the removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .
Repair method:
Replace the seal.
Subtask 72-53-43-220-125
(3)Fretting, or other damage in ID bayonet groove (except within 0.262 inch (6.65 mm) distance from retaining wire slot assembly slot corner). Refer to Figure 801 and as follows:
Maximum serviceable limit (for interstage seal number 2383M85P04 with part serial numbers listed in GEnx-1B SB 72-0484 Table 8):
Not serviceable.
Maximum serviceable limit:
0.005 inch (0.12 mm) in depth, after the removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .
Repair method:
Replace the seal.
Subtask 72-53-43-220-126
(4)Nicks, dents, and scratches, fretting or other damage in ID bayonet groove, within 0.262 inch (6.65 mm) distance from retaining wire assembly slot corner. Refer to Figure 801 and as follows:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-804 (72-53-43, REPAIR 004).
Subtask 72-53-43-220-090
G.Do an inspection of the forward web and aft web, do not include the air crossover holes and hole corners, for:
NOTE:
Visual flaws on the forward web and aft web area (not the adjacent radii) with the appearance of a small scratch, nick, dent, or other surface condition, with a possible blending process to remove high metal with no more than 0.001 inch (0.02 mm) in depth, are permitted. Also, the surfaces that have indications of shot peening are permitted (indications of shot peening can be found from production).
(1)Nicks, dents, scratches, or other damage:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-804 (72-53-43, REPAIR 004).
Subtask 72-53-43-220-091
H.Do an inspection of the air crossover holes and hole corners (15 holes) for:
(1)Nicks, dents, scratches, or other damage:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-092
(2)Damage at the edge radius:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-093
I.Do an inspection of the aft damper rail, but do not include the damper hook aft fillets and the damper hook U fillet, for:
NOTE:
Deleted.
(1)Deleted.
Subtask 72-53-43-220-094
(2)Nicks and scratches:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-804 (72-53-43, REPAIR 004).
Subtask 72-53-43-220-095
(3)Dents:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-804 (72-53-43, REPAIR 004).
Subtask 72-53-43-220-096
J.Do an inspection of the aft rabbet for:
(1)Fretting:
Maximum serviceable limit (for interstage seal part number 2383M85P04 with part serial numbers listed in GEnx-1B SB 72-0484):
Not serviceable.
Maximum serviceable limit (for part numbers 2383M85P03, 2383M85P04, and 2383M85P05):
0.002 inch (0.05 mm) in depth, after the removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .
Maximum serviceable limit (for part numbers 2445M71P01 and 2445M71P02):
0.0035 inch (0.088 mm) in depth, after the 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 72-53-43-220-097
(2)Nicks, dents, and scratches:
Maximum serviceable limit (for interstage seal part number 2383M85P04 with part serial numbers listed in GEnx-1B SB 72-0484 Table 8):
Not serviceable.
Maximum serviceable limit:
0.001 inch (0.02 mm) in depth, after the removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .
Repair method:
Not Repairable.
Subtask 72-53-43-220-098
K.Do an inspection of the forward rabbet for:
(1)Nicks, dents, and scratches:
Maximum serviceable limit (for interstage seal number 2383M85P04 with part serial numbers listed in GEnx-1B SB 72-0484 Table 8):
Not serviceable.
Maximum serviceable limit (for part numbers 2383M85P03, 2383M85P04, and 2383M85P05):
0.005 inch (0.12 mm) in depth, after the removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .
Maximum serviceable limit (for part numbers 2445M71P01 and 2445M71P02):
0.004 inch (0.10 mm) in depth, after the removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .
Subtask 72-53-43-220-101
L.Do an inspection of the forward and aft catenary arms for:
(1)Nicks, dents, scratches, or other damage:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-804 (72-53-43, REPAIR 004).
Subtask 72-53-43-220-113
(2)Localized pitting or isolated deposited material on the inner diameter. Refer to Figure 803.
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit (for interstage seal part number 2383M85P04 with part serial numbers listed in GEnx-1B SB 72-0484):
Not repairable.
Maximum repairable limit:
Not more than 0.005 inch (0.12 mm) in depth, after the removal of high metal.
Repair method (for stage interstage seal part number 2383M85P04 with part serial numbers listed in GEnx-1B SB 72-0484):
Replace the interstage seal.
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 72-53-43-300-804 (72-53-43, REPAIR 004) 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, do a replica estimation 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 estimation, etch, FPI and shot peen the blended areas. Refer to TASK 72-53-43-300-804 (72-53-43, REPAIR 004).
Subtask 72-53-43-220-127
M.Do an inspection of the stage 1 retainer interface for:
(1)Nicks, dents, and scratches:
Maximum serviceable limit (for interstage seal number 2383M85P04 with part serial numbers listed in GEnx-1B SB 72-0484 Table 8):
Not serviceable.
Maximum serviceable limit (for part numbers 2383M85P03, 2383M85P04, and 2383M85P05):
0.002 inch (0.05 mm) in depth, after the removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .
Maximum serviceable limit (for part numbers 2445M71P01 and 2445M71P02):
0.001 inch (0.02 mm) in depth, after the removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .
Subtask 72-53-43-220-128
N.Do an inspection of the lip next to the aft rabbet. Refer to Figure 801 and as follows:
(1)Nicks, dents, scratches, or other damage:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-53-43-300-804 (72-53-43, REPAIR 004).
* * * FOR ALL PIP 2
Figure 803   Examples of Isolated/Localized Pitting and Isolated/Localized Deposited Material
5 . Dimensional Inspection.
Refer to Figure 804.
Subtask 72-53-43-220-102
A.Do an inspection of the interstage seal for:
(1)Diameter U:
Minimum serviceable limit:
22.089 inches (561.07 mm).
Maximum serviceable limit:
22.098 inches (561.28 mm).
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-103
(2)Dimension AY:
Minimum serviceable limit:
3.4125 inches (86.678 mm).
Maximum serviceable limit:
3.4255 inches (87.007 mm).
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-104
(3)Diameter Y:
Minimum serviceable limit:
22.597 inches (573.97 mm).
Maximum serviceable limit:
22.607 inches (574.21 mm).
Repair method:
Replace the interstage seal.
Subtask 72-53-43-220-105
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) or TASK 72-53-43-300-805 (72-53-43, REPAIR 005) .
Subtask 72-53-43-220-106
(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) or TASK 72-53-43-300-805 (72-53-43, REPAIR 005) .
Subtask 72-53-43-220-107
(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) or TASK 72-53-43-300-805 (72-53-43, REPAIR 005) .
Subtask 72-53-43-220-108
(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) or TASK 72-53-43-300-805 (72-53-43, REPAIR 005) .
* * * FOR ALL PIP 2
Figure 804   Interstage Seal - Dimensional Inspection
6 . Post Inspection Procedure.
Subtask 72-53-43-380-005
A.Shot peen the surfaces in the marked zones for the interstage seal (02-170B , 72-53-00) (SIN 150B3) and (02-170C , 72-53-00) (SIN 150B3). 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 72-53-43-350-026
B.Apply the coating to the seal serrations. Refer to TASK 72-53-43-300-801 (72-53-43, REPAIR 001) or TASK 72-53-43-300-805 (72-53-43, REPAIR 005).
Subtask 72-53-43-350-027
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 ALL PIP 2
Figure 805   HPT Mid Seal - Post Inspection Shot Peening Zones