Appendix C STAGE 1 LPC BLADE ASSEMBLY - INSPECTION/CHECK-01
- BLADE TIP
OUTER PORTION - PART SPAN SHROUD
OF BLADE -
SHROUD TO AIRFOIL RADIUS (4 PLACES)
FRONT AND REAR
LEADING EDGE SHROUD RADIUS
AREA (FOUR PLACES)
INNER PORTION OF BLADE • TRAILING EDGE
- PLATFORM TO AIRFOIL
RADIUS (ALL AROUND BLADE
AIRFOIL PLATFORM AND BLADE
ROOT SECTION ROOT SECTION
• PLATFORM SEAL Blade Area Nomenclature Figure 801 (Task 72-31-82-990-002) Page 802 EFF: ALL Page 6
Appendix C Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443) STAGE 1 LPC BLADE ASSEMBLY - INSPECTION/CHECK-01
SECTION A - A L-A0968 1285
1. Minimum Trailing Edge Thickness As Measured At Index 2 To Be 0.020 Inch (0.51 mm).
2. 0.040 Inch (1.02 mm) - Measure Leading And Trailing Edge Thickness At This Dimension
3. 12.229 Inch (310.617 mm) - Minimum Leading Edge Thickness As Measured At Index 2 To Be
0.038 Inch (0.965 mm).
4. Minimum Leading Edge Thickness As Measured At Index 2 To Be 0.027 Inch (0.686 mm).
Leading And Trailing Edge Minimum Thickness Limits Figure 802 (Task 72-31-82-990-002) Page 803 EFF: ALL Page 7
AC 43 - 204 8/14/97 Appendix C STAGE 1 LPC BLADE ASSEMBLY - INSPECTION/CHECK-01 L-A0969 Mean Chordal Length Measured Equidistant Between Blends.
2. Blends Must Be separated By Minimum Dimension Equal To Index 1 Dimension.
Minimum Blend Separation Figure 803 (Task 72-31-82-990-002) Page 804 EFF: ALL Page 8
46/57/8 AC 43-204 Appendix C Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443) STAGE 1 LPC BLADE ASSEMBLY - INSPECTION/CHECK-01
(f) If two or more heavily blended blades are found grouped together, an attempt should be made to redistribute these blades and their matching blades evenly throughout rotor.
(g) Total Length of leading and trailing edge blends must not exceed four inches (101.600 mm) and there must not be more than two blends to maximum depth limit per blade.
(2) Visually check leading and trailing edges ofblade for damage whenever foreign NOTE: Use of strong lights and mirrors as well as fingernails and fingertips may aid in locating damaged areas.
CAUTION: USE EXTREME CAUTION WITH ANY ELECTRICAL EQUIP- MENT IN THE VICINITY OF BLADE. CONTACT WITH
ANY ELECTRICAL SOURCE THAT MAY PASS CURRENT TO BLADE SURFACE CAN CAUSE AN ARC BURN. ARC
BURN CAN RESULT IN LOCAL DEGRADATION MATERIAL PROPERTIES AND CRACK INITIATION.
(3) When checking blades for foreign object damage visually inspect for arc burn.
Arc burn is evidenced by a small circular or semi-circular bead affected area on blade surface that may contain shallow pitting, remelt or a crack. Blades with arc burn are not acceptable for further service.
(4) The following procedure is recommended for inspection of 1st stage blade assembly after refurbishment or repair.
Visually inspect blade using a bright light, mirrors, a 3X glass.
fingertips and fingernails, specifically looking for small depressions that interrupt surface contour. Refer to PWA Color Photographs for conditions that have been observed.
(b) Peening tends to remove evidence of heat discoloration and to smooth damage, making it less visually apparent.
(c) Electrical discharge damage has been observed in two different forms:
Strong geometric shapes such as ovals, crescents, or rectangles depressed into blade surface might be caused by contact with a rod or wire carrying an electrical charge.
Coarse linear indications, typically composed of small overlapping craters or pits.
NOTE: Regardless of form, damage is a local phenomenon.
unlike erosion pitting, and damage boundaries do not have raised material as does damage from foreign object damage.
Page 805 EFF: ALL Page 9
8/14/97 AC 43-204 Appendix C STAGE 1 LPC BLADE ASSEMBLY - INSPECTION/CHECK-01
(5) service immediately, and blue etch anodize-inspected to confirm damage. Blades suspected of having electrical discharge damage must be removed from CAUTION: ELECTRICAL DISCHARGE DAMAGE IS NOT REPAIRABLE BY BLENDING. THIS DAMAGE PRODUCES A HEAT AFFECTED AREA WHICH MAY EXTEND UP TO 0.060 INCH (1.524 MM) DEEPER THAN VISIBLE DAMAGE. ANY
BLADES EXHIBITING THIS DAMAGE SHOULD RETIRED FROM SERVICE.
(6) subsurface as well as surface damage is removed. It is critically important The blending procedures described herein are intended to ensure that all that the blending procedures be followed carefully whether performed in the shop or on the wing. Proper blending must be performed in successive stages:
Removal of the visible damage, confrmation by eddy current or fluorescent penetrant inspection that all surface damage has been removed and, finally, removal of additional material to ensure the removal or subsurface deformed D. Preparation For Inspection
(2) Disassemble and remove attached parts). Not Applicable
(2) Remove surface treatments - See Repair-06 (Task 72-31-82-300-006).
(3) Clean base material - See 72-31-00, Cleaning-01 (Task 72-31-00-100-001).
Page 806 EFF: ALL Page 10
Appendix C Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443) STAGE 1 LPC BLADE ASSEMBLY - INSPECTION/CHECK-03 Task 72-31-82-200-003:
1. Visual Inspection - Stage 1 LPC Blade Assembly NOTE: Comply with the following procedures whenever foreign object damage is suspected.
Prerequisites
(1) See Inspection/Check-00 (Task 72-31-82-990-001) for functional arrangement
(2) See Inspection/Check-01 (Task 72-31-82-990-002) for general inspection data. and part number applicability.
B: Equipment And Materials Required - None
c. Inspect State 1 LPC Blade Assembly For Damage See Figures 801 through 803.
Inspect airfoil, except leading and trailing edges for damage. Following types of damage should be blended per repair-02 (Task 72-31-82-300-002) within limits specified in Figure 801.
NOTE: Limits shown in referenced figure refer to maximum material removal allowed during blending and not to actual depth of damage before blending. Damage at or near maximum limits shown will not be reparable if blending will exceed these limits.
(a) Sustained indentations with compressed material and raised edges.
(b) Injuries with small radii or ragged edges.
(c) Tip curl damage.
(2) Inspect leading and trailing edges for foreign object damage such as nicks and dents. These defects must be blended per Repair-02 (Task 72-31-82-300-002).
See Figures 801, 802 and 803. No cracks or tears are permitted.
(a) Damage, not within critical area, should be blended if it exceeds 0.020 inch (0.51 mm) depth.
(b) Damage, within critical area, should be blended if it exceeds 0.005 inch
(0.127 mm) in depth.
(c) Damage not exceeding 0.005 inch (0.127 mm) in depth need not be blended provided material is not torn.
D. Airfoil Root Section Blend Limits See Figure 803.
NOTE: Amount of material removed in previous blend repairs in root section is marked on blade platform as shown in Figure 804. Amount marked is total of all repairs either to leading or trailing edge and should be a consideration when determining if damage is reparable.
EFF: ALL Page 807 Page 11
Appendix C STAGE 1 LPC BLADE ASSEMBLY - INSPECTION/CHECK-03
PLANE Z
TANGENT -TANGENT 90° 13 SECTION A-A L-A1057
CHORD LENGTH MEASUREMENT Airfoil Inspection Limits Figure 801 (Task 72-31-82-200-003) Page 808 EFF: ALL Page 12
Appendix C Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443) STAGE 1 LPC BLADE ASSEMBLY - INSPECTION/CHECK-03 Blade Tip Blend Radius - 1.500 Inches (38.100 mm) Maximum.
2. Leading Or Trailing Edge And Tip Blend Area - Blend To Be 0.750 Inch (19.050 mm) Deep
3. 19.515 Inches (495.681 mm).
Critical Area - Depth Of Blend To Be 0.250 Inch (6.350 mm) Maximum Except For Airfoil Root Section. See Index 5 Dimension.
1.000 Inch (25.400 mm) - Damage In Airfoil-To-Platform Radius Area Cannot Be Blended Except Per Airfoil Root Section Blend Limits In Paragraph D.
6. No Damage Or Blending Permitted In Shroud-To-Airfoil Radius Or Platform-To-Airfoil Radius.
7. Concave And Convex Blade Surface Blend Area - Depth Of Blend In This Area To Be 0.030 Inch (0.762 mm) Maximum (Round Bottom).
8. Leading Edge Blend Area - Depth Of Blend To Be 0.500 Inch (12.77 mm) Maximum.
9. 6.300 Inches (160.020 mm)
10. 18.500 Inches (469.900 mm)
11. 22.500 Inches (571.800 mm)
12. 0.500 Inch (12.700 mm), Pour Places.
13. Minimum Chord Length To Be 6.950 Inches (176.530 mm) Within 6.390 Inches (160.020 mm) Of Leading Edge Platform. Chord Length Must Be Measured Tangent To Blade Leading And Trailing Edges And Parallel To Phase Z.
NOTE: Damage which affects both Index 1 and Index 2 must be blended by combining both limits to produce a smooth blend.
Key To Figure 801 Page 809 Page 13 (and 14)
8/14/97 A0 43-204 Appendix D APPENDIX D. PRATT & WHITNEY ENGINE GENERAL - INSPECTION/CHECK - 01A
SAMPLE INSPECTION PROCEDURE Task 72-00-00-990-009 Retyped with permission of Pratt & Whitney.
... .
......
Appendix D
SAMPLE INSPECTION PROCEDURE ENGINE GENERAL - INSPECTION/CHECK-01A Task 72-00-00-990-009:
General Borescope Inspection Procedures And Borescope Access Port (AP) Data Equipment And Materials Required Special Tools:
PWA 85572-1 Compressor Rotating Kit (Foot Operated) Optional PWA 85572-2 Compressor Rotating Kit (Hand Operated) Optional to PWA 85572-1 Special Borescope Equipment:
Sèe Paragraph 1. C. Special Borescope Equipment.
Consumable Materials:
Item No. Designation P03-001 Oil, Engine (PWA 521B) P06-003 Compound, Antigalling (PWA 586-3) Expendable Parts:
PARTS CATALOG REFERENCE
PART NAME QUANTITY SECTION FIGURE ITEM Packing 1 72-61-00 8 160 B. General See Figures 801 through 804 and Table 801.
Angular Recommended Location Maximum Probe Access Clockwise Part(s) Viewable Diameter Port From Rear For Inspection Inch/(mm) Thru 1st C-Vane Fan 1st C-Blades AP-1 245° (1) Rear of 4th C-Blade Front of 4th C-Vane AP-2 233° Rear of 5th C-Blade .270/6.8 Front of 6th C-Blade AP-3 231° Rear of 6th C-Blade .270/6.8 Front of 7th C-Blade Borescope Access Port (AP) Data Table 801 Page 802 EFF: ALL Page 2
Appendix D Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443) ENGINE GENERAL - INSPECTION/CHECK-01A Angular Recommended Location Maximum Probe Access Clockwise Part(s) Viewable Diameter Port From Rear For Inspection Inch/(mm) AP-4 127° Rear of Sth C-Blade .270/6.8 Front of 9th C-Blade AP-5 214° Rear of 10th C-Blade .270/6.8 Front of 11th C-Blade AP-6 • 98° Rear of 12th C-Blade .270/6.8 Front of 13th C-Blade AP-7 80° Rear of 14th C-Blade .270/7.8 Front of 15th C-Blade AP-8 277° Fuel Nozzle . 444/11.3 Combustion Chamber 1st T-Vane AP-8 45° Fuel Nozzle . 444/11.3 128° Combustion Chamber 172° (2) Ist T-Vane .444/11.3 225° 338° (3) AP-9 93° Front of 1st T-Vane .270/6.8 Front of 1st T-Blade AP-10 139° Rear of 2nd T-Blade .270/6.8 Front of 3rd T-Blade AP-11 215° (4) Rear of 1st Turbine Blade 444/11.3 Front of 2nd Turbine Blade Thru 6th T-Blade Exhaust 6th T-Vane Case Struts NOTE: (1) Flexible probe required at this access port (optional all other ports).
(2) Right angle eye piece required at this access port.
(3) Right angle eye piece desirable at this access port.
(4) Optional borescope port location.
Borescope Access Port (AP) Data Table 801 (Continued) Page 803 EFF: ALL Page 3