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GE90-100 Service Bulletin No 72-0528 R01 Revised: 04/01/2013 Issued: 11/15/2012 SB 72-0528 R01 ENGINE - HPT Stage 2 Nozzle (72-52-00) - On-Wing Borescope Inspection of Stage 1 HPT Stator Shrouds P/N 1847M52P16
GE PROPRIETARY INFORMATION The information contained in this document is GE proprietary information and is disclosed in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or configuration changes or to obtain FAA or any other government or regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part.
This technical data is considered EAR controlled pursuant to 15 CFR Parts 730-774 respectively. Transfer of this data by any means to a Non- US Person, whether in the United States or abroad, without the proper U.S. Government authorization (e.g., License, exemption, NIR, etc.), is strictly prohibited.
Copyright (2013) General Electric Company, U.S.A.
TRANSMITTAL INFORMATION REVISION 1 TO SERVICE BULLETIN 72-0528 Revision 1 is issued to update paragraph 3., ACCOMPLISHMENT INSTRUCTIONS.
The original was issued November 15, 2012. Revision bars in the left margin identify changes.
1. PLANNING INFORMATION A. Effectivity * * * GE90-110B1 and -115B This Service Bulletin is applicable to these GE90-100 engines:
•GE90-100 engines, serial numbers 906-682 through 906-690, 906- 701 through 906-704, 906-706 through 906-709, 906-712, 906-713, 906-716 and up.
These serial numbers are the best available data.
This Service Bulletin is also applicable to all GE90-100 engines that had the stage 1 high pressure turbine (HPT) stator shrouds GE PROPRIETARY INFORMATION - Not to be used, disclosed to others Date or reproduced without the express written consent of GE. Technical Page Printed: data is considered ITAR and/or EAR controlled; transfer of this 1 of 20 Jun 24, 2013 data to a Non-US Person, without USG authorization, is strictly prohibited.
GE90-100 Service Bulletin No 72-0528 R01 Revised: 04/01/2013 Issued: 11/15/2012 SB 72-0528 R01 ENGINE - HPT Stage 2 Nozzle (72-52-00) - On-Wing Borescope Inspection of Stage 1 HPT Stator Shrouds P/N 1847M52P16 P/N 1847M52P16 installed during a shop visit (post-GE90-100 S/B 72-0363).
B. Description This Service Bulletin provides on-wing borescope inspection (BSI) procedures for the stage 1 HPT stator shrouds P/N 1847M52P16.
C. Compliance Category 2 GE recommends this inspection be performed at a 2,000 cycles since new (CSN) threshold for production engines and 2,000 cycles since installation (CSI) on engines that had the stage 1 HPT stator shrouds P/N 1847M52P16 installed during a shop visit.
GE also recommends this inspection be repeated at 250 cycle intervals thereafter.
NOTE: For engines that have accumulated more than 2,000 cycles on the stage 1 HPT stator shroud P/N 1847M52P16 at the time of initial publication of this Service Bulletin, GE recommends the affected engine be inspected within two months of the initial publication date of this Service Bulletin.
NOTE: For engines that have less than 2,000 cycles on the stage 1 HPT stator shroud P/N 1847M52P16 at the time of initial publication of this Service Bulletin, GE recommends the affected engine be inspected within two months of reaching 2,000 cycles on the stage 1 HPT stator shrouds.
NOTE: Compliance with GE90-100 S/B 72-0348 is a terminating action for this Service Bulletin.
NOTE: This Service Bulletin does not supersede GE90-100 S/B 72-0401, and has a different effectivity.
NOTE: This Service Bulletin can be accomplished on wing or in shop.
This Service Bulletin is offered to improve the reliability or performance of your GE product, or to help prevent the occurrence of the event or condition described in this Service Bulletin. If the operator elects not to participate in the bulletin, that decision will be taken into consideration by GE in evaluating future product performance issues that may arise in the operator's fleet.
D. Concurrent Requirements None.
E. Reason
(1) Objective:
To improve reliability and reduce significant events.
(2) Condition:
The stage 1 HPT stator shrouds show an accelerated deterioration that can result in an unserviceable condition.
(3) Cause :
GE PROPRIETARY INFORMATION - Not to be used, disclosed to others Date or reproduced without the express written consent of GE. Technical Page Printed: data is considered ITAR and/or EAR controlled; transfer of this 2 of 20 Jun 24, 2013 data to a Non-US Person, without USG authorization, is strictly prohibited.
GE90-100 Service Bulletin No 72-0528 R01 Revised: 04/01/2013 Issued: 11/15/2012 SB 72-0528 R01 ENGINE - HPT Stage 2 Nozzle (72-52-00) - On-Wing Borescope Inspection of Stage 1 HPT Stator Shrouds P/N 1847M52P16 The cause for the accelerated distress is currently under investigation.
(4) Inspection:
Inspect the stage 1 HPT stator shrouds for corrosion/oxidation and missing material/holes.
(5) Substantiation:
Substantiation is by fleet experience and analysis.
F. Approval This Service Bulletin contains no modification information that revises the approved configuration and therefore does not require FAA approval.
G. Manpower After you get access to the borescope port of the stage 1 HPT stator shrouds, you will need approximately 4 man-hours to do the inspection portion of this Service Bulletin.
H. Weight and Balance Weight and balance are not changed.
I. References (Use the latest version of these documents) GE90-100 Boeing 777 Aircraft Maintenance Manual (AMM) GEK 110005, GE90-100 Illustrated Parts Catalog (IPC) GE90-100 S/B 72-0348, ENGINE - HPT Stage 2 Nozzle Assembly (72- 52-00) - Stage 1 HPT Stator Shroud and Stage 1 HPT Stator Shroud Hanger - New and Rework GE90-100 S/B 72-0363, ENGINE - General (72-00-00) - Spare Parts Release for GE90-100 Engines GE90-100 S/B 72-0401, ENGINE - HPT Stage 2 Nozzle (72-52-00) - On-Wing Borescope Inspection of Stage 1 HPT Stator Shroud J. Publications Affected GE90-100 Boeing 777 Aircraft Maintenance Manual (AMM) K. Interchangeability Not applicable.
L. Software Accomplishment Summary Not applicable.
2. MATERIAL INFORMATION A. Material - Price and Availability
(1) Parts necessary to do this Service Bulletin:
None.
GE PROPRIETARY INFORMATION - Not to be used, disclosed to others Date or reproduced without the express written consent of GE. Technical Page Printed: data is considered ITAR and/or EAR controlled; transfer of this 3 of 20 Jun 24, 2013 data to a Non-US Person, without USG authorization, is strictly prohibited.
GE90-100 Service Bulletin No 72-0528 R01 Revised: 04/01/2013 Issued: 11/15/2012 SB 72-0528 R01 ENGINE - HPT Stage 2 Nozzle (72-52-00) - On-Wing Borescope Inspection of Stage 1 HPT Stator Shrouds P/N 1847M52P16
(2) Other Spare Parts:
None .
(3) Consumables:
None.
B. Industry Support Information Contact your Customer Support Manager (CSM).
C. Confiquration Chart Not applicable.
D. Parts Disposition None.
E. Tooling - Price and Availability Tool Number Description Torque Wrench capable of up to 220 1b in. (25 N m) Flexible Borescope (flexscope) 6 mm or 8 mm diameter minimum of 3.5 meters in length (recommended equipment) NOTE:A flexscope shorter than 3.5 meters cannot be used to accomplish this inspection.
3. ACCOMPLISHMENT INSTRUCTIONS A. Stage 1 HPT Stator Shroud BSI with a 3.5-Meter or Longer Flexscope NOTE: Video BSI or photos are strongly recommended when this inspection is done.
NOTE: Stage 1 HPT stator shroud damage has been seen at all clock positions.
Damage occurs more at mid chord and aft on stage 1 HPT stator shroud surface. Inspection of the entire stage 1 HPT stator shroud surface is required. You must look between the blades and under the blade tips to make sure that no indications are missed.
WARNING: USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
CAUTION: MAKE SURE THE TEMPERATURE OF THE ENGINE AND THE ADJACENT AREAS NEAR THE BSI PORTS ARE LESS THAN 150 F (66 C) DEGREES. DO NOT DO A BSI IF THE ADJACENT AREAS ARE TOO HOT TO TOUCH. DO THE BSI WHEN THE ENGINE TEMPERATURE IS LESS THAN 150 F (66 C) DEGREES. THIS WILL PREVENT DAMAGE TO THE BORESCOPE EQUIPMENT.
(1) Do a 360-degree BSI of the stage 1 HPT stator shroud (1, Figure 1) leading edge (LE) and mid chord. Refer to the GE90- 100 Boeing 777 AMM, TASK 72-00-00-290-805-H01, SUBTASK 72-00- 00-290-007-H01, and do as follows:
NOTE: A flexscope less than 3.5 meters in length cannot be used to do the BSI of the stage 1 HPT stator shrouds.
GE PROPRIETARY INFORMATION - Not to be used, disclosed to others Date Printed: or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; transfer of this Page Jun 24, 2013 data to a Non-US Person, without USG authorization, is strictly 4 of 20 prohibited.
GE90-100 Service Bulletin No 72-0528 R01 Revised: 04/01/2013 Issued: 11/15/2012 SB 72-0528 R01 ENGINE - HPT Stage 2 Nozzle (72-52-00) - On-Wing Borescope Inspection of Stage 1 HPT Stator Shrouds P/N 1847M52P16
(a) Remove the borescope plug at the "Q" location.
(b) Insert a flexscope into the borescope port of the combustor diffuser nozzle (CDN) and pass it into the flow path.
(c) Follow the direction of the stage 1 HPT nozzle and continue to insert the flexscope over the top of the engine.
Continue to feed the flexscope into the flow path until you can see the flexscope insertion point (flexscope entering through the borescope port).
NOTE: It is very important that you can see the borescope entry point to make sure that a full 360 degrees flexscope travel has been accomplished for the inspection.
(d) Carefully remove the flexscope. Make sure to examine the stage 1 HPT stator shrouds as you remove the flexscope.
Inspect the mid chord of the stage 1 HPT stator shrouds (area of the stage 1 HPT stator shrouds between the blades) and the LE of the stage 1 HPT stator shrouds.
(e) While you examine the stage 1 HPT stator shrouds, evaluate each stage 1 HPT stator shroud as specified in paragraph
3.B., Inspection Results Evaluation, and complete the Inspection Findings Report Form as specified in paragraph
3.C., Inspection Findings Reporting, and Figure 3.
(f) When you complete the inspection, install the borescope plug. Refer to the GE90-100 Boeing 777 AMM, SUBTASK 72-00- 00-410-011-H01.
(2) Do a 360-degree BSI of the stage 1 HPT stator shroud (1, Figure 1) trailing edge (TE) and mid chord as follows:
NOTE:A flexscope less than 3.5 meters in length cannot be used to do the BSI of the stage 1 HPT stator shrouds.
(a) Remove the borescope plug at the "R" location.
(b) Insert a flexscope into the borescope port of the HPT case and pass it into the flow path.
(c) Follow the direction of the stage 2 HPT nozzle and continue to insert the ilexscope under the bottom oi the engine.
Continue to feed the flexscope into the flow path until you can see the flexscope insertion point (flexscope entering through the borescope port).
NOTE: It is very important that you can see the borescope entry point to make sure that a full 360 degrees flexscope travel has been accomplished for the inspection.
(d) Carefully remove the flexscope. Make sure to examine the stage 1 HPT stator shrouds as you remove the flexscope.
Inspect the mid chord of the stage 1 HPT stator shrouds (area of the stage 1 HPT stator shrouds between the blades) and the TE of the stage 1 HPT stator shrouds.
GE PROPRIETARY INFORMATION - Not to be used, disclosed to others Date or reproduced without the express written consent of GE. Technical Page Printed: data is considered ITAR and/or EAR controlled; transfer of this 5 of 20 Jun 24, 2013 data to a Non-US Person, without USG authorization, is strictly prohibited.
GE90-100 Service Bulletin No 72-0528 R01 Revised: 04/01/2013 Issued: 11/15/2012 SB 72-0528 R01 ENGINE - HPT Stage 2 Nozzle (72-52-00) - On-Wing Borescope Inspection of Stage 1 HPT Stator Shrouds P/N 1847M52P16
(e) While you examine the stage 1 HPT stator shrouds, evaluate each stage 1 HPT stator shroud as specified in paragraph
3.B., Inspection Results Evaluation, and complete the Inspection Findings Report Form as specified in paragraph
3.C., Inspection Findings Reporting, and Figure 4.
(f) When you complete the inspection, install the borescope plug. Refer to the GE90-100 Boeing 777 AMM, SUBTASK 72-00- 00-410-014-H01.
B. Inspection Results Evaluation
(1) Use the shroud serviceability limits published in the GE90-100 Boeing 777 AMM, TASK 72-00-00-290-805-H01, SUBTASK 72-00-00- 290-007-H01, except for the following:
NOTE: Refer to Figure 2 for examples of the stage 1 HPT stator shrouds thermal distress.
(a) Holes within 0.35 inch (8.9 mm) of the LE are serviceable on a reduced inspection interval of every 50 cycles.
(b) Holes beyond 0.35 inch (8.9 mm) of the LE less than 0.15 inch (3.8 mm) in diameter [maximum area of 0.018 sq in.
(0.12 sq cm)] are serviceable on a reduced inspection interval of every 25 cycles if the LE of the shroud is present forward of the hole.
NOTE: If you can see the stage 1 hanger internal baffle, the damage is more than 0.35 inch (8.9 mm) from the LE and must be evaluated in accordance with the serviceability requirements listed above in this Service Bulletin.
(c) Holes beyond 0.35 inch (8.9 mm) of the LE between 0.15 inch
(3.8 mm) in diameter [maximum area of 0.018 sq in. (0.12 sq cm)] and 0.25 inch (6.4 mm) in diameter [maximum area of
0.049 sq in. (0.32 sq cm)] are serviceable on a reduced inspection interval of every 10 cycles if the LE of the shroud is present forward of the hole.
NOTE: If you can see the stage 1 hanger internal baffle, the damage is more than 0.35 inch (8.9 mm) from the LE and must be evaluated in accordance with the serviceability requirements listed above in this Service Bulletin.
(d) Lifting of the shroud split line, LE or TE is acceptable if the area of the lifting material meets the requirements in the GE90-100 Boeing 777 AMM, SUBTASK 72-00-00-290-007-H01 for missing material.
(e) Black oxide/corrosion build up around the shroud cooling holes on shroud flow path surface is acceptable for repeat inspection interval of every 250 cycles.
(f) Black oxide/corrosion build up on shroud surface that blocks cooling holes is acceptable for repeat inspection GE PROPRIETARY INFORMATION - Not to be used, disclosed to others Date or reproduced without the express written consent of GE. Technical Page Printed: data is considered ITAR and/or EAR controlled; transfer of this 6 of 20 Jun 24, 2013 data to a Non-US Person, without USG authorization, is strictly prohibited.
GE90-100 Service Bulletin No 72-0528 R01 Revised: 04/01/2013 Issued: 11/15/2012 SB 72-0528 R01 ENGINE - HPT Stage 2 Nozzle (72-52-00) - On-Wing Borescope Inspection of Stage 1 HPT Stator Shrouds P/N 1847M52P16 interval of every 100 cycles.
C. Inspection Findings Reporting
(1) Report the inspection findings to GE Group Field Service/PSE Representative. Fill out the Inspection Findings Report Form.
Refer to Figure 3 and Figure 4.
(2) Video borescope/photograph the inspection of the stage 1 HPT stator shrouds. Retain the inspection records for one year (12 months) .
(3) Send the completed Inspection Findings Report Form and pictures to: kyle.blomgren@ge.com GE PROPRIETARY INFORMATION - Not to be used, disclosed to others Date or reproduced without the express written consent of GE. Technical Page Printed: Jun 24, 2013 data is considered ITAR and/or EAR controlled; transfer of this data to a Non-US Person, without USG authorization, is strictly 7 of 20
88) GE90-100 Service Bulletin No 72-0528 R01 Revised: 04/01/2013 Issued: 11/15/2012 SB 72-0528 R01 ENGINE - HPT Stage 2 Nozzle (72-52-00) - On-Wing Borescope Inspection of Stage 1 HPT Stator Shrouds P/N 1847M52P16 A-A 1 (REF) D LEGEND:
1. STAGE 1 HPT STATOR SHROUD (QTY -40) 1368214-00 Location of the Stage 1 HPT Stator Shroud Figure 1 (Sheet 1) GE PROPRIETARY INFORMATION - Not to be used, disclosed to others Date or reproduced without the express written consent of GE. Technical Printed: Jun 24, 2013 ' 2013 prohibited ion us Person, without data is considered ITAR and/or EAR controlled; transfer of this data to a Non-US Person, without USG authorization, is strictly 8 of 20 Page
06] GE90-100 Service Bulletin No 72-0528 R01 Revised: 04/01/2013 Issued: 11/15/2012 SB 72-0528 R01 ENGINE - HPT Stage 2 Nozzle (72-52-00) - On-Wing Borescope Inspection of Stage 1 HPT Stator Shrouds P/N 1847M52P16 TE STAGE 1 HPT • STAGE 1 HPT STATOR
NOZZLE SHROUD HANGER LE STAGE 2 HPT NOZZLE 1 (REF) STAGE 1 HPT ROTOR
BLADE TIP TE 1368219-00 Location of the Stage 1 HPT Stator Shroud Figure 1 (Sheet 2) GE PROPRIETARY INFORMATION - Not to be used, disclosed to others Date or reproduced without the express written consent of GE. Technical Printed: data is considered ITAR and/or EAR controlled; transfer of this Page Jun 24, 2013 data to a Non-US Person, without USG authorization, is strictly 9 of 20 prohibited.
96) GE90-100 Service Bulletin No 72-0528 R01 Revised: 04/01/2013 Issued: 11/15/2012 SB 72-0528 R01 ENGINE - HPT Stage 2 Nozzle (72-52-00) - On-Wing Borescope Inspection of Stage 1 HPT Stator Shrouds P/N 1847M52P16
DISTANCE FROM SHROUD
LE TO FORWARD
SIDE OF SHROUD RAIL
0.200 LE 0.350
(5.08) (8.89) STAGE 1 SHROUD
APPROXIMATED
DIMENSIONS TO
COOLING HOLE ROWS
0.200 TE LE
(5.08)
1. BLACK DOTS ARE THE AIR FLOW EXIT HOLES OF THE STACE 1 HPT STATOR SHROUD.
2. DIMENSIONS FOR HOLE COOLING HOLE LOCATIONS ARE FOR THE STAGE 1 HPT STATOR SHROUD P/N 1847M52P16.
3. DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES.
4. DIMENSIONS ARE APPROXIMATE AND TO BE USED FOR REFERENCE ONLY. 1368220-00 Location of the Stage 1 HPT Stator Shroud Figure 1 (Sheet 3) GE PROPRIETARY INFORMATION - Not to be used, disclosed to others Date Printed: or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; transfer of this Page Jun 24, 2013 data to a Non-US Person, without USG authorization, is strictly 10 of 20 prohibited.
GE90-100 Service Bulletin No 72-0528 R01 Revised: 04/01/2013 Issued: 11/15/2012 SB 72-0528 R01 ENGINE - HPT Stage 2 Nozzle (72-52-00) - On-Wing Borescope Inspection of Stage 1 HPT Stator Shrouds P/N 1847M52P16
APPROXIMATE DISTANCE BETWEEN COOLING HOLE ROWS 0.300 (7.62)
APPROXIMATE DISTANCE BETWEEN COOLING HOLE ROWS 0.200 (5.08)
BLOCKED COOLING HOLES SERVICEABLE ON A 100 CYCLE
RE-INSPECTION LE HPT STAGE 1 ROTOR BLADE
NO BLOCKED COOLING HOLES REFER TO RE-INSPECTION SERVICEABLE ON A 250 CYCLE LE STAGE 1 HPT TE STAGE 1 HPT NOZZLE OUTER PLATFORM NOTE 3
STATOR SHROUD
MATERIAL BUILD-UP IS A
SERVICEABLE CONDITION
1. THE DISTANCE FROM THE LE OF THE STAGE 1 HPT STATOR SHROUD TO THE LE OF THE STAGE 1 HPT ROTOR BLADE IS APPROXIMATELY 0.35 (8.9).
THIS CAN BE USED AS A REFERENCE TO
DETERMINE THE APPROXIMATE LOCATION
OF ANY MISSING MATERIAL
2. INSPECT BETWEEN THE STAGE 1 HPT ROTOR BLADE AIRFOILS.
3. OXIDE/CORROSION BUILD UP IS BLACK OR SILVER
MATERIAL ON SHROUD FLOW PATH
4. DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES, 1368221-00 Stage 1 HPT Stator Shrouds - Thermal Distress Figure 2 (Sheet 1) GE PROPRIETARY INFORMATION - Not to be used, disclosed to others Printed: Date Jun 24, 2013 data is considered ITAR and/or EAR controlled; transfer of this or reproduced without the express written consent of GE. Technical data to a Non-US Person, without USG authorization, is strictly 11 of 20 Page prohibited.
86) GE90-100 Service Bulletin No 72-0528 R01 Revised: 04/01/2013 Issued: 11/15/2012 SB 72-0528 R01 ENGINE - HPT Stage 2 Nozzle (72-52-00) - On-Wing Borescope Inspection of Stage 1 HPT Stator Shrouds P/N 1847M52P16 HOLED STAGE 1 HPT STATOR
SHROUD FOUND AT SHOP VISIT
NOT A SERVICEABLE CONDITION
1. STAGE I HPT STATOR SHROUD DAMAGE
IS FOUND ANYWHERE AROUND THE CIRCUMFERENCE OF THE ENGINE.
2. DAMAGE IS FOUND AT MID CHORD AND AFT.
3. INSPECTION OF THE ENTIRE STAGE 1 HPT
STATOR SHROUD FROM LE TO TE VUST BE ACCOMPLISHED. 1368223-00 Stage 1 HPT Stator Shrouds - Thermal Distress Figure 2 (Sheet 2) GE PROPRIETARY INFORMATION - Not to be used, disclosed to others data is considered ITAR and/or EAR controlled; transfer of this or reproduced without the express written consent of GE. Technical Page Jun 24, 2013 data to a Non-US Person, without USG authorization, is strictly 12 of 20 prohibited.