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ALERT SER VICE
BULLETIN
REVISION NOTICE ENGINE —
DIFFUSER CASE
ASSEMBL Y —
REPETITIVE EDDY
CURRENT
INSPECTION FOR CRACKS T urbojet Engine Service Bulletin No.
A72-765 Revision No.
1 dated July 13, 2016 R e v i s i o n H i s t o r y Original Issue March 30, 2016 Revision 1 July 13, 2016 R e a s o n f o r t h e R e v i s i o n Added requirement to compliance section which states “The requirements of this Service Bulletin begin August 15, 2016”.
Removed tool list.
Removed Inspection NDIP-1 142 and added Inspection NDIP-1
163.
Made changes to T able
2.
Removed references to HPT Case in several locations.
Added typical PN note to allow for variation from IPC.
Deleted Notes in the Accomplishment section.
Revised Notes in the Accomplishment section.
Added Post Reference 6, Service Bulletin No.
PW2000 72-700 part numbers.
E f f e c t o f R e v i s i o n o n P r i o r C o m p l i a n c e None T h i s i s a C o m p l e t e R e v i s i o n ( N o t A p p l i c a b l e t o t h e S G M L v e r s i o n ) The contents are in accordance with the list of ef fective pages.
All pages have the current revision number .
T echnical changes are marked with black bars.
N o n - D e s t r u c t i v e I n s p e c t i o n P r o c e d u r e s NDIP-(1
163), Revision (Enter Letter) dated (Enter Date) is attached.
Please discard the previously issued copy .
M O D E L A P P L I C A T I O N PW2037, PW2037(M), PW2040 B U L L E T I N I S S U E S E Q U E N C E PW2000 Series A72-765 P & W D i s t r i b u t i o n C o d e 2615 PW2000 A72-765 Page 1 of 2 Published in United States of America Not subject to the EAR per 15 C.F .R.
Chapter 1, Part
734.3(b)(3).
P a g e R e v i s i o n N o .
D a t e 1 thru 25 1 July 13/16 A copy of this Revision Notice and any future revision notices must be filed as a permanent record with your copy of the subject bulletin.
PW2000 A72-765 Page 2 Not subject to the EAR per 15 C.F .R.
Chapter 1, Part
734.3(b)(3).
ALERT SER VICE
BULLETIN ENGINE —
DIFFUSER CASE
ASSEMBL Y —
REPETITIVE EDDY
CURRENT
INSPECTION FOR CRACKS M O D E L A P P L I C A T I O N PW2037, PW2037(M), PW2040 B U L L E T I N I S S U E S E Q U E N C E PW2000 Series A72-765 A T A N U M B E R 72-00-00 U T C / P & W P R O P R I E T A R Y I N F O R M A T I O N This document is the property of United T echnologies Corporation — Pratt & Whitney (UTC/P&W).
Y ou may not possess, use, copy or disclose this document or any information in it, for any purpose, including without limitation to design, manufacture, or repair parts, or obtain F AA or other government approval to do so, without UTC/P&W’ s express written permission.
Neither receipt nor possession of this document alone, from any source, constitutes such permission.
Possession, use, copying or disclosure by anyone without UTC/P&W’ s express written permission is not authorized and may result in criminal and/or civil liability .
Not subject to the EAR per 15 C.F .R.
Chapter 1, Part
734.3(b)(3).
C o m p l i a n c e C a t e g o r y 3 P & W D i s t r i b u t i o n C o d e 2615 l March 30/16 PW2000 A72-765
REVISION NO.
1 - July 13/16 Page 1 of 25 Published in United States of America
S u m m a r y The purpose of this Service Bulletin is to do a repetitive Eddy Current Inspection (ECI) of the Flange M Outer Diameter (OD) of the dif fuser case.
An engine event involved a dif fuser case rupture in October 201
1.
P&W participated in a National T ransportation Safety Board (NTSB) investigation of this event.
The investigation was completed in early May , 2012.
P&W has continued to review these dif fuser cases since that date.
Recently , P&W has analytically identified a potential for cracks in PW2000 series engines dif fuser case rear flanges to develop, and propagate to rupture between shop visit Engine Manual (EM) Fluorescent Penetrant Inspections (FPI).
This condition could lead to an event similar to that described above.
P l a n n i n g I n f o r m a t i o n E f f e c t i v i t y D a t a E n g i n e M o d e l s A p p l i c a b l e PW2037, PW2037(M), PW2040 Engine Serial No.
— All engines C o n c u r r e n t R e q u i r e m e n t s There are no concurrent requirements.
R e a s o n
1.
Problem:
P&W has analytically identified a potential for cracks in some PW2000 series engines dif fuser case rear flanges to develop, and propagate to rupture between shop visit EM fluorescent penetrant inspections.
2.
Cause:
The root cause has been determined to be the fatigue capability of the material found in three groups of dif fuser cases:
(1) initial design configuration dif fuser cases (Pre Service Bulletin PW2000-72-364);
(2) dif fuser cases repaired as per Reference 3, Engine Manual, Chapter/Section 72-41-01, Repair-28;
and
(3) dif fuser cases modified as specified in Reference 6, Service Bulletin No.
PW2000-72-700.
3.
Solution:
P&W has identified certain dif fuser cases currently operating in the field that require a repetitive on-wing, of f-wing but assembled, or module level ECI.
P&W has developed an ECI of the dif fuser case Flange M to look for cracks propagating from bolt holes.
This Service Bulletin provides the ECI process and procedure necessary to perform that inspection.
(Piece part FPI inspection can be substituted for this ECI inspection.)
D e s c r i p t i o n Do a repetitive ECI of the Flange M OD of the dif fuser case.
(Piece part FPI inspection can be substituted for this ECI inspection.)
C o m p l i a n c e Category 3 The requirements of this Service Bulletin begin August 15, 2016.
l March 30/16 PW2000 A72-765
REVISION NO.
1 - July 13/16 Page 2
UTC/P&W
PROPRIET AR Y
INFORMA TION Subject to the restrictions on the cover or first page.
Not subject to the EAR per 15 C.F .R.
Chapter 1, Part
734.3(b)(3).
T a b l e 1 — D i f f u s e r C a s e i n s p e c t i o n t i m i n g ( i n s p e c t i o n c a n b e p e r f o r m e d w h e n e n g i n e i s a t p i e c e p a r t l e v e l , m o d u l e l e v e l , f u l l y a s s e m b l e d o f f - w i n g , o r o n - w i n g ) Last Shop V isit Activity Initial Inspection Subsequent Inspections No flange replacement and piece part FPI performed 2,500 cycles 1,500 - 2,500 cycles New case OR flange replacement 4,500 - 5,500 cycles 1,500 - 2,500 cycles T a b l e 2 — D i f f u s e r C a s e i n s p e c t i o n t i m i n g f o r e n g i n e s a b o v e t h e c y c l e c o u n t s l i s t e d i n T a b l e 1 w h e n t h i s A l e r t S e r v i c e B u l l e t i n ( A S B ) i s r e l e a s e d .
Last Shop V isit Activity Initial Inspection Subsequent Inspections No flange replacement and piece part FPI performed and more than 2,500 cycles have elapsed since the last shop visit within 1,500 cycles of ASB ef fectivity 1,500 - 2,500 cycles New case OR flange replacement and more than 5,500 cycles have elapsed since the last shop visit within 1,000 cycles of ASB ef fectivity 1,500 - 2,500 cycles A p p r o v a l D a t a The times between inspections specified in Compliance and the inspection procedures specified in the Accomplishment Instructions agree with the applicable Federal A viation Regulations and are F AA-Approved for the engine model(s) given.
M a n p o w e r The estimate of man-hours of labor directly necessary to do the intent of this Service Bulletin are as follows:
1.
Necessary to Open and Close Cowl Doors and deactivate/reactivate thrust reversers .
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0.8
2.
Necessary to Make an Eddy Current Inspection .
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4.0
3.
T otal Necessary Man-hours .
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4.8 W e i g h t D a t a No Change.
E l e c t r i c a l L o a d D a t a Not Applicable.
S o f t w a r e A c c o m p l i s h m e n t S u m m a r y Not Applicable.
R e f e r e n c e s
1.
T urbojet Engine Standard Practices Manual, Part No.
585005.
2.
PW2037, PW2040 T urbofan Engines Illustrated Parts Catalog, Part No.
1A6232.
l March 30/16 PW2000 A72-765
REVISION NO.
1 - July 13/16 Page 3
UTC/P&W
PROPRIET AR Y
INFORMA TION Subject to the restrictions on the cover or first page.
Not subject to the EAR per 15 C.F .R.
Chapter 1, Part
734.3(b)(3).
3.
PW2037, PW2040, PW2240, PW2337 T urbofan Engine Manual, Part No.
1A6231.
4.
Boeing 757 Aircraft Maintenance Manual.
5.
Service Bulletin No.
PW2000 72-364;
Engine — Case Assembly , Dif fuser — Incorporation Of T wo 17th Stage Bleed Bosses.
Issue Sequence 72-364, PW2000 Series.
6.
Service Bulletin No.
PW2000 72-700;
Engine — Case Assembly , Dif fuser — Modification Of, T o Incorporate A New Outer Rear Flange.
Issue Sequence 72-700, PW2000 Series.
7.
NDIP-1 163, PW2000 Dif fuser/HPT Case M-Flange/Bolt Hole Eddy Current Inspection.
P u b l i c a t i o n s C h a n g e d
1.
None.
I n t e r c h a n g e a b i l i t y Not Applicable.
I n f o r m a t i o n i n t h e A p p e n d i x Alternate Accomplishment Instructions (No) Progression Charts (No) Added Data (Y es) Revision to T able of Limits (No) Inspection Procedures (No) l March 30/16 PW2000 A72-765
REVISION NO.
1 - July 13/16 Page 4
UTC/P&W
PROPRIET AR Y
INFORMA TION Subject to the restrictions on the cover or first page.
Not subject to the EAR per 15 C.F .R.
Chapter 1, Part
734.3(b)(3).
M a t e r i a l I n f o r m a t i o n M a t e r i a l — C o s t a n d A v a i l a b i l i t y
1.
There is no kit provided to do this Service Bulletin.
2.
Part availability information is provided in material data Instructions — Disposition.
I n d u s t r y S u p p o r t P r o g r a m Not Applicable.
T h e m a t e r i a l d a t a t h a t f o l l o w s i s f o r e a c h e n g i n e .
N O T E :
It is possible to use the Chapter/Section and Figure/Item reference number shown below the old part number to find the part in the Illustrated Parts Catalog.
Because there are many dif ferent configurations used, it is frequently necessary to show more than one group of parts.
When this occurs, parts that are interchangeable are shown line-by-line only , unless this is shown dif ferently .
C A U T I O N :
THE
FOLLOWING MA TERIAL DA T A T
ABLE(S) ARE
ORGANIZED BY
ILLUSTRA TED P AR TS CA T ALOG.
ALL P AR TS IN THE T
ABLE(S) MA Y OR MA Y NOT BE
APPLICABLE T O ALL THE ENGINE MODELS SHOWN IN THE T ABLE HEADING.
YOU MUST REFER T O THE
APPROPRIA TE
ILLUSTRA TED P AR TS CA T ALOG FOR ENGINE MODEL
APPLICABILITY USING THE OLD P AR T NUMBER (PN) AND CA T ALOG
SEQUENCE NUMBER.
F AILURE T O INST ALL THE P AR T(S) IN THE
CORRECT ENGINE MODEL MA Y RESUL T IN A
CONFIGURA TION THA T IS NOT F AA APPROVED.
T h e m a t e r i a l d a t a t h a t f o l l o w s i s f o r e a c h e n g i n e .
F o r P W 2 0 3 7 , P W 2 0 3 7 ( M ) , P W 2 0 4 0 E n g i n e s :
New PN Qty Estimate of Unit Price ($) Keyword Old PN Instructions — Disposition 1 CASE — ASSY OF ,
DIFFUSER 1A9635 (72-41-00-1-1)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B1570 (72-41-00-1-1 A)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B2320 (72-41-00-1-1 B)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3282 (72-41-00-1-1 C)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4091 (72-41-00-1-1 D)
(4)(X) OR l March 30/16 PW2000 A72-765
REVISION NO.
1 - July 13/16 Page 5
UTC/P&W
PROPRIET AR Y
INFORMA TION Subject to the restrictions on the cover or first page.
Not subject to the EAR per 15 C.F .R.
Chapter 1, Part
734.3(b)(3).
New PN Qty Estimate of Unit Price ($) Keyword Old PN Instructions — Disposition 1 CASE — ASSY OF ,
DIFFUSER 1B3055 (72-41-00-1-1 E)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B7407 (72-41-00-1-1 F)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B7461 (72-41-00-1-1 G)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B7477 (72-41-00-1-1 H)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3394 (72-41-00-1-1AA)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3396 (72-41-00-1-1AB)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4087 (72-41-00-1-1AC)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4088 (72-41-00-1-1AD)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4089 (72-41-00-1-1AE)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4317 (72-41-00-1-1AF)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4318 (72-41-00-1-1AG)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4087-001 (72-41-00-1-1AH)
(4)(X) OR l March 30/16 PW2000 A72-765
REVISION NO.
1 - July 13/16 Page 6
UTC/P&W
PROPRIET AR Y
INFORMA TION Subject to the restrictions on the cover or first page.
Not subject to the EAR per 15 C.F .R.
Chapter 1, Part
734.3(b)(3).
New PN Qty Estimate of Unit Price ($) Keyword Old PN Instructions — Disposition 1 CASE — ASSY OF ,
DIFFUSER 1B4318-001 (72-41-00-1-1AJ)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4091-001 (72-41-00-1-1AK)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4089-001 (72-41-00-1-1AL)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4088-001 (72-41-00-1-1AM)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4317-001 (72-41-00-1-1AN)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B1570-001 (72-41-00-1-1AP)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B2320-001 (72-41-00-1-1AQ)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3282-001 (72-41-00-1-1AR)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3394-001 (72-41-00-1-1AS)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3396-001 (72-41-00-1-1A T)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B7407-001 (72-41-00-1-1AU)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3055-001 (72-41-00-1-1A V)
(4)(X) OR l March 30/16 PW2000 A72-765
REVISION NO.
1 - July 13/16 Page 7
UTC/P&W
PROPRIET AR Y
INFORMA TION Subject to the restrictions on the cover or first page.
Not subject to the EAR per 15 C.F .R.
Chapter 1, Part
734.3(b)(3).
New PN Qty Estimate of Unit Price ($) Keyword Old PN Instructions — Disposition 1 CASE — ASSY OF ,
DIFFUSER 1B4087-002 (72-41-00-1-1A W)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4318-002 (72-41-00-1-1A Y)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4091-002 (72-41-00-1-1AZ)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4089-002 (72-41-00-1-1BA)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4088-002 (72-41-00-1-1BB)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4317-002 (72-41-00-1-1BC)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3396-002 (72-41-00-1-1BD)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3394-002 (72-41-00-1-1BE)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3282-002 (72-41-00-1-1BG)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B2320-002 (72-41-00-1-1BH)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B1570-002 (72-41-00-1-1BJ)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B7477-001 (72-41-00-1-1BT)
(4)(X) OR l March 30/16 PW2000 A72-765
REVISION NO.
1 - July 13/16 Page 8
UTC/P&W
PROPRIET AR Y
INFORMA TION Subject to the restrictions on the cover or first page.
Not subject to the EAR per 15 C.F .R.
Chapter 1, Part
734.3(b)(3).
New PN Qty Estimate of Unit Price ($) Keyword Old PN Instructions — Disposition 1 CASE — ASSY OF ,
DIFFUSER 1B7461-001
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3396-003 (72-41-00-1-1BV)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3396-004 (72-41-00-1-1CM)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3396-005 (72-41-00-1-1CW)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4318-004 (72-41-00-1-1CC)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4318-005 (72-41-00-1-1CR)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4318-003 (72-41-00-1-1CA)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4087-004 (72-41-00-1-1CB)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4087-005 (72-41-00-1-1CQ)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4087-003 (72-41-00-1-1BW)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1A9635-001 (72-41-00-1-1BK)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B1570-003 (72-41-00-1-1BL)
(4)(X) OR l March 30/16 PW2000 A72-765
REVISION NO.
1 - July 13/16 Page 9
UTC/P&W
PROPRIET AR Y
INFORMA TION Subject to the restrictions on the cover or first page.
Not subject to the EAR per 15 C.F .R.
Chapter 1, Part
734.3(b)(3).
New PN Qty Estimate of Unit Price ($) Keyword Old PN Instructions — Disposition 1 CASE — ASSY OF ,
DIFFUSER 1B2320-003 (72-41-00-1-1BM)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3282-003 (72-41-00-1-1BN)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4091-003 (72-41-00-1-1BP)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3055-002 (72-41-00-1-1BQ)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B7407-002 (72-41-00-1-1BR)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B3394-003 (72-41-00-1-1BU)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4088-003 (72-41-00-1-1BX)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4089-003 (72-41-00-1-1BY)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4317-003 (72-41-00-1-1BZ)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4091-004 (72-41-00-1-1CD)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4089-004 (72-41-00-1-1CE)
(4)(X) OR 1 CASE — ASSY OF ,
DIFFUSER 1B4088-004 (72-41-00-1-1CF)
(4)(X) OR l March 30/16 PW2000 A72-765
REVISION NO.
1 - July 13/16 Page 10
UTC/P&W
PROPRIET AR Y
INFORMA TION Subject to the restrictions on the cover or first page.
Not subject to the EAR per 15 C.F .R.
Chapter 1, Part
734.3(b)(3).