August 29, 2014

TO: Recipients of AE 3007A Service Bulletins

SUBJECT: Alert Service Bulletin AE 3007A--A--72--408, Engine -- High Pressure

Turbine 2nd--stage Wheel Bore Eddy Current Inspection.

This letter transmits Revision 1 to the subject alert service bulletin. Replace the original

issue with this Revision 1.

This is a complete revision.

Revision 1 changes the Planning Information section.

If you have complied with the previous issue of this bulletin, no additional work is

required.

The following list includes the original issue date and all revisions to this bulletin:

Original issue December 06, 2013

Revision 1 August 29, 2014

CUSTOMER SUPPORT

ROLLS--ROYCE

Rolls--Royce Corporation

450 South Meridian Street

Indianapolis, IN 46225--1103 USA

Mail Code MC--S2--08

Phone: 317--230--3774

Fax: 317--230--6084

email: indy.pubs.services@rolls--royce.com

CHECK THAT ALL PREVIOUS TRANSMITTALS HAVE BEEN INCORPORATED -- if any have not been received please advise

Rolls--Royce Corporation Publication Services, Indianapolis, Indiana, USA

PUBLICATION TRANSMITTAL
Page 1 of 27

December 06, 2013 AE 3007A--A--72--408

Revison 1

August 29, 2014

E COPYRIGHT 2013, 2014 Rolls--Royce Corporation (unpublished)

ENGINE -- HIGH PRESSURE TURBINE 2ND STAGE WHEEL

BORE EDDY CURRENT INSPECTION

1. PLANNING INFORMATION

A. Effectivity

(1) Engines

All AE 3007A1, A1/1, A1/3, A1E, A1P, and A3 engines with the high pressure turbine (HPT)

2nd--stage wheel part numbers and affected serial numbers in the applicable tables below:

ENGINE MODELS HPT2 WHEEL P/N

AE 3007A1, A1/1, A1/3, A1E,

A1P, A3

23084520

23084781

23088817

23088818

(2) Components

All 2nd--stage high pressure turbine wheels (23084520, 23084781, 23088817 or

23088818) with the affected serial numbers in the applicable table below:

Table 1. Serial Numbers of Permanganate Cleaned HPT2 Wheels, P/N 23084520

P/N 23084520

Affected Serial Numbers

All Serial Numbers with prefix XP

MW50462 thru MW63395*

*The following Serial Numbers are excluded

MW51936 MW51946 MW51947 MW51948

MW51951 MW51953 MW51954 MW51955

MW51956 MW51958 MW51959 MW51960

MW51961 MW51962 MW51971 MW51973

MW51974 MW51980 MW51989 MW53634

MW53638 MW53641 MW53647 MW53924

MW56076 MW61025

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Table 2. Serial Numbers of Permanganate Cleaned HPT2 Wheels, P/N 23084781

P/N 23084781

Affected Serial Numbers

MW53627 thru MW63381*

*The following Serial Numbers are excluded

MW53652 MW53654 MW53655 MW53656

MW54422 MW56056 MW56063 MW56065

MW61055 MW61599 MW63360 MW63370

Table 3. Serial Numbers of Permanganate Cleaned HPT2 Wheels, P/N 23088817

P/N 23088817

Affected Serial Numbers

MW63263 MW63265 MW63267 MW63269

MW63296 MW63298 MW63299 MW63332

MW63333 MW63334 MW63335 MW63338

MW63355 MW63367 MW63368 MW63372

MW63377 MW63434 MW63436 MW63438

MW63439 MW63441 MW63469 MW63475

MW64127 MW64166 MW64173 MW64175

MW64176 MW64224 MW64228 MW64241

MW64281 MW64283 MW64294 MW64309

MW64313 MW64315 MW64348 MW64349

MW64352 MW64353 MW64362 MW64363

MW64375 MW64379 MW64400 MW64402

MW64407 MW64504 MW64537 MW64540

XP32055
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Table 4. Serial Numbers of Permanganate Cleaned HPT2 Wheels, P/N 23088818

P/N 23088818

Affected Serial Numbers

MW63177 MW63179 MW63185 MW63186 MW63205

MW63206 MW63262 MW62364 MW63266 MW63270

MW63273 MW63274 MW63277 MW63278 MW63279

MW63280 MW63282 MW63283 MW63286 MW63289

MW63290 MW63291 MW63302 MW63303 MW63331

MW63336 MW63337 MW63340 MW63341 MW63342

MW63345 MW63348 MW63349 MW63356 MW63358

MW63382 MW63384 MW63386 MW63389 MW63390

MW63393 MW63396 MW63397 MW63398 MW63400

MW63401 MW63408 MW63410 MW63411 MW63412

MW63413 MW63414 MW63415 MW63418 MW63422

MW63425 MW63430 MW63432 MW63433 MW63442

MW63444 MW63445 MW63446 MW63447 MW63448

MW63453 MW63456 MW63457 MW63459 MW63461

MW63462 MW63463 MW63465 MW64134 MW64136

MW64138 MW64141 MW64143 MW64153 MW64159

MW64161 MW64164 MW64165 MW64167 MW64171

MW64177 MW64179 MW64180 MW64192 MW64193

MW64196 MW64197 MW64198 MW64204 MW64205

MW64206 MW64208 MW64211 MW64212 MW64214

MW64218 MW64219 MW64220 MW64221 MW64223

MW64225 MW64226 MW64235 MW64239 MW64244

MW64245 MW64249 MW64251 MW64252 MW64257

MW64258 MW64265 MW64267 MW64271 MW64273

MW64276 MW64277 MW64301 MW64303 MW64314

MW64317 MW64325 MW64350 MW64354 MW64366

MW64367 MW64368 MW64371 MW64372 MW64381

MW64383 MW64394 MW64408 MW64412 MW64418

MW64438 MW64441 MW64459 MW64460 MW64462

MW64467 MW64471 MW64473 MW64474 MW64476

MW64477 MW64481 MW64483 MW64484 MW64490

MW94491 MW64494 MW64498 MW64502 MW64523

MW64525 MW64528 MW64534 MW64541 MW64603

MW64630 MW64638 MW64644 MW65121
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E COPYRIGHT 2013, 2014 Rolls--Royce Corporation (unpublished)

B. Reason

Fluorescent Penetrant Inspection results show pitting in the bore of the high pressure turbine

second--stage (HPT2) wheel. Investigation shows that the cleaning process of wheels during

2007 thru 2010 can be the cause of pitting. Pitting in the bore of the HPT2 wheel can reduce the

safe life of the component in service. As a result, all affected HPT2 wheels must have the wheel

bore examined.

C. Description

This service bulletin gives you the procedure to examine the bore of the affected HPT2 wheels

(23084520, 23084781, 23088817 or 23088818) using the eddy current inspection method.

This service bulletin is associated with a pending FAA Airworthiness Directive (AD) that will

mandate the eddy current inspection of the affected HPT2 wheels.

D. Approval

Technical aspects are FAA approved.

E. Manpower

In Service Not applicable.

Shop Visit Approximately 1.0 man--hour is necessary to do this service bulletin.

F. Compliance

Mandatory: Do this bulletin at each shop visit when a major engine flange is separated or at

exposure of the bore and if you have the wheel installed found in the Effectivity section.

NOTE: Facilities performing inspections in accordance with this procedure must be approved

by the appropriate Rolls--Royce Technical Authority.

Personnel performing inspections to this procedure must be qualified and certified to

Level II or Level III in ET in accordance with NAS.

Personnel performing this inspection must have received training and demonstrated

proficiency on the use of the UniWest ES--1000 System or ETC--2000 Systems.

Personnel must be proficient in using personal computers using the Windows 7r

Operating System.

The scan--plans detailed in this procedure were developed using UniWest program

ES--1000 Rev 1.0.

G. Interchangeability -- Not affected

H. Material Availability -- Not applicable

I. Tooling

(1) Uniwest ES--1000 System or ETC--2000 Systems

-- 97842--10 Adapter, Cable 6--pin/socket Lemo to 8--pin Burndy, Reflection

-- ETC--2519 Ballslide Assembly

-- ETC--5231 Tooling Holder

-- ETC--1000 Scanner System

-- ES Program ES1000 Rev. 1.0 or higher; operating under Windows 7r

-- PSDISPLAY Data view program, Rev. 1.6 or higher (not essential but recommended)

-- US--454A Eddy Current Instrument and associated cables
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(2) Uniwest ES--1000 Part Specific Tooling

-- ETC--2517 Probe, differential, reflection

-- ETC--5225 Partmount for calibration standard

-- ETC--5226 Partmount for HPT2 wheel

-- NDT0171 Reference Standard with electron discharge machine (EDM) notch

(fabricated from HPT1 wheel)

J. Weight and Balance -- Not affected

K. Electrical Load Data -- Not affected

L. References

(1) AE 3007A, C Series Engine Manual (EM), CSP31010.

(2) AE 3007A Series Illustrated Parts Catalog (IPC), CSP33002.

(3) Notice to Operators (NTO) AE 3007A--102, Parts Return Process for Authorized

Maintenance Centers.

M. Prerequisites -- None

N. Corequisites -- None

2. ACCOMPLISHMENT INSTRUCTIONS

A. Disassemble the engine.

(1) Remove the high pressure turbine rotor assembly (Ref. TASK 72--00--52--000--801, EM).

B. ES--1000 System drive C file structure.

REF. FIG. 1

The ES1000 software is preinstalled on your ES--1000 System. The main folder

C:\ES1000\RR--AE3007 contains three sub--folders.

(1) DATA -- This folder contains three subfolders, Calibration, Stg1 and Stg2. Keep all scan

data in these data folders. The recommended file naming structure is:

SNXXXXXX_(DATE)MM_DD_YY (e.g. SNRR098765_03_25_13)

(2) REPORT TEMPLATES -- This folder contains two report templates that the system will

need when running the inspection scanplans. The scanplans will open the appropriate

template for the operator to complete. At the end of an inspection, the scanplan evaluates

the data using a “WINDOWING” algorithm. The results of the evaluation can be appended

to the report file automatically if you use the same filename as the report file name when

you save the evaluation.

Report files are TXT files that can be opened with any text editor such as Windows

Notepad or Wordpad.

(3) SCANPLANS -- contains the actual scanplans. It contains five scanplans (Ref. Appendix 1):

-- SET--ZERO--BORE.scn to set the Zero of the system

-- RR CAL--ETC2517.scn to calibrate the system using a reference standard

-- RR POST CAL--ETC2517.scn for post inspection calibration checks

-- RR STG1--BORE.scn is the actual inspection scanplan for the HPT1 wheel

-- RR STG2--BORE.scn is the actual inspection scanplan for the HPT2 wheel
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NOTE: If the files are not structured correctly the inspection scanplan will not find the

appropriate report template and will skip it.

C. Equipment Setup.

(1) Uniwest ES--1000 System preparation.

REF. FIG. 2

(a) Turn on the eddy current instrument and the ES--1000 System and let them warm up

for a minimum of 15 minutes.

(b) Attach the ballslide (ETC--2519) to the tooling holder (ETC--5231).

(c) Mount the probe into the ballslide.

1 Insert the probe in the ballslide. Align the probe collar tab with slot in the ballslide.

2 Lock the probe in position with thumb screws.

3 Probe shoe pivot must be perpendicular to turntable.

(d) Check the condition of the Teflon or Kapton tape over the probe tip/shoe. If necessary,

replace the tape with one layer of tape. Make sure the shoe can still swivel freely in

the probe--fork.

(e) Connect the probe cable to the adapter. Make sure the cable will not get caught or

pinched in the vertical drive mechanism.

CAUTION: BE PREPARED TO PUSH THE E--STOP BUTTON DURING ALL SYSTEM

MOVEMENT TO STOP UNWANTED MOVEMENT.

CAUTION: DO NOT TURN OFF THE SYSTEM OR CLOSE THE SCANPLAN PRIOR TO

COMPLETION THIS PROCESS. IT WILL BE NECESSARY TO RUN THE

SET--ZERO--BORE SCANPLAN AGAIN PRIOR TO RUNNING ADDITIONAL

SCANPLANS.

(2) Set the ES--1000 Zero Position.

REF. FIG. 3

REF. FIG. 4

Scanplan prompts are indicated by underlined words. Items in double “quotation marks“

are commands or buttons available in the ES--1000 windows. Windows are denoted by

single ’quotes’.

(a) Start the program ES--1000.

(b) Open the file folder C:\ES--1000\RR--AE3007\SCANPLANS, and then open the file

SET--ZERO--BORE.scn. This is the scanplan that allows you to set the zero for the

system. The zero is not an absolute position, but a location in space used as a

reference for distances.

(c) Select the “Execute Scanplan” button or “Run” from the scanplan pull down menu to

start the scanplan.

(d) Set ballslide to 0 degrees (Ref. FIG. 3).

If applicable adjust the ballslide/probe so that it points straight down, then select “OK”.

(e) Jog ballslide and probe to turntable center and align (Ref. FIG. 3).

1 Select “OK”. The control of the axes drives is now given to the joystick. Jog the

probe tip towards the center of the turntable.

2 Align the probe tip/shoe with the hole in the center of the turntable. The tip must

be just slightly (3--5 times the thickness of paper) above the hole. Visual

alignment is sufficient.
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3 Adjust the vertical drive assembly by sliding it up or down until the bottom of the

vertical drive’s carriage is approximately 0.5 in. (12.7 mm) from the bottom

end--limiter.

4 Release the joystick by pressing one of the two axis control buttons of the

joystick and return the control to the scanplan.

5 Loop again?

-- If the probe--tip position is satisfactory, select “No”.

-- If the probe--tip position is NOT satisfactory, select “Yes” to do step 2.C.(2)(e)

again.

(f) Jog Y--Axis up a bit, rotate ballslide and align probe then jog Y--axis up (Ref. FIG. 4).

1 Select “OK”. Jog the Y--axis up about 2 in. (51 mm) and turn the ballslide 90

degrees to the left.

2 Use a machinist’s square or other rectangular object to align the probe tip.

Tighten the ballslide when the probe tip is vertical.

3 Jog the Y--axis up until the carriage is about 0.5 in. (12.7 mm) from the top

end--limiter.

4 Put the partmount (ETC--5226) and the HPT2 wheel onto the turntable. Make

sure that the ballslide is above the wheel.

5 Push the joystick release button to return the control to the scanplan.

6 Loop again?

-- If the probe--tip position is satisfactory, select “No”.

-- If the probe--tip position is NOT satisfactory, select “Yes” to do step 2.C.(2)(f)

again.

(g) Click Ok to move X--axis to left.

Select “OK”. The X--axis will move to the left, allowing more space to remove the HPT

wheel and load other wheels.

(h) Set--Zero--Bore complete.

The scanplan is finished. Select the “Close” button.

D. Instrument Parameters Input

(1) Set the instrument to the following default setting prior to beginning system calibration.

PARAMETER VALUE

Mixed Mode OFF

Freq 1 ON

Freq 2 OFF

Freq 3 OFF

Freq 4 OFF

M--Freq View SINGLE

Chart ON

Chart Invert OFF

EC Disp I--PLANE

Trace Dot ON
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Probe Drv HIGH

Alarm OFF

X Null Point 0.0 DIV

Y Null Point 0.0 DIV

Auto Clr OFF

Perst 1.0 s

(2) The calibration scanplan will automatically set up the instrument parameters on the

US--454A instrument to the following values:

PARAMETER VALUE UNIT

Frequency 2.0 MHz

Gain 49.0 dB

Rotation 260 degrees

LP Filter 200 Hz

HP Filter 2 Hz

X--Sens 0.5 V/div

Y--Sens 0.5 V/div

E. System Calibration.

REF. FIG. 5

REF. FIG. 6

REF. FIG. 7

After setting the system to zero, a calibration is performed. Following inspection of a HPT2

wheel or group of HPT2 wheels, a post scan calibration check is required.

Calibration is performed by running the reference standard using a predefined instrument

setting and scan plan. Adjustments to the instrument are made based on inputs from the

operator. If adjustments are made, the reference standard needs to be scanned again to verify

proper calibration.

(1) Open the file folder C:\ES1000\RR--AE3007\SCANPLAN, and then open the file

RR CAL--ETC2517.scn.

(2) Clean the top of the turntable and the bottom of the partmount (ETC--5225) with a clean

cloth.

(3) Clean the bore of the reference standard.

(4) Put the partmount flat and center on the turntable. Install a set--screw that attaches the

partmount to the turntable.

(5) Put the reference standard (NDT0171) on the partmount such that the mid--bore reference

EDM notch is circumferentially aligned with the probe. This will help when locating the

signal in the C--scan image later. The notch must be at the zero or 360 degrees on the

C--scan (Ref. FIG. 5).

(6) Run the scanplan.

(7) Set ballslide to 90 degrees.

Make sure the ballslide is 90 degrees to the left, then select “OK”.
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(8) Click OK to move the X--axis to start position.

Select “OK”. The ES--1000 will move the X--axis to the center of the turntable (X--Zero

position) automatically.

(9) Jog probe to start position and load ballslide to center (Ref. FIG. 6).

(a) Select “OK” to give control of the axes to the operator. Use the joystick to carefully

move the probe into the bore of the reference standard.

(b) Move the ballslide against the bore wall so that the index mark on the probe retainer

aligns approximately with the center index mark on the ballslide..

(c) Move the Y--axis to align the top surface of the probe--fork with the top--surface of the

reference standard. Use a straight--edge or other flat object to gauge the alignment.

(d) Push the joystick release button to return the control to the scanplan.

(e) Loop again?

-- If the probe--tip position is satisfactory, select “No”.

-- If the probe--tip position is NOT satisfactory, select “Yes” to do step 2.E.(8) again.

(10) The scanplan will now set up the eddy current instrument. Make sure that the screen of the

instrument flickers and the screen is erased and nulled (signal dot is in the center of the

screen).

(11) Click OK to start scan.

Select “OK”. The Y--axis will now move down and start the scan upwards.

During the scan, observe the instrument screen. Some background noise can be seen.

When the probe reaches the notch, signals caused by the EDM notch will be seen for 12 to

14 turns.

At the end of the scan a “Save data” window opens up.

(12) Find the subdirectory C:\ES1000\RR--AE3007\DATA\CALIBRATION and open it. Save the

data with a recognizable name e.g. CAL1_(DATE)MM_DD_YY. The extension .dat is

automatically added.

(13) Verify the voltage (Ref. FIG. 7).

(a) A “Calibration Prompt” window opens up. Select the “Verify Voltage” button. The

program will automatically find the largest signal response (peak--to--peak) and display

it (Ref. FIG. 7). Record the voltage reading.

1 If the voltage was between 4.0--4.2 volts, then select “Continue”. Go to step

2.E.(13)(d).

2 If the voltage was NOT between 4.0--4.2 volts, then go to steps 2.E.(13)(b).

(b) Select “Calibrate“. Enter the following data and select “Enter”.

-- Target Voltage 4.1 volts

-- Initial Gain from US--454A instrument dB

-- Target Rotation from US--454A instrument deg

(c) The window of the corrected target voltage, gain and rotation opens. Select “OK”.

(d) The PSDisplay will automatically open. Select “Click to Continue” in the

PSDisplaypop--up window.

1 Make sure that the notch response was the largest signal shown in the C--scan

and that no excessive noise was produced during the scan.
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If you see a noisy scan, accomplish the as--necessary action that follows and

repeat the scan.

a Replace the Teflon tape on the contact face of the probe.

b Clean the bore of the calibration standard.

c Apply a coating of Teflon dry lube to the bore of the calibration standard.

d Apply a coating of Teflon dry lube to the Teflon tape on the probe that touches

the calibration standard.

2 If the notch was aligned circumferentially with the probe at the start of the scan,

the signal from the notch will occur near zero degree in the C--Scan display. See

the screenshot of the data collected during the calibration scan of the reference

standard (NDT0171).

3 Right clicking in the C--Scan window will open an evaluation box that can be

dragged to various locations to evaluate the indications. PSDisplay cannot be

closed while the evaluation box is open. The box can be closed by right clicking a

2nd time.

NOTE: Excessive noise can be caused by probe chatter and/or contamination

or damage to the surface of the reference standard. The calibration

response must appear similar to when the system was initially qualified.

A copy of the initial calibration scan must be retained for future

reference.

(e) When finished, close the PSDisplay.

NOTE: The evaluation window must be closed prior to closing the PSDisplay.

(f) Loop again?

-- If the voltage was NOT between 4.0--4.2 volts or the scan results were

unacceptable, then select “YES”. Select “OK” to re--run the scan. Continue to step

2.E.(12).

-- If the voltage was between 4.0--4.2 volts and the scan results were acceptable, then

select “NO”.

(g) Jog probe out of bore, Y axis up and X--axis close to zero.

Select “OK”. Move probe assembly up until it clears the bore. Push the joystick

release button to return the control to the scanplan.

(h) Click Ok to move X axis to the left.

Select “OK”.

(i) Calibration Complete Close the Scan Plan.

Select “OK”.

CAUTION: USE THE CORRECT PARTMOUNT AND SCANPLAN FOR THE HPT STAGE 2

WHEEL BEING INSPECTED OR INCORRECT INSPECTION RESULTS WILL

OCCUR.

F. Do the eddy current inspection of HPT2 wheels.

REF. FIG. 5

REF. FIG. 7

(1) Open the file folder C:\ES1000\RR--AE3007\SCANPLAN, and then open the file

RR STG2--BORE.scn.

(2) Clean the top of the turntable and the bottom of the partmount (ETC--5226) with a clean

cloth.
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(3) Clean the bore of the reference standard.

(4) Clean the partmount (ETC--5226) flat and center on the turntable. Install a set--screw that

attaches the partmount to the turntable.

(5) Put the HPT2 wheel on the partmount such that the letter “S” in the serial number is

circumferentially aligned with the probe. This will be the zero--degree location for evaluation

purposes (Ref. FIG. 4).

(6) Run the scanplan. A report window opens up (Ref. FIG. 7).

(7) Fill out the all the required fields that are marked with an asterisk (*) and then select “OK”.

NOTE: The report template can be modified to fill the facility, probe serial number and

calibration standard serial number fields automatically.

(8) A window opens up allowing you to save the report. Open the appropriate Data folder (e.g.

C:\ES1000\RR--AE3007\Data\STG2) and save the report with unique file name (e.g.

SNRR098765_03_25_13).

(9) Set ballslide to 90 degrees.

Make sure the ballslide is 90 degrees to the left, then select “OK”.

(10) Click Ok to move X--axis to start position.

Select “OK”. The ES--1000 will move the X--axis to the center of the turntable (X--Zero

position) automatically.

(11) Jog probe to start position and load ballslide to center.

(a) Select “OK” to give control of the axes to the operator. Use the joystick to carefully

move the probe into the bore of the HPT2 wheel.

(b) Move the ballslide against the bore wall so that the index mark on the probe retainer

aligns approximately with the center index on the ballslide

(c) Move the Y--axis to align the top surface of the probe--fork with the top--surface of the

HPT wheel. Use a straight--edge or other flat object to gauge the alignment. Push the

joystick release button to return the control to the scanplan

(d) Loop again?

-- If the probe--tip position is satisfactory, select “No”.

-- If the probe--tip position is NOT satisfactory, select “Yes“ to do step 2.F.(10) again.

(12) Click Ok to move probe down to start of inspection zone.

Select “OK”. The system will move the probe to the start of the inspection zone, about 1.60

in. (40.6 mm) from the top of the HPT2 wheel.

(13) Click “OK” to start scan.

(a) Select “OK”. The scanplan will set up the scan parameters and null the eddy current

instrument. Make sure the instrument screen flickers and the screen is erased and

nulled (signal dot is in the center of the screen).

(b) The turntable will turn and the upwards scan will begin. At the end of the scan the coil

will be slightly above the edge of the bore chamfer and a window opens allowing you

to save the scan data file.

(c) Find the folder C:\ES1000\RR--AE3007\DATA\Stg2 and open it. Save the data with a

recognizable name e.g. SNRR098765_03_25_13. The extension .dat is automatically

added.

(d) After the file is saved, PSDisplay will automatically open. Select ”Click to Continue” in

the PSDisplay pop--up window.
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(e) When the scan evaluation is finished, close the PSDisplay. The probe will move to the

start of the inspection zone and the program will perform an evaluation called

WINDOWING. A window opens up allowing you to save the results of the

WINDOWING evaluation.

(f) If not already selected, find the folder C:\ES1000\RR--AE3007\Data\Stg2. Saving the

file with the same name as the report in step 2.F.(8) will add the results from the

WINDOWING routine to the original report file.

(g) A window will open up with the number of indications found. Select “OK” to continue.

The probe will move to the start of the inspection zone.

(h) Loop again?

-- If the bore scan is satisfactory, select “No”.

-- If the bore scan is NOT satisfactory, select “Yes“ to do step 2.F.(12) again.

(14) Jog probe out of bore, Y--axis up and X--axis close to Zero.

Select “OK“ to give control of the axes to the operator. Move the probe to the right off the

bore wall, and move the Y--axis up to the top. Jog the X--axis until the X--value at the

bottom of the ES--1000 window is within +/--0.2 in. (+/--5.1 mm).

(15) Click OK to move X--axis to the left.

Select “OK” and the system will drive the X--axis to the left and out of the way.

(16) Inspection complete. Close the scanplan.

The inspection is complete. Close the scanplan unless you plan to scan another HPT2

wheel that is the same stage as the one just completed.

Prior to scanning another HPT2 wheel, review the condition of the Teflon or Kapton tape. If

the tape needs replacement, perform a post--calibration prior to changing the tape. After

replacing the tape, perform a calibration prior to scanning more HPT2 wheels.

G. Data evaluation.

PSDISPLAY can be used to view the data stored during the calibration and during each

inspection scan. PSDisplay is launched after the calibration and part scans and can also be

launched manually after scans are completed. When launched manually, the appropriate .dat

file can be opened and evaluated.

By drawing a box around the flaw indication you can evaluate its signal characteristics. The

actual value displayed may differ from the results given by the WINDOWING report since two

different algorithms are used. Rely on the largest value for accept/reject decisions.

H. Acceptance criteria.

The ES--1000 semi--automatic scanning system employs a data--acquisition reject--gate that

monitors and records eddy current signal responses. The system will be calibrated on a 0.020

in. (0.51 mm) long x 0.010 in. (0.25 mm) deep x 0.004 in. (0.10 mm) EDM notch to a vertical

peak--to--peak signal response of 4.0 volts. The reject--gate will automatically be set at 50% Full

Screen Height (FSH) signal, i.e. 2.0 volts. All components that produce a signal with a

peak--to--peak voltage of 2.0 volts or larger are cause for rejection and requires further

evaluation.

I. Post inspection calibration check.

(1) Do the system calibration from step 2.E., except use file RR POST CAL--ETC2517.scn. to

scan the reference standard.

During the post--calibration you will only verify the final calibration voltage. If the voltage is

3.9 volts or above, then the inspection is considered successful. If the voltage is less than

3.9 volts, the system must be recalibrated and all parts examined since the last successful

calibration must be examined again.
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If the voltage is above 4.4 volts, then you have over--inspected the part. If you do not have

rejected parts or suspect indications above 4.4 volts the parts must be considered

acceptable; otherwise, the system must be recalibrated and examined again.

J. As necessary, replace the HPT2 wheel.

(1) Replace the HPT2 wheel.

(a) Disassemble the HPT rotor/case--and--2nd--stage vane assembly (Ref. TASK

72--52--01--000--801, EM).

(b) Disassemble the HPT2 bladed wheel (Ref. TASK 72--52--11--000--801, EM).

(c) Use a new/serviceable HPT2 wheel to assemble the HPT2 bladed wheel (Ref. TASK

72--52--11--400--801, EM).

(d) Assemble the HPT rotor/case--and--2nd--stage vane assembly (Ref. TASK

72--52--01--400--801, EM).

K. Assemble the engine.

(1) Assemble the HPT rotor/case--and--2nd--stage vane assembly (Ref. TASK

72--52--01--400--801, EM).

(2) Install the HPT rotor assembly (Ref. TASK 72--00--52--400--801, EM).

L. Return the removed HPT2 wheel(s) with the Parts Return Report (Ref. AE 3007A--102, NTO).

M. Record the necessary data on the Service Bulletin Compliance Form and return it to

Rolls--Royce.

N. Record compliance with this service bulletin in the applicable section of the engine logbook.
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Drive C File Structure

FIG. 1
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Equipment Setup -- System Preparation

FIG. 2
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Equipment Setup -- ES--1000 Zero Position

FIG. 3
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Equipment Setup -- ES--1000 Zero Position

FIG. 4
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Equipment Setup for Calibration and Wheel Inspection

FIG. 5
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Probe Alignment for Calibration and EDM Notch Signal

FIG. 6
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Calibration and Inspection Window Messages and Displays

FIG. 7
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APPENDIX 1 -- SCANPLANS

(Sheet 1 of 5)
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APPENDIX 1 -- SCANPLANS

(Sheet 2 of 5)
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APPENDIX 1 -- SCANPLANS

(Sheet 3 of 5)
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APPENDIX 1 -- SCANPLANS

(Sheet 4 of 5)
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APPENDIX 1 -- SCANPLANS

(Sheet 5 of 5)
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3. MATERIAL INFORMATION

A. Configuration Chart -- Not applicable

B. Consumable Materials

(1) Lube, Teflon (PTFE) dry.

(2) Tape, Teflon or Kapton -- maximum thickness 0.004 in. (0.10 mm).

C. Expendable Parts -- None

CUSTOMER SUPPORT

ROLLS-ROYCE CORPORATION
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