# SER VICE BULLETIN REVISION NOTICE

ENGINE

— DISK, 15TH ST AGE HIGH PRESSURE COMPRESSOR (HPC)

— REPETITIVE BORESCOPE INSPECTION OR EDDY CURRENT INSPECTION (ECI) FOR CRACKS IN THE FRONT RAIL OF THE OUTER RIM Turbojet Engine Service Bulletin No. PW4G-1 12-72-309 Revision No. 1 dated July 1, 2010. Rev i s i o n H i sto ry Original Issue November 10, 2009 Revision 1 dated July 1, 2010 Re a s o n f o r t h e Rev i s i o n T o update the number of cracks found in service engines to date from 41 to 53. T o revise the compliance to include a drawdown plan and limit disk life to 12,000 cycles. T o attach NDIP-1014, Revision B. T o remove “There is no terminating action for this repetitive inspection at this time.”. T o remove “NOTE: Engine Serial No. P777032 and P777038 were inspected and meet the initial inspection requirement of this Service Bulletin” from the Ef fectivity section. E f fe ct of Rev i s i o n o n P ri o r C o m p l i a n ce None. T h i s i s a C o m p l ete Rev i s i o n ( N ot A p p l i ca b l e to t h e S G M L ve rs 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 st ru ct i ve I n s p e ct i o n P ro ce d u re s NDIP-1014, Revision B dated June 7, 2010 is attached. Please discard the previously issued copy

. M O D E L A P P L I CA T I O N PW4074, PW4077 B U L L E T I N I S S U E S E Q U E N C E PW4G-1 12 Series 72-309

P a g e Rev i s i o n N o

. D a te 1 thru 18 1 July 1/10 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.

P &W D i st ri b u t i o n C o d e 2641, 2648 

# PW4G-1 12-72-309 Page 1 of 1
Printed in United States of America

# SER VICE BULLETIN

ENGINE

— DISK, 15TH ST AGE HIGH PRESSURE COMPRESSOR (HPC)

— REPETITIVE BORESCOPE INSPECTION OR EDDY CURRENT INSPECTION (ECI) FOR CRACKS IN THE FRONT RAIL OF THE OUTER RIM

M O D E L A P P L I CA T I O N PW4074, PW4077

B U L L E T I N I S S U E S E Q U E N C E PW4G-1 12 Series 72-309

A T A N U M B E R 72-35-00

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

. C o m p l i a n ce C a te g o ry 3 P &W D i st ri b u t i o n C o d e 2641, 2648


## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 1 of 18 Printed in United States of AmericaS u m m a ry The purpose of this Service Bulletin is to provide instructions to do a repetitive borescope inspection or Eddy Current Inspection (ECI) of the 15th stage High Pressure Compressor (HPC) disk for cracks. Inspection of 15th stage disks of in service engines found 53 cracks in the front rail of the blade loading and/or locking slots on the outer rim. Metallurgical examination of the 15th stage HPC disk cracks revealed that the initiation was the result of Thermal Mechanical Fatigue (TMF). Remove from service any disk that has a crack. The ECI is in NDIP-1014 Revision B and is provided in the Appendix section of this Service Bulletin. P l a n n i n g I n f o rm a t i o n E f fe ct i v i ty D a ta E n g i n e M o d e l s A p p l i ca b l e PW4074, PW4077 Engine Serial No.

— All engines that have 15th Stage HPC Disk, PN 55H615 installed.
C o n c u rre n t Re q u i re m e n ts There are no concurrent requirements. Re a s o n 1. Problem: Inspection of 15th stage disks of in service engines found 53 cracks in the front rail of the blade loading and/or locking slots on the outer rim. 2. Cause: Metallurgical examination of the cracks revealed that the initiation was the result of TMF

. 3. Solution: Do a repetitive borescope inspection or ECI of the 15th stage HPC disk. D e s c ri pt i o n Do a borescope inspection or ECI of the 15th stage HPC disk. C o m p l i a n ce Category 3 15th stage HPC Disks, PN 55H615 with 12,000 part cycles since new must be removed from service. For engines with disks that have accumulated less than or equal to 9,865 cycles when this Service Bulletin is released, the engine must be removed when the 15th disk accumulates 12,000 cycles since new

. For engines with disks that have accumulated more than 9,865 cycles when this Service Bulletin is released, the engine must be removed by 2,135 cycles after Service Bulletin release. If a disk exceeds 12,000 cycles since new before the engine is removed, perform an inspection of the disk before 12,000 cycles, and repeat the inspection before 1,200 additional cycles until the disk is removed within 2,135 cycles, or a crack is found. The repeat inspection is waived if the previous inspection was accomplished with ECI. N O T E : FPI can be done as specified in Reference 4, CIR Manual, Chapter/Section 72-35-92, Inspection/Check-02 or Reference 6, Service Bulletin No. PW4G-1 12-72-243. ECI can be done as specified in Reference 7, NDIP-1014 Revision B

. NDIP-1014 Revision B is provided in the Appendix section of this Service Bulletin.


## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 2 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.If a crack is suspected by borescope inspection, but cannot be visually confirmed, do an ECI within 5 cycles.

A p p rova l D a ta 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 owe r The estimate of man-hours of labor directly necessary to do the intent of this Service Bulletin are as follows:
F o r E n g i n e s I n sta l l e d O n T h e A i rc raf t 1. Open and Close Cowl Doors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 2. Necessary to do the Inspection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 3. T otal Necessary Man-hours

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0
F o r E n g i n e s Re m ove d F ro m T h e A i rc raf t 1. Necessary to do the Inspection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 2. T otal Necessary Man-hours

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 We i g h t D ata No Change. E l e ct ri ca l L o a d D a ta Not Applicable. S of twa re Acco m p l i s h m e n t S u m m a ry Not Applicable. Refe re n ce s 1. Turbojet Engine Standard Practices Manual, Part No. 585005. 2. PW4074, PW4077 Turbofan Engines, Illustrated Parts Catalog, Part No. 51A346. 3. PW4074, PW4077 Turbofan Engines, Engine Manual, Part No. 51A345. 4. PW4000 Series 1 12 Inch PW4074, PW4077, PW4077D, PW4084D, PW4090, PW4098 Turbofan Engines, Engine Cleaning, Inspection And Repair (CIR) Manual, Part No. 51A750. 5. Boeing 777 Aircraft Maintenance Manual. 6. Service Bulletin No. PW4G-1 12-72-243; Engine

— Disk, 15Th Stage High Pressure Compressor (HPC)

— Inspection For Cracks In The Blade Slot Loading And Locking Locations And Knife Edge Seal Location. Issue Sequence 72-243, PW4G-1 12 Series. 7. Non-Destructive Inspection Procedure NDIP-1014, Revision B , — PW4074 / PW4077 15th Stage HPC Disk Front Rail Blade Loading Slot and Locking Areas Eddy Current Inspections (Assembled/Aircraft Installed).



## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 3 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.P u b l i ca t i o n s C h a n g e d Not Applicable. I n te rc h a n g e a b i l i ty Not Applicable. I n f o rm at 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 November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 4 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.M a te ri a l I n f o rm a t i o n M a te ri a l

— C o st a n d A va i l a b i l i ty 1. The estimated price to do the Borescope Inspection procedure in this Service Bulletin is $12.90 for a new borescope plug key washer

. 2. There is no kit provided to do this Service Bulletin. 3. Part availability information is provided in material data Instructions

— Disposition. I n d u st ry S u p p o rt P ro g ra m Not Applicable. T h e m ate ri a l d ata t h at f o l l ows 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. CA U T I O N : THE FOLLOWING MA TERIAL DA T A T ABLE(S) ARE ORGANIZED BY ILLUSTRA TED P ARTS CA T ALOG. ALL P ARTS IN THE T ABLE(S) MA Y OR MA Y NOT BE APPLICABLE TO ALL THE ENGINE MODELS SHOWN IN THE T ABLE HEADING. YOU MUST REFER TO THE APPROPRIA TE ILLUSTRA TED P ARTS CA T ALOG FOR ENGINE MODEL APPLICABILITY USING THE OLD P ART NUMBER (PN) AND CA T ALOG SEQUENCE NUMBER. F AILURE TO INST ALL THE P ART(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 ate ri a l d ata t h at f o l l ows i s f o r e a c h e n g i n e

. F o r PW4 0 74 , PW4 0 7 7 E n g i n e s : New PN Qty Estimate of Unit Price ($) Keyword Old PN Instructions

— Disposition 1 DISK

— HPC, 15STG 55H615 (72-35-00-1-210) (4)(X)

58H216 1 12.90 KEY W ASHER 58H216 (72-35-00-25-20 A) (E)

M o d i fi ca t i o n a n d S p a re s I n f o rm a t i o n Estimated part prices are provided when they are available at time of publication. The Estimate of Unit Price is only for planning purposes and does not constitute a firm quotation. An asterisk (*) is shown where part pricing information was unavailable. In either case, contact Pratt & Whitney Spares Management & Logistics for firm quotations. Parts Modification Conditions (4) Do an inspection as specified in the Accomplishment Instructions. Spare Parts A vailability (E) The part is an expendable item necessary to do this bulletin. (X) See Reference 2, Illustrated Parts Catalog for applicable replacement parts. Cleaning, Inspection and Repair Information Not Applicable.


## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 5 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.V endor Services or Special Components/Materials Not Applicable. M a te ri a l D ata f o r E a c h S p a re E n g i n e The material for each spare engine is as stated in the preceding material information section. Re i d e n t i fi e d P a rts Not Applicable. N e ce s s a ry T o o l s N ew S u p p o rt E q u i p m e n t t h a t i s n e ce s s a ry T ool No. Name Standard Flexible borescope with articulating tip and 150 watt minimum light source. (A 4mm flexible borescope is recommended; however, other size flexible borescopes can be used if the viewing quality is the same or better than a 4mm flexible borescope.) PW A 88247 Rotator (Or equivalent as specified in Reference 5, Aircraft Maintenance Manual) O t h e r M ate ri a l I n f o rm a t i o n D ata Not Applicable.



## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 6 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.Acco m p l i s h m e n t I n st ru ct i o n s N O T E : Service Bulletin incorporation on engines installed on aircraft may be desirable and should be individually evaluated.
F O R E N G I N E S I N S T A L L E D O N T H E A I R C RA F T 1. Do an inspection of the 15th Stage Disk, PN 55H615 by one of the procedures that follow

. See Figure 1. A. Do an ECI of the disk as specified in Reference 7, NDIP-1014 Revision B

. NDIP-1014 Revision B is provided in the Appendix section of this Service Bulletin. Or B. Do a borescope inspection of the disk as follows: (1) Open fan cowl doors and thrust reversers as specified in Reference 5, Aircraft Maintenance Manual, Chapter/Section 71-1 1-04 and 78-31-00. N O T E : The variable vanes must be fully open when the engine is shutdown. If the vanes are not open use a large wrench or a crows foot wrench to rotate the bellcrank on the stator vane actuator to the fully open position. (2) Access the disk through the AP-7 (borescope) port as specified in the Reference 5, Aircraft Maintenance Manual, Chapter/Section 72-00-00. See Figure 2, Sheets 1 and 2. (3) Insert the borescope into the AP-7 port to view the front rail of the disk. See Figure 2, Sheets 3 and 4. (4) Remove the gearbox crank pad cover and use a PW A 88247 Rotator or equivalent to rotate the rotor at the gearbox crank pad. (5) Rotate the rotor until the first blade lock is seen. Use the blade lock locations for angular reference. See Figure 3. (6) Rotate the rotor in the same direction past two additional blades. If another blade lock is found just past the second blade then the current location is a lock and loading location. The loading slot (which is not visible) is between the two blade locks. See Figure 3. (7) Do an inspection of the front rail in the areas adjacent to the locking slots and the area between the two locking slots for cracks. Cracks typically run in the radially inboard direction from the outer rim of the rail. See Figure 2, Sheet 4. (8) If another blade lock is not found just past the second blade, then the present location is a blade lock only

. See Figure 3. (9) Do an inspection of the front rail for cracks adjacent to the blade lock. Cracks typically run in the radially inboard direction from the outer rim of the rail. See Figure 2, Sheet 4. (10) Rotate the rotor until the next blade lock is visible and do the inspection of the two blade lock and loading areas and four blade lock areas. N O T E : Rotating the crack pad 360 degrees represents more than 360 degrees of rotor rotation. (1 1) The inspection criteria is as follows:



## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 7 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.(a) If the disk does not have a crack, the disk is acceptable. (b) If the disk does have a crack, replace the disk. (c) If a crack is suspected, but cannot be visually confirmed, do an ECI within 5 cycles, as specified in Reference 7, NDIP-1014 Revision B

. NDIP-1014 Revision B is provided in the Appendix section of this Service Bulletin. (12) Remove the borescope and install the AP-7 borescope plug and new Key Washer, PN 58H216 as specified in Reference 5, Aircraft Maintenance Manual, Chapter/Section 72-00-00. (13) Remove the PW A 88247 Rotator or equivalent and install the gearbox crank pad cover

. (14) Close fan cowl doors and thrust reversers as specified in Reference 5, Aircraft Maintenance Manual, Chapter/Section 71-1 1-04 and 78-31-00. (15) Record the inspection results. For all disks that have cracks: operators are requested to provide the results of the inspection to their local Pratt & Whitney service representative. See Figure 4 for the data retrieval form.
F O R E N G I N E S R E M OV E D F R O M T H E A I R C RA F T (AS S E M B L E D E N G I N E S A N D/O R H P C M O D U L E S N O T S C H E D U L E D F O R D I SAS S E M B L Y O R I N S P E C T I O N ) 1. Do an inspection of the 15th stage disk, PN 55H615 by one of the procedures that follow

. See Figure 1. N O T E : This inspection does not supersede or replace Reference 6, Service Bulletin No. PW4G-1 12-72-243. This procedure is intended for assembled engines and/or HPC modules not scheduled for disassembly or inspection as specified by Reference 4, CIR Manual, Chapter/Section 72-35-92, Inspection/Check-02 or Reference 6, Service Bulletin No. PW4G-1 12-72-243. A. Do an ECI of the disk as specified in Reference 7, NDIP-1014, Revision B

. NDIP-1014, Revision B is provided in the Appendix section of this Service Bulletin.
or B. Do a borescope inspection of the disk as follows: (1) Access the disk through the AP-7 (borescope) port as specified in the Reference 3, Engine Manual, Chapter/Section 72-00-00, Inspection/Check-03. See Figure 2, Sheets 1 and 2. N O T E : The variable vanes must be fully open when the engine is shutdown. If the vanes are not open use a large wrench or a crows foot wrench to rotate the bellcrank on the stator vane actuator to the fully open position. (2) Insert the borescope into the AP-7 port to view the front rail of the disk. See Figure 2, Sheets 3 and 4. (3) Remove the gearbox crank pad cover and use a PW A 88247 Rotator or equivalent to rotate the rotor at the gearbox crank pad. (4) Rotate the rotor until the first blade lock is seen. Use the blade lock locations for angular reference. See Figure 3. (5) Rotate the rotor in the same direction past two additional blades. If another blade lock is found just past the second blade then the current location is a


## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 8 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.lock and loading location. The loading slot (which is not visible) is between the two blade locks. See Figure 3. (6) Do an inspection of the front rail in the areas adjacent to the locking slots and the area between the two locking slots for cracks. Cracks typically run in the radially inboard direction from the outer rim of the rail. See Figure 2, Sheet 4. (7) If another blade lock is not found just past the second blade, then the location is a blade lock only

. See Figure 3. (8) Do an inspection of the front rail for cracks adjacent to the blade lock. Cracks typically run in the radially inboard direction from the outer rim of the rail. See Figure 2, Sheet 4. (9) Rotate the rotor until the next blade lock is visible and do the inspection of the two blade lock and loading areas and four blade lock areas. N O T E : Rotating the crack pad 360 degrees represents more than 360 degrees of rotor rotation. (10) The inspection criteria is as follows: (a) If the disk does not have a crack, the disk is acceptable. (b) If the disk does have a crack, replace the disk. (c) If a crack is suspected, but cannot be visually confirmed, do an ECI within 5 cycles, as specified in Reference 7, NDIP-1014 Revision B

. NDIP-1014 Revision B is provided in the Appendix section of this Service Bulletin. (1 1) Remove the borescope and install the AP-7 borescope plug and new Key Washer, PN 58H216 as specified in Reference 3, Engine Manual, Chapter/Section 72-00-00, Inspection/Check-03. (12) Remove the PW A 88247 Rotator or equivalent and install the gearbox crank pad cover

. (13) Record the inspection results. For all disks that have cracks: operators are requested to provide the results of the inspection to their local Pratt & Whitney service representative. See Figure 4 for the data retrieval form.



## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 9 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.LOCA TION OF THE 15TH ST AGE HPC DISK 72-35-00 FIGURE 1



## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 10 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.INSPECTION OF THE 15TH ST AGE HPC DISK FIGURE 2, SHEET 1



## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 1 1 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.INSPECTION OF THE 15TH ST AGE HPC DISK FIGURE 2, SHEET 2



## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 12 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.INSPECTION OF THE 15TH ST AGE HPC DISK FIGURE 2, SHEET 3



## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 13 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.INSPECTION OF THE 15TH ST AGE HPC DISK FIGURE 2, SHEET 4



## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 14 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.TYPICAL VIEW OF BLADE LOADING SLOT AREAS FIGURE 3



## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 15 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.DA T A RETRIEV AL FORM FIGURE 4



## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 16 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.A p p e n d i x Ad d e d D a ta I n te rn a l Refe re n ce I n f o rm at i o n
Revision No. Reference Document Origination
Original EA09KA050 EA09KCC43 DB/IEL
1 EA09KCC43 DB/JEJ Non-Destructive Inspection Procedure NDIP-1014, Revision B follows:



## l November 10/09 

# PW4G-1 12-72-309 REVISION NO. 1

- July 1/10 Page 17 UTC/P&W PROPRIET AR Y INFORMA TION Subject to the restrictions on the cover or first page.NDIP-1014

### REV. B Effective 06/07/2010

1 

## PW4074 / PW4077 15th Stage HPC Disk Front Rail Blade Loading Slot and Locking Areas Eddy Current Inspections (Assembled/Aircraft Installed)

NDIP–1014 REVISION B

WARNING THIS DOCUMENT MAY CONTAIN INFORMATION SUBJECT TO THE INTERNATIONAL TRAFFIC IN ARMS REGULATION (ITAR) OR THE EXPORT

ADMINISTRATION REGULATION (EAR) OF 1979. THIS INFORMATIO N MAY NOT BE EXPORTED, RELEASED, OR DISCLOSED TO FOREIGN NATIONALS OUTSIDE THE UNITED STATES WITHOUT FIRST COMPLY ING WITH THE EXPORT LICE NSE REQUIREMENTS OF THE INTERNATIONAL TRAFFIC IN ARMS REGULATION (ITAR) AND/OR THE EXPORT ADMINISTRATION REGULATION (EAR). A VIOLATION OF THE ITAR OR EAR MAY BE SUBJECT TO A PENALTY OF UP TO 10 YEARS IMPRISONMENT AND A FINE OF $1,000,000 UNDER 22 U.S.C 2778 OR

SECTION 2410 OF THE EXPORT ADMINISTRATION ACT OF 1979. I NCLUDE THIS NOTICE WITH ANY REPRODUCED PORTION OF THIS DOCUMENT.

RESTRICTION PAGES OF THIS DOCUMENT MARKED WITH THE NOTICES SET FORTH BELOW CONTAIN CO NTRACTOR COMPETITION SENSITIVE DATA AND/OR PRATT & WHITNEY PROPRIETARY DATA WHICH IS SUBMITTED IN CONFIDENCE. NO DI SCLOSURE OR USE OFTHIS INFORMATION

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NOTICES P&W PROPRIETARY INFORMATION ECCN 9E991 - EXPORT CONTROLLEDNDIP-1014

### REV. B Effective 06/07/2010

Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this document 

### 2 PW4074 / PW4077 15th Stage HPC Disk Front Rail Blade Loading Slot and Locking Areas Eddy Current Inspections (Assembled/Aircraft Installed)

NDIP–1014 Revision B

Issue Date: June 07, 2010 Written By: Wenji Peng Approved By: Jonathan Sullivan PL3

Instructions described within this procedure do not replace, amend or supersede any instructions included in other Pratt & Whitneytechnical publications. Active Service Bulletins and other technical publications published by Pratt & Whitney compri se approved technical data.
The purpose of Revision A: 1. Apply this procedure only to engine models PW4074 / PW4077. 2. Add the requirements of eddy current inspectionson all blade loading and locking areas of 15th stage HPC disk front rail. The purpose of revision B: Remove Figure 4, inwhich the AP7 and gear box locations have already been depicted and described in page 11- 13 of the revision of Service Bulletins PW4G-112- 72-309, from NDIP-1014 A.NDIP-1014

### REV. B Effective 06/07/2010

Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this document 

### 3 PW4074 / PW4077 15th Stage HPC Disk Front Rail Blade Loading Slot and Blade Locking Areas Eddy Current Inspections (Assembled/Aircraft Installed) 

### I. GENERAL The objective of this eddy current inspection is toverify crack indicationsin the front rail at the blade loading slot or blade locking areas of the 15th stage high pressure compressor (HPC) disk for the PW4074/PW4077 enginemodels. The inspection is conducted on assembled engines and may be applied to an aircraft installed engine. The inspection is accomplished by inserting and manipulating an eddy current probe assembly through the AP-7 borescope access port toplace the probe tip in contact with the front rail, and then rotating the HPC rotor to traverse the blade loading slot or blade locking area(s) past the probe. A borescope isin the AP-7 borescope access port alongside the probe assembly to visually aid in the placement of the eddy current probe and verification of proper probeposition during inspection. This manual is provided as an inspection training guide.NDIP-1014

### REV. B Effective 06/07/2010

II. ACCOMPLISHMENT INSTRUCTIONS A. EQUIPMENT REQUIRED, Figure 1.

FIGURE 1 EQUIPMENT REQUIRED



### 4 Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this documentNDIP-1014

### REV. B Effective 06/07/2010

1. PWA 105249, Eddy Current Probe Assembly, Figure 2.

FIGURE 2 PWA 105249 EDDY CURRENT PROBE ASSEMBLY NOTE: The PWA 105249 eddy current probe assembly consists of an absolute coil at the tip of a shaft attached to a handle with the electrical cables located within the shaft.

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2. PWA 26964 Sensitivity Setting Standard, Figure 3.

FIGURE 3 PWA 26964 SENSITIVITY SETTING STANDARD

NOTE: The PWA 26964 sensitivity setting standard consists a flat plate with a simulated defect, 0.750 inch (19.1 mm) long by 0.025 inch (0.64 mm) deep by 0.010 inch (0.25 mm) wide, electro-discharged machined into the surface



### 6 Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this documentNDIP-1014

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Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this document 7 3. Eddy Current Instrument, Foerster Defectometer® Model H 2.835 or equivalent — available from:

Foerster Instruments Inc. RIDC Park West 140 Industry Drive Pittsburgh, PA 15275 U.S.A. or Institut Dr. Friedrich Forster Prufgeratebau GmbH & Co. KG In Laisen 70 D-7410 Reutlingen Germany

NOTE: This inspection uses an eddy current instrument operating at a frequency of 2 MHz. NOTE: The equipment described in this procedure is consistent with the listed requirements but is not intended to prevent the use of alternate equivalent eddy current instruments. NOTE: The operating manual for the eddy current instrument applied to this inspection should be referenced to obtain a complete understanding of instrument operating procedure. 4. Oscillographic Recorder, Yokogawa OR100 or equivalent — available from: Yokogawa Electric Corp. or Yokogawa Corp. of America 2 Dart Road 9-32, Nakacho 2-chome Shenandoah Industrial Musashino-shi Newman, GA 302650 Tokyo 18 U.S.A. Japan
NOTE: This inspection uses an oscillographic recorder operating at a chart speed of 2 seconds per division with an input amplifier gain set to 0.5 volts per division.

The equipment described in this procedure is consistent with the listed requirements but is not intended to prevent the use of alternate equivalent recorders. NOTE: The operating manual for the recorder applied to this inspection should be referenced to obtain a complete understanding of recorder operating procedure. 5. Patch Cord, Defectometer® H 2.835 to Yokogawa OR100 or equivalent. Purchase from the eddy current instrument manufacturer or fabricate locally. Refer to instrument and recorder operating manuals for wiri ng diagrams and approp riate connectors. 6. Borescope, Flexible, 0.181 inch (4 mm) maximum diameter by 39 inches (100 cm) long, direct view, 50 degree minimum field of view, Machida FBA-4D-100, or equivalent — available from: Machida, Inc. 40 Ramland Road Orangeburg, NY 10962 U.S.A. www.machidascope.comNDIP-1014

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Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this document 8 7. Light Source, Model LB-24, 24 watt xenon or equivalent — available from: Machida, Inc. 40 Ramland Road Orangeburg, NY 10962 U.S.A. www.machidascope.com NOTE: The operating manual for the Model LB-24 light source applied to this inspection should be read to obtain a familiarization with the light source operating procedure. 8. Magic Arm Assembly, Bogen Model 2930-Art #143A, with two (2) Super Clamps, Bogen Model 2900-Art. #035 — available from:

Bogen Photo Corporation 565 East Crescent Avenue P.O. Box 506 Ramsey, NJ 07446-0506 U.S.A. www.bogenphoto.com info@bogenphoto.com or Manfrotto & Co. Italy

9. Engine Turning Tool — Breaker bar with spline socket. NOTE: It is acceptable to use a motorized engine turning tool, SMI Model TT-70 or equivalent — available from: Machida, Inc. 40 Ramland Road Orangeburg, NY 10962 U.S.A. www.machidascope.com 10.Low Friction Tape, 3M Electrical Tape, Scotch® #60-1/4, 0.003 inch (0.08 mm) thick adhesive backed or equivalent — available from: 3M St. Paul, MN 55144 U.S.A. NOTE: Low friction tape is used to cover the probe coil area to minimize probe wear and to provide a low friction contact surface between the probe and the 15th stage HPC disk front rail surface.

11. Refer to the similar Instructional Videotape, PN 01V039, “PW4090/PW4098 15th Stage HPC Disk Borescope and Eddy Current On-Wing Inspections ′′

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Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this document 9 B. INSPECTOR QUALIFICATION/TRAINING REQUIREMENT
CAUTION: INSPECTION PERSONNEL PERFORMING THE EDDY CURRENT INSPECTION PER NDIP-1014 MUST MEET THE FOLLOWING REQUIREMENTS:

• MUST HAVE EXPERIENCE IN EDDY CURRENT INSPECTION THEORY AND APPLICATION PER THE INTERNAL REQUIREMENTS OF THE OPERATOR/OVERHAUL FACILITY, OR EQUIVALENT TO THE NAS-410 LEVEL II REQUIREMENTS; AND

• SHOULD VIEW THE SIMILAR INSTRUCTIONAL VIDEOTAPE, PN 01V039, “PW4090/PW4098 15TH STAGE HPC DISK BORESCOPE AND EDDY CURRENT ON-WING INSPECTIONS ′′TO OBTAIN A FAMILIARIZATION WITH THE INSPECTION APPLICATION.

C. AIRFRAME/ENGINE PREPARATION

CAUTION: THIS INSPECTION IS CONDUCTED ON AN ASSEMBLED ENGINE AND ON AN AIRCRAFT INSTALLED ENGINE. EVERY PRECAUTION MUST BE TAKEN TO INSURE THE INSPECTION IS CONDUCTED IN A SAFE MANNER TO PREVENT ACCIDENT OR INJURY. NOTE: The engine must cool down for a minimum of 4 hours prior to the inspection to allow the HPC area to achieve a temperature equal to or less than 150 degrees Fahrenheit (65 degrees Celsius).

CAUTION: APPLICATION OF THE INSPECTION TO AN ENGINE WITH AN HPC TEMPERATURE OF GREATER THAN 150 DEGREES FAHRENHEIT (65 DEGREES CELSIUS) WILL DAMAGE THE PWA 105249 EDDY CURRENT PROBE ASSEMBLYAND/OR PROVIDE ERRONEOUS EDDY CURRENT INSPECTION RESULTS.

1. Close the thrust reverser and open the cowl panels as required to obtain access to the AP-7 borescope access port and gearbox. 2. Remove AP-7 borescope access port plug and sleeve. 3. Remove the gearbox crank pad cover and install engine rotating device. 4. Position and secure inspection equipm ent in locations convenient to the AP-7 borescope access port which will allow comfortable viewing during inspection and connection of power cords, connecting cables and light guide.NDIP-1014

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Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this document 10 5. Attach and secure the magic arm assembly at an appropriate location on the engine. CAUTION: IT IS IMPORTANT TO ATTACH THE MAGIC ARM ASSEMBLY ON AN EXTERNAL COMPONENT THAT WILL NOT BE DAMAGED BY THE ATTACHMENT CLAMP. 6. Set the magic arm assembly in a position that will hold the borescope and allow placement of the borescope in the AP-7 borescope access port without interference with external engine components and set the locking lever. 7. Assemble the borescope.

a. Attach the light guide of the borescope to the light source. b. Place the section of the borescope control body away from the focusing and articulating controls into the clamp of the magic arm assembly and secure. 8. Turn on the light source.

D. CALIBRATION PROCEDURE NOTE: The instructions described in these instructions are based on the Defectometer® H 2.835 eddy current instrument. If an equivalent eddy current instrument is used, the system application and control settings should be adjusted to duplicate the Defectometer® H 2.835 instrument parameters described in this procedure. 1.Carefully cover the probe coil contact surfaces of the PWA 105249 eddy current probe assembly with a smooth and wrinkle-free layer of low friction tape. NOTE: Check the low friction tape for damage prior to calibration and inspection and replace if damage is noted. It is necessary to conduct the calibration procedure after replacement of the teflon tape. 2. Connect the probe cable to the Defectometer® H 2.835 eddy current instrument. 3. Connect the eddy current instrument to the oscillographic recorder using the patch cord. 4. Turn on the eddy current instrument.NDIP-1014

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Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this document 11 5. Select the Fe mode by depressing and releasing the Material (M) button until Fe appears on the LCD panel. 6. Turn on the oscillographic recorder. 7. Set controls of oscillographic recorder as follows: Speed — 2 second/division Range — 0.5 Volts/division
8. Perform the lift-off compensation procedure using the PWA 26964 sensitivity setting standard, Figure 4.

FIGURE 4 POSITION OF PWA 105249 EDDY CURRENT PROBE ASSEMBLY ON PWA 26964 SENSITIVITY SETTING STANDARD DURING LIFT-OFF COMPENSATION PROCEDURENDIP-1014

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a. With the coil end of the probe approximately 2 inches (51 mm) away from the sensitivity setting standard and any other electrically conductive or magnetically permeable material or magnet ic field, depress the Lift-Off (L) button. b. After the Z indicator on the LCD panel starts to flash, place the coil end of the probe perpendicular to and on the inspection surface of the standard at a location midway between the edges and the simulated defect.
c. Apply a load to the probe to contact the surface of the standard and depress the Zero (Z) button.
9. Set the inspection sensitivity, Figure 5.

FIGURE 5 POSITION OF PWA 105249 EDDY CURRENT PROBE ASSEMBLY ON PWA 26964 SENSITIVITY SETTING STANDARD DURING SENSITIVITY SETTING

Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this document 12NDIP-1014

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Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this document 13 a. Slowly traverse the probe along the standard while monitoring the recorder for the eddy current indication (rapid upscale and return pen movement) from the simulated defect, Figure 6.

FIGURE 6 TYPICAL RECORDER TRACE OF EDDY CURRE NT INDICATION FROM THE SIMULATED DEFECT ON THE PWA 26964 SENSITIVITY SETTING STANDARD DURING CALIBRATION

1) Maintain the coil perpendicular to the standard and traverse the probe across the simulated defect at a constant speed of approximately 0.5 inch (12.7 mm) per second.

b. The recorder trace will exhibit a rapid upscale and return pen movement as the probe traverses over the simulated defect.
c. Adjust the eddy current instrument and/or recorder gain control to reproduce the recorder trace and amplitude provided on the back of the certification card. d. Turn off the osc illographic recorder. NOTE: The calibration procedure using the PWA 105249 eddy current probe assembly and PWA 26964 sensitivity setting standard should be conducted at the beginning and end of each inspection sequence and whenever the inspection has been interrupted to maintain accurate inspection results.NDIP-1014

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E. INSPECTION PROCEDURE

FIGURE 7 BLADE LOADING SLOT and Blade Lock AREAS

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1. Carefully insert and manipulate the articulating end of the borescope into the AP-7 borescope access port. The location distribution of the blade loading slot or locking areas to be inspected is referred to Figure 7.

a. Manipulate the borescope to obtain the viewrequired for inspection, Figure 8a and 8b.

FIGURE 8a A TYPICAL INSPECTION VIEW SHOWING BLADE LOADING SLOT AREA

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16 Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this document FIGURE 8b A TYPICAL INSPECTION VIEW SHOWING BLADE LOOKING AREA

2. Rotate the HPC through the gearbox to locate the blade loading slot or locking area to be inspected within the inspection view, refer to Figure 8a and 8b. 3. Rotate the HPC counterclockwise through the gearbox to locate a position on the front rail of the 15th stage HPC disk approximately three (3) blades away from the blade loading slot or blade locking area to be inspected. 4. Carefully insert the coil end of the PWA 105249 eddy current probe assembly into the AP7 borescope port alongside the borescope. 5. Continue to insert the probe into the engine cavity until the coil tip contacts the front rail of the 15th stage HPC disk, refer to Figure 9. Verify the position of the coil tip against the front rail of the disk using the view provided by the borescope.

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17 Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this document EDDY CURRENT PROBE

FRONT RAIL

FWD POSITION EDDY CURRENT PROBE FOR INSPECTION IN THIS AREA

Figure 9 Eddy Current Inspection on the Front Rail of the HPC 15 thStage Disk

6. Inspect the blade loading slot or blade locking area on the front rail of the 15th stage HPC disk.
a. Turn on the oscillographic recorder. b. Apply a slight radial inward pressure to the probe handle to maintain contact of the coil tip on the front rail.
c. Starting at the area three (3) blades away from the blade loading slot or blade locking area, rotate the HPC clockwise through the gearbox towards the blade loading slot area to be inspected while monitoring the eddy current response. d. Continue the HPC rotation until the probe has inspected an area of the front rail that encompasses eight (8) blades.
e. Rotate the HPC counterclockwise through the gearbox back towards the blade loading slot area until the area encompassing a total of eight (8) blades has been re-inspected to verify the eddy current response.
e. Turn off the oscillographic recorder. 7. The recorder trace will exhibit a baseline eddy current response with an amplitude of less than 0.5 inch (12.7 mm) as the probe traverses along the inspection area, Figure 10.NDIP-1014

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18 Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this document FIGURE 10 A TYPICAL BASELINE RESPONSE

a.The recorder trace should be approximately 2 inches (50 mm) long for each traverse, refer to Figure 10. b.The baseline response should have a wavy appearance with an amplitude less than 0.5 inch (12.7 mm) due to a minimal response from the blade platforms.
8. An eddy current indication is a rapid upscale and return pen movement, A typical eddy current inspection is shown in Figure 11.NDIP-1014

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19 Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this document FIGURE 11 A TYPICAL EDDY CURRENT INDICATION

a.If an indication is observed, evaluate the eddy current response from the two scans. b. If necessary, re-traverse the area to repeat and verify the amplitude of the eddy current indication. 9. Remove the eddy current probe from the AP-7 borescope access port.NDIP-1014

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20 Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is su bject to the restriction on th e title page of this document F. ENGINE RE-ASSEMBLY 1. Carefully remove the borescope from the AP-7 borescope access port. 2. Carefully disconnect and remove all test equipment and fixturing from the engine and store in the container provided to prevent damage. 3. Remove the engine rotating device and replace the gearbox crank pad cover. 4. Replace the AP-7 borescope access port sleeve and plug. 5. Close the cowl panels and open the thrust reverser.

G. REPORTING CRITERIA 1. Any 15th stage HPC disk front rail which exhibits an eddy current indication with an amplitude equal to or greater than 1.0 inch (25.4 mm) must be removed from service.

H. REPORTING 1. Report inspection results to local Pratt & Whitney Field Representative detailing the following information.

a. Aircraft serial number and engine position. b . Engine model, engine serial number, and engine total time and total cycles.

c . 15th stage HPC disk part number, total part time and total part cycles since new and last inspection, if available. d . Inspection method and results.