# ALERT SER VICE BULLETIN REVISION NOTICE

ENGINE

— AIR SEAL ASSEMBL Y
, 2ND ST AGE HIGH PRESSURE TURBINE (HPT)

— INSPECTION OF THE SEAL FOR CRACKS T urbojet Engine Service Bulletin No. PW4G-1 12-A72-330 Revision No. 2 dated July 1 1, 2013

. R e v i s i o n H i s t o r y Original Issue December 3, 2012 Revision 1 dated February 14, 2013 Revision 2 dated July 1 1, 2013
R e a s o n f o r t h e R e v i s i o n T o replace NDIP-1 137, Revision B with NDIP-1 137, Revision C dated June 19, 2013. The List of Required T ools in the Necessary T ools section was updated. The T raining and Certification for the inspection personnel is found in NDIP-1 137. The same information was removed from the Accomplishment Instructions because it is not necessary to state it again. The Accomplishment Instructions step “One isolated spike of greater than 1.2 volts after a 2nd EC inspection is performed would be considered acceptable to continue in service if this Service Bulletin inspection is performed on a reduced interval of 600 cycles.” was changed to “One isolated spike of greater than 1.2 volts after a 2nd EC inspection is performed would be considered acceptable to continue in service if this Service Bulletin inspection is performed on a reduced interval of 600 cycles. During that next 600 cycle interval if there are no isolated spikes of greater than 1.2 volts for two EC inspections the engine could return to the 1200 cycle inspection interval.” More HPT stage 2 air seal OD cavity surface inspection criteria was added in the Accomplishment Instructions.
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-1 137, Revision C dated June 19, 2013 is attached. Please discard the previously issued copy

. M O D E L A P P L I C A T I O N PW4074, PW4074D, PW4077, PW4077D, PW4084D, PW4090, PW4090-3
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 A72-330

P & W D i s t r i b u t i o n C o d e 2642 

# PW4G-1 12-A72-330 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 32 2 July 1 1/13 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.



# PW4G-1 12-A72-330 Page 2

Not subject to the EAR per 15 C.F .R. Chapter 1, Part 734.3(b)(3).

# ALERT SER VICE BULLETIN

ENGINE

— AIR SEAL ASSEMBL Y
, 2ND ST AGE HIGH PRESSURE TURBINE (HPT)

— INSPECTION OF THE SEAL FOR CRACKS

M O D E L A P P L I C A T I O N PW4074, PW4074D, PW4077, PW4077D, PW4084D, PW4090, PW4090-3

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 A72-330

A T A N U M B E R 72-52-00

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 2642



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 1 of 32 Published in United States of AmericaS u m m a r y The function of this Alert Service Bulletin is to provide a Non-Destructive Inspection Procedure (Reference 16, NDIP-1 137) for an Eddy Current Inspection (ECI) of the Air Seal Assembly in the 2nd Stage High Pressure T urbine (HPT), PN 54L041. This inspection is to find cracks in the forward Outer Diameter (OD) radii. See Reference 16, NDIP-1 137, Figure 1 for the inspection area. This inspection will need to be done again until a new Service Bulletin is released that supplies a new design air seal.
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 PW4074, PW4077 Engine Serial Nos.

— All engines that have a 2nd Stage HPT Air Seal, PN 54L041 installed (Post Reference 13, Service Bulletin No. PW4G-1 12-72-271). PW4074D, PW4077D, PW4084D, PW4090, PW4090-3 Engine Serial Nos.

— All engines that have a 2nd Stage HPT Air Seal, PN 54L041 installed (Post Reference 13, Service Bulletin No. PW4G-1 12-72-271). 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: Cracks are starting, and increasing in size, in the 2nd stage HPT Air Seal, PN 54L041, at the forward OD area of the part. The cracks can cause an engine event. 2. Cause: An investigation has determined that loading on the forward OD flange can cause cracks on the OD radius of the HPT 2nd stage air seal. 3. Solution: Do an Eddy Current Inspection of the 2nd Stage air seal to find cracks. D e s c r i p t i o n Inspect the 2nd Stage HPT Air Seal, PN 54L041, to find cracks. See Figure 1. C o m p l i a n c e Category 3 Do this Alert Service Bulletin as follows: PN 54L041 Air Seals that have accumulated less than or equal to 1,200 total cycles since new , when this Alert Service Bulletin is released, must be inspected within 2,200 T otal Cycles (TC) since new

. Air Seals that have accumulated more than 1,200 total cycles since new , when this Alert Service Bulletin is released, must be inspected within 1,000 cycles of Alert Service Bulletin release. Once the inspection is accomplished, it must be repeated every 1,200 cycles until the engine is removed. This information is also shown in the table below

. If a piece part air seal is in the shop after the of release of this Alert Service Bulletin, and is inspected using Fluorescent Penetrant Inspection (FPI) per the requirements in Reference 4, CIR Manual, and shows no crack indications, the part will require an Eddy Current Inspection within 1,200 cycles following that piece part FPI.



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 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).A i r S e a l I n s p e c t i o n I n t e r v a l s

Engine Model T otal Part Cycles Since New (TC) Initial Inspection Threshold Cycles Subsequent Inspection Cycles TC ≤ 1200 2,200 1,200 TC > 1200 1,000 1,200 PW4074, PW4077, PW4074D, PW4077D, PW4084D, PW4090, PW4090-3 TC > 1200 and Air Seal receives in-shop FPI per Reference 4, CIR Manual 1,200 1,200

C A U T I O N : CUMULA TIVE T OT AL AIR SEAL CYCLES MUST NOT EXCEED REFERENCE 5 OR 6, ENGINE MANUAL, CHAPTER 5 LIFE. IF THE CHAPTER 5 LIFE CYCLE IS EXCEEDED, THE P AR T IS NOT AUTHORIZED FOR USE.
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 Alert Service Bulletin are as follows:

1. Open the cowl doors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 2. Remove the parts to gain access to the HPT turbine exhaust case manifold port

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 3. Do Reference 16, NDIP-1 137 Eddy Current Inspection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 4. Install the parts that were removed for access

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 5. Close the cowl doors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 6. T otal Necessary Man-hours

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 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.



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 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).2. PW4074, PW4077 T urbofan Engines, Illustrated Parts Catalog, Part No. 51A346. 3. PW4074D, PW4077D, PW4084D, PW4090, PW4090-3, PW4090D, PW4098 T urbofan Engines, Illustrated Parts Catalog, Part No. 51A742. 4. PW4000 Series 1 12 Inch PW4074, PW4077, PW4077D, PW4084D, PW4090, PW4098 T urbofan Engines, Engine Cleaning, Inspection And Repair (CIR) Manual, Part No. 51A750. 5. PW4074, PW4077 T urbofan Engines, Engine Manual, Part No. 51A345. 6. PW4074D, PW4077D, PW4084D, PW4090, PW4090-3, PW4090D, PW4098 T urbofan Engines, Engine Manual, Part No. 51A751. 7. Boeing 777 Aircraft Maintenance Manual (AMM). 8. Service Bulletin No. PW4G-1 12-72-77; Engine

— Seal Assembly
, Second Stage HPT Air

— Replacement Or Modification Of; The Air Seal Assembly For Improved Durability

. Issue Sequence 72-77, PW4G-1 12 Series. 9. Alert Service Bulletin No. PW4G-1 12-A72-172; Engine

— Seal Assembly
, Air
, 2nd Stage High Pressure T urbine (HPT)

— Borescope Inspection For Cracks And Cycle Limit Reduction. Issue Sequence 72-172, PW4G-1 12 Series. 10. Alert Service Bulletin No. PW4G-1 12-A72-197; Engine

— Seal Assembly
, Air
, 2nd Stage High Pressure T urbine (HPT)

— Borescope Inspection For Cracks And Cycle Limit Reduction. Issue Sequence 72-197, PW4G-1 12 Series. 1 1. Alert Service Bulletin No. PW4G-1 12-A72-222; Engine

— Air Seal Assembly
, 2nd Stage High Pressure T urbine (HPT)

— Borescope Inspection For Cracks. Issue Sequence 72-222, PW4G-1 12 Series. 12. Alert Service Bulletin No. PW4G-1 12-A72-233; Engine

— Air Seal Assembly
, 2nd Stage High Pressure T urbine (HPT)

— Inspection For Cracks And Cycle Limit Reduction. Issue Sequence 72-233, PW4G-1 12 Series. 13. Service Bulletin No. PW4G-1 12-72-271; Engine

— Seal Assembly
, 2nd Stage High Pressure T urbine (HPT) Air— Replace The Seal Assembly And Related Parts For Improved Durability

. Issue Sequence 72-271, PW4G-1 12 Series. 14. Service Bulletin No. PW4G-1 12-75-30; Air

— Metering Orifice Plate And Seal Assemblies

— Replacement Of With Gaskets. Issue Sequence 72-30 PW4G-1 12 Series. 15. Service Bulletin No. PW4G-1 12-72-84; Engine

— T urbine V ane And Blade Modulated Cooling Air System

— Removal Of, T o Provide A W eight Saving. Issue Sequence 72-84 PW4G-1 12 Series. 16. Non-Destructive Inspection Procedure, NDIP-1 137, PW4000-1 12” 2nd Stage HPT Air Seal Forward Outer Diameter Eddy Current Inspection (On-Wing) N O T E : References 8. through 15. are shown to help find configurations in relation to this bulletin. P u b l i c a t i o n s C h a n g e d See the Material Information Part Number Instruction

— Disposition codes for cleaning, inspection and repair compatibility between the new and old part number(s). PW4074, PW4077 T urbofan Engines, Illustrated Parts Catalog, Part No. 51A346. 72-52-00, Figure 1



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 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).75-25-00, Figure 2, 8 and 9 PW4074D, PW4077D, PW4084D, PW4090, PW4090-3, PW4090D, PW4098 T urbofan Engines, Illustrated Parts Catalog, Part No. 51A742. 72-52-00, Figure 1 75-25-00, Figure 2 and 9 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 (Y es) Added Data (Y es) Revision to T able of Limits (No) Inspection Procedures (Y es)



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 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).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. The estimated price of new material to do this Alert Service Bulletin depends on which parts are replaced. 2. There are tool kits, number PW A 107958, and Machida Engine Rotator Kit, and Machida V ideo Scope Kit, to do this Alert Service Bulletin. Contact your Pratt & Whitney T ool Support Services sales manager directly
, or by e-mail to pwtools@pw .utc.com for assistance with new PW A tools, kits, calibrations, and repairs. 3. 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 4 0 7 4
, P W 4 0 7 7 E n g i n e s :
New PN Qty Estimate of Unit Price ($) Keyword Old PN Instructions

— Disposition 1 389,400.00 SEAL ASSY

— AIR, HPT
, 2STG 54L041 (72-52-00-1-160 B) (4)(C)(X)

AR 68.60 GASKET OPTION ST1 142-032 (75-25-00-9-80) (75-25-00-9-150) (C)(E)(O1)

AR 61.20 GASKET OPTION ST1 141-60 (75-25-00-9-130) (C)(E1)(O2)

AR 196.30 GASKET

— SPRING, TURB CLG AIR 55T843 (A0946) (75-25-00-8-40) (C)(E1) (V)

AR 74.60 BOL T MS9716-10 (75-25-00-9-140 B) (C)(E2)



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 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 AR 49.70 BOL T MS9716-05 (75-25-00-9-90) (75-25-00-9-160) (C)(E2)

AR 20.20 BOL T ST2601-10 (75-25-00-9-20 A) (C)(E2)

AR 296.20 BOL T ST2601-16 (75-25-00-9-25 A) (C)(E2)

AR 63.80 GASKET OPTION ST2422-039 (75-25-00-9-10) (C)(E1)(O3)

AR 45.50 BOL T

— TCA MS9715-08 (75-25-00-2-20) (C)(E2)

1 317.80 GASKET OPTION ST1 141-03 (75-25-00-2-1) (C)(E)(O4)

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 4 0 7 4 D
, P W 4 0 7 7 D
, P W 4 0 8 4 D
, P W 4 0 9 0
, P W 4 0 9 0

- 3 E n g i n e s :
New PN Qty Estimate of Unit Price ($) Keyword Old PN Instructions

— Disposition 1 389,400.00 SEAL ASSY

— AIR, HPT
, 2STG 54L041 (72-52-00-1-160 B) (4)(C)(X)

1 68.60 GASKET OPTION ST1 142-032 (75-25-00-9-146) (C)(E)(O1)

AR 61.20 GASKET OPTION ST1 141-60 (75-25-00-9-130) (C)(E)(O2)

AR 74.60 BOL T MS9716-10 (75-25-00-9-140 B) (C)(E2)

AR 49.70 BOL T MS9716-05 (75-25-00-9-90) (75-25-00-9-160) (C)(E2)

AR 20.20 BOL T ST2601-10 (75-25-00-9-20 A) (C)(E2)

AR 296.20 BOL T ST2601-16 (75-25-00-9-25 A) (C)(E2)

AR 63.80 GASKET OPTION ST2422-039 (75-25-00-9-10) (C)(E1)(O3)

AR 45.50 BOL T

— TCA MS9715-08 (75-25-00-2-20) (C)(E2)



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 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 1 317.80 GASKET OPTION ST1 141-03 (75-25-00-2-1) (C)(E)(O4)

2 434.80 GASKET

— SPRING 50U285 (72-25-00-9-145) (C)(E)

M o d i fi c a t i o n a n d S p a r e s I n f o r m 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 (C) The old part will continue to be supplied. (E) The old part is an expendable item that is necessary to do this bulletin. (E1) The old part is an expendable item that may be necessary to do this bulletin depending on which parts are removed from the engine. (E2) The old part is a bolt that can break when it is removed from the engine. It may be necessary to replace it. (O1) Gasket Option, PN ST1 142-032, consists of a gasket, PN ST1 1 12-032 (P14U51-0039-02 PerkinElmer Inc. part number) or PN ST1 122-032. (O2) Gasket Option, PN ST1 141-60, consists of a gasket PN P13U51-0049-2 (PerkinElmer Inc. part number) or PN ST1 121-60. (O3) Gasket Option, PN ST2422-039, consists of a gasket PN P14U5N0046-2 (PerkinElmer Inc. part number) and ST2412-039. (O4) Gasket Option, PN ST1 141-03, consists of a gasket PN ST1 1 1 1-03 (P13U51-0004-2 PerkinElmer Inc. part number) and ST1 121-03. (V) This is the PerkinElmer Inc. part number

. (X) See Reference 2 or 3, Illustrated Parts Catalog for applicable replacement parts.



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 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).V endor Services or Special Components/Materials V e n d o r S e r v i c e s o r S p e c i a l C o m p o n e n t s / M a t e r i a l s
P&W Designation V endor Designation Name V endor Name & Address

55T843 A0946 GASKET

— SPRING, TURB CLG AIR ST2402-039 P14U5N0046-2 GASKET ST1 1 12-032 P14U51-0039-02 GASKET ST1 1 1 1-60 P13U51-0049-02 GASKET ST1 1 1 1-03 P13U51-0004-2 GASKET PERKINELMER INC. 1 1642 OLD BAL TIMORE PIKE BEL TSVILLE, MD 20705-1210 USA

V endor Manufacturer ’ s Code: 15284 See Illustrated Parts Catalog V endor Manufacturer ’ s Code List
N O T E : EXCEPT FOR WORK OR SUPPLIES T O BE PERFORMED OR FURNISHED BY PRA TT & WHITNEY
, IT IS UNDERST OOD THA T PRA TT & WHITNEY DOES NOT ENDORSE THE WORK PERFORMED BY THE COMP ANY OR COMP ANIES NAMED HEREIN OR ANY OTHER COMP ANY AND DOES NOT ACCEPT RESPONSIBILITY T O ANY DEGREE FOR THE SELECTION OF SUCH COMP ANY OR COMP ANIES FOR THE PERFORMANCE OF ANY WORK OR PROCUREMENT OF SUPPLIES. M a t e r i a l D a t a f o r E a c h S p a r e E n g i n e The material for each spare engine is as stated in the preceding material information section. R e i d e n t i fi e d P a r t s Not Applicable. N e c e s s a r y T o o l s The following tools are required to accomplish this Alert Service Bulletin. Contact your Pratt & Whitney Customer Representative for information regarding acquiring these tools. L i s t o f R e q u i r e d T o o l s
KIT NUMBER NOMENCLA TURE UNITS PER ENGINE PW A 107958* EDDY CURRENT INSPECTION Kit 1 N/A* MACHIDA ENGINE ROT A T OR Kit Model MA-TT -70 with Adapters 1

N/A* MACHIDA VIDEO SCOPE Kit Model VSC-2-86 with Monitor 1

* Detail tool listing is found in NDIP-1 137



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 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).O t h e r M a t e r i a l I n f o r m a t i o n D a t a Not Applicable.



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 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).A c c o m p l i s h m e n t I n s t r u c t i o n s F O R P W 4 0 7 4
, P W 4 0 7 7 E N G I N E S I N S T A L L E D O N A I R C R A F T

1. Open the cowl doors to gain access to the T urbine V ane Cooling Air (TVCA) Ducts. See Reference 7, Boeing 777 Aircraft Maintenance Manual (AMM) Chapter/Section 71-1 1-04. Allow engine to cool. 2. It is permitted to use the optional TVCA duct entry port location for Eddy Current (EC) inspection access. Remove the Upper Right TVCA Duct (AP01 or AP1 14) as specified in Reference 7, Boeing AMM T ask 75-25-05-000-818 or the lower left TVCA Duct (AP02) as specified in Reference 7, Boeing AMM T ask 75-25-05-000-819 based on accessibility

. The AP01 or AP1 14 TVCA Duct is located at the two o’clock position (See Figures 2 through 5) and the AP02 air duct is located at the four o’clock position (See Figure 6).
The Upper Right TVCA is one of three configurations: N O T E : Removal of the bolts from the TVCA Duct access ports when the engine is hot without lubrication can cause the bolts to break. Apply penetration oil to the TCA Duct Bolts prior to removal per Reference 7, Boeing 777 AMM, Chapter/Section 70-00-00, SPOP 427. See Chapter/Section 70-00-00, T ask 70-00-00-910-808-N00 for repair of broken bolts (SPOP 416). A. Configuration 1

— Engines with the Modulated TVCA System Pre Reference 15, SB PW4G-1 12-72-84. This system has a TVCA valve located between the (AP01) duct and the (AP05) elbow

. With this configuration, you must use O-ring gaskets at all four HPT case boss locations, (AP01), (AP02), (AP03), and (AP04). See Figure 2 and 4. B. Configuration 2

— Engines without the Modulated TVCA System (Post Reference 15, SB PW4G-1 12-72-84, Method 2). This system has a optional duct (AP1 15) in place of the TVCA valve. The duct (AP1 15) is located between the (AP01) duct and the (AP05) elbow

. With this configuration, you must use O-ring gaskets at the two HPT case bosses, (AP02) and (AP04). The (AP01) and (AP03) locations use metering orifice plate and seal assemblies (Engines Pre Reference 14, SB PW4G-1 12-75-30). The (AP01) and (AP03) locations use O-ring gaskets at the two HPT case bosses (Engines Post Reference 14, SB PW4G-1 12-75-30). See Figure 3 and 4. C. Configuration 3

— Engines manufactured without the Modulated TVCA system or Engines Post Reference 15, SB PW4G-1 12-72-84, Method 1. This system has a duct AP1 14 in place of the TVCA valve, the AP01 duct, and the AP05 elbow

. With this configuration, you must use O-ring gaskets at the two HPT case bosses, (AP02) and (AP04). The (AP1 14) and (AP03) locations use metering orifice plate and seal assemblies (Engines Pre Reference 14, SB PW4G-1 12-75-30). The (AP01) and (AP03) locations use O-ring gaskets at the two HPT case bosses (Engines Post Reference 14, SB PW4G-1 12-75-30). See Figure 5. 3. It is permitted to use the optional entry port location for HPT stage 2 air seal temperature measurements. Measure the HPT stage 2 air seal temperature through the EC inspection port (previous step) with the use of a borescope to verify the thermocouple position is on the HPT Stage 2 air seal outside diameter or remove the TCA Probe as specified in Reference 7, Boeing 777 AMM T ask 75-25-07-000-801. See Figure 7. See Reference 16., NDIP-1 137, Section 3. N O T E : Removal of the nuts from the TCA probe port studs when the engine is hot without lubrication can result in stud breakage. Apply penetration oil to the TCA Duct studs prior to removal per Reference 7, Boeing 777 AMM,



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 1 1 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).Chapter/Section 70-00-00, SPOP 427. See Chapter/Section 70-00-00, T ask 70-00-00-910-808-N00 for repair of broken bolts (SPOP 416). 4. Remove the main gearbox crank pad cover as specified in Reference 7, Boeing 777 AMM Subtask 72-00-00-980-807. 5. Remove the starter as specified in Reference 7, Boeing 777 AMM T ask 80-1 1-01-000-801. 6. Install the N2 rotor turning equipment as specified in Reference 7, Boeing 777 Aircraft Maintenance Manual, Chapter/Section 72-00-00. A. Install the rotator drive unit to the starter pad on the main gearbox. B. Follow the instructions provided by the manufacturer for the assembly of the rotator kit. C. Use the instruction manual provided by the manufacturer to operate the rotator

. 7. Do Reference 16, Non-Destructive Inspection Procedure NDIP-1 137. NDIP-1 137 is attached in the Appendix. See Figure 9, Sheets 1 and 2.

A. Provide the inspection result (Appendix 2 of the NDIP) to the Pratt & Whitney local representative who will forward the results to the responsible customer technical service contact. B. If the mock up probe tip or EC probe tip liberates into the engine, every ef fort should be used to remove the liberated material from the engine. If the mock probe tip or EC probe tip is not accessible, it is acceptable to continue in service. C. If the grind blend tip liberates, every ef fort should be used to remove the liberated material from the engine. If the grind tip is not accessible it is acceptable to continue in service if a visual borescope of the HPT stage 2 air seal OD cavity using the criteria below is performed on reduced inspection interval not to exceed 60 cycles. If the inspection is found acceptable, at this interval (60 cycles) the inspection interval can be increased not to exceed 180 cycles. If the inspection is found acceptable at this interval (180 cycles) the inspection interval can be increased not to exceed 360 cycles. At this 360 cycle interval this service bulletin EC NDIP 1 137 Inspection should be performed. If the inspections are found acceptable at this inspection interval, then the HPT stage 2 air seal OD cavity and EC inspections should continue on a repetitive 600 cycle interval. HPT stage 2 air seal OD cavity inspection criteria as follows. See Figure 9, Sheet 3 for the specified surfaces. Surface damage on the forward barrel fillet shown is not permitted, remove engine in 5 cycles. Missing material on the rear 1st stage side plate surface 1 or the forward air seal knife edge surface 2 is not permitted, remove engine. Missing coating of > 25% on the forward air seal knife edge surface 2 is not permitted, remove engine in 5 cycles. Nicks and dents greater than 0.010 inch (0.254 mm) depth in surface 4 and 5 is not permitted, remove engine in 5 cycles. Imbedded grind tip or dents in the forward T2V inner air seal honeycomb surface 3 is not permitted, remove engine in 5 cycles.



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 12 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).8. If HPT Stage 2 Air Seal indications are found greater than or equal to 1.2 volts peak amplitude remove engine within five Flight Cycles (FC) (Reference 16, NDIP-1 137 Step 6.1) A. One isolated spike of greater than 1.2 volts after a 2nd EC inspection is performed would be considered acceptable to continue in service if this Service Bulletin inspection is performed on a reduced interval of 600 cycles. During that next 600 cycle interval if there are no isolated spikes of greater than 1.2 volts for two EC inspections the engine could return to the 1200 cycle inspection interval. 9. If indications are within Reference 16, NDIP-1 137 criteria the HPT Stage 2 Air Seal should continue in service and be inspected on the repetitive inspection interval listed in this Alert Service Bulletin. 10. Remove the rotator adapter from the gearbox crank pad location. 1 1. Install the gearbox crank pad cover as specified in Reference 7, Boeing 777 AMM T ask 72-00-00-840-805. 12. Remove the N2 rotor turning equipment from the starter pad on the main gearbox. 13. Install the starter as specified in Reference 7, Boeing 777 AMM Subtask 80-1 1-01-400-801. 14. If removed, install the Upper Right TVCA Duct (AP01 or AP1 14) as specified in Reference 7, Boeing 777 AMM, T ask 75-25-05-400-818. The AP02 air duct is located at the two o’clock. See Reference 14, Service Bulletin PW4G-1 12-75-30 to ensure a gasket is installed at the HPT port in place of a metering orifice & seal assembly

. See Figures 2 through 5. 15. If access to an optional HPT stage 2 vane cluster access was used, install the lower left TVCA Duct (AP02) as specified in Reference 7, Boeing 777 AMM, T ask 75-25-05-400-819. This air duct is located at the four o’clock position. See Figure 6. 16. If removed, install TCA Probe as specified in Reference 7, Boeing 777 AMM, T ask 75-25-07-400-801. See Figure 7. 17. Close the cowl doors as specified in Reference 7, Boeing 777 AMM, Chapter/Section 71-1 1-04.



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 13 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).F O R P W 4 0 7 4 D
, P W 4 0 7 7 D
, P W 4 0 8 4 D
, P W 4 0 9 0
, P W 4 0 9 0

- 3 E N G I N E S I N S T A L L E D O N A I R C R A F T

1. Open the cowl doors to gain access to the T urbine V ane Cooling Air (TVCA) Ducts. See Reference 7, Boeing 777 Aircraft Maintenance Manual (AMM) Chapter/Section 71-1 1-04. Allow engine to cool. 2. It is permitted to use the optional TVCA duct entry port location for Eddy Current (EC) inspection access. Remove the TVCA Elbow (AP83) as specified in Reference 7, Boeing AMM T ask 75-25-05-000-824 or the upper right TVCA Duct AP1 14) as specified in Reference 7, Boeing 777 AMM, T ask 75-25-05-000-823. The AP83 elbow is attached to the AP02 air duct and is located at the four o’clock location. See Figure 8. N O T E : Removal of the bolts from the TVCA Duct access ports when the engine is hot without lubrication can cause the bolts to break. Apply penetration oil to the TCA Duct Bolts prior to removal per Reference 7, Boeing 777 AMM, Chapter/Section 70-00-00, SPOP 427. See Chapter/Section 70-00-00, T ask 70-00-00-910-808-N00 for repair of broken bolts (SPOP 416). 3. It is permitted to use the optional entry port location for HTP stage 2 air seal temperature measurements. Measure the HPT stage 2 air seal temperature through the EC inspection port (previous step) with the use of a borescope to verify the thermocouple position is on the HPT stage 2 air seal OD or remove the TCA Probe as specified in Reference 7, Boeing 777 AMM T ask 75-25-07-000-801. See Figure 7. See reference 16., NDIP 1 137. N O T E : Removal of the nuts from the TCA probe port studs when the engine is hot without lubrication can result in stud breakage. Apply penetration oil to the TCA Duct studs prior to removal per Reference 7, Boeing 777 AMM, Chapter/Section 70-00-00, SPOP 427. See Chapter/Section 70-00-00, T ask 70-00-00-910-808-N00 for repair of broken bolts (SPOP 416). 4. Remove the main gearbox crank pad cover as specified in Reference 7, Boeing 777 AMM Subtask 72-00-00-980-807. 5. Remove the starter as specified in Reference 7, Boeing 777 AMM T ask 80-1 1-01-000-801. 6. Install the N2 rotor turning equipment as specified in Reference 7, Boeing 777 Aircraft Maintenance Manual, Chapter/Section 72-00-00. A. Install the rotator drive unit to the starter pad on the main gearbox. B. Follow the instructions provided by the manufacturer for the assembly of the rotator kit. C. Use the instruction manual provided by the manufacturer to operate the rotator

. 7. Do Reference 16, Non-Destructive Inspection Procedure NDIP-1 137. NDIP-1 137 is attached in the Appendix. See Figure 9, Sheets 1 and 2.

A. Provide the inspection result (Appendix 2 of the NDIP) to the Pratt & Whitney local representative who will forward the results to the responsible customer technical service contact. B. If the mock up probe tip or EC probe tip liberates into the engine, every ef fort should be used to remove the liberated material from the engine. If the mock probe tip or EC probe tip is not accessible, it is acceptable to continue in service.



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 14 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).C. If the grind blend tip liberates, every ef fort should be used to remove the liberated material from the engine. If the grind tip is not accessible it is acceptable to continue in service if a visual borescope of the HPT stage 2 air seal OD cavity using the criteria below is performed on reduced inspection interval not to exceed 60 cycles. If the inspection is found acceptable, at this interval (60 cycles) the inspection interval can be increased not to exceed 180 cycles. If the inspection is found acceptable at this interval (180 cycles) the inspection interval can be increased not to exceed 360 cycles. At this 360 cycle interval this service bulletin EC NDIP 1 137 Inspection should be performed. If the inspections are found acceptable at this inspection interval, then the HPT stage 2 air seal OD cavity and EC inspections should continue on a repetitive 600 cycle interval. HPT stage 2 air seal OD cavity inspection criteria as follows. See Figure 9, Sheet 3 for the specified surfaces. Surface damage on the forward barrel fillet shown is not permitted, remove engine in 5 cycles. Missing material on the rear 1st stage side plate surface 1 or the forward air seal knife edge surface 2 is not permitted, remove engine. Missing coating of > 25% on the forward air seal knife edge surface 2 is not permitted, remove engine in 5 cycles. Nicks and dents greater than 0.010 inch (0.254 mm) depth in surface 4 and 5 is not permitted, remove engine in 5 cycles. Imbedded grind tip or dents in the forward T2V inner air seal honeycomb surface 3 is not permitted, remove engine in 5 cycles. 8. If HPT Stage 2 Air Seal indications are found greater than or equal to 1.2 volts peak amplitude remove engine within five Flight Cycles (FC) (Reference 16, NDIP-1 137 Step 6.1) A. One isolated spike of greater than 1.2 volts after a 2nd EC inspection is performed would be considered acceptable to continue in service if this Service Bulletin inspection is performed on a reduced interval of 600 cycles. During that next 600 cycle interval if there are no isolated spikes of greater than 1.2 volts for two EC inspections the engine could return to the 1200 cycle inspection interval. 9. If indications are within Reference 16, NDIP-1 137 criteria the HPT Stage 2 Air Seal should continue in service and be inspected on the repetitive inspection interval listed in this Alert Service Bulletin. 10. Remove the rotator adapter from the gearbox crank pad location. 1 1. Install the gearbox crank pad cover as specified in Reference 7, Boeing 777 AMM T ask 72-00-00-840-805. 12. Remove the N2 rotor turning equipment from the starter pad on the main gearbox. 13. Install the starter as specified in Reference 7, Boeing 777 AMM Subtask 80-1 1-01-400-801. 14. If removed, install the TVCA elbow (AP83) as specified in Reference 7, Boeing 777 AMM, T ask 75-25-05-400-824. The AP83 elbow is attached to the AP02 air duct and is located at the four o’clock position. See Figure 8. N O T E : Reference 13, Service Bulletin PW4G-1 12-72-271 replaces the metering orifice and seal assembly with a gasket. 15. If access to an optional High Pressure T urbine (HPT) 2nd stage vane cluster was used, install the upper right TVCA Duct (AP1 14). The air duct is located at the two



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 15 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).o’clock position. Install the duct as specified in Reference 7, Boeing 777 AMM, T ask 75-25-05-400-823. See Figure 5. 16. If removed, install TCA Probe as specified in Reference 7, Boeing 777 AMM, T ask 75-25-07-400-801. See Figure 7. 17. Close the cowl doors as specified in Reference 7, Boeing 777 AMM, Chapter/Section 71-1 1-04.



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 16 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).LOCA TION OF THE PW4074, PW4077, PW4074D, PW4077D, PW4084D, PW4090, AND PW4090-3 2ND ST AGE HPT AIR SEAL ASSEMBL Y 72-52-00 FIGURE 1


## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 17 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).ENGINES WITH THE MODULA TED TVCA SYSTEM (PRE REFERENCE 15, SB PW4G-1 12-72-84) 75-25-00 FIGURE 2



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 18 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).ENGINES WITHOUT THE MODULA TED TVCA SYSTEM (POST REFERENCE 15, SB PW4G-1 12-72-84, METHOD 2) 75-25-00 FIGURE 3


## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 19 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).TURBINE V ANE COOLING AIR V AL VE AND AP1 15 TUBE ASSEMBL Y 75-25-00 FIGURE 4



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 20 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).ENGINES ORIGINALL Y MANUF ACTURED WITHOUT THE MODULA TED TVCA SYSTEM OR ENGINES POST REFERENCE 15, SB PW4G-1 12-72-84, METHOD 1 75-25-00 FIGURE 5


## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 21 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).LOCA TION OF THE TVCA DUCT (AP02) FOR THE PW4074 AND PW4077 ENGINES 75-25-00 FIGURE 6



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 22 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).LOCA TION OF THE TURBINE COOLING AIR (TCA) PROBE 75-25-00 FIGURE 7



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 23 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).LOCA TION OF THE TVCA DUCT (AP02) FOR THE PW4074D, PW4077D, PW4084D, PW4090, AND PW4090-3 ENGINES 75-25-00 FIGURE 8


## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 24 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).INSPECTION OF THE 2ND ST AGE HPT AIR SEAL FIGURE 9, SHEET 1



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 25 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).INSPECTION OF THE 2ND ST AGE HPT AIR SEAL FIGURE 9, SHEET 2



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 26 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).INSPECTION OF THE 2ND ST AGE HPT AIR SEAL FIGURE 9, SHEET 3



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 27 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).A p p e n d i x P a r t s P r o g r e s s i o n T o S h o w t h e C h a n g e d P a r t i n R e l a t i o n t o O t h e r P a r t s



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 28 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).PROGRESSION OF THE PW4074 AND PW4077 2ND ST AGE HPT AIR SEAL ASSEMBL Y CHAR T A



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 29 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).PROGRESSION OF THE PW4074D, PW4077D, PW4084D, PW4090, PW4090-3 2ND ST AGE HPT AIR SEAL ASSEMBL Y CHAR T B



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 30 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).A d d e d D a t a
I n t e r n a l R e f e r e n c e I n f o r m a t i o n

Revision No. Reference Document Origination Original EA1 1KCB91 BE/JEJ 1 EA1 1KCB91 BE/JEJ 2 EA1 1KCB91 BE/MJS
Number values shown in parentheses adjacent to U.S. values are International System of units (SI) equivalents. T o calculate part life, include the hours and/or cycles since the part was made. Use the total hours or cycles to calculate life limits that are the result of part modification, a part used in an engine with dif ferent thrust, or for some other reason. I n s p e c t i o n P r o c e d u r e s N O T E : EXCEPT FOR WORK OR SUPPLIES T O BE PERFORMED OR FURNISHED BY PRA TT & WHITNEY
, IT IS UNDERST OOD THA T PRA TT & WHITNEY DOES NOT ENDORSE THE WORK PERFORMED BY THE COMP ANY OR COMP ANIES NAMED HEREIN OR ANY OTHER COMP ANY AND DOES NOT ACCEPT RESPONSIBILITY T O ANY DEGREE FOR THE SELECTION OF SUCH COMP ANY OR COMP ANIES FOR THE PERFORMANCE OF ANY WORK OR PROCUREMENT OF SUPPLIES. Reference 16, Non-Destructive Inspection Procedure, NDIP-1 137, PW4000-1 12” 2nd Stage HPT Air Seal Forward Outer Diameter Eddy Current Inspection (On-Wing), follows.



## l December 3/12 

# PW4G-1 12-A72-330 REVISION NO. 2

- July 1 1/13 Page 31 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).

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

1 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 

### Applies to Models: PW4074, PW4074D, PW4077, PW4077D, PW4084D, PW4090 and PW4090
- 3

P/N 54L041 /54L043 

# NDIP 1137 Rev. C

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

REGULATION (EAR) OF 1979. THIS INFORMATION MAY NOT BE EXPORTED, RELEASED, OR DISCLOSED TO FOREIGN NATIONALS OUTSIDE THE UNITE D STATES WITHOUT FIRST COMPLYING WITH THE EXPORT LICEN SE 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. INCLUDE THIS NOTICE WITH ANY REPRODUCED PORTION OF THIS DOCUMENT.
RESTRICTION PAGES OF THIS DOCUMENT MARKED WITH THE NOTICES SET FORTH BELOW CONTAIN CONTRACTOR COMPETITION SENSITIVE DATA AND/OR PR ATT & WHITNEY PROPRIETARY DATA WHICH IS SUBMITTED IN CONFIDENCE. NO DISCLOSURE OR USE OF THIS INFORMATION IS PERMISSIBLE WITHOUT PR IOR WRITTEN CONSENT OF UNITED TECHNOLOGIES CORPORATION EXCEPT FOR OFFICIAL PURPOSES WITHIN THE U.S. GOVERNMENT.
DOCUMENT PRO PERTY RIGHTS NOTICE THIS DOCUMENT IS THE PROPERTY OF UNITED TECHNOLOGIES CORPORATION (UTC). YOU 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 P ARTS, OR OBTAIN

FAA OR OTHER GOVERNMENT APPROVAL TO DO SO, WITHOUT UTC’S EXPRESS WRITTEN PERMISSION. NEITHER RECEIPT NOR POSSESSION OF THIS DOCUMENT ALONE, FROM ANY SOURCE, CONSTITUTES SUCH PERMISSION. POSSESSION, USE, COPYRIGHT OR DISCLOSURE BY ANYONE W ITHOUT UTC’S EXPRESS WRITTEN PERMISSION IS NOT AUTHORIZED AND MAY RESULT IN CRIMINAL AND OR CIVIL LIABILITY.
NOTICES P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 

## Approved By: Jonatha n Sullivan, PL 3

Date: June 1 9 , 201 3

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

2 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 

### 0.0 General The objective of this procedure is to perform an eddy current (EC) inspection of the forward outer diameter radii of the HPT 1

- 2 Seal for possible indications

. Since the part cannot be directly accessed (located inboard of the gas path) this is accomplis hed using a borescope and hand held remote wand eddy current probes. The probes enter the engine through a TCA manifold port on the HPT case, then through the 2 nd stage vane transfer tube to then contact the seal in the desired area. The proper probe pla cement on the part surface is monitored via a 2. 0 mm flexible borescope which is inserted through an adjacent 2 nd vane transfer tube. The high pressure rotor is then rotatated via an engine rotator to effect scanning of the part. Figure 1 shows the cross section of the 1

- 2 seal , related parts and the zones of inspection.



### FIGURE 1

0.0 Training and Certification
Formal instruction in eddy current testing : 0.1.1. Inspection personnel shall be certified to ASNT Level II, NAS 410 Level II, ATA Spec 105 Level II or equivalent qualification in eddy current method

. Required for this procedure: 0.1.2. Approximately two days of instruction and familiarization with test equipment, probes and this inspection technique. 0.1.3. Inspector shall demonstrate Probability of Detection (POD) flaw capability on the POD (EDM notched) test part . The 90% probability of detection, 95% confidence level maximum allowable flaw size shall be 0.012” notch depth. 1
- 2 Seal
OD Inspection Zone 2 nd Vane Assy.

Transfer tube exit
Honeycomb

Aft Fwd Transfer tube elbow

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

3 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 0.1.4. Inspector recertification is required if more than 4 months elapse without having performed an engine inspection or completed training /refresher training

. Recertification will require an app roximately one day refresher course given by a Pratt & Whitney approved instructor. 

### 1.0 Equipment Required
1.1. Inspection Kit , PWA 107958 consisting of the following:
1.1.1. EC Probe , PWA 107921 ** ( US

- 2823 , red stripe on handle ), Figure 2 1.1.2. EC Mock

- Up (dummy) Probe , 71993 (green stripe on handle) 1.1.3. Cleaning Probe, 71992, (white stripe on handle) 1.1.4. Cleaning Brush , P/N CB

- 2010 , Figure 11, 12 1.1.5. Cleaning Brush cable clamp, P/N 74096 1.1.6. EC Probe Cable , US

– 94032 1.1.7. Calibration Standard, PWA107922 ** , Figure 5 1.1.8. Probe Tip Holder , 71984 , Figur e 4 1.1.9 Eddy Current Instrument, UniWest US

- 454 , Figure 3 , with accessory compact flash m emory c ard 1.1.10 6 0 cc Syringe & plastic tube * 1.1.1 1 Fluke 16 Multi

- meter and flexible thermocouple ( or equivalent ) 1.1.1 2 Probe to HPT Case Holder, 71987 , Figure 1 9 1.1. 1 3 Extension cord * 1.1. 1 4 Power Strip * 1.1. 1 5 Flashlight * 1.1.1 6 Clip Board * 1.1. 1 7 Misc. hand tools (allen wrench set, needlenose pliers, wire stripper/cutters, screw driver, duct tape, electrical tape, tie wraps ) (*) 1.1. 18 Machida blend tool kit, BT

- 4000PW, consisting of: power supply, foot pedal control, motor handle, blending guide tube, grinding bits, collet, misc. tools in pouch, tool holder 1.1. 19 Custom case for items 1.1.1 through 1.1.18

. 

# *

- Common tools/items can use an equiva lent substitute 

# **

- PWA tools can be replaced by latest revision letter tool
1. 2 Additional Equipment Required: 1.2.1 Machida Video Scope, consisting of Model 7

- 6060 , integrated processor/light unit and VSC

- 2

- 86 , 2.0 mm diameter , flexible videoscope

. The 7

- 6060 includes AC power cable, video cable, 2 GB SD storage card, reference card , users manual and roll around case, see Figure 2 4

. Equivalent borescope /videoscope may be used (note: maximum borescope diameter that will fit through 2 nd Vane transfer t ube is 2.5 mm). 1. 2.2 Machida Engine Rotator Kit , MA

- TT

- 70 includes: drive motor, 12” offset drive adapter, DR

- 00 drive adapter, TT

- 70

- A controller, AC power cable, unit to motor cable, allen wrenches, spare 10

- 32 screws, user manual , roll around case, see Figure 2 5. Also in case are AD

- 03 adapter plate and DR

- 03 drive adapter

. An equivalent rotator may be used but must be adaptable to engine starter location and capable of turning engine at constant one rpm (within 5%).

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

4 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 

### 2.0 EC Calibration
2.1. Connect the PWA107921 probe to the probe cable and US

- 454 EC instrument ( see Kit 1.1.1, 1.1.6, Figure 2).

. 2.2. Power on the US

- 454 EC instrument and allow it to warm up for a period of 5 minutes, or as specified in the instrument user manual ( see Kit 1.1.9, Figure 3).



### FIGURE 2 PWA107921 Eddy Current Probe

NOTE: Once set, the detailed instrument settings can be loaded into the unit’s memory via the “Save Settings” function. This will help the operators reset the unit to the desired values. All p arameters shall be verified before proceeding with the calibration.

NOTE: To ensure all parameters are properly set, the inspector can recall the instrument default settings by selecting “ ENTER SETUP ” then selecting “ LOAD DEFAULTS ” and pressing enter. If this is done, each and every parameter identified below must be manually entered.



### FIGURE 3 Eddy Current instrument (UniWest US

- 454)

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

5 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 2.3. Set up US

- 454 EC instrument to the following initial settings : 2.3.1. FREQ 1: 3 MHz 2.3.2. F1 GAIN : 6 6 dB 2.3.3. F1 ROT: 90 degrees (initial phase angle) 2.3.4. DRIVE: HIGH (probe drive) 2.3.5. LP FLT: 50 Hz (low pass filter) 2.3.6. HP FLT: 2 Hz. (High pass filter) 2.3.7. CHART: ON 2.3.8. EC DISP (Screen Mode): I

- PLANE (Impedance plane) Settings below are u nder ‘ Enter Setu p’ sub

- menu 2.3.9. Sample Rate: 504 samples/sec 2.3.10. O

- scope sweep rate: 1 sec/div 2.3.11. O

- scope trigger source: free run 2.3.12. Report Files: BMP + TXT 2.3.13. Circular Buffer: No 2.3.14. Rundown Battery Monitor: Off (white letters on red background) , then ‘cancel’. 2.4. Install probe tip in probe tip holder ( 71984 ) as shown in Figure 4

. The back of the probe tip (with white line) should be flat against the cavity in the probe holder. Tighten the thumb screw sufficiently to hold the probe tip firmly but do not over tighten ( see Kit 1.1. 8 , Figure 4).



### FIGURE 4 Probe in probe tip holder for calibration

2.5. Place the probe/tip holder on the PWA107922 gauge standard and line it up approximately 1⁄4 inch from the left end (as marked) while facing the front of the standard (Figure 5 ). Push “ null” while holding the probe in contact with the OD radius of the calibration standard ( see Kit 1.1. 8 , Figure 5 ). 2.6 Scan the probe to the right at a constant speed of approximately 1

. 4 inches per second towards the EDM calibration notch ‘A’ , making sure to keep the probe tip holder in square contact with the standard

. Observe the indication in the impedance plane display and adjust the r otation (phase angle) to vertic al as shown in Figure 6

. The cable end of the probe should not be held; it should be allowed to slide smo othly along the bench/table. This will help avoid signal noise.

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

6 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 

### FIGURE 5 PWA107922 calibration standard consists of actual section of seal with EDM notch

2.7 Once phase angle is set, rotate knob to “EC Display”, push “Enter” and change to “O

- Scope”. Then briefly push the “Display|on/off” button to switch to horizontal sweep oscilloscope display, as in Figure 7

. 2.8 Rotate the knob so that “Save Report” is highlighted on the instrument screen (do not push enter yet ). 2.9 W ith the probe holder lined up to left as in 2.5, push the “Erase” button and then start to scan the probe steadily to the right side and past the EDM notch A. Press “Enter”, and then press “Enter” again to access report file naming function. Enter a convenient single character for a file name and this push “Enter”. 2.10 Rotate the knob to “R ecall Report” and press “Enter”. U se scroll knob to highlight the file name just saved and press “Enter” to display the scan. Scan speed can be estimated as follows: since the horizontal sweep rate of the instrument is set to 1 second/division, the scan, at constant speed , should take between 5 and 6 seconds to scan reach the notch signal ( from the start of the scan ) , see Figure 7

. NOTE: It is important to scan at the proper speed ( and especially not too fast ) . Scanning too fast can result in significantly lower amplitude for the notch leading to excessively high gain levels. Calibration gain should not exceed 72 dB; if it does, re
- check scan speed.

2.11 If scan speed is acceptable, o bserve the notch signal peak to peak amplitude ( count screen divisions, each division is divided into 5 subdivisions or 0.2 divisions each dot) . If necessary, adjust g ain and repeat 2.8

- 2. 1 1 to produce an EC signal equal in amplitude to t he set up card to within +/

- 0. 4 divisions. See Figure 7 for typical trace over the gage standard. Note the slight increase in noise once the probe starts moving; this is where time of scan starts. OD Radius

forward flange Scan start

position

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

7 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 

### FIGURE 6 Phase angle set to vertical on calibration notch

.



### FIGURE 7 O
- Scope d isplay of EDM notch signal on calibration standard

.

2.12 Fill in the required information on a fresh Eddy Current Inspection Data Sheet (Appendix 1 ), noting the calibration notch ‘A’ response amplitude, the phase angle, the calibration gain, and the inspection (total) gain settings. Also note the seal temperature, part number, serial number and engine cycles/hours (if available) on the inspection sheet

. . 2.13 Rotate knob to “EC Display”, push “Enter” and change back to “I

- Plane” display prior to collecting engine data. **This step is required to ensure phase angle data is collected during inspection.**  scan start notch signal

between 5 and 6 seconds amplitude (peak to peak)

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

8 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 2.14 Add 12 dB of gain to the calibration gain prior to the inspection. 2.15 The Calibration should be re

- performed if the inspection has been interrupted for more than 30 minutes or instrument loses power (shuts off) before inspection and post

- inspection calibration are completed

. Remove probe tip holder, 71984, before using probe in engine.

3 Engine Access Precautions and Procedure WARNING : Follow site protocols concerning clothing and procedures for entering engine nacelle as well as rules on making electrical connections. Refer to AMM 78

- 31

- 00 for tasks and safety precautions related to the engine thrust reverser system.

NOTE : Local management m ay c ontact the local P&W Representative to arrange for an on

- site protocols briefing of special engine access ru les.

3.1 Engine must be cool or ambient. If necessary , forced air cool ing or heating may be performed (also see 3.3) Gain entry to the inspection area by having the nacelle fully open. Optimal access to inspection location is via HPT case TCA manifold port located at approximately 4:00 on the case (viewed aft looking forward) on all affected PW4000 engine model s (see title page)

. HPT case ports at 2:00 and 10:00 are optional choices for access if 4:00 port cannot be used (see Accomplishment section in the Service Bulletin).

3.2.1 Locate a suitable ladder or scaffold to allow one person comfortable access to the TCA port location (s) being utilized

. B orescope and EC instrument should be positioned so probe and borescope can comfortably reach the HPT case port. 3.3 The 1

- 2 Seal temperature is measured via flexible thermocouple ( see Kit 1.1.11 ) through the 2 nd Vane transfer tube (same location as utilized for EC inspection (see Figure 10 ). The borescope must be used to visually verify that thermocouple tip is touching the 1

- 2 seal. An optional alternative to the 2 nd Vane transfer tube is the TCA temperature p robe location (adjacent to 10:00 TCA manifold port, see Figure 8 )

. The TCA temperature probe is removed and then the flexible thermocouple is inserted ( it should go in for approximately 9 inches before the tip reaches the seal , visual confirmation is not required ) . Allow reading to stabilize and record temperature on inspection sheet (Appendix 1 )

. NOTE: Metal t emperature must be no greater than 1 1 0 F (44 C) before inspection can take place or damage to EC probe may result.



### FIGURE 8 Alternate location for taking seal temperature

3.4 Entry of Inspector s and Equipment into Engine for Inspection

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

9 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 3.4.1 Set up the Engine Rotator co ntrol unit by connecting power cable, motor cable and controller (see Kit 1.2 .2 , Figure 25)

. 3.4.2 Remove the engine air starter (at approximately 5:30, aft looking forward) per the accomplishment section of S ervice B ulletin. 3.4.2.1 Set up the Engine Rotator and connect drive mechanism to the starter adapter plate per the accomplishment section of serv ice bulletin. Also install the rotator gearbox adapter as shown in Figure 9 . The adapter is only used to keep track of part rotation (see 4.1.2). NOTE: Verify that the engine rotor is smoothly turning the seal in CW direction when aft looking forward (t he OD surface of seal moving away from you on the borescope monitor ) . Line up the index marks on the rotator gearbox adapter (by turning rotor as needed), Figure 9 . The woodruff key slot should be positioned at 12:00 for convenience in keeping track of rotations. The slot will rotate 3⁄4 of a revolution for one complete rotation of the N2 rotor

. Speed control on engine rotator should be adjusted so that 3/4 revolution of key slot is completed in approximately 1 minute (plus or minus 5 seconds). Rotate t he engine slowly for 2 revolutions of the woodruff key and look for any debris or deposits on the seal inspection area that might cause problems with probe contact. If the inspector observes any unusual condition or debris, borescope photographs can be ta ken and forwarded to Pratt & Whitney representative for consultation. See Quick Reference card in kit for instructions on how to take borescope photos (see Kit 1.2.1, Figure 24)

.



### FIGURE 9

3.5 Power up the borescope and car e fully insert the borescope into the 2 nd Vane transfer tube entrance exposed near the lower edge of case port ( prior to Figures 10 & 1 1 which show EC probe inserted at this location) . Look for any debris, damage or edge obstruction in tube or at tube exit that might obstruct passage of the EC probe wand. Carefully push the borescope tip past the transfer tube exit until the white tape on borescope wand is approximately even with tube entrance

. Articulate the sta lk as n ecessary to view the 1

- 2 Seal. Woodruff key slot 12:00 11:00

6:00

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

10 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 

### FIGURE 10

FIGURE 1 1

3.6 Carefully remove the borescope stalk from this 2 nd Vane tube and re

- insert it in the transfer tube adjacent to ( and above ) the full view tube. It is slightly behind the HPT case outer wall but the borescope can easi ly be maneuvered to gain access. See Figure 10 ,1 1

. 3.7 Prior to insertion of an actual eddy current probe, the ‘ M ock

- U p’ P robe , 71933, should be inserted to test transfer tube clearance (see Kit 1.1.2)

. 3.8 Carefully insert the M ock

- U p probe tip in the 2 nd Vane transfer tube ( fully visible tube entrance toward the lower edge of the port that was previously checked for debris in 3.5 ). The white line on the tip should be facing down (towards the convex side of transfer tube entrance , see Figure 1 1 )

. Some resistance will be felt as the probe is pushed past the transfer tube elbow and tube exit (more resistance than borescope stalk). Be careful not to buckle the yellow tube; use two fingers to support it while pushing it through. Do not use excessive force; it may help to rotate the probe handle a bit from side to side to help ingress and using fingers to support the yellow stalk as i n HPT Case Port at 4:00 (AP02) position , aft looking forward 2 nd Vane transfer tube entry location for borescope (partially hidden

under case) black mark for insertion depth transfer tube entrance for

EC probe

c onvex side of opening

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

11 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED Figure 12 . Insert probe until the edge of black mark ing on the probe stalk is even with the transfer tube entrance (Figure s 10 , 1 1 ).

3.9 Observe the probe tip by moving the borescope stalk as needed. The probe tip should be positioned in the groove as described in Figures 13 and 14 . When tip is in correct position, rotate engine for two full rotations of the gearbox adapter key slot. Observe the probe wand/tip on the borescope screen and look for any signs of probe movement as the seal rotates. The probe should not show any noticeable movement which could cause lift

- off and false calls. If such movement is present remove probe and investigate OD groove with borescope to try and determine if any surface debris is present that m ight cause the problem. If probe movement cannot be remedied, make a note of this on the inspection data sheet. After the first 3

– 5 seconds, the engine should rotate smoothly and consistently. If this cannot be achieved, make note if it on the inspection sheet. NOTE: Be mindful that if the borescope wand is touching the seal the entire display may appear to move (n ot just the probe). If the vane honeycomb appears to be moving at same time as probe, this is the reason. If this occur s the it may help to reposition the borescope and check again.



### FIGURE 12

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

12 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 

### FIGURE 1 3

FIGURE 1 4 Cross section showing proper side to side placement of probe tip

Remove the mock

- up probe by gently pulling the handle away from the HPT case but still aligned with the transfer tube (avoid excessive bending of probe wand ). Some resistance will be felt as the probe tip negotiates the transfer tube elbow. If the probe feels to be stuck, try to get a view with the borescope of the problem

. If necessary, push probe ba ck in to inspection position and p ush plunger end to extend vane honeycomb Intersection of groove and cylindrical surface

right side of probe tip

0.020” (0.51 mm) Seal OD surface

inspection zone Fwd

Aft knife edge seal

Probe tip radius sits

evenly in groove

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

13 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED the coil , (see Figure 1 6 ) and rotate tip to an alternate position and then let tip retract (let off plunger). Try and extract probe again while preventing plunger spring from compressing (do not let tip self

extend)

. Once probe is extracted, re

- inspect tube with borescope to determine cause of problem. DO NOT USE EXCESSIVE FORCE TO REMOVE PROBE OR TIP MAY PULL OFF AND DROP IN ENGINE. Carefully inspect the transfer tube exit for signs of excess casting flash (lip) or excessively rough casting surface in elbow that may impede probe tip movement. Also look for signs of transfer tube neck down at joint between tube and elbow (see Figure 1 5 )

. If any of these condition s are observed, it will be necessary to de

- burr /blend this area using the procedure in Appendix 2

. After blending , try mock

- up probe again and verify it can be inserted and extracted with out issue. Fill in Yes/No at bottom of inspection data sheet ( Appendix 1) next to “Blending Required”. **NOTE: If EC**  **probe tip or Mock Up**  **probe tip**  **liberates from probe stalk during withdrawal**  **from engine or**  **if a grinding tip (during transfer tube blending) separates from flexible shaft and cannot be recovered**  **from inside engin e**  **, see Service Bulletin for disposition.** 



### FIGURE 1 5

FIGURE 1 6 Borescope view showing example of transfer tube/elbow joint with restricted a rea, preventing probe tip from pas s ing through

.

extended probe tip

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

14 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 3.10 Seal cleaning procedure

Note: Water is the primary solution to be used for seal cleaning but in some cases it may be necessary to use a stronger solvent. Isopropyl Alcohol and Acetone are permissible if water will not remove adhered debris on seal. It is recommended that no m ore than 120 cc of either solvent be introduced into engine. Either solvent should only be used when seal temperature is at or below 110 ° F (44 ° C). The syringe and plastic tube are resistant to these chemicals.

3.10.1 Fill the 60 cc syringe with clean water (se e Kit 1.1.10) . Insert the plastic tube end through the vane transfer tube and position it so the black mark on the tube is even with the transfer tube entrance. Note: When seal metal temperature has dropped to 200 °F (93°C), i t is permissible to initiate cleaning of seal with water . It is not recommended to use alcohol or acetone until temperature has dropped to 110 F (44 C)

. 3.10 .2 While rotating the engine, spray water into the seal area by slowly pushing the syringe plung er. Try to push uniformly such that the entire seal OD is wet in the inspection zone ( avoid spraying directly on borescope tip ). If necessary, spray another 6 0 cc of water to ensure the whole inspection zone is wet. Use the borescope to view the nozzle tip to ensure that water is spraying onto the OD groove feature (inspection zone). 3.10 .3 Remove syringe/plastic tube and wait 10 minutes. 3.10 .4 In sert the brush / cable into the Cleaning Probe , 71992 (see Kit 1.1. 4 , 1.1. 3 ) , and secure the cable end to the cable clamp on the probe handle (tighten white knob) see Figure 1 7 (also see Kit 1.1.5)

. 3.10 .5 Insert the Cleaning Probe with brush and position the brush so it is in contact and centered in the OD groove on the seal , see Figure 1 8

. Use borescope to view brush position. NOTE: Use a dark colored permanent marker to blacken approximately t he last inch (25 mm) of the probe stalk (Figure 1 7 ). This will help reduce light reflection from the probe and prevent the borescope from auto

- dimming. It may also help to change from ‘auto’ to ‘max’ (8) on the borescope light control and to change ‘gain’ to ‘on’. 3.10 .6 Rotate the engine for 3 key slot revolutions while observing the brush through the borescope to verify it stay s in contact with the part. Remove cleaning probe/brush when complete.



### FIGURE 1 7 Cleaning Brush Use dark permanent marker to color end of probe stalk to reduce light reflection (approximately 1 inch)

.

brush cable cable clamp

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

15 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 

### FIGURE 1 8 Cleaning Brush in position (borescope view)

3.10 .7 Remove brush from Cleaning Probe and then re

- insert the probe handle/wand, 71992, (without the brush) and position the end of the yellow tube so it sits in the center of the OD groove

. 3.10.8 Apply shop air to the cleaning probe handle to force air through the tube. Rotate the engine for 3 key slot revolutions while blowing compressed air through the tube. This will help remove any loose debris in the inspection zone.

4.0 Inspection

4.1 On the PWA107921 Eddy Current probe, a lign the probe tip with the black dot on the (yellow) probe wand, see Figure 16. The tip can be rotated by pushing in probe plunger and rotating, but be careful to rotate no more than 180 degrees in either direction or coil signal wires may twist inside handle and break (resulting in a dead probe). Carefully insert the calibrated Eddy Current probe tip in to the transfer tube with the white line on the probe tip facing the convex side of the tube (facing down in Figure 10 ). Failure to do so may result in probe tip getting stuck in tube! Some resistance will be felt as the probe is pushed past the transfer tube elbow and elbow exit (more resistance than borescope stalk). Be careful not to buckle the yellow tube; use fingers to support it while pushing it through (Figure 1 2 ). Do not use excessive force; it may help to rotate the probe handle a bit from side to side to help ingress

. Once fully inserted , i t is also permissible to push in plunger end of handle to extend probe tip to help positioning tip (it is spring loaded , also see Figure 1 6 ). Insert probe until the black marking on the probe stalk is even with the transfer tube entrance (Figure 11 ).

4.2 Articulate the borescope as necessary to view the probe tip. Adjust probe tip position, if necessary, to **ensure the tip is in full contact and is properly centered in the OD radius**

. This step is critical to a good inspection. When viewed with vane honey comb on right side of borescope monitor screen, t he right edge of the probe tip should be close to the intersection

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

16 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED of the OD groove with the flat area (aft side of groove) as shown in Figure 1 3

. Figure 1 4 shows a scale drawing of the seal cross section a nd how the probe tip should fit in the OD groove. NOTE: Be careful that the borescope tip does not get under the probe stalk and push the probe up off the part surface. NOTE: Use a dark colored permanent marker to blacken approximately the last inch (25 mm) of the probe stalk (Figure 1 7 ). This will help reduce light reflection from the probe and prevent the bores cope from auto

- dimming . It may also help to change from ‘auto’ to ‘max’ (8) on the borescope light control and to change ‘gain’ to ‘on’. 4.3 Nu ll the probe by pressing the ‘Null’ button on US

- 454 EC instrument. Double check that 12 dB of gain was added to the calibration gain. Also check that Strip Chart and Impedance Plane are being displayed on US

- 454 display

.

4.4 Observe signal trace on eddy current instrument screen. If it appears unusually flat (i.e. no baseline noise), double check to make sure tip is in proper contact with the OD radius and probe cable connections are correct and working

. If proper probe tip contact cannot be achieved, try a different probe from the kit. 4.5 Once the probe is satisfactorily positioned, install the Probe to Case Holder, 71987 ( see Kit 1.1.12 , Figure 1 9 ). This device keeps the probe steady and prevents signal noise due to movement of probe handle

.

NOTE **:** Prior to starting inspection scan, pull the borescope back away from probe tip by approximately 1.5

– 2.0 inches (40

– 50 mm) to avoid borescope tip bumping into probe during engine rotation (which can cause false call signals)

NOTE : the inspector should not hold the probe handle during the inspection scan.

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

17 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 

### FIGURE 1 9

4.6 Rotate engine clockwise (aft looking forward) with the Engine Rotator , as required to align key slot at the 11:00 location on gearbox adapter (Figure 9 ).

4.7 Prepare the US

- 454 eddy current instrument for recording the engine scan data by d isplaying the selection menu on the right side if the screen (push enter button once if menu is not displayed). Scroll as necessary to find ‘Save Data’ on the menu (Figure 20 ) and leave it highlighted (do not hit enter). Turn on the engine rotator and wh en key slot reaches the 12:00 position, push the ‘Erase’ button on the US

- 454 to start scan data collection (see Figure 3 ). The erase button clears the instrument buffer so that all data collected will be from th is point in time

. Note: the engine shou ld be up to one rpm scan speed before the data collection begins.

4.8 The inspector shall monitor the instrument screen for signal s exceeding the rejection threshold criteria. When the key slot has completed 360 degrees ( reaches 12:00 again ) , push ‘Enter’ button on U S

- 454 Eddy Current Instrument ( i t is critical to make sure the scan overlaps the start position to ensure no portion of seal is missed ). This will stop data collection

. Push ‘Enter’ once more and the instrument will then be ready for naming of the scan data file as shown in Figure 20

. T he scan data file must be named (with en gine serial number and dash number for scan 1, 2 , etc.) and saved on the instrument (see 4.9 )

. Probe to Case holder sits in lower half of boss. Hand tighten red thumb screw, then close and tighten probe handle clamps.

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

18 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED Note: file name is limited to 8 characters



### FIGURE 20

4.9 Rotate the scroll knob to select the first letter/number in the file name. Then use the F2 key to move the cursor to next location. Rotate scroll knob until next desired digit is shown, push F2 key, etc. The F1 key can be used to back space in case of e rror. Once the file name is completed, push “Enter” enter and the file name should appear highlighted.

4.10 All data must be reviewed by inspector. This is done by choosing ‘Recall Data’ from the screen menu and then selecting the file from the list of saved files (using scroll knob). The data review screen will appear as shown in Figure 2 1 . The electronic st rip chart of Y signal component for entire scan is on the left while a zoomed up portion of th is signal between the green cursor lines is on the right. The operator shall set the controls for the zoomed portion by hitting ‘Enter’ and then adjusting ‘Fram e Length’ to minimum value , ‘Scroll Step’ to 15 %, ‘Chart Display’ to Y and sensitivity to 0. 5 v/div, s ee Figure 2 2

. After setting these parameters push the ‘cancel’ button. The inspector may use other sensitivity settings as convenient during data analysis (data does not change, only voltage scale on instrument changes).

4.11 Use the scroll knob to move the green cursor lines through the scan and record positive or negative indications equal to or above 1.2 volts peak amplitude

. B e su re and record data file name on data sheet

. In addition, if only a single (1) peak /event exceeds 1.2 volts after the re
- inspection t he seal is not rejectable (see 4. 12 and Figure 23 ). However, i f this situation occurs, the seal will need re
- inspection at a reduced interval per the S ervice B ulletin. Depending on the spacing between indications, frame length may need to be raised or lowered to ensure the entire signal in question (and no more) is wit hin the green frame lines. Note: if more than 6 signals are above reject threshold, record only the 6 of highest amplitude and note “numerous rejectable indications” on the inspection data sheet ( Appendix 1)

. c ursor control for moving to next letter (or backspace) f ile nam ing

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

19 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 

### FIGURE 21

FIGURE 2 2 Green lines ( cursor ) define portion of scan to be zoomed on right

Largest Positive and Negative Peak Amplitude within zoomed area of signal

possible indications phase information

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

20 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 

### FIGURE 23
4.12 If rejectable indications are found , the inspection should be repeated one time (repeat section s 2 and 4). If the data appears to have other anomalies, rectify problem and re

inspect. EC probe can be removed from the 2 nd Vane after all data are reviewed. If debris is suspect as cause of rejection it is permissible to repeat cleaning procedure, 3. 11

. NOTE: If rejectable indications ( equal to or greater than plus or minus 1.2 volts peak amplitude ) are observed , repeat inspection (a spare probe may be used) per sections 2 and 4 . If 2 nd scan is acceptable (see single peak exception in 4.11) , the seal is acceptable. Both scans must be recorded. If debris on seal surface is suspect, repeat cleaning procedure before re
- scan.

4.13 At end of work shift , all scan files on the EC instrument compact flash storage card must be backed up to an external storage device (i.e. laptop computer). This is done by shutting off Single ‘event’ above reject threshold Although both positive and negative peaks are above threshold, this example shows a single event and counts as a single peak above reject

Example showing two separate peaks above reject threshold It is uncertain if these peaks result from a single or double indication since they are clearly separated in time. As such, they would be considered as two peaks above reject threshold

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

21 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED EC instrument, removing the card and, using a suitable card reader, copy the data files f or each engine to a folder name with engine serial number.

5.1 P ost - inspection probe calibration check. 5.1.1 Reinstall probe shoe, 71984, on probe tip, bring gain down 12 dB (to original calibration gain) and check probe cal ibration on notch A. It should re ad within 15 % of original calibration amplitude. If these criteria cannot be met, re

- inspect OD radius per section 4.0. 5.1.2 The final determination of all reportable indications is based on the accept / reject criteria in section 6 .0. 6.0 Analysis and Rep orting of Inspection Data 6 .1 Indications equal to or greater than 1.2 volts peak amplitude (positive or negative) are rejectable and should be recorded on Inspection Data Sheet (Appendix 1 ). 7.0 Reporting / Disposition 7.1 Provide inspection results (Appendix 1 data sheets) to the l ocal Pratt & Whitney Field Representative ( electronic or hard copies)

. 7.2 Electronic c opies of the eddy current data files (as saved on the compact flash storage card) and a copy of the corresponding data sheet (Appendix 1 ) should be given/transferred to the local Pratt & Whitney Field Representative who will then forward the se documents to Pratt & Whitney Materials & Process Engineering, Non

- Destructive Evaluation group.



### FIGURE 2 4 Bores cope Kit

### NDIP 1137 Technique Sheet for PW4000
- 112” HPT 1
- 2 Seal NDI (On
- wing application)

22 P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 

### FIGURE 2 5 Engine Rotator Kit

### APPENDIX 1 NDIP 1137 

## PW40 0 0

- 112” HPT 1

- 2 Seal On

- Wing EC Inspection ECI of OD Forward Radius

Engine Models: PW4074, PW4074D, PW4077, PW4077D, PW4084D, PW4090, PW4090

- 3
Probe P/N ______________ Probe S/N __________________ Seal Temp.:__________ Date: _________

______ Seal P/N ____________ Seal S/N ____________ Engine Cycles/Hrs ___________ Seal Cycles/Hrs ____________

Ai rcraft Number _______________ Engine S /N

_____________ _ Engine Position ______ Inspector: ___________

Calibration Gain : ________ @ notch ‘ A’ amplitude per cal card, Gauge Standard S/N :

_________ , Phase Angle :

________ Total Gain :

_______ (+12 dB ), set Y sensitivity to 0.5 v/div , US

- 454 Data File Name :

_________________________

Indication # Time (in scan) Peak Amplitude + or - (volts) Comments



## V ane B lending R equired ______ (yes/no)

### NDIP 1137

P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 24 

## APPENDIX 2 

# Special Blending Procedure ( Rev0 8 ) PW4000

- 112” 2 nd 

## Stage HPT Vane Transfer Tube Air Passage Tube Engine Models: PW4074, PW4074D, PW4077, PW4077D, PW4084D, PW4090, PW4090

- 3
Subject:
This blend procedure is used to provide clearance for the eddy current probe by removing material from the T2 V transfer tube air passage. This tube allows access for eddy current inspection and if it is distorted or if cast portion has an excessively rough surface or ha s a lip of excess cast flash material at the transfer tube exit , the eddy current probe may not be able to pass through.

1. Equipment: 2.0 mm Machida Video Borescope (see Kit 1.2.1, Figure 24) Machida blend tool kit, BT

- 4000PW (see Kit 1.1.18, Figure A)

F IGURE A

Machida B lend T ool

### NDIP 1137

P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 25 2. Inspection Preparation:
2.1. Insert the 2 mm bore scope into the HPT 2 nd stage vane transfer tube entrance port and inspect the passage for distortion,/bulging material ( F igure B ) or for excessive casting flash ( F igure C)

.

FIGURE B Distorted bulging ma terial is below the arrows (above)

F IGURE C Lip of flashing material is between the arrows (above)

2. 2 . If distortion or bulging or rough casting surface is visual ( F igure B , C ) remove the bore scope, assemble the blend equipment per section 3.0 and follow the blend procedure per section 4.0 for the T2V air tube passage distortion/bulging

Note : a small amount of distortion is enough to impede the ECI probe

2. 3 . If no distortion, bulging or rough casting surface is present inside the T2V transfer tube air passage, and then push the scope thru the tube until the inner passage or exit opening is visible. Verify and/or Inspect

### NDIP 1137

P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 26 exit opening for evidence of a lip of casting flash material at the “U” shaped portion (lef t side) of the opening (Figure C). If flash lip i s evident , assemble the blend equipment per section 3.0 and follow the blend procedure per section 5.0 for excess casting flash. Note a small amount of flashing is enough to impede the ECI probe

Note: Some vanes have excess flash material only at the bottom of the “U” shaped opening that must be removed, while others may have additional excess material on the sides of the “U” that must also be removed
3. Assembly of Blend Equiptment
3.1. Assemble the blend equi pment. See Fig. A. and refer to instruction manual. Make sure control box power switch is in the off position, the direction of rotation switch is in the forward position, and speed adjustment is in the min position. Attach the foot pedal, put switch in fo ot position, move 110/220 voltage selector switch to the applicable supply voltage, and connect the handle power cord to the control box. NOTE: Always use the foot pedal. Unlock the collet on the handle by rotating the collet release ring. Insert the blend tool drive cable thru the Teflon tube and attach to handle by inserting the drive cable end of cone - shaped blend tool (red color on shaft) into the collar, leaving a gap of approximately 1/8” (3 mm) between Teflon tube end and blend tip. Lock the collet b y rotating the collet release ring. Finger tighten the hose clamp that secures the Teflon tube to handle. Turn the power switch to the on position, and depress foot pedal to test the rotation of blend tool.
4. Blend Procedure for distorted/bulged T2V transfer tube air passage 4.1. If there is distorted, bulging material, or a rough casting surface to be blended, partially insert the blend tool first into the vane transfer tube opening, and then insert the bore scope slightly behin d the blend tool. Push the bore scope and blend tool together thru the opening, viewing the blend tool ahead of the borescope on the borescope monitor. Position the cone shaped blend tip slightly in front of the bulged, distorted materia l or rough casting surface. Keep a safe distance between the borescope and blend tool tip. See Fig ure D.

FIGURE D Blending tip in correct position while blending bulging material

### NDIP 1137

P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 27 4.2. Always blend at a slow speed. Always start with the smallest diameter blend tip and gradually change to a larger diameter tip as needed to remove additional material. The shaft of the blend tool may fail if the blend tip gets jammed. U se only the forward motor direction

. Blend tool shaft failure may result from using reverse motor directions. NOTE: Use caution not to jam blend tip in bulge area of vane transfer tube . If the blend tip liberates, every effort should be used to remove the liberated material. If the liberated material is not recoverable see the S er vice B ulletin accomplishment section for continue in service direction.

4.3. Turn motor switch to on position. With blend tip slightly before bulge location, press foot pedal and gently move cone blend tool in and out slightly to remove excess bulging material. It is possible the transfer tube wall becomes slightly compromised with open holes on both sides of bulged area

. This is considered acceptable ( if there is more significant distress is the result of grinding , provide borescope photo to PW for evaluation).
4.4. Move power switch to off position on control box, .Remove blend tool and bore scope from vane. Insert mock up eddy current probe to see if it passes thr ough vane inner passage.

4.5. If additional excess material is present, or the mock up probe cannot not pass thr ough , the spherical blend tool (green color on shaft) can be used to remove more excess material.

4.6. Repeat the above steps as necessary to allow access for the edd y current probe.

4.7. When blending is completed, move power switch to off position on control box. Remove all equipment from vane.

5. Blend Procedure for T2V Excess Casting Flash @ air passage exit to air seal 5.1. Bore scope and blend tool are placed into the same T2V transfer tube , but you must insert them and remove them in a certain order o r damage may result to the bore scope. Insert the bore sc ope first, and remove the bore scope last. If you need to alter from this order, use caution not to damage the bore scope with the blend tool.

5.2. Insert th e 2 mm bore scope into the aft side of the vane transfer tube opening and push scope thru the tube until the exit opening is visible. Inspect exit opening for evidence of a lip of flashing material at the “U” shaped portion of the opening to the inspector’s left. Continue inserting the bore scope thru and past the opening towards the inner air seal.
5.3. Insert the cone shaped blend tool into the forward side of the vane transfer tube opening and gently push blend tool thru the vane tube. Some resistance may be experienced as it goes thru the tightly curved portion near ID of vane . Gently push and twi st as necessary while inserting until marked portion of blend tool’s Teflon tube is lined up with entrance of the transfer tube opening . The blending tool tip is now in approximately the correct blending location at the I.D. of the T2V transfer tube exit. 5.4. Gently pull bore scope back to view blend tool tip at the air passage exit (see Figures E and F) . Twist and position bore scope to get a good view of blending area. Keep a safe distance between the borescope and blend tool. Reposition blend tip as nec essary to grind away edge of excess flash material. See Fig. E.

### NDIP 1137

P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 28 F IGURE E : Blending tip in correct position while blending

5.5. Always blend at a slow speed. Always start with the cone shaped blend tip and gradually change to the spherical tip as needed to remove additional material. The flexible shaft of the blend tool may fail if the blend tip gets jammed

. Use only the forward motor direction

. Blend tool shaft failure may resu lt from using the reverse motor direction

. NOTE:: Use caution not to jam blend tip or cable may break . If the blend tip liberates, every effort should be used to re cover the liberated material. If the liberated material is not recoverable, see the S ervice B ulletin accomplishment section for continue in service direc tion. 5.6. Turn motor switch to on position. With blend tip at correct location, press foot pedal and gently move cone blend tool in and out slightly to remove excess flash material on the bottom of the “U” shaped opening . Remove as much excess material as possible with the cone blend tool. Also remove excess material from the sides of the “U” shaped slot if present. Move the power to off position on the control box. Remove blend tool from vane. Inspect area with borescope. If sufficient material is removed (Figure F), remove borescope and try mock up probe for passage through the transfer tube

.

### NDIP 1137

P&W PROPRIETARY INFORMATION ECCN 9E991

- EXPORT CONTROLLED 29 F IGURE F

HPT T2V transfer tube air passage exit after blending
5.7. If the mock up probe does not pass thru, the spherical ball blend tool (green color on shaft) can be used to remove additional material further up the sides of the “U” shaped opening

. 5.8. Repeat the above steps as necessary to allow pass through for mock up probe

. 5.9. When blending is completed, move power switch to of f position on control box. Remove all equipment from vane

.