This document transmits the Initial Issue of Non-Modification Service Bulletin V2500-ENG-72-0625.

Non-Modification Service Bulletin Initial Issue Remove Incorporate Reason for change Pages 1 to 47 of the Non-Modification Service Bulletin. Initial Issue. Sep.20/11

V2500-A1/A5/D5 SERIES PROPULSION SYSTEM NON-MODIFICATION SERVICE BULLETIN



# V2500−ENG−72−0625 Transmittal - Page 1 of 1

IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG (date as above). All rights reserved. **CHECK THAT ALL PREVIOUS TRANSMITTALS HAVE BEEN INCORPORATED If any have not been received please advise IAE International Aero Engines AG** 1. Planning Information A. Effectivity

(1) Airbus A319 (a) All V2522-A5, V2524-A5, V2527M-A5 Engines (A5 Standard and A5 SelectOne TM Retrofit Standard). All V2522-A5, V2524-A5, V2527M-A5 Engines (A5 SelectOne Production Standard). (i) Applicable High Pressure (HP) Compressor Stage 3 to 8 Drum Part Numbers: 6A4900, 6A5467, 6A6473, 6A7383, 6A7384, 6A7385, 6A7401, 6A7705, 6A8316, 6B1379, 6B1380, 6B1384, 6B1385, 6B1386 and 6B1404.

(2) Airbus A320 (a) All V2500-A1 Engines. (i) Applicable High Pressure (HP) Compressor Stage 3 to 8 Drum Part Numbers: 6A3508, 6A3648, 6A3934, 6A3936, 6A4189, 6A5467, 6A5592, 6A5594, 6A5659, 6A6473, 6A7379, 6A7380, 6A7382, 6A7384, 6A7385, 6A7401, 6A8236, 6A8318, 6A8350, 6B1379, 6B1380, 6B1381, 6B1382, 6B1383, 6B1384, 6B1401, 6B1402, 6B1403 and 6B1406. (b) All V2524-A5, V2527-A5, V2527E-A5 Engines (A5 Standard and A5 SelectOne TM Retrofit Standard). All V2524-A5, V2527-A5, V2527E-A5 Engines (A5 SelectOne TM Production Standard). (i) Applicable High Pressure (HP) Compressor Stage 3 to 8 Drum Part Numbers: 6A4900, 6A5467, 6A6473, 6A7383, 6A7384, 6A7385, 6A7401, 6A7705, 6A8316, 6B1379, 6B1380, 6B1384, 6B1385, 6B1386 and 6B1404. NON-MODIFICATION SERVICE BULLETIN - ENGINE - HIGH PRESSURE (HP) COMPRESSOR STAGE 3 TO 8 COMPRESSOR DRUM - EDDY CURRENT INSPECTION (ECI)



# V2500−ENG−72−0625 Page 1 of 47 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(3) Airbus A321 (a) All V2530-A5, V2533-A5 Engines (A5 Standard and A5 SelectOne TM Retrofit Standard). (b) All V2530-A5, V2533-A5 Engines (A5 SelectOne TM Production Standard). (i) Applicable High Pressure (HP) Compressor Stage 3 to 8 Drum Part Numbers: 6A4900, 6A5467, 6A6473, 6A7383, 6A7384, 6A7385, 6A7401, 6A7705, 6A8316, 6B1379, 6B1380, 6B1384, 6B1385, 6B1386 and 6B1404. (4) Boeing MD-90 (a) All V2525-D5, V2528-D5 Engines. (i) Applicable High Pressure (HP) Compressor Stage 3 to 8 Drum Part Numbers: 6A4900, 6A5467, 6A6473, 6A7383, 6A7384, 6A7385, 6A7401, 6A7705, 6A8316, 6B1379, 6B1380, 6B1384, 6B1385, 6B1386 and 6B1404.

NOTE : This Non-Modification Service Bulletin provides an Eddy Current Inspection procedure which allows the delay of the ultrasonic inspection by 13000 cycles related to the achieved drum life, as instructed in Service Bulletin V2500-ENG-72-0608 and V2500-ENG-72-0615.

B. Reason

(1) Condition: Crack indications have been found on the High Pressure (HP) compressor stage 3 to 8 drums during overhaul. (2) Background: Crack indications were highlighted during a crack inspection of the HP compressor stage 7 to 8 disc internal cavity. An Airworthiness Directive (AD) requires repetitive Ultrasonic Inspection (USI). The intent of this Non-Modification Service Bulletin is to minimise the on-wing burden associated with the AD for the affected engines. (3) Objective: To do an Eddy Current Inspection of the HP compressor stage 3 to 8 drum, at the stage 7 to 8 disk internal cavity during overhaul.



# V2500−ENG−72−0625 Page 2 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(4) Substantiation: Crack indications have been found on the HP compressor stage 3 to 8 drum assembly during overhaul. An Eddy Current Inspection has been developed which is capable of detecting cracks at overhaul more accurately and minimises the variability of detection between overhaul shops. C. Description This Non-Modification Service Bulletin introduces two Eddy Current Inspection procedures to accomplish and record an inspection for the HP compressor stage 3 to 8 drum assemblies for V2500-A1/A5/D5 engines.

VARIANT I "APPLICABLE FOR THE USE OF UNIWEST EDDY CURRENT EQUIPMENT"

VARIANT II "APPLICABLE FOR THE USE OF ROHMANN EDDY CURRENT EQUIPMENT" D. Compliance Category 8 Accomplish based upon the experience with the prior configuration. E. Approval The compliance statement at paragraph 1.E. and the procedures in Section 3. Accomplishment Instructions of this Non-Modification Service Bulletin comply with the Federal Aviation Authority (FAA) Regulations and are FAA-APPROVED for the engine models listed. F. Manpower Estimated man-hours to accomplish this Non-Modification Service Bulletin in full:

(1) In Service Not applicable.

(2) At Overhaul Eight (8) hours for the Eddy Current inspection.

NOTE : The inspection defined in this Non-Modification Service Bulletin must only be carried out by personnel qualified in Eddy Current inspections to the appropriate national standard (EN4179, NAS 410 or equivalent) at level 2 or higher.



# V2500−ENG−72−0625 Page 3 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.G. Tooling price and availability Equipment required to accomplish Eddy Current Inspection:

ITEM NUMBER DESCRIPTION Variant I (Uni West) IAE 2R19890 ETC-2002 Scan Plan Rev. 3.0 (Software)

ETC-5201 Part-Mount ETC-5206 Probe-Alignment-Guide ETC-5207 Probe-Arm ETC-5208 Probe-Holder ETC-2477 Probe ETC-2496 Holder, Calibration Standard for V2500 3 to 8 Spool Variant II (Rohmann CNS) IAE 2R19891 LD-22 H-1881.01.1 Chamfer Probe LD-22 H-1881.02.1 Inner Diameter Probe LD-22 H-1881.03.1 Outer Diameter Probe Variant I and II IAE 2R19892 Reference Inspection Standard

NOTE : ETC-2002 tooling and Rohmann B300 or any equivalent Eddy Current Equipment is required to accomplish this inspection, but not part of the tooling provided by IAE.

H. References (1) IAE V2500 Engine Manual (E-V2500-1IA/3IA), Chapters 72-00-40, 72-41-00 and 72-41-11.

(2) Overhaul Processes and Consumables Index.

(3) IAE Service Bulletin V2500-ENG-72-0608.

(4) IAE Service Bulletin V2500-ENG-72-0615. (5) Engineering Change No. 11VR581.

I. Other Publications Affected

None. J. Interchangeability of Parts Not applicable.



# V2500−ENG−72−0625 Page 4 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.2. Material Information

None.



# V2500−ENG−72−0625 Page 5 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.3. Accomplishment Instructions

A. VARIANT I "APPLICABLE FOR THE USE OF UNIWEST EDDY CURRENT EQUIPMENT"

(1) General (a) This Non-Modification Service Bulletin V2500-ENG-72-0625 gives the Eddy Current Inspection procedure for the inspection of the HP compressor stage 3 to 8 drum, stage 7 to 8 disk internal cavity. (b) Eddy Current Inspection must be accomplished after the special enhanced cleaning procedure in accordance with Engine Manual and binocular and fluorescent penetrant inspection in accordance with the Engine Manual.

NOTE : Make sure that your ETC system is upgraded with appropriate ETC 2002 scan plan (CD-ROM) which is part of IAE 2R19890. (c) The calibration scan-plan automatically sets the instrument parameters on a US-450 or US-454/454A (part of the ETC-2002 system) instrument to the values stated in the table in Figure 2.

NOTE : During calibration the ETC program will assist in setting the gain and rotation (phase). The calibration process is faster if the gain is preset to 46dB and the rotation to 59 degrees. The data-collection sampling is set to 0.004 inch, the index between the scan-lines is set at 0.008 inch. The calibration and inspection operate at a surface speed of 4 inches/sec. (d) The ETC-2002 semi-automatic scanning system uses a data-acquisition reject-gate that monitors and records Eddy Current signal responses. (e) The system will be calibrated on a 0,75 mm long * 0,4 mm deep * 0,1 mm wide ( 0.030 inch long * 0.016 inch deep * 0.004 inch wide) EDM notch (IAE 2R19892 Inspection Reference Standard) which sets a Full Screen Height (FSH) signal response of 2.0 V for all scans. The reject gate automatically sets at 50 percent FSH (1.00 V). (f) The scanning system will inspect EDM notch in Zone 1 and will then evaluate the signal amplitude for the calibration on the Inspection Reference Standard IAE2R19892. The voltage level (2.0V), the gain and rotation will be entered in the "calibrate" submenu from the instrument screen. The program will then automatically set the correct gain and rotation, loop again and save the data.



# V2500−ENG−72−0625 Page 6 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(g) During post calibration, only the final calibration voltage will be verified . The acceptable range for the voltage is between 1.9 V and 2.2 V.

NOTE : If the voltage is not in the acceptable range, the complete calibration process must be repeated. (2) Boroscope Inspection for weld spatter on the stage 7 to 8 disc internal cavity of the HP compressor stage 3 to 8 drum (Refer to Figure 1)

NOTE : It is possible that weld spatter can be found on the HP compressor stage 3 to 8 drum, stage 7 to 8 disk internal cavity. This weld spatter can cause suspicious signals during the Eddy Current Inspection. This Borescope Inspection and the recording of the areas where weld spatter is found, can confirm the acceptance of these suspicious signals. (a) Visual inspect Zone 1 to 4 for weld spatter, use standard Borescope Inspection tooling (Refer to Figure 1).

NOTE : For the Borescope inspection, it is not necessary to place the HP compressor stage 3 to 8 drum on the Base-Plate of the ETC-2002 system. (b) If weld spatter is found in one of the Zones, mark the location of the weld spatter on the drum (Refer to SPM TASK 70-09-01-400-501) and record the location using the tick boxes within the Weld Spatter Record Sheet (Refer to Figure 1 detail B and Figure 1a). (3) System preparation and Initial Setup (Refer to Figure 3)

(a) General (i) Align the ETC system flatness and concentricity (Refer to the Operation Manual of the ECI equipment, Section 3 "Preparation for Use"). (ii) Make sure the recess on the Base-Plate (part of the ETC-2002 system), the contact surfaces of the Part-Stand (part of the ETC-2002 system) and the Calibration Stand (part of the ETC-2002 system) are free of burrs and debris. (iii) Turn on the Eddy Current Instrument, ETC computer and ETC controller modules. Allow them to warm up for at least 15 minutes.



# V2500−ENG−72−0625 Page 7 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(b) M-axis configuration (i) Configure the Downtube (part of the ETC-2002 system), the Part-Stand (part of the ETC-2002 system) and the M-axis. Make sure the cable between the M-axis and the Downtube is connected and cannot get damaged during the operation (the cable will touch the base of the swing arm). (c) Power up (i) Start the ETC program and log on. If the E-stop is pressed or the M-axis is not connected, an error message is displayed and the program will close down. Configure the Downtube (part of the ETC-2002 system) and M-axis and start the ETC program again. (ii) In the ETC program under "File" - "Preferences" make sure the M-axis is selected as "Radial axis". Run the program in "Data acquisition type" - "Position - based" mode. (iii) The program PSDISPLAY is not required for this inspection, but it is a valuable tool for Eddy Current signal evaluation.

NOTE : NOTATIONS related to the operation of the ETC program within this inspection procedure: Replace C:\ with the path that the scan-plans are stored in. The default directory is C:\V2500-Drum\ Items in "quotation marks" are tabs or buttons available in the ETC program windows ETC windows are denoted by single 'quotes'



# V2500−ENG−72−0625 Page 8 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(4) Setting the scanner zero position

CAUTION : PRIOR TO RUNNING SCANS, THE SYSTEM ZERO (HOME POSITION) MUST BE SET. ALL SCANNER MOTIONS ARE RELATIVE TO THIS ZERO. IF THE ZERO POSITION IS NOT SET ACCURATELY, THE PROBE MAY NOT BE POSITIONED CORRECTLY AND THIS CAN RESULT IN AN INACCURATE INSPECTION, A DAMAGED PROBE OR A DAMAGED DRUM.

NOTE : If during the Eddy Current Inspection or Zero setting procedure the probe crashes into the drum or a part of the ETC-System, the ETC-System must be realigned and the Zero setting procedure must be repeated. (a) Equipment required: ETC2002-System Eddy Current Inspection equipment ETC-2222 M-Axis Extension ETC-2133 Ball-Slide Assembly ETC-2217 Zeroing Tool ETC-5030 Calibration-Stand ETC-5025 Part-Stand

IAE 2R19890 ETC-5201 Part-Mount ETC-5206 Probe-Alignment-Guide ETC-5207 Probe-Arm ETC-5208 Probe-Holder ETC-2477 Probe ETC-2496 Holder, Reference Standard ETC-2002 Scan Plan Rev. 3.0 (Software) (b) Setup (i) Attach the Ball-Slide Assembly, ETC-2133 to the M-Axis Extension, ETC-2222. (ii) Attach this assembly to the M-Axis saddle. (iii) Slide the Zeroing Tool, ETC-2217 into the Ball-Slide Assembly, ETC-2133 probe receptacle and secure it with the two thumb-screws. Make sure the Zeroing Tool, ETC-2217 is positioned against the bottom side of the Ball-Side Assembly. (iv) Set the angle of the Ball-Slide Assembly to zero degrees (0 ° - vertical position). (v) Set the Part-Stand, ETC-5025 into the recess of the Baseplate of the EDI equipment, ETC-2002 and position the Calibration-Stand, ETC-5030 in the third set of holes from the Baseplate of the EDI equipment, ETC-2002 (Refer to Figure 3). 

# V2500−ENG−72−0625 Page 9 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(c) Set to Zero Procedure (i) Press "File" in the ETC Program and open the file folder:

C:\V2500-Drum\SCANPLAN (ii) Press "SET-ZERO.SCN" and then press "OPEN".

NOTE : SET-ZERO.SCN is the scan-plan (program) to set the System Zero If necessary, Replace "C:\" with the path where you stored the scan-plans in. (iii) The scan-plan "SET-ZERO" is now shown on the computer screen. To start the program, press "Run". (iv) The program will state "Move tool tip to part stand surface". Press "OK" to activate the joystick. Use the joystick to position the tip of the Zeroing Tool at the center of the cross-hairs on the top surface of the Part-Stand, ETC-5025.

NOTE : This alignment sets the vertical X-Axis and the radial M-Axis positions and is critical. Move the X-Axis (vertical) to align the lower dashes of the Ball-Slide Assembly, ETC-2133 and the Zeroing Tool, ETC-2217 (Refer to Figure 3a). (v) Tighten the thumb screws. (vi) Release/deactivate the joystick control by pressing one of the two buttons on the joystick. The system will now pre-set the Zero for the M- and X-Axis. (vii) C-Axis Zeroing Press "OK" to activate the joystick and drive the X-Axis up until the assembly is free. Set the Ball-Slide, ETC-2133 angle to 90 ° degrees. Align the tip of the Zeroing Tool, ETC-2217 with the vertical dash on the Calibration Stand, ETC-5030.

NOTE : The tip should not press onto the Calibration Stand, the tip must only point at the line to set the C-Axis Zero. 

# V2500−ENG−72−0625 Page 10 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(viii) Release the joystick control. (ix) Move the equipment to the Zero position, by pressing "OK".

NOTE : The equipment will now automatically move to the correct Zero position. (x) Press "OK", close the "Run Scanplan" window and the "SET-ZERO.SCN" program. "Set ZERO is now complete" Press "OK"

NOTE : Set ZERO is now complete. (xi) Remove the Zeroing Tool, ETC-2117, the Ball-Slide Assembly, ETC-2133, the M-Axis Extension, ETC-2222 and the Part-Stand, ETC-5025. (5) Calibration of the Probe, ETC-2477 (a) Visually inspect the Probe, ETC2477 for damage, replace the probe if damaged. (b) Use two layer of Kapton tape (CoMat 02-390) with a maximum thickness of 0.0035 inch, to protect the sensor-side of the Probe, ETC2477.

CAUTION : APPLY NEW KAPTON TAPE FOR ANY FIRST INSPECTION OF A DRUM

(c) Setup (i) Attach the Holder, Calibration Standard, ETC-2496 together with the Reference Standard, IAE 2R19892 to the top of the Calibration-Stand, ETC-5030. (ii) Position the Calibration-Stand, ETC-5030 in the second set of holes from the recess in the Baseplate, ETC-2002 (Refer to Figure 3b). (iii) Apply Kapton tape (CoMat 02-390) to the face of the probe-shoe to protect the sensor coil. Make sure the probe-shoe can still move freely. (iv) Attach the Probe-Holder, ETC-5208 to the M-Axis carriage. (v) Slide the shaft of the Probe-Arm, ETC-5207 into the bottom-hole of the Probe-Holder, ETC-5208 until the tab of the probe-shaft fits into the slot of the Probe-Holder. Check if this assembly is approximately vertical and secure it tightly with the thumb-screws. 

# V2500−ENG−72−0625 Page 11 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(vi) Connect the probe cable to the Downtube, ETC-2230 receptacle.

(d) Calibration Scan (i) In the ETC-Program, press on "File" and open the folder "C:\V2500-Drum\SCANPLAN". (ii) Select the scan-plan "CAL-ETC2477.SCN" and press "Open". (iii) Run the program: "CAL-ETC2477.SCN". (iv) The following message will appear on the screen:

"Position the ETC-5030 Calibration Stand in the 2nd set of holes on the baseplate".

"Press OK to continue". Make sure the Calibration-Stand is positioned as requested (Refer to step A.(5)(c)(ii)) then press "OK". (v) "ETC-2496 with Calibration Standard in place?". Make sure the Calibration-Standard is positioned as requested (Refer to step A.(5)(c)(i)) then press "OK".

CAUTION : IF THE REFERENCE STANDARD, IAE 2R19892, THE HOLDER, CALIBRATION STANDARD, ETC-2496 AND THE PROBE-ARM, ETC-5207 ARE NOT MOUNTED CORRECTLY, DAMAGE CAN OCCUR TO ANY OF THESE ITEMS, INCLUDING THE ETC-2002 SYSTEM. (vi) "Move probe to calibration scan start position.

Press "OK". The scanner will now move the probe onto the Reference Standard, IAE 2R19892. Make sure the Probe, ETC-2477 (part of the Probe-Arm, ETC-5207) fits as shown in Figure 3c.

NOTE : The calibration process is faster if the gain is preset to 46dB and the rotation to 59 degrees.

(vii) "Run calibration scan".

Press "OK" to start the calibration scan.

Real-time data is shown on the instrument screen as the scan runs. 

# V2500−ENG−72−0625 Page 12 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.When the scan is completed, the "Save Data" window opens. (viii) To save the data, press on the arrow in the "Save in" window and go to folder:

"C:\V2500-Drum\Data". Press the right button on an empty spot of the blank large window and create a file-folder with the serial number of the part to be inspected e.g.: "6A7401_RRDXX". Open this file-folder and save the calibration data e.g.:

"CAL"

NOTE : If the name already exists, add an index number e.g. "CAL2". Use the same index number (2) for the corresponding inspection runs so that they are correlate. If the folder already exists, open it and save the calibration with the name "CALn", where "n" is the index number. After the data is saved, the "Calibration Prompt" window opens. Press on "Verify Voltage" to read the signal peak-to-peak amplitude and scan-index. The amplitude shall be 2.0 Volts (a value between 1.9 V and 2.2 V is acceptable). Press "OK" to get the "Calibration Prompt" window again. If the voltage is not in the acceptable range, press on "Calibrate". (ix) If the voltage is acceptable, press on "Continue", and proceed with step A.(5)(d)(xii). The "Target Voltage" window opens. Enter "2.0" as the Target Voltage. Enter the Gain and Rotation readings of the Eddy Current instrument in the two fields provided.

Press "Enter" when done.

NOTE : The program automatically calculates the corrected gain and rotation and displays the window. 

# V2500−ENG−72−0625 Page 13 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Press "OK". Make sure the instrument has been automatically updated. (x) "Loop again". Press "Yes" to repeat the calibration scan. When the scan is complete, the "Save Data" window opens again. Save the data in the same file as before, i.e. overwrite it. (xi) Verify the voltage again to make sure it is now 2.0 V (a value between 1.9 V and 2.2 V is acceptable). If it is not, repeat above steps until it is. (xii) Make sure that the Index value in the "Calibration" Voltage and Index window is between 6 and 24.

NOTE : The calibration scan performs 30 index-moves in total. If the Index value is not between 6 and 24, the probe may not cross the reference notch correctly. Adjust the position of the reference standard, realign the probe (or modify the scan-plan) and repeat the calibration scans. (xiii) "Loop again."

Press "No". (xiv) "Move probe to ZERO position". Press "OK" to return all axes to System Zero. (xv) "Calibration complete".

Press "OK" to end the scan. (xvi) On the "Run Scanplan" window, press "Close" and close the scan-plan.

NOTE : If a satisfactory calibration can not be achieved, select another probe and repeat the calibration scan. If this is still not satisfactory, contact your supervisor.



# V2500−ENG−72−0625 Page 14 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(6) Part Marking (a) Locate the Stage 3 blade slot marked as No.1 of the HP compressor Stage 3 to 8 drum to be inspected. Use an approved marker to identify this position at the rear face of the stage 8 disc surface. (b) Place the drum on the Base-Plate of the ETC-2002 system. Align the mark in the same direction as the M-axis when it is in the zero position (to the right side of the system). Number the bolt holes (Refer to Figure 6). This serves as an angular reference location for any flaw indications recorded in the inspection report-file and in the data files. (7) Inspect the stage 7 to 8 disc internal cavity of the HP compressor stage 3 to 8 drum (Refer to Figure 4) (a) System setup

NOTE : DO NOT DISCONNECT THE PROBE CABLE. (i) Carefully loosen the thumb-screw of the Probe-holder, ETC-5208 and reposition the Probe-arm horizontally. This will hold the probe in position whilst the remainder of the system setup is performed (Refer to Figure 5). (ii) Remove the Holder, Calibration Standard, ETC-2496 together with the Reference Inspection Standard, IAE 2R19892 from the Base-Plate (part of the ETC-2002 system). Take care not to damage the probe and fixtures. (iii) Loosen the retaining clamp of the Swing-Arm (part of the ETC-2002 system) and rotate the swing arm to the right. (iv) Install the Part-Mount, ETC5201 into the recess of the Base-Plate (part of the ETC-2002 system), the lettering uppermost. (v) Carefully install the drum on to the Part-Mount, ETC-5201, refer to Figure 6. Rotate the swing arm back and lock it in position with the retainer clamp. Position the blade slot No.1 of the drum to the right (Refer to step A.(6)). (vi) Position the Probe-Alignment-Guide, ETC-5206 on to the stage 7 bore face of the drum, with the flat slot aligned with the M-axis. This holder keeps the probe in position during repositioning in the steps that follow. (vii) The setup steps that remain will be performed with the ETC inspection scan-plan running.



# V2500−ENG−72−0625 Page 15 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.WARNING : REMOVE YOUR HANDS, FINGERS AND OTHER BODY PARTS FROM ALL FIXTURES DURING AUTOMATED MOVES OF THE SYSTEM AXES. (b) Inspection scan

NOTE : It is possible that weld spatter can be present on the HP compressor stage 3 to 8 drum, stage 7 to 8 disk internal cavity. This weld spatter can cause suspicious signals during the Eddy Current Inspection. (i) In the ETC program, press on "File" and open the folder: "C:\V2500-Drum\SCANPLAN". Press on the scan-plan "6ATx-STG8-CAVITIES.SCN (where x stands for the appropriate drum type number: 6AT1 is for drums of type 1, 6AT2 is for drums of type 2), open it and run it. (ii) The program may raise the X-axis to make sure there is vertical clearance in the motions that follow. (iii) Setup system per procedure. Press "OK" when the system is ready. Make sure the system is configured as described above, then press "OK". (iv) The program opens the 'Report' window. Fill out the report form, particularly the settings obtained from the instrument screen. Press "OK" when done. The program will now prompt for a location in which to save the report-file. Browse for the folder created during the calibration and open it, e.g.: "C:\V2500-Drum\DATA\6A7401_RRDXXXX". Save the report-file using the name RUNn where n is the index you gave the CAL file (If you run more than one inspection using the same CAL file notation, name the report RUNn-01). The report-file, e.g.: "RUN1.TXT", is now saved. Attach the inspection evaluation results to this file. (v) "ETC-5206 in place??" Press "OK" to move M-axis in. Press "OK". The scan-plan now moves the M-axis so that the Probe-Holder, ETC-5208 is above the centre of the drum bore. (vi) Press "OK" to activate Joystick, place the Probe-Arm, ETC-5207 with the Probe, ETC-2477 into bore and attach it to the Probe-Holder, ETC-5208. Press "OK" to activate the joystick. Install the Probe-Arm, ETC-5207 with the Probe, ETC-2477 into the bore on to the slot of the Probe-Alignment-Guide, ETC-5206 so that the shaft of the Probe-Arm, ETC-5207 is vertical (Refer to Figure 7). 

# V2500−ENG−72−0625 Page 16 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Use the joystick to move the Probe-Holder, ETC-5208 over the shaft of the Probe-Arm, ETC-5207 and gently insert the shaft into the probe slot. Move the X-axis downwards and align the tabs on the shaft with the slot of the Probe-Holder,ETC-5208 and move the shaft upwards as far as possible. Tighten the two thumb-screws (Refer to Figure 8).

NOTE : Step 6 is in a Loop. If the joystick control is released before the probe is seated correctly, type "Yes" to Loop again? type "No" to continue. (vii) Move the Probe-Arm, ETC-5207 into place to remove the Probe-Alignment-Guide, ETC-5206. Press "OK". The scan-plan will move the probe shaft towards the edge of the bore so that there is enough room to remove the Probe-Alignment-Guide, ETC-5206. Carefully remove the Probe-Alignment-Guide, ETC-5206. Position the probe cable over the black thumb-screw knob to prevent damage (cut by the M-axis saddle). The system is now ready to perform the inspections.

CAUTION : REMOVE THE PROBE-ALIGNMENT-GUIDE, ETC-5206 OR DAMAGE WILL OCCUR. (viii) Remove the Probe-Alignment-Guide, ETC-5206. Press "OK" to move probe to scan-start position. Press "OK". The scan-plan moves the probe tip on to the start of zone 1.

(ix) Run scan in Zone 1 - Outer Radius. Press "OK". Zone 1 will be scanned from the bottom upwards. At the end of the scan, the 'Save data' window will open. Open the folder which contains the CAL file, e.g.: "C:\V2500-Drum\DATA\6A7401_RRDXXXX". Enter a file name, e.g.: "RUNn-Zone1" (n is the index number which corresponds to the index number of the report) and press "Save" to store the data for zone 1. The program evaluates the data for signals that exceed the reject threshold. If the number of rejects exceeds the count-limit set by the program, a warning message appears. Use a text-editor program to add this to the report-file. The program may give the number of indications and open the folder which contains the report-file saved above. Press on the report-file name, e.g.: "RUNn.TXT" to attach the results of the evaluation.

Press "OK" when done. 

# V2500−ENG−72−0625 Page 17 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(x) Run scan in Zone 2 - Chamfer. Press "OK". Zone 2 will now be scanned from the bottom upwards. At the end of the scan, save the data in file "RUNn-Zone2" and attach the evaluation results to the report-file "RUNn.TXT".

(xi) Run scan in Zone 3 - Inner Radius. Press "OK". Zone 3 will now be scanned from the bottom upwards. At the end of the scan, save the data in file RUNn-Zone3 and attach the evaluation results to the report-file "RUNn.TXT".

(xii) Run scan in Zone 4 - Web. Press "OK".

Zone 4 will now be scanned from the outside inwards. At the end of the scan, save the data in file RUNn-Zone4 and attach the evaluation results to the report-file "RUNn.TXT". (xiii) "Repeat inspection run?" "Loop again?" The inspection of all Zones can be repeated. Press "YES" to return to step 9. Press "NO" to continue. At the end of the scan, the probe will be located where the Probe-Alignment-Giude, ETC-5206 can be re-installed.

WARNING : REMOVE YOUR HANDS, FINGERS AND OTHER BODY PARTS FROM ALL FIXTURES DURING AUTOMATED MOVES OF THE SYSTEM AXES. (xiv) Place the Probe-Alignment-Giude, ETC-5206 in the bore of the drum. Press "OK" to continue. Install the Probe-Alignment-Giude, ETC-5206 back in to the bore of the drum. Press "OK" and the Probe-Arm, ETC-5207 will move horizontally to the middle of the bore. (xv) Press "OK" to activate Joystick, REMOVE PROBE from drum. Press "OK". DO NOT DISCONNECT THE PROBE CABLE Loosen the two thumb-screws that hold the Probe-Arm, ETC-5207 shaft and gently position the Probe-Arm, ETC-5207 on to the Probe-Alignment-Giude, ETC-5206. Use the joystick to raise the Probe-Holder, ETC-5208 off the shaft and raise the Probe-Arm, ETC-5207 out of the bore. Put the Probe-Arm, ETC-5207 back into the side hole of the Probe-Holder, ETC-5208 at a 90 degree angle.

NOTE : As an alternative: Drive the X- axis up, and the M-axis all the way out, then attach the Probe, ETC-2477. Deactivate the joystick. 

# V2500−ENG−72−0625 Page 18 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(xvi) "PROBE REMOVED??" Press "OK" to continue. Make sure that the Probe-Arm, ETC-5207 is removed from the bore so that the axes can move without causing damage to the probe or the drum.

CAUTION : MAKE SURE THE PROBE-CABLE IS SAFE. IF THE AXES MOVE, IN PARTICULAR THE M-AXIS, THE PROBE-CABLE CAN BE CAUGHT BETWEEN THE SADDLE AND THE DOWNTUBE AND DAMAGE THE CABLE.

Press "OK". (xvii) Move all axes to START position. Press "OK" to move all axes to the start position. This is not the Zero position. The X-axis will be positioned higher to allow for clearance for setting up the drums. (xviii)Inspection complete. Press "OK". Press on "Close" to close the 'Run Scanplan' window and close the scan-plan. (8) Post Inspection Setup (a) Release the ETC-2002 swing arm and rotate it to the right. (b) Remove the drum from the Part-Mount, ETC-5201. (c) Make a check on the wear of the Kapton tape (CoMat 02-390) on the Probe, ETC-2477.

CAUTION : DO NOT REMOVE THE KAPTON TAPE FROM THE PROBE UNTIL THE POST CALIBRATION HAS BEEN FINISHED (d) If the Kapton tape (CoMat 02-390) is worn or torn, make sure that there are no residuals of the tape in the drum cavity.

(9) Post-Calibration (IAE 2R19890 Probe ETC-2477) (a) Follow the Calibration Process described in step A.(5), EXCEPT: (b) DO NOT replace the Kapton tape (CoMat 02-390). (c) DO NOT adjust or change the gain and rotation settings, i.e.: DO NOT calibrate. (d) Make sure that the voltage is between 1.9 and 2.2 V. If yes, finish the Post-Calibration run and proceed to the next section.



# V2500−ENG−72−0625 Page 19 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(e) If the voltage is not in the acceptable range, replace the Kapton tape (CoMat 02-390) on the probe, repeat the inspection and inspect all parts that have been run since the last successful Post-Calibration. (10) Reporting (a) Use a text editor such as Notepad or Wordpad to open the report-file, e.g.: RUN1.txt. (Refer to Figure 9). (b) The report-file contains all information related to the inspection, including the Windowing Reports generated by the ETC program. (c) Use the text editor to identify the Windowing Reports: Add labels - Zone1, -Zone2 etc. as shown. (d) If no indications are found, add the word - ACCEPT to the Accept/Reject line, else add - REJECT. (e) If any of the zones exhibit "excessive number of indications", add this note to the Windowing Data. (f) Close and save the report-file. Use the PSDISPLAY program to view the data files and provide additional information. (g) The zoom-window is positioned around a response typical of a crack or pit. The Eddy Current signal is detailed in the windows on the left side of the display; the signal amplitude is 1.68 Vpp (Refer to Figure 10). (h) Note the "SCAN pos" and "INDEX pos" values are highlighted with a circle (Refer to Figure 10). These correspond to the locations listed in the Windowing Section of the report-file. (i) The report-file groups indications by angular location from the blade slot No.1 of the drum (if aligned towards System Zero) and vertical position from the start of the inspection run. It also provides peak to peak voltage of the indications. (11) Acceptance and Rejection of HP Compressor Stage 3 to 8 Drum (Refer to Figure 15) (a) Accept components not exhibiting crack indications or producing signals with a voltage up to 1.00V. (b) Accept components with indications or producing signals with a voltage between 1.00V and 2.0V if the following applies: 1. The location of the signal can be correlated to weld spatter.



# V2500−ENG−72−0625 Page 20 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.2. An additional visual inspection of the indicated area with a 10x magnification does not reveal any crack indication. (c) Reject components exhibiting crack indications or producing a signal with a voltage of 1.00V or larger if step A.(11)(b) does not apply. (i) If the drum is rejected, record the details on the rejection pro-forma and send a copy to the IAE representive.

Quarantine the drum and wait for advice from IAE. (12) Accomplish all the steps that remain of the Engine Manual Inspection TASK 72-41-11-200-001, from paragraph 5.C. onwards.



# V2500−ENG−72−0625 Page 21 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Borescope Inspection Figure 1 

# V2500−ENG−72−0625 Page 22 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Weld Spatter Record Sheet Figure 1a 

# V2500−ENG−72−0625 Page 23 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Nominal Setup Values of the Eddy Current Equipment Figure 2 

# V2500−ENG−72−0625 Page 24 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Figure 3 

# V2500−ENG−72−0625 Page 25 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Figure 3a 

# V2500−ENG−72−0625 Page 26 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Figure 3b 

# V2500−ENG−72−0625 Page 27 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Figure 3c 

# V2500−ENG−72−0625 Page 28 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Inspection Zones of Stage 7-8 Disk Internal Cavity Figure 4 

# V2500−ENG−72−0625 Page 29 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Reposition the Probe Arm Figure 5 

# V2500−ENG−72−0625 Page 30 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Drum in Position on Base Plate Figure 6 

# V2500−ENG−72−0625 Page 31 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Probe Positioned in Drum Bore Figure 7 

# V2500−ENG−72−0625 Page 32 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Tab Alignment and Tighten Thumb-Screws Figure 8 

# V2500−ENG−72−0625 Page 33 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Example of Report File Figure 9 

# V2500−ENG−72−0625 Page 34 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Example Data Review Using PSDISPLAY Figure 10 

# V2500−ENG−72−0625 Page 35 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.B. VARIANT II "APPLICABLE FOR THE USE OF ROHMANN EDDY CURRENT EQUIPMENT"

(1) General (a) This Non-Modification Service Bulletin V2500-ENG-72-0625 gives the procedure for the inspection of the HP compressor stage 3 to 8 drum, stage 7 to 8 disk internal cavity. (b) Eddy Current Inspection must be accomplished after the special cleaning procedure in accordance with Engine Manual, TASK 72-41-11-110-001 and binocular and fluorescent penetrant inspection in accordance with the Engine Manual. (2) Boroscope Inspection for weld spatter on the stage 7 to 8 disc internal cavity of the HP compressor stage 3 to 8 drum (Refer to Figure 10)

NOTE : It is possible that weld spatter can be found on the HP compressor stage 3 to 8 drum, stage 7 to 8 disk internal cavity. This weld spatter can cause suspicious signals during the Eddy Current Inspection. This Borescope Inspection and the recording of the areas where weld spatter is found, can confirm the acceptance of these suspicious signals. (a) Visual inspect the inspection area for weld spatter, use standard Borescope Inspection tooling (Refer to Figure 10). (b) If weld spatter is found in one of the Zones, mark the location of the weld spatter on the drum (Refer to SPM TASK 70-09-01-400-501) and record the location using the tick boxes within the Weld Spatter Record Sheet (Refer to Figure 10 detail B and Figure 10a). (3) Calibrate the Eddy Current Equipment (Refer to Figure 11 and Figure 12) (a) Visually inspect each probe and coil for damage. (b) Protect the underside of the probe to be used, IAE 2R19891, with (Teflon tape) low friction tape (CoMat 02-195). (c) For Rohmann B300 settings, refer to the table in Figure 11. (d) Make sure basic instrument settings have been initially set as in step B.(3)(c) for each probe when installed. (e) Position the probe on the calibration test standard. Make sure the probe is installed correctly. (f) Put the probe on the IAE 2R19892 (Refer to Figure 13 EDM-notched reference inspection standard), away from the notch. Balance or null the instrument so the spot is centralised on the screen. 

# V2500−ENG−72−0625 Page 36 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(g) Use a constant scanning speed to scan over the 0.015 in. (0,4 mm) deep Electro Discharge Machine (EDM) notch of the working standard. Make sure the scan is overlapped by at least 4.00 in. (100 mm) as when the scan starts and stops the constant speed will not have been maintained. (h) While the probe is moving, adjust the phase angle so that the figure of eight signal from the EDM is vertical. Adjust the gain control to produce the notch signal at 75 percent screen height from the screen centre. The HP filter setting will make sure the spot returns to the screen centre (Refer to Figure 12). (i) The first Eddy Current probe/instrument combination is now calibrated. Make a record of the instrument settings to use again. (j) Do the inspection, refer to step B.(4). (4) Examine the HP Compressor stage 3 to 8 Drum (Refer to Figure 13 and Figure 14) (a) Locate the Stage 3 blade slot marked as No.1 of the HP compressor Stage 3 to 8 drum to be inspected. Use an approved marker to identify this position at the rear face of the stage 8 disc surface. (b) If available, put the drum on a suitable turntable. Make sure that no damage occurs and centralise the drum on the turntable. (c) Position the probe in the drum. Make sure the probe is installed correctly (Refer to Figure 13 and Figure 14). (d) If a turntable is used, hold the probe assembly with one hand and slowly move the turntable with a constant scanning speed. If a turntable is not used, make sure the drum is stable and rotate the probe assembly with a constant scanning speed. Make sure a complete 360 degree rotation of the probe across the drum surface is completed. Make sure the scan start and finish is overlapped by at least 4.00 in. (100 mm) to make sure a constant speed is maintained for a minimum of one revolution of the probe over the inspection surface.

NOTE : Scanning must be carried out at the same speed as that used for calibration or cracks may be missed. (e) During scanning, a random slow movement of the spot about the screen centre, caused by the structure of the material, is acceptable.

NOTE : Spatter occurs in the drum. Depending on the size of spatter, it is difficult or impossible to inspect in that area and possible cracks could be missed. Record the area of spatter. 

# V2500−ENG−72−0625 Page 37 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(f) On completion of the inspection visually inspect the probe and coil for damage. (g) On completion of the inspection, make a check that the calibration sensitivity is acceptable in accordance with the steps B.(3)(e) to B.(3)(g). If the calibration is not acceptable, inspect the HP compressor stage 3 to 8 drum again. (h) Genuine cracks produce a rapid vertical, or near vertical deflection in the form of a figure of eight. A small distortion of the signal, caused by high pass filtering, may occur. (i) Repeat the calibration and inspection for all three Eddy Current probes used. (5) Acceptance and Rejection of HP Compressor Stage 3 to 8 Drum (Refer to Figure 15) (a) Accept components not producing a rapid spot deflection in a vertical or near vertical direction up to 25 percent screen height. (b) Accept components producing rapid vertical movement about the screen centre and more than 25 percent screen height if the following applies: 1. The location of the signal can be correlated to weld spatter. 2. An additional visual inspection of the indicated area with a 10x magnification does not reveal any crack indication. (c) A drum which displays a rapidly moving spot in a vertical or near vertical direction and is more than 25 percent screen height. Reject the drum if step B.(5)(b) does not apply. (i) If the drum is rejected, make a record of the details on the rejection pro-forma and send a copy to the IAE representative.

Quarantine the drum and wait for advice from IAE (Refer to Figure 15). (6) Accomplish all the steps that remain of the Engine Manual Inspection TASK 72-41-11-200-001, from paragraph 5.C. onwards.



# V2500−ENG−72−0625 Page 38 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.C. Record of Accomplishment (1) Record the accomplishment of Non-Modification Service Bulletin V2500-ENG-72-0625 in the applicable engine records.

(2) Inform the local IAE office that Non-Modification Service Bulletin V2500-ENG-72-0625 has been accomplished and provide the completed Inspection Report. The local IAE Technical Representative will record the accomplishment of this Non-Modification Service Bulletin V2500-ENG-72-0625 in the Fleet Data Management System (FDMS).



# V2500−ENG−72−0625 Page 39 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Borescope Inspection Figure 10 

# V2500−ENG−72−0625 Page 40 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Weld Spatter Record Sheet Figure 10a 

# V2500−ENG−72−0625 Page 41 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Calibration of Eddy Current Equipment (Rohmann B300) Figure 11 

# V2500−ENG−72−0625 Page 42 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Calibration Signal from Surface Notch in Working Standard at FSH from Centre of Screen Figure 12 

# V2500−ENG−72−0625 Page 43 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Probe Installation in the Stage 8 Disk Bore Figure 13 

# V2500−ENG−72−0625 Page 44 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.HP Compressor Stage 3 to 8 Drum Stage 8 Cavities EC Inspection Location Figure 14 

# V2500−ENG−72−0625 Page 45 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.HP Compressor Stage 3 to 8 Drum Stage 8 Cavities Inspection Record Sheet Figure 15 

# V2500−ENG−72−0625 Page 46 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Assembly of Probe Lead Figure 16 

# V2500−ENG−72−0625 Page 47 Sep.20/11 Sep.20/11 Initial Issue IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.

# SERVICE BULLETIN FEEDBACK FORM

Sep.20/11 IAE PROPRIETARY INFORMATION V2500-ENG-72-0 625 Initial Issue © IAE International Aero E ngines AG. All rights reserved. Page 1 of 1 

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