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

SelectOneTM 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

SelectOneTM Retrofit Standard).

All V2524-A5, V2527-A5, V2527E-A5 Engines (A5 SelectOneTM 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

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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 SelectOneTM

Retrofit Standard).

(b) All V2530-A5, V2533-A5 Engines (A5 SelectOneTM 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.

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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.

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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.

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© IAE International Aero Engines AG. All rights reserved.
2. Material Information

None.

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© 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.

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(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.

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(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'

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(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).

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(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.

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(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.

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(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.

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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.

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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.

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(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.

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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).

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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.

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(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.

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(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.

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(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.

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© 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.

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© IAE International Aero Engines AG. All rights reserved.
Borescope Inspection

Figure 1

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© IAE International Aero Engines AG. All rights reserved.
Weld Spatter Record Sheet

Figure 1a

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© IAE International Aero Engines AG. All rights reserved.
Nominal Setup Values of the Eddy Current Equipment

Figure 2

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Figure 3

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© IAE International Aero Engines AG. All rights reserved.
Figure 3a

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© IAE International Aero Engines AG. All rights reserved.
Figure 3b

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© IAE International Aero Engines AG. All rights reserved.
Figure 3c

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© IAE International Aero Engines AG. All rights reserved.
Inspection Zones of Stage 7-8 Disk Internal Cavity

Figure 4

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© IAE International Aero Engines AG. All rights reserved.
Reposition the Probe Arm

Figure 5

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© IAE International Aero Engines AG. All rights reserved.
Drum in Position on Base Plate

Figure 6

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Probe Positioned in Drum Bore

Figure 7

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© IAE International Aero Engines AG. All rights reserved.
Tab Alignment and Tighten Thumb-Screws

Figure 8

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© IAE International Aero Engines AG. All rights reserved.
Example of Report File

Figure 9

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© IAE International Aero Engines AG. All rights reserved.
Example Data Review Using PSDISPLAY

Figure 10

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© 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.

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© 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.

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© 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.

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© 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

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© IAE International Aero Engines AG. All rights reserved.
Borescope Inspection

Figure 10

V2500−ENG−72−0625

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Weld Spatter Record Sheet

Figure 10a

V2500−ENG−72−0625

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© IAE International Aero Engines AG. All rights reserved.
Calibration of Eddy Current Equipment

(Rohmann B300)

Figure 11

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Calibration Signal from Surface Notch in Working Standard

at FSH from Centre of Screen

Figure 12

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Probe Installation in the Stage 8 Disk Bore

Figure 13

V2500−ENG−72−0625

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© IAE International Aero Engines AG. All rights reserved.
HP Compressor Stage 3 to 8 Drum Stage 8 Cavities

EC Inspection Location

Figure 14

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© IAE International Aero Engines AG. All rights reserved.
HP Compressor Stage 3 to 8 Drum Stage 8 Cavities

Inspection Record Sheet

Figure 15

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© IAE International Aero Engines AG. All rights reserved.
Assembly of Probe Lead

Figure 16

V2500−ENG−72−0625

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© IAE International Aero Engines AG. All rights reserved.
 

SERVICE BULLETIN FEEDBACK FORM

Sep.20/11 IAE PROPRIETARY INFORMATION V2500-ENG-72-0625 

Initial Issue © IAE International Aero Engines AG. All rights reserved. Page 1 of 1 

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If you have had difficulties to perform this Service Bulletin please quote below the area(s) and give a short 

description of the issue:

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Section: 

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