CLARIFICATION ON 11 RECOMMENDATIONS BY OEM

FOR ANY CLARIFICATION DURING VISIT, PLEASE CONTACT SRI S R SAMAL(ONE OF THE MEMBERS TO BE DEPUTED TO M/S UMPO, UFA FOR ISSUES RELATED TO 11 OEM RECOMMENDATIONS) , MANAGER (METHODS), HAL, KPT, SED MOBILE NO. : +919437526527

DETAILS OF MODIFICATION : DOCUMENTS RECEIVED FROM OEM

Sl. No. Recommendation Activity / Manufacturing Remarks

1
(Ref. 1.10 Protoco l)

Drive shaft and LPT rotor in angular position are to be assembled observing markings to compensate maximum spline eccentricity. Maximum permitted run out : 0.15mm

Implemented Ref .: DCN No. 4458 & -4489, TCN No. : 96T-20896. Applicability : TC962

Runout checking on splines of drive shaft

NO CLARIFICATION FROM OEM.

DETAILS OF MODIFICATION : DOCUMENTS RECEIVED FROM OEM

Sl. No. Recommendation Activity / Manufacturing Implemented Ref. : DCN No -4482 -4483 TCN No. : 96T20882,96T20886,96T20888,96T-20889 Applicability : 104.04.02.000 TC96-21 104.04.22.020 TC96-23 Remarks

2
(Ref. 1.11 Protoco l)

Reduce the value of face run out of LPT and HPT discs to 0.05 mm during Balancing checks.
CLARIFICATION :
1. Face runout on LPT rotor for engine no. 16-96-215 & 16-96-217 (supplied by OEM) is observed as 0.08 & 0.12mm respectively during balancing at HAL, Koraput after first test. To check IRS (available at OEM) for both the engines to verify the actual face runout as shown in the figure. 2. Difficulty is experienced during implementation of this change (face r/o of LPTR) notice at HAL, Koraput. The detail manufacturing and assembly technology at OEM is to be witnessed to bring clarity and machining procedure is being followed to maintain the r/o within 0.05mm.

Runout checking on LPTR

Runout checking on HPTR

CLARIFICATION :
3. As per TCN96T- 20888 (for LPTR), face run out of LPT disc in opn. No. 40035 has been changed to 0.04mm. In subsequent turning operation (opn. No. 40095 & 40100), face run out of disc is mentioned as 0.02mm. It is requested to clarify how to maintain the face runout within 0.02mm in turning operation if face runout already maintained within 0.04mm in opn. No. 40035. 4. The face runout of HPTR as recommended is achievable and implemented at HAL, Koraput.

DETAILS OF MODIFICATION : DOCUMENTS RECEIVED FROM OEM

Sl. No Recommendation Damping rings are to be installed in Turbine support with guaranteed interference (0.010.03) mm. Action Involved : Fitment of two new pins part no. 104.04.23.003 & Vibropacket part no. 104.04.00.061 as per post mod drawing. Revised Indent SUMPOS12-068 dated 05.12.2013 sent for procurement of VibroPackets (50 Nos). Activity / Manufacturing Remarks

3
(Ref. 1.12 Proto col)

Vibro packet manufactured. Modification carried out on Turbine support. Ref .: DCN No. 4480, -4481, 4472, -4473, 4474, -4484 TCN No. : 96T21012, 96T21098 96T-21028, 96T21056 Applicability : TC962, TC96-32, 104.04.00.061, 104.04.00.060, 104.04.23.030

CLARIFICATION :Ovality

is observed during pressing of bush, part no. 104.04.00.061 into bearing area of turbine support, part no. 104.04.23.030 (in one of the Phase-IV mfg. engine) at HAL, Koraput . As per technology provided incorporating the change notice, further polishing is to be carried out on ID of part no. 104.04.00.061 to maintain taper & ovality within 0.020mm and ensuring ID within 153.5 + 0.025mm. It is not understood how at OEM the same technology is being followed. During discussion with OEM rep. on 21.01.14, it was told that certain technological process modification is envisaged for implementation of the change notice. Thus, the process of fitment of bush (part no. 104.04.00.061) ensuring all technological conditions to be witnessed at OEM. Further development in modification of the process may be discussed in details.

Locking of ring in turbine support with two pins

DETAILS OF MODIFICATION : DOCUMENTS RECEIVED FROM OEM

Sl. No Recommendation Activity / Manufacturing Implemented Ref .: DCN No. -4476 TCN No. : 96T-21013 Applicability : TC95-38 Remarks

4
(Ref. 1.13 Proto col)

Locking nut of the Inter Shaft bearing to be made of VJ-98 material. Premod part no. : 104.04.22.046-02 & 104.04.22.046-03 is changed to 104.04.22.096-01 & 104.04.22.096-02 with material change from 12X18H10T to VJ-98

Lock washer material VJ-98

ADDITIONAL CLARIFICATION : The reason for change of material of lock washer.

DETAILS OF MODIFICATION : DOCUMENTS RECEIVED FROM OEM

Sl. No.
5 (Ref. 1.18 Proto col)

Recommendation

Activity / Manufacturing

Remarks
Balancing at 1st stage HPC Disc, Labyrinth, HPT Disc

To introduce three plane balancing of HP rotor and limit the max vibration limit to 25 mm/sec in place of 40 mm/sec.

Implemented Ref .: DCN No. 4459 TCN No. : 96T20884 Applicability : 104.0160 (DI) TC96-21

6
(Ref. 1.17 Proto col)

To carry out dimensional Implemented measurements / inspection of critical parts in controlled temperature condition at assembly area & CMM.

NO FURTHER CLARIFICATION

DETAILS OF MODIFICATION : DOCUMENTS RECEIVED FROM OEM

Sl. No. Recommendation Activity / Manufacturing Remarks

7
(Ref. 1.14 Proto col)

To optimize the clearance values of Change in Inter Rotor Bearing inner race with fitting LPT Nose. diameter of LPT Nose Existing Fitment : Interference : 0.010mm, Clearance : 0.015mm Ref .: DCN No. -4643, Fitment after Modification: 4644, -4645, Interference : 0.030.0.005mm TCN No. : 96T21747, 96TAction Involved : Change in fitting diameter 21748, 96Tof LPT nose from 110 0.015 mm to 110 21741 (+0.020 + 0.005) mm. During grinding of LPT Nose, dimension to Applicability : 104.04.22. be maintained. 063, 104.04.22.020, TC96-38

Interference : 0.030 0.005mm

CLARIFICATION: Whether Chrome plating can be carried out on inner race of bearing to restore the fitment condition for already manufactured parts for PY2013-14.

DETAILS OF MODIFICATION : DOCUMENTS RECEIVED FROM OEM

Sl. N Recommendation Activity / Manufacturing Remarks

8
(Ref. 1.15 Proto col)

To optimize the radial clearance values for Inter Rotor Bearing and Inter Shaft Bearings. Existing radial clearance : Minimum 0.025 mm Radial clearance after Modification: 0.025 . 0.075 mm REMARKS / CLARIFICATION : 1.DCN and TCN received by HAL,
Koraput for change in fitment condition and radial clearance values of interrotor bearing (implemented at HAL, Koraput). 2.How-ever for intershaft bearing, DCN & TCNs are not received. As per discussion with Mr. Permyakov at HAL, Koraput on 21.01.14, it was clarified that the implementation of change of fitment and radial play of intershaft bearing is not required. The reason for withdrawing this change notice for intershaft bearing to be discussed.

Ref .: DCN No. -4480 TCN No. : 96T21013 Applicability : TC96-38

DETAILS OF MODIFICATION : DOCUMENTS RECEIVED FROM OEM

Sl. No.

Recommendation

Activity / Manufacturing

Remarks

9
(Ref. 1.16 Proto col)

To revise torque values for Inter Rotor Bearing races. (Existing Torque Value on outer race : 5 +0.5 kgf m Final Existing Torque Value on inner race : 50 +10 kgf m Final)

As per OEM letter no. 60/4-691 dated 31.12.13, modification of the document is not required.

CLARIFICATION: Reason for not implementing the change notice?

DETAILS OF MODIFICATION : DOCUMENTS RECEIVED FROM OEM

Sl. No. Recommendation Activity / Manufacturing Remarks

10
(Ref. 1.19Proto col)

To introduce better cooling method for Inter rotor bearing by change of oil supply pattern. Remarks : As per DCN -4720, bearing part no. has been changed from 5-272822P2Y to 5-272822P6Y, oil collector rings part no. 104.04.22.068 & 104.04.22.073 has been cancelled and replaced by new part no. 104.04.22.087 & 104.04.22.086 respectively. Drawings & technology for both the new parts are not available. On LPT Nose, part no. 104.04.22.063, angular drilling carried out on bearing dimension has been cancelled. New TR added for ensuring the fitting diameter after heat treatment. For oil collector part no. 104.04.00.030, diameter of jet changed from dia. 1.85 to dia. 2.04mm.

Ref .: DCN No. -4719, 4720, -4721, -4722, 4723, -4724, -4729, -4730

As per OEM letter no. 60/4-691 dated 31.12.13, technological change notice will be forwarded in Feb14.
CLARIFICATION:
1.Whether these change notices to be carried out for Overhaul or not? If required, the detail technology to be accessed & if already in vogue, the process to be witnessed. Further commitment for implementation of the change notice for both mfg. & ROH programme to be obtained. 2. Whether any change to be carried out for HPT nose for flow of oil. 3. The total flow increased to 12.114 ltr/min. But the rig no. EY-700 being used for measuring flow is having max. capacity of 13 ltr/min. Whether any other / alternate Rig is being used at OEM for measuring the flow. 4. What is the type of change (material, dimension) in post- mod bearing. What is the salvage method for existing pre mod bearings. 5. Date of incorporation of the change notice for Phase-III engines to be supplied to HAL, Koraput. 6. To provide test result of engine where the said change notice had been implemented at OEM.

DETAILS OF MODIFICATION : DOCUMENTS NOT RECEIVED FROM OEM

Sl. No. Recommendation EDC for receipt of Documents From OEM

Introduce spectral method of vibration diagnostics during first test on Test Bed.

Feb2014

CLARIFICATION: Status of implementation of the change notice at OEM.

ADDITIONAL POINTS

12

OVERHAUL POINTS
SL
1

BRIEF POINTS
Crack on compensating holes of HPT NGV Part no. : 104.04.03.060/060-01 Book-13, Sub-section : 072.50.01 Shop no. : 615

BRIEF DESCRIPTION / CLARIFICATION

As per overhaul technology, crack upto 3mm is permitted on compensating slots of HPT NGV. Reply has been received from OEM vide letter no. 60/4-658 dated 16.12.2013 for forwarding of further statistics regarding cracks beyond 3mm observed on HPT NGV in overhaul engines. As per above mentioned letter 30 engines (TBO 750 .1000 hrs.) were overhauled at OEM from 2010 to 2013. During discussion with Mr. Permyakov at HAL, Koraput on 21.01.14, it was clarified that during overhauling of engines at OEM, no cracks beyond 3mm is observed on HPT NGV. To see the data ad check overhaul NGV (if available) at OEM. 19 cases of oil leakage from AAGB were reported. It may be noted that in all the AAGB, mentioned change notices have already been implemented. Letter had been sent to OEM vide reference HAL/KPT/UPP/12-4/2/2013/880 dt. 13.12.2013 for the same. What is the reason fro failure of gaskets. Whether similar defects are observed at OEM. As per discussion with MR. Permyakov on 21.01.14 at HAL, Koraput new change notice regarding tightening of AAGB cover nuts after 10 hrs. of curing time will be provided to HAL, Koraput by Feb2014. Whether any changes as suggested being followed at OEM. Drill jig no. E6302-5787 is not suitable for locating the component and carrying out drilling operation. The jig is used for manufacturing purpose and not suitable during overhaul. New jig no. E6304-37056 was forwarded to HAL, Koraput for dong the re-work. To see whether the same jig or any local jig is being used at OEM for carrying out re-work. During overhaul, it is observed that Stem mesh fitted in Hydraulic filter (11CH-1) is broken in Filter assembly 96.10.10.000. Overhaul technology doesnt call for any re-work scheme. This part is getting rejected continuously in all the overhaul engines. To see whether similar defects are observed at OEM. If observed, what is the re-work practice being followed at OEM.

19 cases of AAGB leak cases noticed. Shop no. : 620

104.16.16.060 External Flap, Shop no. : 609 Book no. : 26, Part no. : 2 Sub-section : 072.55.04 T.K. No. : 432, Page : 414/1 Wire Stem mesh breakage Detail Part number : 11CH-1 NA Part Number : 96.10.10.000 Album no : A-05107 OHT-A31-023 Shop no. : 614

13

MANUFACTURING POINTS
SL
1

BRIEF POINTS
Dimensional difference between measurement before and after heat treatment operation on HPT disc, LPT nose, LPT disc HPT Disc, 104.04.02.008, A-01337, Inv No. 8189 LPT Disc, 104.04.22.028, A-01354, Inv No. 7328 LPT Nose, 104.04.22.063, A-01360, Inv. No. 7647 Shop no. : 610 96.01.32.140/140-01 A-00321, Inv No. 5507 96.01.32.150/150-01/150-02 A-00322, Inv No. 5508 96.01.32.160/160-01/160-02 A-00323, Inv No. 5509 Shop no. : 615 Non-uniform nitriding depth during ion-nitriding process of part no. 104.06.30.008-1 (Gear), Album no. : A-06390, Part no. 104.06.30.013 (Roller), Album no. : A-06390, 104.01.31.018 (Quill shaft), Album no. : A-06243 Shop no. : 603

BRIEF DESCRIPTION / CLARIFICATION

Machining of HPT disc, LPT Disc and LPT nose had been carried out as per technology and dimensions were checked as per intermediate inspection. But it is observed that after heat treatment operation, dimensional deviations on certain diameters are observed on the components. For LPT disc, dimensional variation is observed on the machine and off the machine during CNC turning operation no. 52040 & 52050. During discussion with Mr. Permyakov at HAL, Koraput on 21.01.14 it was clarified that change notices will be forwarded to HAL, Koraput during March2014. Whether the change notives already implemented at OEM or not.

As per recommendation given by OEM specialist, before brazing of sectors spot tack welding on joints of blades on upper and lower platform are to be carried out in Glove chamber. Whether the same practice is being followed at OEM before brazing operation.

While carrying out ion-nitriding process on part nos. 104.06.30.008-1 (Gear), 104.06.30.013 (Roller), 104.01.31.018 (Quill shaft), non-uniform nitriding depth had been observed on the parts (please refer letter no. HAL/KPT/UPP/124/2/2013/ 920 dated 26.12.13). It is requested to clarify the following points : The reason for increase / non-uniformity of ion nitrding layers. Study of the ion nitriding process and rectification if any to be carried out during the process. Please forward the programme details as mentioned in the technology

14