Repair_Standard_for_the_LM2500_HSCS_Mar_2017.pdf

Repair Standard for the LM2500

High Speed Coupling Shaft (HSCS)

Rev: 3/2017

1 PURPOSE

2 SCOPE

3 PROCEDURE

3.1 Disassembly

3.2 Cleaning

3.3 Non Destructive Testing (NDT)

3.4 Mechanical Inspection

3.5 Repair

3.6 Balancing

3.7 Reassembly

3.8 Markings

3.9 Storage Preparation

Appendix A: HSCS Parts Breakdown

Appendix B: Inspection Drawings

1 PURPOSE

This document defines the general procedure for recertification of the LM2500 High Speed Coupling Shaft Assembly. The procedures detailed are for the purposes of determining the disposition, continued use and repair or replacement as part of the recertification. Although this procedure can be applied to alternative designs, this procedure applies to p/n L21733G11.

2 SCOPE

This document will detail the procedures and specifications for performing the mechanical inspection, metallurgical evaluation, disposition of components and hardware based on the evaluation and final balance and marking details. The procedures included in this document are intended to guide prospective qualified entities in performing the necessary tasks to recertify an LM2500 HS coupling shaft assembly for continued use.

3 PROCEDURE

3.1 Disassembly

3.1.1 Prior to uncrating the material and beginning the disassembly procedures, make note of any obvious anomalies and or damage caused by transporting the material.

3.1.2 Prior to disassembly, match mark all mating components as visible. On the first components to be removed, match mark the anti-deflector ring (#3) and distance piece (#17). As each component is removed, match marks should be applied to each component in relation to the location of the distance piece. These would include the forward adapter (#1), flexible couplings (#2), diaphragm damper (#23), flexible coupling (#24), aft adapter (#25).

3.1.3 Make note of any obvious anomalies as components as removed from the shaft assembly.

3.1.4 Removal of the slabbed head or ‘D’ head bolts, ref item #’s 4, 5, 11, 12, will require special tooling in order to separate the flexible couplings (#2 & #24). Care should be taken so that the coupling flanges are not separated by more than an estimated .60”.

Also note that there are (2) different size bolts; 3/8-24” and 7/16-20”, with (2) different shank lengths.

3.2 Cleaning

3.2.1 All components should be thoroughly cleaned in preparation for non-destructive testing. This would include any coatings still present and or surface rust, scale, etc.

Any residue present can hinder the effectiveness of the NDT process. Acceptable cleaning methods are as follows:

3.2.1.1 Glass Bead Blast; recommended media is MIL-PRF-9954 or equivalent. This cleaning method to be used on all components with the exception of the flexible couplings (#2 & 24) and the forward adapter (#1)

3.2.1.2 Hand cleaning with a mild solvent such as alcohol is the recommended method for the flexible couplings and forward adapter components.

3.3 Non Destructive Testing (NDT)

3.3.1 All major components to be undergo nondestructive testing (NDT) to determine material integrity to include the following items; 1, 2, 3, 17, 23, 24, & 25. Any indications will deem components unusable for continued service and must be replaced.

3.3.1.1 The following components are to be tested via florescent penetrant method per ASTM E1417; forward adapter (#1), flexible couplings (#2, 24).

3.3.1.2 The following components are to be tested via magnetic particle indication (MPI) per ML-STD-4907B; anti-deflector ring (#3), distance piece (#17), diaphragm damper (#23), aft adapter (#25), piston plate damper (#27), piston ring damper (#28), piston plate damper spacer (#29)

3.3.1.3 All hardware items; bolts, washers, nuts, retaining rings will be replaced and not undergo NDT; items include #4, 5, 6, 7, 9, 11, 12, 13, 14, 15, 19, 21, 22, 26, 30.

3.4 Mechanical Inspection

3.4.1 All major components to undergo mechanical (dimensional) inspection. This will also include notation of visual condition. Per Appendix B, all dimensional requirements are noted in absence of detailed OEM drawings. The results of the mechanical inspection along with NDT results to be documented on the L21733G11_Inspection_Drawing.

3.4.2 All hardware as noted in section 3.4.1.3 will be replaced. Any anomalies should be documented as required.

3.4.3 Any anomalies noted during the mechanical inspection to be reviewed and reported to end user for disposition.

3.4.4 All documented results to be summarized on evaluation report to be submitted to end user.

3.5 Repair

3.5.1 All repair recommendations to be performed as noted. In general, the only approved repairs will be minor hand work to smooth nicks and dings and polishing of components as needed. Any machining work proposed to be approved by NSWCPD.

3.5.2 Retap of thread holes is acceptable to clean or deburr as required.

3.6 Balancing

3.6.1 The LM2500 HS Shaft Assembly is to be balanced in accordance with API-671 4th edition; method #3 per section 9.2.3. Residual unbalance in accordance with 9.3.5 for the component balance and section 9.3.7 for the assembly balance specifications.

The following general procedures should apply to balance processes.

3.6.1.1 The component balance required should be for both flexible couplings (#2 & 24), distance piece (#17) and the aft adapter subassembly which includes items #23, 26, 27, 28, 29 &30. Component balance not required for forward adapter (#1), anti-deflector ring (#3) and diaphragm adapter (#23) unless material is removed or the component is otherwise altered.

3.6.1.2 The flexible couplings must be retrained using special tooling to restrict movement during component and assembly balance. Caution as referred to during assembly as noted in section 3.8.1.1.

3.6.1.3 All hardware to be weigh balanced in accordance with API-671 4th edition section 9.3.4 to include items #4, 5, 9, 11, 12, 15, 19, and 22. The only exception is hardware items # 28 & 30 which are balanced as a subassembly with the aft adapter. Items #6, 7, 13, 14 and 21 are not required to be balanced prior to assembly.

3.7 Reassembly

3.7.1 After completion of the repair scope as documented, the components will be reassembled. In general, the procedure will be the reverse of the disassembly of the shaft assembly. Prior to assembly, all components should be marked with the OEM part number. This can be done via ink stencil or light pen etching. The following steps should be noted for reassembly.

3.7.1.1 When installing the slabbed head (D head) bolts, caution should be taken to not spread the flanges of the flexible couplings (#2 & 23) beyond .600”.

3.7.1.2 Make sure that the push on nuts or retainer rings, item #6 and 13), are seated properly so that the slabbed bolts are tight on the flexible couplings to limit them from being displaced. Care should be taken to install the forward adapter (#1), anti-deflection ring (#3) and distance piece (#17) to the flexible coupling on the forward side. The same is true for installing the diaphragm damper (#23), aft adapter (#25) and distance piece (#17) to the flexible coupling on the aft side.

3.7.1.3 In the event that a slabbed head (D head) bolt is dislodged, it can be reseated by turning and pulling forward the bolt until it is seated.

3.7.1.4 All locknuts to be torqued to the following specifications: ¼” nuts to 192 in-lbs; 3/8” nuts to 350 in-lbs; 7/16” nuts to 400 in-lbs; 5/8” nuts to 1,080 in-lbs.

3.7.1.5 Torque pattern of slabbed head (D Head) bolts to be criss-cross, 180 deg at a time.

3.7.1.6 The entire shaft assembly is to be assembled for shipment

3.8 Markings

3.8.1 As noted prior to assembly, each component is to be marked with the OEM part number.

3.8.2 Alignment match mark as follows:

3.8.2.1 1A: distance piece (#17) to flexible coupling (#2)

3.8.2.2 2A: flexible coupling (#2) to forward adapter (#1)

3.8.2.3 3A: anti-deflector ring (#3) to distance piece (#17

3.8.2.4 1B: diaphragm damper (#23) to flexible coupling (#24)

3.8.2.5 2B: flexible coupling (#24) to aft adapter (#25)

3.8.2.6 3B: aft adapter (#25) to distance piece (#17)

3.9 Storage Preparation

3.9.1 After assembly, the entire exposed coupling shaft assembly should be coated with Molykote Metal Protector, Dow Corning Corp, or equivalent.

3.9.2 After the Molykote product is applied, the entire coupling shaft assembly will be vacuum packaged for shipment.

3.9.3 LM2500 HSCS to be shipped in custom wood crate; heat treated lumber and lined with wax paper.

Appendix A: HSCS Parts Breakdown

Appendix B: Inspection Drawings

Page intentionally left blank

D A

T E

9/

/2

R E

V .M ea su re d

R u n o u t

(f la n g e)

M ea su re d R u n o u t (e n d f ac e)

F la n g e H o le

D ev ia ti o n s:

S u rf ac e A n o m al ie s

N o te d

M ea su re d R u n o u t (s p lin e d ia

JL

W

IN

IT

IA

L

R E

L E

A S

E , R

E F

L M

H

IG

H S

P E

E D

C P

L G

A S

S Y

, L

3G

A

R E

V

IS

IO

N

D E

S C

R

IP

T

IO

N

JL

W

B Y

D W

G

JL

W

A D

A P

T E

R

F O

R W

A R

D C

O M

P O

N E

N T

D

R A

W N

9/

/2

R E

V

IT

E

M

D A

T E

1Q T

Y

O F

S

O

/1

5/

R E

L

R E

F C

O U

P

LI

N G

A S

S Y

L

M

H

IG

H

S P

E E

D C

P L

G , P

/N L

3G

4.

F la ng e H ol es

.3

5"

; a to ta l o f ( 6) h ol es m ay b e .0 ov er m ax s iz e, n o m or e th an

8)

L

7P

D A

T E

N O

T E

S

A

3.

F la ng e/ E nd F ac e/

D ia

R un ou t:

.0

1.

M at er ia l:

In co ne l

2.

N

D T

: F lo ur D ye P en et ra nt

T E

9/

/2

R E

V

A

S u rf ac e A n o m al ie s

N o te d

4.

F la ng e H ol es

.3

5"

; a to ta l o f ( 6) h ol es m ay b e .0 ov er m ax s iz e, n o m or e th an

8)

IT

E M

O

F

2.

N

D T

: F lo ur D ye P en et ra nt

/1

5/

R

E F

C O

U P

LI

N

G A

S S

Y

L M

H

IG

H S

P E

E D

C P

L G

, P /N

L

3G

3.

F la ng e

R un ou t:

.0 pe r fla ng e fa ce

Q T

Y

S

N

T E

S

R E

L

D W

G

L

0P

JL

W 1.

M at er ia l:

In co ne l D

A T

E

9/

/2

JL

W

D A

T E

C O

M P

O N

E N

T

C O

U P

L

IN

G F

L E

X

IB

L E

D

IA

P

H R

A G

M

F

R

W A

R D

A

IN

IT

IA

L R

E L

E A

S E

, R E

F L

M

H

IG

H

S P

E E

D C

P L

G A

S S

Y , L

3G

JL

W

D R

A W

N

M ea su re d R u n o u t (f la n g e

A

M ea su re d R u n o u t (f la n g e

B

F la n g e H o le

D ev ia ti o n s:

R E

V

R E

V

IS

IO

N

D E

S C

R

IP

T

IO

N B

Y

T E

9/

/2

A 4.

F la ng e

H ol es

.3

6"

.3

5" ; a to ta l o f (

6) h ol es m ay b e

.0 ov er m ax s iz e, n o m or e th an

8)

IT

E

M

O F

2.

N

D T

: M ag ne tic

P ar tic le

In sp ec tio n

/1 5/

R E

F C

O U

P

LI

N G

A S

S Y

L

M

H

IG

H

S P

E E

D C

P L

G , P

/N L

3G

3.

F la ng e R un ou t:

.0

Q T

Y

S

R E

V

N O

T E

S

R E

L

D W

G

L

0P

JL

W 1.

M at er ia l:

Lo w C ar bo n S te el

D A

T E

9/

/2

JL

W

D A

T E

C O

M P

O N

E N

T

R

IN

G , A

N T

I- D

E F

L E

C T

O R

A

IN

IT

IA

L R

E L

E A

S E

, R E

F L

M

H

IG

H

S P

E E

D C

P L

G A

S S

Y , L

3G

JL

W

D R

A W

N

M ea su re d R u n o u t (f la n g e

A

F la n g e H o le

D ev ia ti o n s:

S u rf ac e A n o m al ie s

N o te d

R E

V

R E

V

IS

IO

N

D E

S C

R

IP

T

IO

N

T E

9/

/2

R E

V

A

F la n g e H o le

D ev ia ti o n s:

4.

F la ng e H ol es

.3

6"

.3

5"

; a to ta l o f ( 6) h ol es m ay b e .0 ov er m ax s iz e, n o m or e th an

8)

IT

E M

O

F

2.

N

D T

: M ag ne tic

P ar tic le

In sp ec tio n

/1 5/

R E

F C

O U

P

LI

N G

A S

S Y

L

M

H

IG

H

S P

E E

D C

P L

G , P

/N L

3G

3.

F la ng e R un ou t:

.0

Q T

Y

S

T E

S

R E

L

D W

G

L

3G

JL

W 1.

M at er ia l:

Lo w C ar bo n S te el

D A

T E

9/

/2

JL

W

D A

T E

C O

M P

O N

E N

T

D

IS

T A

N C

E P

IE

C

E A

IN

IT

IA

L

R E

L E

A S

E , R

E F

L M

H

IG

H S

P E

E D

C P

L G

A S

S Y

, L

3G

JL

W D

R A

W N

M ea su re d R u n o u t (f la n g e

A

M ea su re d R u n o u t (f la n g e

B

S u rf ac e A n o m al ie s

N o te d

R E

V

R E

V

IS

IO

N

D E

S C

R

IP

T

IO

N

T E

9/

/2

A 4.

F la ng e

H ol es

.3

6"

.3

5" ; a to ta l o f (

6) h ol es m ay b e

.0 ov er m ax s iz e, n o m or e th an

8)

IT

E

M

O F

2.

N

D T

: M ag ne tic

P ar tic le

In sp ec tio n

/1 5/

R E

F C

O U

P

LI

N G

A S

S Y

L

M

H

IG

H

S P

E E

D C

P L

G , P

/N L

3G

3.

F la ng e R un ou t:

.0

Q T

Y

S

V

N O

T E

S

R E

L

D W

G

L

4P

JL

W 1.

M at er ia l:

Lo w C ar bo n S te el

D A

T E

9/

/2

JL

W

D A

T E

C O

M P

O N

E N

T

D A

M P

E R

R

IN

G A

IN

IT

IA

L

R E

L E

A S

E , R

E F

L M

H

IG

H S

P E

E D

C P

L G

A S

S Y

, L

3G

JL

W D

R A

W N

M ea su re d R u n o u t (f la n g e

A

F la n g e H o le

D ev ia ti o n s:

S u rf ac e A n o m al ie s

N o te d

R E

V

R E

V

IS

IO

N

D E

S C

R

IP

T

IO

N

T E

9/

/2

A 4.

F la ng e

H ol es

.3

6"

.3

5" ; a to ta l o f (

6) h ol es m ay b e

.0 ov er m ax s iz e, n o m or e th an

8)

IT

E

M

O F

2.

N

D T

: M ag ne tic

P ar tic le

In sp ec tio n

/1 5/

R E

F C

O U

P

LI

N G

A S

S Y

L

M

H

IG

H

S P

E E

D C

P L

G , P

/N L

3G

3.

F la ng e R un ou t:

.0

Q T

Y

S

V

N O

T E

S

R E

L

D W

G

L

9P

JL

W 1.

M at er ia l:

Lo w C ar bo n S te el

D A

TE

9/

/2

JL

W

D A

TE

C O

M P

O N

E N

T

D

IA

P H

R A

G M

D A

M P

E R

A

IN

IT

IA

L R

E L

E A

S E

, R E

F L

M

H

IG

H

S P

E E

D C

P L

G A

S S

Y , L

3G

JL

W

D R

A W

N

M ea su re d R u n o u t (f la n g e

A

F la n g e H o le

D ev ia ti o n s:

S u rf ac e A n o m al ie s

N o te d

R E

V

R E

V

IS

IO

N

D E

S C

R

IP

T

IO

N

T E

9/

/2

A 4.

F la ng e

H ol es

.3

5" ; a to ta l o f (

6) h ol es m ay b e

.0 ov er m ax s iz e, n o m or e th an

8)

IT

E

M

O F

2.

N

D T

: F lo ur D ye P en et ra nt

/1

5/

R

E F

C O

U P

LI

N

G A

S S

Y

L M

H

IG

H S

P E

E D

C P

L G

, P /N

L

3G

3.

F la ng e

R un ou t:

.0 pe r fla ng e fa ce

Q T

Y

S

V

N O

T E

S

R E

L

D W

G

L

0P

JL

W 1.

M at er ia l:

In co ne l D

A T

E

9/

/2

JL

W

D A

T E

B Y

C O

M P

O N

E N

T C

O U

P L

IN

G

F L

E X

IB

L

E

D

IA

P H

R A

G M

A

F T

A

IN

IT

IA

L R

E L

E A

S E

, R E

F L

M

H

IG

H

S P

E E

D C

P L

G A

S S

Y , L

3G

JL

W

D R

A W

N

M ea su re d R u n o u t (f la n g e

A

M ea su re d R u n o u t (f la n g e

B

F la n g e H o le

D ev ia ti o n s:

S u rf ac e A n o m al ie s

N o te d

R E

V

R E

V

IS

IO

N

D E

S C

R

IP

T

IO

T E

9/

/2

A 4.

F la ng e

H ol es

.3

5" ; a to ta l o f (

6) h ol es m ay b e

.0 ov er m ax s iz e, n o m or e th an

8)

IT

E

M

O F

2.

N

D T

: M ag ne tic

P ar tic le

/1

5/

R

E F

C O

U P

LI

N

G A

S S

Y

L M

H

IG

H S

P E

E D

C P

L G

, P /N

L

3G

3.

F la ng e/

E nd

F ac e R un ou t:

.0

Q T

Y

S

V

N O

T E

S

R E

L

D W

G

L

8P

JL

W 1.

M at er ia l:

Lo w C ar bo n S te el l D

A T

E

9/

/2

JL

W

D A

T E

B Y

C O

M P

O N

E N

T

A D

A P

T E

R

A F

T A

IN

IT

IA

L

R E

L E

A S

E , R

E F

L M

H

IG

H S

P E

E D

C P

L G

A S

S Y

, L

3G

JL

W D

R A

W N

M ea su re d R u n o u t (f la n g e)

M ea su re d R u n o u t (e n d f ac e)

M ea su re d R u n o u t (s p lin e d ia

F la n g e H o le

D ev ia ti o n s:

S u rf ac e A n o m al ie s

N o te d

R E

V

R E

V

IS

IO

N

D E

S C

R

IP

T

IO

111 LM2500 Coupling Shaft (HSCS)