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diameter of the inner barrel had two un-containment locations at approximately the 6’O clock
location. Accurate dimensions could not be determined.
1.16.2 Seal Plate Lapping Process Review
After the strip examination of the involved engine S/N V0118 at JEOC, Air India, some of
the damaged engine parts were sent to NTSB (IAE/ Prat & Whitney), USA for detailed
metallurgical testing. The damaged engine parts like fractured HPT 1-2 seal and other
damaged parts were analysed for probable root cause of engine fire/failure. No. 4 seal plate
of engine # 2 (V0118) was analysed and it was observed that the weep grooves and holes of
the seal plate were mostly blocked with lapping debris. In order to confirm the same, on site,
lapping process review was carried out at JEOC overhaul shop by IAC Personnel.
Observations
A review of the shop processing procedures and records for a typical seal plate was
conducted. To accomplish this, a used seal plate was provided by IAE. The seal plate part
number was 2A3432, which is representative of a front seal plate used in the #4 compartment
in the V2500 engine. No serial number or other identification markings were present on this
seal plate. It was observed that the JEOC seal plate lapping process matches with the IAE
Engine Manual (EM) and Standard Practices Manual (SPM). The process sheet follower was
properly signed off as per standard JEOC procedures. The JEOC process sheets utilized
during this review were provided.
The entire lapping process was observed from beginning to end as per the JEOC process
sheets. Before lapping, the IAE supplied seal plate used in the review was processed through
the pre-lapping cleaning procedure. After this initial cleaning process, carbon and staining
were removed but the grooves had black residue remaining. See image #1.
After cleaning and prior to the lapping process, the subject seal seat was dimensionally and
visually inspected. Instead of performing a Magnetic Particle Inspection (MPI), JEOC
performs a Fluorescent Penetrant Inspection (FPI) via a waiver which was not documented,
granted by IAE. FPI was not carried out in the interest of time as this was a demonstration
article and was not germane to the intent of this process review. The seal seat was examined
for a chipped hard face condition, deep scratches or pits, and blocked oil slots.
The first step as per the process before physical lapping was to clean the table. This involved
wetting the table with a locally available product consistent with the EM recommendation,