Professional Documents
Culture Documents
Part-66
JAR 66 CATEGORY B1
MODULE 15
uk GAS TURBINE
engineering ENGINES
CONTENTS
1 FUNDAMENTALS ........................................................................ 1-1
1.1 WORK, POWER & ENERGY ...................................................... 1-1
1.1.1 Work ............................................................................. 1-1
1.1.2 Power............................................................................ 1-1
1.1.3 Energy .......................................................................... 1-2
1.2 FORCE AND MOTION ............................................................... 1-3
1.2.1 Force............................................................................. 1-3
1.2.2 Velocity ......................................................................... 1-3
1.2.3 Acceleration .................................................................. 1-4
1.3 PRINCIPLES OF JET PROPULSION ......................................... 1-4
1.3.1 Thrust Calculation. ........................................................ 1-4
1.4 GAS TURBINES ......................................................................... 1-6
1.5 THE BRAYTON CYCLE ............................................................. 1-7
1.6 CHANGES IN TEMPERATURE, PRESSURE AND VELOCITY . 1-9
1.6.1 Temperature and Pressure ........................................... 1-9
1.6.2 Velocity and Pressure ................................................... 1-10
1.6.3 How The Changes are Obtained. ................................. 1-10
1.7 DUCTS AND NOZZLES ............................................................. 1-10
Continuity equation. .................................................................... 1-10
1.7.2 Incompressible fluid flow. .............................................. 1-11
1.7.3 Bernoulli’s Theorem ...................................................... 1-11
1.7.4 Total energy. ................................................................. 1-12
1.8 CONTINUITY EQUATION AND BERNOULLI’S THEOREM ....... 1-13
1.8.1 Incompressible fluid. ..................................................... 1-13
1.8.2 Gas Laws ...................................................................... 1-15
1.9 SUBSONIC AIRFLOW THROUGH DIVERGENT AND CONVERGENT DUCTS 1-
16
Divergent Duct ............................................................................ 1-16
1.9.2 Convergent Duct ........................................................... 1-16
SONIC AIRFLOW THOUGH DIVERGENT AND CONVERGENT DUCTS 1-17
1.11 THE WORKING CYCLE ON A PRESSURE VOLUME DIAGRAM 1-18
1.12 ENGINE CONFIGURATIONS. .................................................... 1-19
1.12.1 Reaction engines .......................................................... 1-19
1.12.2 Power Engines .............................................................. 1-21
2 ENGINE PERFORMANCE ........................................................... 2-1
2.1 METHOD OF CALCULATING THE THRUST FORCES ............. 2-1
2.2 CALCULATING THE THRUST OF THE ENGINE ....................... 2-2
2.2.1 Comparison between thrust and horse-power ............... 2-6
2.3 ENGINE THRUST IN FLIGHT .................................................... 2-7
2.3.1 Effect of forward speed ................................................. 2-9
2.3.2 Effect of afterburning on engine thrust........................... 2-11
2.3.3 Effect of altitude ............................................................ 2-11
2.3.4 Effect of temperature..................................................... 2-13
2.4 PROPULSIVE EFFICIENCY ....................................................... 2-14
1 FUNDAMENTALS
1.1 WORK, POWER & ENERGY
Work, power, and energy are all interrelated. Work is the amount of movement a
given force causes; energy is the ability to do work, and power is the rate of doing
work.
1.1.1 WORK
In its technical sense, work is the product of force and distance, and work is done
only when a force causes movement. We can see this by the formula:
Work = Force x Distance
We normally measure distance in feet or inches, and force in pounds or ounces.
This allows us to measure work in foot-pounds or inch-ounces.
Example:
To find the amount of work done when a 500 pound load is lifted for a distance of
6 feet, we can use the formula:
Work = Force x Distance
= 500 X 6
= 3,000 foot-pounds
1.1.2 POWER
The rate of doing work is called power, and it is defined as the work done in unit
time. As a formula, this would be:
power = work done
time taken
Power is expressed in several different units, such as the watt, ergs per second,
and foot-pounds per second. The most common unit of power in general use in
the United States is the horsepower. One horsepower (hp) is equal to 550 ft-lb’s
or 33000 ft-1b/min. In the metric system the unit of power is the watt (W) or the
kilowatt (kW). One hp is equal to 746 watts; and 1 kW = 1.34 hp.
Example:
To compute the power necessary to raise an elevator containing 10 persons a
distance of 100 ft in 5 s (assuming the loaded elevator weighs 2500 lb), proceed
as follows:
Power = work done = 2500 x 100 = 50,000 ft-lb’s/sec
Time taken 5
1.1.3 ENERGY
The term energy may be defined as the capacity for doing work. There are two
forms of energy: potential energy and kinetic energy.
1.1.3.1 POTENTIAL ENERGY
Potential energy is the stored energy possessed by a system, because of the
relative positions of the components of that system. If work done raises an object
to a certain height, energy will be stored in that object in the form of the
gravitational force. This energy, waiting to be released is called potential energy.
The amount of potential energy a system possesses is equal to the work done on
the system previously.
Potential energy can be found in forms other than weights and height. Electrically
charged components contain potential (electrical) energy because of their position
within an electric field. An explosive substance has chemical potential energy that
is released in the form of light, heat and kinetic energy, when detonated.
Example :
A weight of 50 pounds is raised 5 feet. Using the formula:
Potential Energy = Force x Distance
= 50 x 5
= 250 ft-lb’s.
Note: That energy is expressed in the same units as those used for work and in all
cases energy is the product of force x distance.
1.1.3.2 KINETIC ENERGY
Kinetic energy is the energy possessed by an object, resulting from the motion of
that object. The magnitude of that energy depends on both the mass and speed
of the object. This is demonstrated by the simple equation:
Energy =½mv2 or w v2
2g
where m = mass, v = velocity (in feet or metres per second), w = weight, g =
gravity (32 ft/sec2 or 9.81m/sec2).
All forms of energy convert into other forms by appropriate processes. In this
process of transformation, either form of energy can be lost or gained but the total
energy must remain the same.
Example:
A weight of 50lbs dropped from a height of 5 ft has kinetic energy of
KE = 50 x 25
2 x 32
= 19.53 ft-lb’s
Path of Aircraft
B
A C
1.2.3 ACCELERATION
This term describes the rate at which velocity changes. If an object increases in
speed, it has positive acceleration; if it decreases in speed, it has negative
acceleration. A reference to Newton's Second law of Motion will explain the
principles of acceleration. Acceleration can be in a straight line, which is referred
to a linear acceleration and it can apply to rotating objects whose speed of rotation
is increasing, (or decreasing), when it is called angular acceleration.
1.3 PRINCIPLES OF JET PROPULSION
the acceleration of the mass is proportional to the force applied: second law,
there must be an equal and opposite reaction, in our case this is THRUST, a
forward acting force: third law.
1.3.1 THRUST CALCULATION.
The amount of thrust produced depends upon two things:-
If we let: -
V2 = the air velocity at exit (in ft/sec/sec or 9.81m/sec2)
and
V1 = the air velocity at inlet (in ft/sec/sec or 9.81m/sec2)
It may be expressed as V2 – V1
Taking these expressions for Mass and Acceleration, the thrust produced by an
engine or propeller can be calculated from the following formula:-
THRUST =
W
V2 - V1
g
Example 1.
The airflow through a propeller is 256 lbs/sec, Inlet velocity 0 ft/sec, outlet velocity
700 ft/sec.
Thrust developed will be:
THRUST =
W
V2 - V1
g
THRUST = 256 x (700 – 0)
32
= 5600 lbs
Example 2.
The mass airflow through a gas turbine engine is 128lbs/sec, inlet velocity is 0
ft/sec, outlet velocity is 1400 ft/sec. Using the formula :
THRUST = 128 x (1400 – 0)
32
= 5600lbs
By comparing both examples, you can see that the gas turbine produced the same
thrust as the propeller by giving a greater acceleration to a smaller mass. It can
be said that a propeller accelerates a large mass slowly whilst the gas turbine
produces the same thrust by giving a greater acceleration to a smaller mass.
Note that in both of the examples the inlet velocity was zero ft/sec. The aircraft
was stationary so the thrust produced is referred to as STATIC THRUST.
Duct System
Figure 1.7.
Kinetic energy.
This kind of energy is more often called ‘dynamic pressure’ and this term is used
to define the extra pressure created by the movement of the medium. Dynamic
pressure is proportional to ½ mass x velocity 2 (ie. ½mv2).
When the medium (gas or fluid) is moving, the total energy = static pressure +
dynamic pressure.
Consider a duct which is filled with an incompressible fluid and pressurised from
one end by an external force (Fig 1.8.). The other end of the duct is sealed by a
valve, which can be opened or closed, and a pressure gauge is fitted into the wall
of the duct to indicate the static pressure (PS). With the valve closed, static
pressure and total energy are the same. However, when the valve is opened to
allow a fluid flow, the circumstances changes and, although the total energy must
remain the same, it now consists of static pressure + dynamic pressure. As the
velocity V increases, so dynamic pressure increases and the static pressure is
reduced.
In a situation where there is a no fluid flow, the static pressure (PS) gauge, and the
total head pressure (PT) gauge will show the same value, but when there is a fluid
flow, the total pressure reading remains the same although the static pressure
drops.
Diffuser Section
Figure 1.12.
A divergent duct widens out as the airflow progresses through it. At subsonic
speeds the effect of this kind of duct is to decrease the velocity and increase the
pressure and temperature of the air passing through it.
Divergent Duct.
Figure 1.13.
A convergent duct is such that the space inside reduces as the airflow progresses
through it. At subsonic speeds the effect of this kind of duct is to increase the
velocity and decreases the pressure and temperature of the air passing through it.
Convergent Duct.
Figure 1.14.
When a flow of fluid (i.e. gas) flows at sonic speed through a convergent duct a
shock wave forms at the exit area of the duct - The exit area is said to be choked.
The shock wave forms a restriction to the fluid and pressure will increase,
temperature will increase and velocity will decrease.
A Con-Di Nozzle
Figure 1.14.
When a gas flow reaches sonic velocity in a convergent duct the nozzle will choke
and the pressure will increase. To prevent a pressure rise that would eventually
prevent a 'fluid' flow and completely choke the duct a divergent section is added
making the duct convergent/divergent (Con/DI). The pressure of gas released into
the divergent section of the nozzle causes the velocity of the 'fluid' to increase,
pressure to decrease, and therefore temperature to decrease. Gas pressure acts
on the walls of the divergent section, this pressure gives additional thrust that is
known as pressure thrust.
Air is drawn from the atmosphere (Ambient Air) into the compressor. The
compressor raises the pressure of the air (A to B) on diagram. If the pressure of
the air is increased the volume is decreased. The air passes to the combustion
system and heat is added by burning fuel with a proportion of the air. From the
diagram (B to C) it is seen that combustion takes place at constant pressure so the
gas turbine working cycle is known as the constant pressure cycle. In the
combustion system the air expands rearwards and the volume of the gas
increases and the gas kinetic energy increases. The gas flow passes to the
turbine section to drive the turbine (s), energy is extracted and the pressure
decreases. The gas passes via an exhaust unit to the propelling nozzle which
forms a convergent duct. The velocity of the gas increases. The reaction to the
high velocity jet produces thrust (C to D on diagram).
b. Low and Medium By-pass or turbofan engines. These engines will have two or
three shafts. The Low Pressure (LP) shaft drives a larger diameter compressor.
Some of the air produced by-passes the core engine (hence the name) and is
used to provide thrust. The core airflow provides power for the compressors
and thrust. These engine are quieter than turbojets and more fuel efficient. The
Spey and Tay engines fall into this category.
The by-pass ratio is determined by the ratio of the air in flowing through the by-
pass to the air passing through the core of the engine. Low by-pass less than
2:1, medium by-pass 2:1 to 4:1, high by pass greater than 5:1.
Turboprop Engines
Figure 1.19.
There are other types of engine such as ram jets, pulse jets, turbo-ram jet and
turbo - rockets, but none of these are used commercially if at all.
2 ENGINE PERFORMANCE
2.1 METHOD OF CALCULATING THE THRUST FORCES
The thrust forces or gas loads can be calculated for the engine, or for any flow
section of the engine, provided that the areas, pressures, velocities and mass flow
are known for both the inlet and outlet of the particular flow section.
The distribution of thrust forces shown in Fig 2.1. can be calculated by considering
each component in turn and applying some simple calculations. The thrust
produced by the engine is mainly the product of the mass of air passing through
the engine and the velocity increase imparted to it (ie. Newtons Second Law of
Motion), however the pressure difference between the inlet to and the outlet from
the particular flow section will have an effect on the overall thrust of the engine and
must be included in the calculation.
FORWARD GAS LOAD 57836 lbs REARWARD GAS LOAD 46678 lbs
TOTAL THRUST 11158 lbs
153 406
= (182 94) 0
32
= 19,049lb. of thrust in a forward direction.
Choked Nozzle
Considering the formula for thrust under “choked” nozzle conditions:
Wv J
Thrust = ( P P0 )A +
g
Where: P = Pressure
P = Ambient Pressure
A = Area
W = Mass Flow
V = Velocity
It can be seen that the thrust can be further affected by a change in the mass flow
rate of air through the engine and by a change in jet velocity. An increase in mass
airflow may be obtained by using water injection to cool the air and increases in jet
velocity by using after-burning.
Changes in ambient pressure and temperature considerably influence the thrust
of the engine. This is because of the way they affect the air density and hence the
mass of air entering the engine for a given engine rotational speed.
Thrust Correction - Turbojet
To enable the performance of similar engines to be compared when operating
under different climatic conditions, or at different altitudes, correction factors must
be applied to the calculations to return the observed values to those which would
be found under I.S.A. conditions. For example, the thrust correction for a turbo-jet
engine is:
30
Thrust (lb) (corrected) = thrust (lb) (observed) x
PO
Where P0 = atmospheric pressure in inches of mercury (in Hg)
(observed)
30 = I.S.A. standard sea level pressure (in Hg)
Shaft Horsepower Correction - Turboprop
The observed performance of the turbo-propeller engine is also corrected to I.S.A.
conditions, but due to the rating being in s.h.p. and not in pounds of thrust the
factors are different. For example, the correction for s.h.p. is:
30 273 15
S.h.p. (corrected) = s.h.p. (observed)
PO 273 TO
Where P0 = atmospheric pressure (in Hg) (observed)
T0 = atmospheric temperature in deg. C (observed)
30 = I.S.A. standard sea level pressure (in Hg)
273 + 15 = I.S.A. standard sea level temperature in deg. K
273 + T0 = Atmospheric temperature in deg. K
Since one horse-power is equal to 550ft.lb. per sec. and 550 ft. per sec. is
equivalent to 375 miles per hour, it can be seen from the above formula that one
lb. of thrust equals one t.h.p. at 375 m.p.h. It is also common to quote the speed
in knots (nautical miles per hour); one knot is equal to 1.1515 m.p.h. or one pound
of thrust is equal to one t.h.p. at 325 knots.
Thus if a turbo-jet engine produces 5,000 lb. of net thrust at an aircraft speed of
5,000 600
600 m.p.h. the t.h.p. would be 8,000
375
However, if the same thrust was being produced by a turbo-propeller engine with a
propeller efficiency of 55 percent at the same flight speed of 600 m.p.h., then the
100
t.h.p. would be: 8,000 14,545
55
Thus at 600 m.p.h. one lb. of thrust is the equivalent of about 3 t.h.p.
2.3 ENGINE THRUST IN FLIGHT
Since reference will be made to gross thrust, momentum drag and net thrust, it will
be helpful to define these terms:
Gross or total thrust is the product of the mass of air passing through the engine
and the jet velocity at the propelling nozzle, expressed as:
Wv J
( P P0 )A +
g
The momentum drag is the drag due to the momentum of the air passing into the
WV
engine relative to the aircraft velocity, expressed as where:
g
W = Mass flow in lb. per sec.
V = Velocity of aircraft in feet per sec.
G = Gravitational constant 32.2 ft. per sec. per sec.
WVJ
Momentum Thrust
WV wv g
Momentum Drag Gross Thrust ( P Po ) A J
g g Pr essure Thrust ( P PO ) A
The net thrust or resultant force acting on the aircraft in flight is the difference
between the gross thrust and the momentum drag. From the definitions and
formulae stated earlier under flight conditions, the net thrust of the engine,
W Vj V
simplifying, can be expressed as: P Po A
g
All pressures are total pressures except P which is static pressure at the propelling
nozzle
W = Mass of air passing through engine (lb. Per sec.)
VJ = Jet velocity at propelling nozzle (ft. per sec)
P = Static pressure across propelling nozzle (lb. Per sq. in)
PO = Atmospheric pressure (lb. Per sq. in)
A = Propelling nozzle area (sq. in)
V = Aircraft speed (ft. per sec.)
G = Gravitational constant 32.2
The Balance of Forces and Expression for Thrust and Momentum Drag.
Figure 2.4.
3 INLET
3.1 INTRODUCTION
An air intake should deliver air to the engine compressor with a minimum loss of
energy and at a uniform pressure under all engine operating conditions. The inlet
duct is built in the shape of a subsonic divergent diffuser, so that the kinetic energy
of the rapidly moving air can be converted into a ram pressure rise within the duct.
This condition is referred to as “Ram Recovery”.
3.2 RAM COMPRESSION
The degree of Ram Compression depends upon the following:-
i. Frictional losses at those surfaces ahead of the intake entry which are
“wetted” by the intake airflow.
ii. Frictional losses at the intake duct walls.
iii. Turbulence losses due to accessories or structural members located in the
intake.
iv. Aircraft speed.
v. In a turbo-prop, drag and turbulence losses due to the prop blades and
spinner.
Ram compression causes a re-distribution in the forms of energy existing in the
air-stream. As the air in the intake is slowed up in endeavouring to pass into and
through the compressor element against the air of increasing pressure and density
which exists therein so the kinetic energy of the air in the intake decreases. This
is accompanied by a corresponding increase in its pressure and internal energies
and consequently compression of the air-stream is achieved within the intake, thus
converting the unfavourable intake lip conditions into the compressor inlet
requirements.
Although ram compression improves the performance of the engine, it must be
realised that during the process there is a drag force on the engine and hence the
aircraft. This drag must be accepted since it is a penalty inherent in a ram
compression process. (The added thrust more than makes up for this drag).
3.2.1 IMPORTANCE OF RAM COMPRESSION
At subsonic flight speeds, the ram pressure ratio is apparently quite small, say
1.33: 1 at 0.8M. Nevertheless, since the pressure rise due to ram compression is
multiplied by the pressure ratio of the compressor, the ram pressure rise becomes
significant even at subsonic speeds.
Furthermore, the greater the forward speed of the aircraft becomes, the more
significant is the ram compression; e.g. at 1.5M the ram pressure ratio may be
about 3.5 : 1, and at 2.5M about 8 : 1.
The pitot type intake can be used for engines that are mounted in pods or in the
wings although the latter sometimes requires a departure from the circular cross
section due to the wing thickness.
On a single engine aircraft with fuselage mounted engines, either a wing root inlet
or a side scoop inlet may be used. The wing root inlet presents a problem to
designers in the forming of the curvature necessary to deliver the air to the engine
compressor. The side scoop inlet is placed as far forward of the compressor as
possible to approach the straight line effect of the single inlet. Both types suffer
faults, in a yaw or turn, a loss of ram pressure occurs on one side of the intake and
separated, turbulent boundary layer air is fed to the engine compressor.
Divided Intakes.
Figure 3.3.
Supersonic Intakes.
Figure 3.4.
This type of intake produces a series of mild shock waves without reducing the
intake efficiency, as the aircraft speed increases, so also does the intake
compression ratio. At high mach numbers it becomes necessary to have an air
intake which has a variable thrust area and spill doors to control the column of air.
3.4 IDEAL INTAKE CONDITIONS
For air to flow smoothly through a compressor, its velocity should be about 0.5
mach at the compressor inlet; this includes aircraft flying faster than the speed of
sound. Hence intakes are designed to decelerate the free stream airflow to this
condition over the range of aircraft speeds. Intakes should also convert the kinetic
energy into pressure energy without undue shock or energy loss. This means
that the ideal compressor inlet pressure should be the same as the total head
pressure at the intake lip.
(Total head pressure = stagnation pressure, ie. static and dynamic pressure).
Intake Efficiency
The magnitude of the losses occurring in an intake during ram compression are
measured by means of the intake efficiency. Typical optimum efficiencies of some
common types of intake, at subsonic speeds assuming straight-through flow, are:
a Turbo-jet engine Pitot 99 to 96%
Wing root 95 to 87%
Side 89 to 80%
b Turbo-prop engine Annular 82 to 74% (DART)
In cases where the direction of flow of the air is reversed within the intake, these
values are reduced by about 10%.
3.5 INTAKE ANTI-ICING
Operations of present day aircraft necessitates flying in all weather conditions plus
the fact that high velocity air induced into the intakes means a provision must be
made for ice protection. There are three systems of thermal anti-icing; hot air, hot
oil or electrical There is, however, one disadvantage and that is the loss of
engine power. This loss must be corrected for on ground runs and power checks.
3.5.1 ENGINE HOT AIR ANTI-ICING
The hot air system provides surface heating of the engine and/or power plant
where ice is likely to form. The affected parts are the engine intake, the intake
guide vanes, the nose cone, the leading edge of the nose cowl and, sometimes,
the front stage of the compressor stator blades. The protection of rotor blades is
rarely necessary, because any ice accretions are dispersed by centrifugal action.
The hot air for the anti-icing system is usually taken from the latter stages of the
HP compressor and externally ducted, through pressure regulation valves, to the
parts requiring protection. When the nose cowl requires protection, hot air
exhausting from the air intake manifold may be collected and ducted to the nose
cowl. Exhaust outlets are provided to allow the air to pass into the compressor
intake or vent to atmosphere, thus maintaining a flow of air through the system.
Spraymat Construction.
Figure 3.6.
Heater mats differ in design and construction according to their purpose and
environment. The latest mats have elements which are made from a range of
alloys woven in continuous filament glass yarn. Other elements are made from
nickel chrome foil. The insulating material is usually polytetrafluoroethylene
(PTFE) and the electrical control may be continuous or intermittent.
Intentionally Blank
4 COMPRESSORS
4.1 COMPRESSORS GENERAL
Compressors impart energy to the air stream raising its pressure and temperature.
They are designed to operate efficiently over as wide a range of operating
conditions as possible. The two basic types of compressor are:
a Centrifugal flow
b Axial flow
4.2 CENTRIFUGAL FLOW
The figure below illustrates different types of centrifugal compressors.
4.2.1 OPERATION
The centrifugal impeller is rotated at high speed by the turbine and centrifugal
action causes the air between the impeller vanes to accelerate radially outwards
until it is thrown off at the tip into the diffuser. The radial movement of the air
across the impeller, from eye to tip, causes a drop in air pressure at the eye and
the faster the impeller is turning, the lower the pressure at the eye becomes. The
low pressure existing at the eye of the revolving impeller induces a continuous flow
of air through the engine intake and into the eye of the impeller. The air, in turn, is
accelerated across the impeller and passed into the diffuser. The kinetic energy in
the air is then converted to pressure energy ready to enter the combustion
chamber. The action of the diffuser is illustrated in figure 4.3.
VANELESS
SPACE
The final volume and mass airflow delivered by the centrifugal compressor is
dependent on:
a Pressure ratio
b Operating RPM
c Diameter of the impeller
NOTE: This is assuming a constant air density at the inlet of the compressor.
4.2.1.1 Pressure Ratio
The ratio of the inlet pressure to outlet pressure of the compressor is called
pressure ratio. The higher the pressure of the air the more efficiently the thrust will
be produced with a corresponding improvement to the fuel economy of the engine.
The maximum pressure ratio normally obtainable from a single stage centrifugal
compressor is approximately 5:1 and from a two stage, approximately 8:1.Design
of the more modern centrifugal compressors sees them approaching pressure
ratios of 15:1.
4.2.1.2 Diameter of Impeller
A large impeller will deliver a greater mass of air than a small impeller, however a
large diameter compressor leads to an increase in the frontal area of the engine
causing excess drag forces on the aircraft.
4.3 THE AXIAL FLOW COMPRESSOR
The axial flow compressor is by far the most popular type of compressor and,
although it is more difficult to manufacture, it is a more efficient compressor.
Handling a larger mass of air for any given diameter, it produces more power; and
because the compression ratio is high – at least 9:1 and, it can be very much
higher – it is a more economical engine. The airflow through the engine is parallel
with the axis, hence the name ‘axial flow compressor’.
The compressor consists of a single or multi-rotor assembly that carries blades of
aerofoil section; it is mounted in a casing, which also houses the stator blades.
The axial flow compressor increases the pressure of the air gradually (by
approximately 1.2:1 per stage) over a number of ‘stages’, each stage comprising
of a row of ‘rotor blades’, followed by a row of ‘stator blades’. Both the rotor and
stator blades are of aerofoil section and form divergent passageways between
adjacent blades of the same row. Figure 4.4 refers.
4.3.1 OPERATION
The compressor rotor spool is driven by the turbine. The rotor blades accelerate
the air rearwards, inducing a continuous flow of air into the inlet of the combustion
chamber. The airflow emerges from the rotor stage with an increase in velocity,
due to the rotating action of the blades, and with a rise in pressure and
temperature caused by flowing through the divergent passage formed by the rotor.
The airflow then passes through the divergent passages formed by the stator
blades which convert some of the kinetic energy into pressure energy and directs
the airflow onto the next set of rotors at the correct angle. The airflow emerges
from each stage at approximately the same velocity as it entered, but with an
increase (approximately 1.2:1) in pressure and, an increase in temperature. See
graph below.
To present the airflow onto the first stage rotor blades at a suitable angle, some
engines have inlet guide vanes in the air intake casing. The last row of stator
blades is normally of wider chord than the preceding ones and serve to straighten
the airflow before it enters the combustion system.
In order to maintain the overall axial velocity more or less constant, the
passageway between the stator casing and the compressor rotor forms a
convergent duct in the direction of airflow, with long blades at the low pressure end
and progressively shorter ones towards the high pressure end. (Figure 4.6 refers)
The stator vanes are secured into the compressor casing or into stator vane
retaining rings, which are themselves secured to the casing.
The engine rotor assembly forms a hollow “drum” and is supported in ball and
roller bearings and coupled to a turbine shaft. The rotor discs make up the drum
and the rotor blades are attached as shown in the figure. On some smaller
engines it becomes difficult to design a practical fixing, this is overcome by
designing and producing blades integral with the disc and is called a “BLISK”.
The mass and final volume of the airflow delivered by the compressor is
dependent on:
a. Pressure Ratio. Dependent on the number of stages employed. Axial flow
compressors can achieve a much higher value than centrifugal.
b. Diameter. For a similar mass flow capability, the axial flow compressor can be
made smaller in diameter than the centrifugal type.
c. Operating RPM. As with the centrifugal type, the RPM and hence the mass
flow, is controlled by varying the amount of fuel delivered to the combustion
system, but because of the way that the pressure rise takes place, the
maximum pressure ratio in an axial flow compressor is achieved at a lower
RPM, than in a centrifugal compressor.
4.4 COMPRESSOR STALL AND SURGE
‘Surge’ can occur in both centrifugal and axial flow compressors and is the
reversal of the airflow in the compressor. It is a very undesirable condition, which
can rapidly cause serious damage to the engine.
In an axial flow compressor, ‘surge’ is nearly always preceded by stalling of some
of the compressor blades. An aerofoil is said to be in a stalled condition when the
airflow over its surface has broken down and no lift is being produced. If a row of
compressor blades stall, then they will not be able to pass the airflow rearwards to
the next stage and the airflow to the combustion chamber will ultimately stop.
The lack of rearward airflow will allow the air in the combustion chamber to flow
forward into the compressor until it reaches the row of stalled blades. Then a
violent backwards and forwards oscillation of the airflow is likely to occur, which
can rapidly cause extensive damage to the compressor blades and also over-
heating of the combustion and turbine assemblies.
Stalling of the compressor blades can occur for various reasons and to appreciate
how the condition comes about, a review of aerofoil theory and its application to
the compressor is required.
4.4.1 AIRFLOW CONTROL SYSTEM PRINCIPLES
4.4.1.1 Compressor Stall and Surge
For any given engine there is only one set of conditions, mass flow, pressure ratio
and rpm, at which all the compressor components are operating at their optimum
effect. Compressors are designed to be most efficient in the higher rpm range of
operation. The point at which the compressor reaches its maximum efficiency is
known as the DESIGN POINT. Under design conditions the compressor produces
Volume 2
a given compression ratio (ie. ) and the axial velocity (average velocity)
Volume 1
of the gas remains approximately constant from the front to the rear of the
compressor.
The Angle of Attack of the airflow to the compressor aerofoil blades will be at its
optimum. This is the design condition and the compressor is operating at its
optimum performance. Although compression ratio varies with rpm it is not
proportional to rpm. This fact emerges due to the fixed blade angles, which can
only be correct at the design point. To illustrate this fact, refer to the diagram
showing rpm and compression ratio. Consider a compressor running at 8,000 rpm
and its compression ratio is 10:1. Let us say that the volume of air entering the
compressor is 100cm3. The volume of the air passing through the fixed outlet
annulus of the compressor will be 10cm3.
10:1
COMPRESSION RATIO
4:1
4000 8000
RPM
Graph of Compression Ratio to RPM.
Figure 4.12.
Compressor R.P.M = 8,000 Compressor R.P.M. = 4,000
Compression Ratio = 10:1 Compression Ration = 4:1
Volume of gas (V1) = 100cm3 Volume of gas (V1) = 50cm3
Volume of gas (V2) = 10cm3 Volume of gas (V2) = 12.5cm3
Now consider the same compressor operating at 4,000 rpm, the volume of air
entering the compressor will be halved, eg. 50cm 3 there will also be a reduction in
compression ratio to 4:1. Therefore the volume of air passing through the
compressor fixed outlet annulus will be 12.5cm3. The following conditions will
occur:
a. Axial velocity will increase as it moves towards the rear stages relative to the
front Low pressure stages.
b…Since all stages are rotating at the same speed, there will be a NEGATIVE
angle of attack at the rear high pressure stages and a POSITIVE angle of attack at
the front low pressure stages.
Front Rear
Due to the increased velocity at the rear of the compressor, the outlet of the
compressor will choke as the airflow reaches sonic velocity. At this point there will
be a dramatic reduction in axial velocity resulting in the front compressor blades
stalling. The end result will be compressor surge. To overcome the problem, a
bleed valve is normally fitted in an intermediate stage of the compressor to bleed
off the excess volume of air. This relieves the rear stages of the excess air
causing choking while inducing an increased axial airflow through the early stages
of the compressor, thus establishing conditions which are not conducive of stall
and surge. Unfortunately this bleed valve does not completely cure the problem of
stall as far as the first rotor stages are concerned and stall is still likely to occur.
The blades stall when the angle of attack increases to too large a value. To
overcome this problem, inlet guide vanes are used to pre-swirl the air onto the
rotor blades. The effect of pre-swirling the air alters the angle of attack from a
large value to the correct angle of attack. See figure 4.14.
UNSTABLE SAFETY
AREA MARGIN
PRESSURE RATIO - Increasing
SURGE LINE
WORKING LINE
100
%
90%
80% CONSTANT
60% 70% RPM LINES
AIRFLOW - Increasing
The speed of the object is the compressor blade, if as previously stated, the mach.
Number is raised with a decrease in temperature, the ‘fixed’ blade speed relative
to the speed of the air, will be increased. To cater for this situation the operating
point at which the variable inlet guide vanes move will have to be altered for
varying air temperatures. To achieve this the actuator or ram of an airflow control
system is temperature compensated. On a ‘cold’ day, the variable inlet guide
vanes will operate earlier than on a ‘warm’ day.
At a temperature of +60F Local speed of sound is Mach 0.9 , no need for the
VIGV’s as the compressor out let is not choked.
At a temperature of –40°F Local speed of sound is Mach 1.0, the compressor
outlet is choked, the first stages may stall, VIGV’s
must start to open.
Intake Guide
Variable Vane
Guide Ram
Vane Setting Curve.
Hydraulic
Figure 4.18.
Actuator Figure 4.20.
To further improve airflow control, some engines will adopt a system of Variable
Stator Vanes (VSV’s) as well as Variable Inlet Guide Vanes (VIGV’s) figure 4.21.
VT VT
VT
VA VA VT
VA
VA
Low R.P.M R.P.M Increasing High R.P.M
At very large angles of attack the airflow breaks down and the aerofoil stalls.
All aerofoils have an ‘optimum’ angle of attack at which they produce most lift for
the least drag. (‘Lift/drag ratio’) [2-4°].
3-D Blades
Figure 4. 28.
The total number of stages of compression is divided between two spools, each
spool being driven at a different speed by separate turbines. This eases the
problems of compressor blade matching and results in a very powerful, efficient
and flexible engine.
4.12 COMPARING THE FEATURES OF CENTRIFUGAL AND AXIAL FLOW
COMPRESSORS
4.12.1 CENTRIFUGAL
Merits.
Simplicity, cheaper, lighter, less prone to damage by FOD.
Not critical to surge and stall.
Will tolerate icing conditions.
Associated Problems
Max pressure ratios 4:1 or 5:1. (on early types)
Capacity limited by tip speed.
Larger diameter of engine which leads to more drag.
Severe directional changes of gas flow which leads to friction.
High specific fuel consumption.
4.12.2 AXIAL FLOW
Merits
High Pressure Ratio.
Low specific fuel consumption.
More capacity for development.
Greater axial thrust.
Associated Problems
Complex and expensive to produce.
Critical to stall/surge.
5 COMBUSTION SECTION
5.1 INTRODUCTION
The combustion chamber has the difficult task of burning large quantities of fuel,
supplied through the fuel burners, with extensive volumes of air, supplied by the
compressor, and releasing the heat in such a manner that the air is expanded and
accelerated to give a smooth stream of uniformly heated gas at all conditions
required by the turbine. This task must be accomplished with the minimum loss in
pressure and with the maximum heat release for the limited space available.
The amount of fuel added to the air will depend upon the maximum temperature
rise required and, as this is limited by the materials from which the turbine blades
and nozzles are made, the rise must be in the range of 700 to 1,200 deg.C.
Because the air is already heated by the work done during compression, the
temperature rise required at the combustion chamber may be between 500 and
800 deg.C. Since the gas temperature required at the turbine varies with engine
speed, and in the case of the turbo-prop engine upon the power required, the
combustion chamber must also be capable of maintaining stable and efficient
combustion over a wide range of engine operating conditions.
Efficient combustion has become more and more important because of the rapid
increase in commercial aircraft traffic and the consequent increase in atmospheric
pollution, which is seen by the general public as exhaust smoke.
5.2 COMBUSTION PROCESS
Air from the engine compressor enters the combustion chamber at a velocity up to
500 feet per second, but because at this velocity the air speed is far too high for
combustion, the first thing that the chamber must do is to diffuse it, i.e. decelerate
it and raise its static pressure. Because the speed of burning kerosene at normal
mixture ratios is only a few feet per second, any fuel lit even in the diffused air
stream, which now has a velocity of about 80 feet per second, would be blown
away. A region of low axial velocity has therefore to be created in the chamber, so
that the flame will remain alight throughout the range of engine operating
conditions.
In normal operation, the overall air/fuel ratio of a combustion chamber can vary
between 45:1 and 130:1. Kerosene, however, will only burn efficiently at, or close
to, a ratio of 15:1, so the fuel must be burned with only part of the air entering the
chamber, in what is called a primary combustion zone. This is achieved by means
of a flame tube (combustion liner) that has various devices for metering the airflow
distribution along the chamber.
Approximately 20 per cent of the air mass flow is taken in by the snout or entry
section. Immediately downstream of the snout are swirl vanes and a perforated
flare, through which air passes into the primary combustion zone. The swirling air
induces a flow upstream of the centre of the flame tube and promotes the desired
recirculation. The air not picked up by the snout flows into the annular space
between the flame tube and the air casing.
Through the wall of the flame tube body, adjacent to the combustion zone, are a
selected number of holes through which a further 20 per cent of the main flow of
air passes into the primary zone. The air from the swirl vanes and that from the
primary air holes interacts and creates a region of low velocity recirculation. This
takes the form of a toroidal vortex similar to a smoke ring, and has the effect of
stabilising and anchoring the flame. The recirculating gases hasten the burning of
freshly injected fuel droplets by rapidly bringing them to ignition temperature.
It is arranged that the conical fuel spray from the burner intersects the recirculation
vortex at its centre. This action, together with the general turbulence in the
primary zone, greatly assists in breaking up the fuel and mixing it with the
incoming air.
The temperature of the combustion gases released by the combustion zone is
about 1,800 to 2,000 deg.C., which is far too hot for entry to the nozzle guide
vanes of the turbine. The air not used for combustion, which amounts to about 60
per cent of the total airflow, is therefore introduced progressively into the flame
tube. Approximately half of this is used to lower the gas temperature before it
enters the turbine and the other half is used for cooling the walls of the flame tube.
Combustion should be completed before the dilution air enters the flame tube,
otherwise the incoming air will cool the flame and incomplete combustion will
result.
An electric spark from an igniter plug initiates combustion and the flame is then
self-sustaining.
The design of a combustion chamber and the method of adding the fuel may vary
considerably, but the airflow distribution used to effect and maintain combustion is
always very similar to that described.
A Spray Nozzle.
Figure 5.6.
Main
Pilot fuel
fuel
BMW Rolls Royce are testing an axially staged combustion chamber for the BR715
engine, they claim it will cut the NOx by 50% without increasing CO, UHC and smoke
emissions.
Figure 5.12.
x
Issue 2 – April 2003 Page 5-13
JAR 66 CATEGORY B1
MODULE 15
uk GAS TURBINE
engineering ENGINES
5.10 MATERIALS
The containing walls and internal parts of the combustion chamber must be
capable of resisting the very high gas temperature in the primary zone. In
practice, this is achieved by using the best heat resisting materials available, the
use of high heat resistant coatings and by cooling the inner wall of the flame tube
as an insulation from the flame.
The combustion chamber must also withstand corrosion due to the products of the
combustion, creep failure due to temperature gradients and fatigue due to
vibrational stresses.
6 TURBINE SECTION
6.1 INTRODUCTION
The turbine has the task of providing the power to drive the compressor and
accessories and, in the case of engines which do not make use solely of a jet for
propulsion, of providing shaft power for a propeller or rotor. It does this by extracting
energy from the hot gases released from the combustion system and expanding
them to a lower pressure and temperature. High stresses are involved in this
process, and for efficient operation, the turbine blade tips may rotate at speeds over
1,500 feet per second. The continuous flow of gas to which the turbine is exposed
may have an entry temperature between 850 and 1,700 deg.C. and may reach a
velocity of over 2,500 feet per second in parts of the turbine.
To produce the driving torque, the turbine may consist of Several stages each
employing one row of stationary nozzle guide vanes and one row of moving blades.
The number of stages depends upon the relationship between the power required
from the gas flow, the rotational speed at which it must be produced and the diameter
of turbine permitted.
The number of shafts, and therefore turbines, varies with the type of engine., high
compression ratio engines usually have two shafts, driving high and low pressure
compressors. On high by pass ratio fan engines that feature an intermediate
pressure system, another turbine may be interposed between the high and low
pressure turbines, thus forming triple-spool system. On some engines, driving torque
is derived from a free-power turbine. This method allows the turbine to run at its
optimum speed because it is mechanically independent of other turbine and
compressor shafts.
The mean blade speed of a turbine has considerable effect on the maximum
efficiency possible for a given stage output. For a given output the gas velocities,
deflections, and hence losses, are reduced in proportion to the square of higher
mean blade speeds. Stress in the turbine disc increases as the square of the speed,
therefore to maintain the same stress level at higher speed the sectional thickness,
hence the weight, must be increased disproportionately. For this reason, the final
design is a compromise between efficiency and weight. Engines operating at higher
turbine inlet temperatures are thermally more efficient and have an improved power
to weight ratio. By-pass engines have a better propulsive efficiency and thus can
have a smaller turbine for a given thrust.
When the gas is expanded by the combustion process, it forces its way into the
discharge nozzles of the turbine where, because of their convergent shape, it is
accelerated to about the speed of sound which, at the gas temperature, is about
2,500 feet per second. At the same time the gas flow is given a 'spin' or 'whirl' in the
direction of rotation of the turbine blades by the nozzle guide vanes. On impact with
the blades and during the subsequent reaction through the blades, energy is
absorbed, causing the turbine to rotate at high speed and so provide the power for
driving the turbine shaft and compressor.
The torque or turning power applied to the turbine is governed by the rate of gas flow
and the energy change of the gas between the inlet and the outlet of the turbine
blades. The design of the turbine is such that the whirl will be removed from the gas
stream so that the flow at exit from the turbine will be substantially 'straightened out'
to give an axial flow into the exhaust system (Part 6). Excessive residual whirl
reduces the efficiency of the exhaust system and also tends to produce jet pipe
vibration which has a detrimental effect on the exhaust cone supports and struts.
It will be seen that the nozzle guide
vanes and blades of the turbine are
'twisted', the blades having a stagger
angle that is greater at the tip than at
the root. The reason for the twist is to
make the gas flow from the
combustion system do equal work at
all positions along the length of the
blade and to ensure that the flow
enters the exhaust system with a
uniform axial velocity. This results in
certain changes in velocity, pressure
and temperature occurring through the
turbine.
The 'degree of reaction' varies from
root to tip, being least at the root and
highest at the tip, with the mean
section having the chosen value of
Twisted Contour of Blades about 50 per cent.
Figure 6.6.
The losses which prevent the turbine from being 100 per cent efficient are due to a
number of reasons. A typical uncooled three-stage turbine would suffer a 3.5 per
cent loss because of aerodynamic losses in the turbine blades. A further 4.5 per cent
loss would be incurred by aerodynamic losses in the nozzle guide vanes, gas
leakage over the turbine blade tips and exhaust system losses; these losses are of
approximately equal proportions. The total losses result in an overall efficiency of
approximately 92 per cent.
6.3 CONSTRUCTION
The basic components of the turbine are the combustion discharge nozzles, the
nozzle guide vanes, the turbine discs and the turbine blades. The rotating assembly
is carried on bearings mounted in the turbine casing and the turbine shaft may be
common to the compressor shaft or connected to it by a self-aligning coupling.
6.3.1 NOZZLE GUIDE VANES
The nozzle guide vanes are of an aerofoil shape with the passage between adjacent
vanes forming a convergent duct. The vanes are located in the turbine casing in a
manner that allows for expansion.
The nozzle guide vanes are usually of hollow form and may be cooled by passing
compressor delivery air through them to reduce the effects of high thermal
stresses and gas loads.
A gap exists between the blade tips and casing, which varies in size due to the
different rates of expansion and contraction. To reduce the loss of efficiency through
gas leakage across the blade tips, a shroud is often fitted. This is made up by a
small segment at the tip of each blade which forms a peripheral ring around the blade
tips. An abradable lining in the casing may also be used to reduce gas leakage.
Active Clearance Control (A.C.C.) is a more effective method of maintaining minimum
tip clearance throughout the flight cycle. Air from the compressor is used to cool the
turbine casing and when used with shroudless turbine blades, enables higher
temperatures and speeds to be used.
In the past, turbine discs have been made in ferritic and austenitic steels but nickel
based alloys are currently used. Increasing the alloying elements in nickel extend the
life limits of a disc by increasing fatigue resistance. Alternatively, expensive powder
metallurgy discs, which offer an additional 10% in strength, allow faster rotational
speeds to be achieved.
6.5.3 TURBINE BLADES
A brief mention of some of the points to be considered in connection with turbine
blade design will give an idea of the importance of the correct choice of blade
material. The blades, while glowing red-hot, must be strong-enough to carry the
centrifugal loads due to rotation at high speed. A small turbine blade weighing only
two ounces may exert a load of over two tons at top speed and it must withstand the
high bending loads applied by the gas to produce the many thousands of turbine
horsepower necessary to drive the compressor. Turbine blades must also be
resistant to fatigue and thermal shock, so that they will not fail under the influence of
high frequency fluctuations in the gas conditions, and they must also be resistant to
corrosion and oxidisation. In spite of all these demands, the blades must be made in
a material that can be accurately formed and machined by current manufacturing
methods-
From the foregoing, it follows that for a particular blade material and an acceptable
safe life there is an associated maximum permissible turbine entry temperature and a
corresponding maximum engine power. It is not surprising, therefore, that
metallurgists and designers are constantly searching for better turbine blade
materials and improved methods of blade cooling.
The early materials used were high temperature steel forgings, but these were rapidly
replaced by cast nickel base alloys which give better creep and fatigue properties.
Close examination of a conventional turbine blade reveals a myriad of crystals that lie
in all directions (equi-axed). Improved service life can be obtained by aligning the
crystals to form columns along the blade length, produced by a method known as
'Directional Solidification'. A further advance of this technique is to make the blade
out of a single crystal. Each method extends the useful creep life of the blade and in
the case of the single crystal blade, the operating temperature can be substantially
increased.
A non-metal based turbine blade can be manufactured from reinforced ceramics.
Their initial production application is likely to be for small high speed turbines which
have very high turbine entry temperatures.
Centrifugal Forces.
Figure 6.16..
Centrifugal force acts on every particle which makes up the mass of the rotating
element impelling each particle outwards and away from the axis, about which it is
rotating, in a radial direction.
If the mass of the rotating element is EVENLY DISTRIBUTED about the axis of
rotation, the part is BALANCED and rotates WITHOUT VIBRATION. However, if
there is a greater mass on one side of the rotor than the other, the centrifugal force
acting on this heavy side exceeds the centrifugal force on the light side and pulls the
entire assembly in the direction of the heavy side.
Eccentric Mass.
Figure 6.17.
The rotor has a heavy mass M on one side. The centrifugal force exerted by M
causes the entire rotor to be pulled in the direction of force F.
6.6.3 CAUSES OF UNBALANCE
Unbalance may be caused by a variety of factors occurring singly or in combination
with others. These factors include:-
a) Eccentricity
Eccentricity exists when the geometric centreline of a part or assembly does not
coincide with its axis of rotation. This may be as a result of locating features (eg.
spigot location, bolt holes, splines, serration’s, couplings), being eccentric to the
bearing location.
Eccentricity.
Figure 6.18.
c) Blade Distribution
Unbalance can be caused by an unequal or unsymmetrical arrangement of a set of
blades, either by reference to their mass moments or their dead weights depending
on the size of the blades. This can be as a result of faulty weighting, inaccurate or
illegible recording or assembly errors.
d) Unsymmetrical Features
These may be due to manufacturing processes, such as blow holes in castings or
design features such as offset holes, locating dogs, slots, keyways, etc.
Unsymmetrical Features
Figure 6.20.
e) Distortion
This can be caused by stress relieving, eg. after welding, or by unequal thermal
growth during running.
f) Fits and Clearances
Clearance between mating parts allows relative movement of the parts and a
consequent shift of the axis of rotation during running (or even during balancing).
Joints incompletely assembled, eg. chamfers fouling radii, abutment faces not pulled
together, may cause a ‘bent’ rotor or an unsuitable joint, which may cause a shift
during running. It is important to prevent separate locating, or fixing, features from
influencing each other eg. bolt holes, spigot locations, serration’s, etc. must be
geometrically controlled to prevent ‘fighting’ between more than one feature. See
also the section on tooling, adapters, drives, dummy rotors, etc.
g) Swash
Swash.
Figure 6.21.
Swash is caused by out of squareness of abutment faces relative to the bearing
diameter, abutment faces not being parallel across the component, eg. spacers,
adjusting washers, disks, etc. It is important that the bolted joints are tightened in
sequence and in increments according to the torquing instructions.
h) Miscellaneous
Foreign bodies inside assemblies, oil accumulation, carbon deposits, usually found
when check balancing after running.
6.6.4 OBJECTIVE OF BALANCING
The objective of balancing is to determine how the unbalanced mass of the rotor
must be compensated for in order to keep the bearings free of centrifugal force
loading.
6.6.5 DEFINITION OF UNBALANCE
Unbalance can be defined as that condition which exists in a rotor when vibratory
force or motion is imparted to its bearings as a result of centrifugal forces.
Unbalance will, in general, be distributed throughout the rotor but can be reduced to:-
a) static unbalance
b) couple unbalance
c) dynamic unbalance
Static Unbalance
In a gas turbine engine, static unbalance is primarily associated with thin discs such
as turbine wheels or single compressor discs. It can be corrected by adding mass to
the light side of the rotor. This can be achieved by a single weight DIAMETRICALLY
OPPOSITE to the out of balance or by adding a number of smaller distributed
weights having the same effect as a single weight. (This distribution can be
determined by vectors).
Static Balance.
Figure 6.22.
Couple Unbalance
This arises when two EQUAL unbalance masses are positioned at opposite ends of a
rotor and spaced at 180 from each other. If placed on knife-edges, the rotor would
be statically balanced. However, when the rotor is rotated, the out of balance
masses will cause a centrifugal force to act at each end and hence each end will
vibrate independently as shown in figure 6.23.
Couple Unbalance.
Figure 6.23.
Dynamic Unbalance
This occurs when the unbalanced masses may be either unequal in size or
positioned at some angle other than 180 to each other, or even both of these
conditions. These unbalanced forces now cause the rotor to vibrate.
Velocity Transducer
This device operates on the principle of a permanent magnet to move within a coil,
inducing voltage. Because of the moving parts with all the inherent disadvantages of
wear, friction, etc. they have been superseded by the peizo electric principle.
(1) DYNAMIC RANGE. The amplitude range over which the device is required to
perform.
(2) SENSITIVITY. The severity of the vibration liable to be encountered.
(3) FREQUENCY RESPONSE. The full operating frequency range required.
(4) TEMPERATURE RANGE. The upper and lower temperature extremities to
which the device will be subjected and also any heat soak conditions.
7 EXHAUST
7.1 INTRODUCTION
Aero gas turbine engines have an exhaust system which passes the turbine
discharge gases to atmosphere at a velocity, and in the required direction, to provide
the resultant thrust. The velocity and pressure of the exhaust gases create the thrust
in the turbo-jet engine, but in the turbo-propeller engine only a small amount of thrust
is contributed by the exhaust gases, because most of the energy has been absorbed
by the turbine for driving the propeller. The design of the exhaust system therefore,
exerts a considerable influence on the performance of the engine. The areas of the
jet pipe and propelling or outlet nozzle affect the turbine entry temperature, the mass
airflow and the velocity and pressure of the exhaust jet.
The temperature of the gas entering the exhaust system is between 550 and 850
deg.C. according to the type of engine and with the use of afterburning can be 1,500
deg.C. or higher. Therefore, it is necessary to use materials and a form of
construction that will resist distortion and cracking, and prevent heat conduction to
the aircraft structure.
A basic exhaust system is shown in fig. 7.1. The use of a thrust reverser, noise
suppressor and a two position propelling nozzle entails a more complicated system
as shown in fig. 7.2. The low by-pass engine may also include a mixer unit to
encourage a thorough mixing of the hot and cold gas streams.
An Exhaust System with a Thrust Reverser and Variable area propelling nozzle.
Figure 7.2.
From the illustration (fig. 7.4), it will be seen that the convergent section exit now
becomes the throat, with the exit proper now being at the end of the flared divergent
section. When the gas enters the convergent section of the nozzle, the gas velocity
increases with a corresponding fall in static pressure. The gas velocity at the throat
corresponds to the local sonic velocity. As the gas leaves the restriction of the throat
and flows into the divergent section, it progressively increases in velocity towards the
exit. The reaction to this further increase in momentum is a pressure force acting on
the inner wall of the nozzle. A component of this force acting parallel to the
longitudinal axis of the nozzle produces the further increase in thrust.
The propelling nozzle size is extremely important and must be designed to obtain the
correct balance of pressure, temperature and thrust. With a small nozzle these
values increase, but there is a possibility of the engine surging, whereas with a large
nozzle the values obtained are too low.
A fixed area propelling nozzle is only efficient over a narrow range of engine
operating conditions. To increase this range, a variable area nozzle may be used
(Fig. 7.2.). This type of nozzle is usually automatically controlled and is designed to
maintain the correct balance of pressure and temperature at all operating conditions.
In practice, this system is seldom used as the performance gain is offset by the
increase in weight. However, with afterburning a fully variable area nozzle is
necessary.
The by-pass engine has two gas streams to eject to atmosphere, the cool by-pass
airflow and the hot turbine discharge gases.
In a low by-pass ratio engine, the two flows are combined by a mixer unit (fig. 7.5.)
which allows the by-pass air to flow into the turbine exhaust gas flow in a manner that
ensures thorough mixing of the two streams.
In high by-pass ratio engines, the two streams are usually exhausted separately.
The hot and cold nozzles are co-axial and the area of each nozzle is designed to
obtain maximum efficiency. However, an improvement can be made by combining
the two gas flows within a common, or integrated, nozzle assembly. This partially
mixes the gas flows prior to its ejection to atmosphere. An example of both types of
high by-pass exhaust system is shown in fig. 7.6.
The exhaust system must be capable of withstanding the high gas temperatures and
is therefore manufactured from nickel or titanium. It is also necessary to prevent any
heat being transferred to the surrounding aircraft structure. This is achieved by
passing ventilating air around the jet pipe, or by lagging the section of the exhaust
system with an insulating blanket. Each blanket has an inner layer of fibrous
insulating material contained by an outer skin of thin stainless steel, which is dimpled
to increase its strength. in addition, acoustically absorbent materials are sometimes
applied to the exhaust system to reduce engine noise.
When the gas temperature is very high (for example, when afterburning is employed),
the complete jet pipe is usually of double-wall construction with an annular space
between the two walls. The hot gases leaving the propelling nozzle induce, by
ejector action, a flow of air through the annular space of the engine nacelle. This
flow of air cools the inner wall of the jet pipe and acts as an insulating blanket by
reducing the transfer of heat from the inner to the outer wall.
The cone and streamline fairings in the exhaust unit are subjected to the pressure of
the exhaust gases; therefore, to prevent any distortion, vent holes are provided to
obtain a pressure balance.
The mixer unit used in low by-pass ratio engines consists of a number of chutes
through which the by-pass air flows into the exhaust gases. A bonded honeycomb
structure is used for the integrated nozzle assembly of high by-pass ratio engines to
give lightweight strength to this large component.
Due to the wide variations of temperature to which the exhaust system is subjected, it
must be mounted and have its sections joined together in such a manner as to allow
for expansion and contraction without distortion or damage.
An Insulation Blanket
Figure 7.7
a) Exhaust jet
b) Turbine
c) Compressor and/or front fan.
Exhaust Jet
Jet noise is an externally generated source, which radiates in a rearward direction. It
is caused by the mixing process of the high-speed exhaust gases with the
surrounding air. In the mixing regions, a severe gradient of velocity exists normal to
the jet and due to the viscosity of the air, this gradient produces vortices and shear
forces which, in turn, produce quadrupole noise sources.
The noise produced by such a source will be proportional to p2Vje8, where p is the air
density and Vje is the jet efflux velocity.
Noise Suppression
It has been seen that the first step towards noise suppression is at the design stage
of the rotating and static parts of the engine. Thereafter, further reduction in the
noise level emanating from a particular engine may be achieved by the incorporation
of special materials and innovations during its construction. These additional
methods of noise suppression are briefly described as:
a) Absorption by acoustic linings.
b) Turbine, compressor and fan noise alleviated by control of nozzle area and
shape.
Acoustic Linings
One method of suppressing the noise from the fan stage of a high by-pass ratio
engine is to incorporate a noise absorbent liner around the inside wall of the by-pass
duct. The lining comprises a porous face-sheet, which acts as a resistor to the
motion of the sound waves and is placed in a position such that it senses the
maximum particle displacement in the progression of the wave. The depth of the
cavity between absorber and solid backing is the tuning device, which suppresses
the appropriate part of the noise spectrum. The figure shows two types of noise
absorbent line; the figure shows the location of a liner to suppress fan noise from a
high by-pass ratio engine and also the use of a liner to suppress the noise from the
engine core. The disadvantage of using liners for reducing noise are the addition of
weight and the increase in specific fuel consumption caused by increasing the friction
of the duct walls.
These serrated ducts will improve flow mixing and reduce noise on the Trent 800.
Figure 7.17.
g. The reverser must not operate until required to do so. It is necessary to ensure
that:
1. Accidental selection of reverse thrust is impossible.
2. No single failure in the operating system selects reverse thrust.
3. The thrust changing elements are biased away from the reverse thrust
position.
7.5.3 LAYOUT AND OPERATION OF TYPICAL THRUST REVERSING SYSTEMS
Clamshell Doors.
Figure 7.19.
In the forward thrust mode (stowed) the thrust reverser doors form the convergent-
divergent final nozzle for the engine.
The thrust reverser hydraulic system is only pressurised when thrust reverser
actuation is required, or when required to resist motion from the stow commanded
position.
A throttle interlock system restricts application of engine thrust when the reverser is
not in its commanded position and automatically reduces engine thrust if
uncommanded reverser translation occurs.
Amber lights on the centre panel identify when the reversers are in the unlocked
position.
A "fault light" for each reverser is located in the Engine Module on the aft overhead
panel. When this fault light is illuminated, the Master Caution is triggered after 12
seconds to indicate that a subsequent failure in the reverser system may cause
uncommanded reverser motion.
Labyrinth Seal
Figure 8.3.
The labyrinth seal may be used in conjunction with an abradable coating on the
stationary member as shown in the figure 8.3.
8.2.3 THREAD SEALS
Thread seals or screw back seals work in the same way as labyrinth seals, with a
screw thread instead of the rings of a labyrinth seal. This means that any oil leakage
towards the air will be driven back by the thread. This type of seal is used with
other types of seal to reduce migration of oil to those seals.
Thread Seal
Figure 8.4.
Carbon Seal.
Figure 8.5.
Hydraulic Seal
Figure 8.7.
The seal consists of a circular baffle ring mounted on a rotating shaft; the rim of this
ring sits in the centre of a circular depression in an outer rotating shaft. Oil from the
bearing will fill this depression and be held there by centrifugal force. This oil
reservoir will form a liquid seal with the rim of the rotating baffle ring. Any tendency
for the oil to leak across this seal will be counteracted by air leakage across a back-
up seal.
Thermal fatigue and a reduction in engine performance, due to the radial driveshaft
disturbing the gasfiow, create greater problems within the turbine area than the
compressor area. For any given engine, which incorporates an axial-flow
compressor, the turbine area is smaller than that containing the compressor and
therefore makes it physically easier to mount the gearbox within the compressor
section. Centrifugal compressor engines can have limited available space, so the
internal gearbox may be located within a static nose cone or, in the case of a turbo-
propeller engine, behind the propeller reduction gear as shown in fig.8.8.
On multi-shaft engines, the choice of which
compressor shaft is used to drive the
internal gearbox is primarily dependent
upon the ease of engine starting. This is
achieved by rotating the compressor shaft,
usually via an input torque from the external
gearbox. In practice the high pressure
system is invariably rotated in order to
generate an airflow through the engine and
the high pressure compressor shaft is
therefore coupled to the internal gearbox.
To minimise unwanted movement between
the compressor shaft bevel gear and radial
driveshaft bevel gear, caused by axial
movement of the compressor shaft, the
drive is taken by one of three basic
methods (fig. 8.9.). The least number of
components is used when the compressor
shaft bevel gear is mounted as close to the
compressor shaft location bearing as
possible, but a small amount of movement
has to be accommodated within the
meshing of the bevel gears. Alternatively,
the compressor shaft bevel gear may be
mounted on a stub shaft that has its own
location bearing. The stub shaft is splined
onto the compressor shaft that allows axial
movement without affecting the bevel gear
mesh. A more complex system utilises an
idler gear that meshes with the compressor
shaft via straight spur gears,
accommodating the axial movement, and
drives the radial driveshaft via a bevel gear
arrangement. The latter method was widely
employed on early engines to overcome
Types of Internal Gearbox gear engagement difficulties at high speed.
Figure 8.9.
To spread the load of driving accessory units, some engines take a second drive
from the slower rotating low pressure shaft to a second external gearbox (fig.8.8.).
This also has the advantage of locating the accessory units in two groups, thus
overcoming the possibility of limited external space on the engine. When this
method is used, an attempt is made to group the accessory units specific to the
engine onto the high pressure system, since that is the first shaft to rotate, and the
aircraft accessory units are driven by the low pressure system. A typical internal
gearbox showing how both drives are taken is shown in fig.8.10. This method may
also be used to drive speed sensors and governors for the low pressure shaft.
An External Gearbox.
Figure 8.11.
Gears
The spur gears of the external or auxiliary gearbox gear train (figs.8.11. and 8.12.)
are mounted between bearings supported by the front and rear casings which are
bolted together. They transmit the drive to each accessory unit, which is normally
between 5000 and 6000 r.p.m. for the accessory units and approximately 20,000
r.p.m. for the centrifugal breather.
All gear meshes are designed with 'hunting tooth' ratios which ensure that each
tooth of a gear does not engage between the same set of opposing teeth on each
revolution. This spreads any wear evenly across all teeth.
Spiral (helical) bevel gears are used for the connection of shafts whose axes are at
an angle to one another but in the same plane. The majority of gears within a gear
train are of the straight spur gear type, those with the widest face carry the greatest
loads. For smoother running, helical gears are used but the resultant end thrust
caused by this gear tooth pattern must be catered for within the mounting of the
gear.
Gearbox sealing
Sealing of the accessory drive system is primarily concerned with preventing oil
loss. The internal gearbox has labyrinth seals where the static casing mates with
the rotating compressor shaft. For some of the accessories mounted on the
external gearbox, an air blown pressurised labyrinth seal is employed. This
prevents oil from the gearbox entering the accessory unit and also prevents
contamination of the gearbox, and hence engine, in the event of an accessory
failure. The use of an air blown seal results in a gearbox pressure of about 3 lbs.
per sq. in. above atmospheric pressure. To supplement a labyrinth seal, an 'oil
thrower ring' may be used. This involves the leakage oil running down the driving
shaft and being flung outwards by a flange on the rotating shaft. The oil is then
collected and returned to the gearbox.
Materials
To reduce weight, the lightest materials possible are used. The internal gearbox
casing is cast from aluminium but the low environmental temperatures that an
external gearbox is subjected to allows the use of magnesium castings which are
lighter still, The gears are manufactured from non-corrosion resistant steels for
strength and toughness. They are case hardened to give a very hard wear resistant
skin and feature accurately ground teeth for smooth gear meshing.
Fractioning Tower.
Figure 9.1.
The use of these side-strippers enables kerosene and gas oil to be obtained direct
from the plant. Lubricating oil distillate, if such is present, can usually be drawn
direct from a tray without the use of a side-stripper, while gasoline leaves the top of
the column as a vapour and must be cooled to condense it to liquid gasoline.
9.3 PROPERTIES
9.3.1 EASE OF FLOW
The ease of flow of a fuel is mainly a question of viscosity, but impurities such as
ice, dust, wax, etc., may cause blockages in filters and in the fuel system generally.
Most liquid petroleum fuels dissolve small quantities of water and if the temperature
of the fuel is reduced enough, water or ice crystals are deposited from the fuel.
Adequate filtration is therefore necessary in the fuel system. The filters may have to
be heated, or a fuel de-icing system fitted, to prevent ice crystals blocking the filters.
Solids may also be deposited from the fuel itself due to the solidification of waxes or
other high molecular weight hydrocarbons. Distillates heavier than kerosene, such
as gas oil, generally have a pour point temperature too high for use in aircraft
operating in low temperatures. If these fuels were to be used, some form of heating
in the aircraft’s tanks and fuel system would be necessary. Such heating would
obviously be an unreasonable complication.
9.3.2 EASE OF STARTING
The speed and ease of starting of gas turbines depends on the ease of ignition of
an atomised spray of fuel. This ease of ignition depends on the quality of the fuel in
two ways:
a) The volatility of the fuel at starting temperatures.
b) The degree of atomisation, which depends on the viscosity of the fuel as well
as the design of the atomiser.
The viscosity of fuel is important because of its effect on the pattern of the liquid
spray from the burner orifice and because it has an important effect on the starting
process. Since the engine should be capable of starting readily under all conditions
of service, the atomised spray of fuel must be readily ignitable at low temperatures.
Ease of starting also depends on volatility, but in practice the viscosity is found to be
the more critical requirement. In general, the lower the viscosity and the higher the
volatility, the easier it is to achieve efficient atomisation.
9.3.3 COMPLETE COMBUSTION
The exact proportion of air to fuel required for complete combustion is called the
theoretical mixture and is expressed by weight. There are only small differences in
ignition limits for hydrocarbons, the rich limit in fuels of the kerosene range being
5:1 air/fuel ratio by weight and the weak limit about 25:1 by weight.
Flammable air/fuel ratios each have a characteristic rate of travel for the flame
which depends on the temperature, pressure and the shape of the combustion
chamber. Flame speeds of hydrocarbon fuels are very low and range from 0.3 –
0.6 m/sec. These low values necessitate the provision of a region of low air velocity
within the flame tube, in which a stable flame and continuous burning are ensured.
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Flame temperature does not appear to be directly influenced by the type of fuel,
except in a secondary manner as a result of carbon formation, or of poor
atomisation resulting from a localised over-rich mixture. The maximum flame
temperature for hydrocarbon fuels is roughly 2,000C. This temperature occurs at a
mixture strength slightly richer than the theoretical, owing to dissociation of the
molecular products of combustion, which occurs at the theoretical mixture.
Dissociation occurs above about 1,400C and reduces the energy available for
temperature rise.
The problem of the flame becoming extinguished in flight is not perfectly
understood, but it appears that the type of fuel is of relatively minor importance.
However, wide cut gasoline’s are more resistant to extinction than kerosene and
engines are easier to relight using wide cut fuel. This is due to the higher vapour
pressure of these fuels.
9.3.4 CALORIFIC VALUE
The calorific value is a measure of the heat potential of a fuel. It is of great
importance in the choice of fuel, because the primary purpose of the combustion
system is to provide the maximum amount of heat with the minimum expenditure of
fuel. The calorific value of liquid fuels is usually expressed in megajoules (MJ) per
litre. When considering calorific value, it should be noted that there are two values
which can be quoted for every fuel, the gross value and the net value. The gross
value includes the latent heat of vaporisation and the net value excludes it. The net
value is the quantity generally used. The calorific value of petroleum fuels is related
to their specific gravity. With increasing specific gravity (heavier fuels) there is an
increase in calorific value per litre but a reduction in calorific value per kilogram.
Thus, for a given volume of fuel, kerosene gives an increased aircraft range when
compared with gasoline, but weighs more. If the limiting factor is the volume of the
fuel tank capacity, a high calorific value by volume is the more important.
9.3.5 CORROSIVE PROPERTIES
The tendency of a turbine fuel to corrode the aircraft’s fuel system depends on two
factors:-
a) Water.
b) Other corrosive substances, notably sulphur compounds.
The water which causes corrosion is dissolved water. It leads to corrosion of the
fuel system, which is particularly important with regard to the sticking of sliding
parts, especially those with small clearances and only small or occasional
movement.
Corrosion can also be caused by secondary effects, such as biological corrosion
caused by plant spores, which are not killed off by the cracking process. Kerosene
and diesel suffer from this form of contamination.
In film lubrication, viscosity is the important factor because it controls the ability of
the oil to keep the surfaces apart. A shaft revolving at high speed in a bearing must
be free to carry oil round with it, with as little drag as possible. The rapid movement
of one layer of oil slipping over another, with minimum drag, can only be achieved
with a low viscosity oil. As the rotational speed decreases, the rate of deformation
of the oil decreases, therefore the drag decreases and consequently an oil of higher
viscosity may be needed if it is to be successfully carried round the bearing.
The running temperature of the bearing is equally as important as the speed of
rotation, as it controls the viscosity of the oil to be used. Bearing temperatures may
vary, hence the need for oils with high VIs.
9.4.3 BOUNDARY LUBRICATION
If a shaft carries an appreciable load and rotates very slowly it will not carry round
sufficient oil to give a continuous film and boundary lubrication will occur in which
the friction is many times greater than in fluid film lubrication.
Boundary lubrication is said to exist when the oil film is exceedingly thin and may
only consist of a very few layers of molecules. It occurs due to high bearing loads,
inadequate viscosity (possibly due to excessive bearing temperatures), oil
starvation or loss of oil pressure. The friction is independent of the viscosity of the
oil, but depends on the load and the “oiliness” of the lubricant. When a lubricating
oil reduces the friction in a bearing to a lower value than that given by another
lubricant of the same viscosity at the same bearing temperature, it is said to have a
greater oiliness. It is thought that the reduction in friction is achieved by the fatty
acids in the oil combining chemically with the bearing metal to form a “soap” which
gives a boundary layer between the thin oil film and the bearing material to protect
the metals from welding together.
Boundary lubrication is not a desirable phase of lubrication as rupture of the thin film
means wear, a very high surface temperature and possible seizure; therefore
lubrication is designed to be hydro-dynamic if possible. However, boundary
lubrication often occurs during starting conditions and may occur in piston engines
at the end of reciprocating strokes. There is no precise division between boundary
and fluid film lubrication although each is quite distinct in the way in which
lubrication is achieved. In practice both forms occur at some time giving mixed film
lubrication.
9.5 LUBRICATING OILS
General
Viscosity and VI are the factors which decide the lubricant for a particular purpose.
The desirable viscosity for a given purpose is decided by bearing loads and
clearances, sliding speeds, oil pump capacity, operating temperatures, etc.
Therefore, in a lubricating oil specification, the desired viscosity is specified,
together with VI and other safeguards to prevent the use of oil, which would
deteriorate excessively or corrode the engine. Special engine tests are also carried
out in test engines for each main batch of lubricating oil.
There is much less risk of fire with oil, however it will burn if the conditions are right.
The main risk with oil is to the body; prolonged contact with oil can cause dermatitis
and/or cancer. The use of barrier cream and gloves cannot be overstated. Washing
of hands before going to the toilet or eating is important, as is the reapplication of
protection afterwards.
Oil spills should be cleaned up as soon as possible and waste disposed of in
accordance with company procedures.
Intentionally Blank
10 LUBRICATION SYSTEMS
10.1 INTRODUCTION
There is always friction when two surfaces are in contact and moving, for even
apparently smooth surfaces have small undulations, minute projections and
depressions and actually touch at only a comparatively few points. Motion makes
the small projections catch on each other and, even at low speeds when the surface
as a whole is cool, intense local heat may develop leading to localised welding and
subsequent damage as the two surfaces are torn apart. At higher speeds and over
longer periods, intense heat may develop and cause expansion and subsequent
deformation of the entire surface; in extreme cases large areas may be melted by
the heat, causing the metal surfaces to weld together.
The gas turbine engine is designed to function over a wider environment and under
different operating conditions from its piston engine equivalent and therefore special
lubricants have been developed to cope with the following main problems:
a. High rpm compared with piston engines.
b. Cold starting in winter can mean initial bearing temperatures of -54C which
rapidly increases after starting to 232C. Therefore a good viscosity index and
adequate cooling are required.
On the other hand, the following advantages can be claimed for the gas turbine:
a. There are fewer bearings and gear trains.
b. Oil does not lubricate any parts directly heated by combustion and therefore oil
consumption is low.
c. There are no reciprocating loads.
d. Bearings are generally of the rolling contact type and therefore only low oil
pressures are needed (40 psi is normal).
Turbo-prop engine lubrication requirements are more severe than those of a turbo-
jet engine because of the heavily loaded reduction gears and the need for a high-
pressure oil supply to operate the propeller pitch control mechanisms. (For
example, a twin relief valve in the Dart provides 35 psi for engine lubrication and 70
psi, which is fed to the propeller controller and boosted by a further pump to a
pressure of 600 psi).
10.2 BEARINGS
The early gas turbines employed pressure lubricated plain bearings but it was soon
realised that friction losses were too high and that the provision of adequate
lubrication of these bearings over the wide range of temperatures and loads
encountered was more difficult than for piston engine bearings.
As a result, plain bearings were abandoned in favour of the rolling contact type as
the latter offered the following advantages:
a Lower friction at starting and low rpm.
b Less susceptibility to momentary cessation of oil flow.
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c The cooling problem is eased because less heat is generated at high rpm.
d The rotor can be easily aligned.
e The bearings can be made fairly small and compact.
f The bearings are relatively lightly loaded because of the absence of power
impulses.
g Oil of low viscosity may be used to maintain flow under a wide range of
conditions and no oil dilution or pre-heating is necessary.
The main bearings are those which support the turbine and compressor assemblies.
In the simplest case (a single spool engine), these usually consist of a roller bearing
at the front of the compressor and another in front of the turbine assembly, with a
ball bearing behind the compressor to take the axial thrust on the main shaft.
“Squeeze film” main bearings have been introduced to reduce transfer of rotor
vibration to the aircraft. In this type of bearing pressure oil is fed to a small annular
space between the bearing outer track and the housing. Figure 10.1. shows that the
bearing will therefore “float” in pressure oil, which will damp out much of the
vibration. Squeeze film bearings are fitted to the Spey and all subsequent aero
engines produced by Rolls-Royce (1971) Ltd. They have also been fitted
retrospectively to existing engines. In addition to the main bearings, lubrication will
also be required for the wheelcase, tacho-generator, CSDU, alternator, starter and
fuel pump drives.
Single Spool
Turbojet
The air-cooled oil cooler is similar to the fuel-cooled type both in construction and in
operation – except, of course, that air replaces the fuel as the cooling agent. On
some engines, the airflow through the matrix is controlled by a flap valve, which is
automatically operated when the temperature of the return oil rises to a pre-
determined value. A turbo-propeller engine may be fitted with an oil cooler that
utilises the external airflow as a cooling medium. This type of cooler incurs a large
drag factor and, as kinetic heating of the air occurs at high forward speeds, it is
unsuitable for turbo-jet engines.
10.4.4 PRESSURE FILTER
The pressure oil filter housing contains a wire-wound or mesh, Paper or felt
elements and incorporates a by-pass valve. The filter housing can be drained
independently of the main oil system. This is done through a drain valve in the
housing base. When drained, the filter can be removed for examination, servicing,
or replacement, as necessary, without disturbing the rest of the system. Typical
pressure filters are illustrated in figure 10.13.
Filters are usually fitted with an impending by-pass indicator. This is usually a red
pop out indicator which will pop out and stay out it the differential pressure across
the filter element exceeds a predetermined value. This value will be less than the
by-pass valve value, to allow the filter to be replaced before the filter goes into by-
pass. The pop out usually has a thermal lock on it, which prevents the pop out
extending when the oil is cold and thick.
10.4.8 DE-AERATOR
We have already noted that air from the bearing sealing system mixes with the oil
and causes frothing. If the air is allowed to remain in the oil it may cause a
lubrication failure. To prevent this, a de-aerating device may be installed; this
removes air from the oil before the oil is re-circulated round the engine by the
pressure pump; the air can be vented to atmosphere via the centrifugal breather.
De-aerators are usually tray types fitted in the oil tank or centrifugal type as a
separate item.
Centrifugal Breather.
Figure 10.17.
It is more usual to find a pressure relief valve that varies the pressure with engine
speed or breather pressure. These valves are usually adjustable but usually only
effect the max speed oil pressure see Figure 10.19.
This type of valve uses the oil system breather pressure and an adjustable spring to
balance the oil pressure in the main oil feed line to the engine bearings.
Consider Fig. 10.19. With the engine running, the breather pressure plus the spring
push the sliding valve to the left and restrict the pump spill back to return. This is
balanced by the pressure from the main feed line trying to move the slide valve to
the right. Should the pressure in the main feed line fall, the breather pressure and
spring will move the slide valve further to the left and restrict the oil spill still further.
This will allow more oil to flow to the system, and the oil pressure in the main feed
line will increase. The slide valve will then move to the right, and the oil spill to the
return will be controlled by the main feed line pressure balancing the spring and
breather pressure.
10.4.11 BY-PASS VALVE
This is similar in construction to the normal pressure relief valve just discussed. It is
connected in the system in such a way that, should the oil cooler or the pressure
filter become blocked (so that the oil flow is restricted), the appropriate by-pass
valve will operate to re-route the oil. Although the cooling or the filtering has now
been by-passed, oil starvation of the oil bearings is prevented. Pop–out indicators
are used to warn of an impending by-pass.
The oil cooler will usually have a thermal by-pass valve which will by-pass the
cooler when the oil is cold, thus ensuring that the oil gets up to running temperature
quickly.
10.5 INDICATIONS AND WARNINGS
Indications and warnings vary from aircraft to aircraft, in both the warnings given
and the priority that they are given.
The engine oil level is usually checked after flight or after an engine run. It is not
checked straight after shut-down, as entrained air will give a false reading. It cannot
be checked accurately if left too long as the oil may run out of the tank into the
gearbox. So it is normally checked between 20 minutes and 2 hours or as defined in
the aircraft maintenance manual.
The oil system magnetic chip detectors will be checked at the periodicity defined in
the maintenance schedule. Spectrometric Oil Analysis Program (SOAP) samples of
the oil may be taken when required.
Filters are replaced when required by the maintenance schedule or if the pop out
indicator is out.
Burners.
The type of burners employed will vary with design. Two basic types are in common
use, atomisers and vaporisers, and their common purpose is to supply fuel in a
readily combustible form over the whole operating range of the engine.
11.4 FACTORS GOVERNING FUEL REQUIREMENTS
The factors that determine the quantity of fuel that constitutes ‘the correct amount’
to be delivered to the combustion system at any one time are:-
a) The RPM selected.
b) The density of the air at the compressor inlet.
c) The rate at which the engine can accept the fuel into the combustion system
under conditions of engine acceleration.
11.5 REQUIREMENTS OF THE ENGINE FUEL SYSTEM
a) The selection of the RPM must be under the control of the pilot and the system
must ensure that the maximum permissible RPM is not exceeded.
b) The fuel must be introduced into the combustion system in a readily
combustible form and the system must be able to automatically adjust the
fuel flow to match the air available in order to maintain the selected RPM
under all operating conditions.
11.6 ENGINE FUEL SYSTEM COMPONENTS
In order to achieve its purpose, the engine fuel system will incorporate the following
components:-
a) High pressure fuel pump.
b) Fuel flow-controlling devices.
c) Burners.
11.7 FUEL PUMPS
The type of fuel pump used may vary from one engine type to another and their
common purpose is to supply the correct amount of fuel to the burners at a
sufficient rate of flow to ensure operation over the whole range of engine operation.
The pump is driven by the engine via a suitable gear train.
11.7.1 FUEL PUMP REQUIREMENTS
Because the fuel flow requirements of an engine running at a constant RPM will
vary with changing atmospheric conditions, the fuel pump must be capable of
delivering fuel at flow rates in excess of the maximum engine demand at any
particular RPM, eg. its output must be variable independently of its speed of
rotation.
The output of the engine driven fuel pump is dependent on engine RPM and
controlling signals from various fuel flow controlling devices.
There are two basic types of fuel pump, the plunger-type pump and the constant
delivery gear-type pump; both of these are positive displacement pumps. Where
lower pressures are required at the burners (spray nozzles), the gear-type pump is
preferred because of its lightness.
Throttle Variations.
If the throttle is opened, its pressure drop is reduced and the proportioning valve
closes until the pressures across the diaphragm are equalised. Thus secondary
flow and pressure are reduced, the piston drops, the half-ball valve closes and
pump stroke increases. The increased fuel flow increases secondary pressure until
the half-ball valve resumes its sensitive position, but the proportioning valve
remains more closed than previously, taking a small proportion of the increased
flow.
P1 Variations.
Variations in P1 will cause the capsule to expand or contract, thus altering the
position of the half-ball valve and altering fuel flow. This tends to cause rapid
changes in secondary pressure with resultant instability; damping is provided by the
sensing valve, which adjusts to control the outflow to LP, thus damping secondary
pressure fluctuations. The valve is contoured to operate only over a small range of
pressure drops so that during throttle movements it acts as a fixed orifice.
Air Switch.
Air Switch
Figure 11.12.11.12.
Figure
Power Limiter.
Figure 11.14.
Centrifugal Governor
Figure 11.15.
Centrifugal LP
Figure 11.16.
Governor
HP Hydro-Mechanical Governor.
Figure 11.17.
11.11 BURNERS
11.11.1 ATOMISER BURNERS
This type of burner presents the fuel in a finely atomised spray by forcing the fuel to
pass through a small orifice. The size of the orifice is critical because it must
atomise the fuel effectively over a wide range of fuel flows, from idling to take off
RPM.
Some engines have such a wide range of fuel flow requirements that a single orifice
is unable to perform the task effectively unless extremely high fuel pressures are
used and to combat this a burner with two different sized orifices are used. During
low fuel flow requirements, only the small or primary orifice is supplied with fuel and
at higher flow rates both primary and secondary orifices are in operation.
Both types of atomiser burners incorporate an air shroud, which directs some of the
primary air into the burner to assist atomisation and to cool the burner head to
prevent the formation of carbon.
The usual method of atomising the fuel is to pass it through a swirl chamber where
tangentially disposed holes or slots impart swirl to the fuel by converging its
pressure energy to kinetic energy. In this state, the fuel passes through the
discharge orifice where the swirl motion is removed as the fuel atomises to form a
cone-shaped spray. The shape of the spray is an important indication of the degree
of atomisation; thus, the rate of swirl and therefore the pressure of the fuel at the
burner are important factors in good atomisation.
A Simplex Burner.
Figure 11.19.
The Simplex burner shown in the figure 11.19. was first used on early jet engines. It
consists of a chamber, which induces a swirl into the fuel and a fixed area atomising
orifice. This burner gave good atomisation at the higher fuel flows, that is at the
higher burner pressures, but was very unsatisfactory at the low pressures required
at low engine speeds and especially at high altitudes. The reason for this is that the
Simplex burner was by the nature of its design a “square law” burner, that is the
flow through the burner is proportional to the square of the pressure drop across it.
This meant that if the minimum pressure for effective atomisation was 30 lbf/in 2, the
pressure needed to give maximum flow would be about 3,000 lb/in 2.
A Spray Nozzle.
Figure 11.21.
Check Valve
A check is fitted in the starter jet line downstream of the Priming Solenoid Valve to
prevent fuel dribbling into the combustion chamber on shut down.
It is a spring-loaded valve, which is closed at rest and opens when fuel pressure
reaches a pre-determined value.
Starter Jets
As vaporisers do not atomise the fuel sufficiently for combustion until they become
heated, for starting purposes initial heating during start is provided by four jets, two
of which are combined with High Energy Igniters. The starter jets ensure that, even
at the low flows encountered during start, the fuel is atomised as required for light
up.
Pressurising Valve
A pressurising valve is fitted in the main gallery feed line. It is spring-loaded which
functions to build up and stabilise the metering system servo pressures before any
flow to the main gallery. Thereby it ensures the correct delivery of fuel to the
vaporisers during start.
More power and efficiency result from “rich” mixtures, but these are limited by
maximum turbine temperatures. Therefore fuel supplies must be limited so that an
overall air/fuel ratio of about 60:1 at maximum rpm is achieved. At other rpm the
ratio will change due to changing efficiencies of turbine and compressor. The
“correct” mixture strength is 15:1 hence only about a quarter of the air passing
through the engine is used for combustion. (15% - 25% is the typical range).
In the flame area the ratio is about 13:1 and around the flame centre a weaker ratio
of 18:1 is used to ensure complete combustion with no carbon formation.
The flame rate at an atomising burner is 2-10 ft/sec and at a vaporiser, 60 ft/sec.
Both figures are low compared with the air velocity through the combustion zone,
hence the requirement for a low velocity zone at the burner to (a) aid ignition and (b)
maintain the flame at the burner.
Theoretically, combustion in a gas turbine is at “constant pressure”, ie. the pressure
along the combustion chamber does not change due to combustion but could alter
due to changes in rpm and air intake pressure.
In practice the combustion chamber shape affects the pressure and they are
designed to minimise this and a drop of 4% along its length is usual.
Flame temperature is high; a constant 2,000C at the centre. Flame size, however,
can change and the bigger the flame becomes the higher goes Turbine Entry
Temperature and Jet Pipe Temperature (TET and JPT).
“Over-fuelling” gives a larger flame and “Under-fuelling” a smaller; the significance
of these will be seen in a later note.
Operation
The fuel flow supplied to the nozzles is mainly obtained through two valves:
a bypass valve
a metering valve.
The fuel enters the HMU from pump outlet with a constant flow. This flow is split by
the bypass valve into two flows, one for the nozzles (via the metering valve) and one
bypass return flow to the pump. The position of the bypass valve is a function of the
loss of fuel pressure caused by the metering valve. The metering valve is
pneumatically actuated. In the pneumatic servo block, the reference pressure is the
HP compressor outlet pressure, P3. A controlled reduction of the P3 pressure results
in a variable Py pressure which when opposed to a bellows device, moves the piston
of the metering valve.
The pneumatic servo block is managed:
in normal operation by the EEC
in manual operation, by the power input lever.
Normal Operation (EEC Mode)
According to the input data (pressures, temperatures, speeds) and to the
commanded power (power lever), the EEC controls a stepper motor located in the
HMU.
The stepper motor regulates Py pressure thus modulating the fuel flow as
requested. A governor acts on the Py pressure, thus setting an NH speed limit
function of the compression of a spring by a cam (EEC cam) connected to the
power lever.
Manual Operation (Manual Mode)
Py pressure is not regulated by the stepper motor but by the simultaneous
actions of the NH speed governor and the spring, compressed by a second cam
(manual cam) connected to the power lever.
Transfer from the EEC Mode to the Manual Mode.
In normal operation the EEC manages the fuel regulation. The manual
operation is automatically connected when the operation in the EEC mode is
switched off. A solenoid in the HMU selects the manual cam instead of the EEC
cam and cancels the regulation control through the stepper motor.
Operation of the HMU in the fail mode
In case of failure of the EEC, the position of the stepper motor is "frozen".
Whatever the increase of power through the power lever, the last N H speed
remains unchanged (the load applied by the spring on the N H speed governor
increases).For any power reduction through the power lever, the N H speed
decreases according to the curve of the EEC cam (decreasing spring load).
Fuel Distribution
During operation, fuel flows from the aircraft fuel tank to the fuel-pump boost-stage
inlet. The pressurised fuel from the boost stage of the engine-driven fuel pump then
leaves the pump and is delivered to the fuel/oil cooler, whose purpose is to keep the
fuel sufficiently warm to prevent ice from forming in the fuel, and at the same time,
keep the maximum temperature of the oil within the correct limits. This engine is
also equipped with an air/oil heat exchanger, which uses fan air and 2.5 bleed air to
prevent the fuel from getting too hot.
From the fuel/oil cooler, the fuel is returned to the fuel pump, where it is filtered and
sent to the main pump stage to be further pressurised before it is sent to the fuel-
metering unit, which actually does the metering on the basis of information it
receives from the FADEC. The fuel-metering unit sends fuel to the fuel-flow
transmitter, and then to the fuel distribution valve. (Servo fuel, used as an actuation
pressure to some interface components, also comes from the fuel-metering unit.)
Bypass fuel not sent to the fuel distribution valve or servo supply is returned to
pump interstage flow. From the fuel distribution valve, the metered fuel flows
through the fuel manifolds to the fuel injectors.
The FADEC is the primary interface between the engine and the aircraft. The
FADEC contains two channels that are called "A" channel and "B" channel. Each
time the engine starts, alternate channels will automatically be selected. The
channels are linked together by an internal mating connector for crosstalk data
transmission. Much more is accomplished by this control than simply sending a
signal to the fuel-metering unit to establish a fuel flow to the nozzles.
The engine electronic control (EEC) programming plug is used to determine the
engine thrust rating and EPR correction.
Burner pressure (Pb), which comes from the diffuser case, is used for limiting and
surge detection. • Ambient pressure (Pamb), which comes from the inlet cowl, is
used to validate altitude and Pt2.
Based on information received from its various sources the FADEC will:
1. Monitor, control and protect:
Anti surge bleed valves/variable stator vanes
Cooling airflows
Engine oil cooling and IDG oil cooling
Nacelle cooling
Fuel heating
Starting
Idle speed
Acceleration/Deceleration
While electronic controls are highly reliable, malfunctions can occur. A hierarchy of
fault-tolerance logic will take care of any single or multiple faults. The logic also
identifies the controlling channel, and if computational capability is lost in the primary
channel, the FADEC automatically switches to the secondary channel. If a sensor is
lost in the primary channel, the secondary channel will supply the information. If data
from the secondary channel is lost, the FADEC will produce usable synthesised
information from the parameters that are available. If there is not enough data
available for synthesising, the control modes switch. For example, if EPR is lost, the
engine will be run on its N1 ratings.
In the unlikely event both channels of electronic control are lost, the torque motors
are spring-loaded to their fail-safe positions. The fuel flow will go to minimum flow,
the stator vanes will move to fully open, the air-oil cooler will open wide, and the
ACC will shut off.
The FADEC includes extensive self-test routines which are continuously actuated.
BITE, or built-in test equipment, can detect and isolate faults within the EEC and its
input and output devices. The fault words of the control are decoded into English
messages by a maintenance monitor, and they identify the faulty line-replaceable
unit (LRU). In-flight fault data is recorded so it can be recalled during shop repair.
The FADEC is able to isolate problems and indicate whether the fault is within itself
or in a sensor or actuator. In the shop, computer-aided troubleshooting can identify
a fault at the circuit-board level.
EEC Programming Plug
The EEC programming plug located on the FADEC "A" channel housing, selects the
applicable schedules within the FADEC for the following:
Engine thrust rating
EPR modification data
Engine performance package
Variable-stator-vane schedule
2.9 bleed-valve thermocouple selection
The EEC programming plug data is input to the FADEC "A" channel, while the "B"
channel EEC programming-plug input is crosswired and crosstalked from the "A"
channel. During test-cell operation, the EPR/thrust relationship is compared, and the
engine gets a correct EEC programming plug. If the FADEC must be replaced, the
EEC programming plug must remain with the engine.
If the engine is started without the EEC programming plug installed, the FADEC
goes to the N1 mode. But nothing will happen with the FADEC operation if the EEC
programming plug disconnects in flight.
Figure 11.32.
Alternator.
The alternator provides the FADEC with power and an N2 speed signal. It also
sends N2 information to the flight deck.
FADEC Alternator
Figure 11.33.
Speed Transducer. The speed transducer supplies the FADEC "A" and "B" channels
with the N1 signal by sensing the frequency at which the 60 teeth on the low-
pressure compressor/low-pressure turbine (LPC/LPT) coupling pass by them.
Temperature Probes.
A dual-element, alumel-chromel thermocouple, located on the top right side of the
fuel pump, provides the FADEC with information relating to fuel heating and engine
oil cooling. Oil Temperature Probes. Two other similar devices inform the FADEC
about scavenge oil temperature and No. 3 bearing-oil temperature, and provide
input for engine oil cooling-system control, oil-temperature warning indication, and
IDG oil-cooling override.
Tt3 Temperature Probe.
This dual-element probe is located on the diffuser case and provides the FADEC
with information for heat-soaked engine start logic.
Pt2/Tt2 Probe. The inlet pressure/temperature probe supplies the FADEC with
engine-inlet pressure and temperature information. The pressure sensor is a total
pressure probe that sends its signal to both FADEC channels. The temperature
sensor is a dual-element resistance type. One element sends its signal to the "A"
channel, while the other sends its signal to the "B" channel. The probe is
continuously electrically heated.
Pt2/Tt2 Probe.
Figure 11.38.
Combined Speed and Acceleration Control with Air Bleed Control. (ALF502.)
Figure 11.46.
Figure 11.47.
12 AIR SYSTEMS
12.1 INTRODUCTION
In the working cycle and airflow section we discussed the main airflow and working
cycle of a gas turbine engine and found that a major function of the airflow through
the engine was to act as a cooling medium and that only a small proportion of the
air was used to support combustion. In fact, because of the intense heat
developed, gas turbine engines only became practical power units when it was
discovered that the airflow could be used to ‘insulate’ the structural materials and
thus provide acceptable working temperatures for the materials. Many parts of the
engine, made from light alloy or ferrous metals, have to be protected from the very
high temperatures. To achieve this, an efficient and effective cooling system is
needed and this is provided by ducting cooling air from the main gas stream.
12.3 SEALING
Air at low pressure is used to seal the main shaft bearings and prevent oil from
leaking into the engine casing. For effective sealing, the air pressure must always
by greater than that of the oil. However, it must not be too much greater, otherwise
an excessive amount of air will enter the oil system. De-aeration by means of the
de-aerator and the centrifugal breather (see lubrication) may then become difficult.
Figure 12.2. shows that the mechanical seals used in air pressure oil sealings are
designed to reduce clearance to a minimum; air is fed into the seal at the end
remote from the oil feed.
12.4 COOLING.
Figure 12.3. illustrates the turbine cooling airflow of a typical gas turbine engine.
The outward flow of cooling air is controlled by air seals of multi-groove construction
and the arrangement is such that the turbine discs obtain the maximum possible
cooling from the airflow. Interstage seals are incorporated and they are made in
such a way that the front sections provide less restriction to the passage of air than
the rear sections do. The result is that the rate at which the cooling air flows across
the seals is sufficient to prevent any inward flow of hot gases. The front face of
each disc receives a greater airflow than the rear.
High pressure cooling air is also directed to the engine’s nozzle guide vanes and
turbine blades. These components, which are externally heated by the high
temperature gas stream, are cooled by ducting air through air passages formed
inside the items themselves. After completing its task, the air is exhausted into the
engine exhaust gas flow and thence to atmosphere.
Figure 12.7. shows (highlighted) air tubes (Bird Cage) that cools the HP and LP
turbines. The air is taken from just aft of the fan and ducted through the cowls (not
shown).
By means of a Y manifold and two shut-off valves, cooling air can be selectively
directed to the core compartment or to the LPT case. The valves are not positively
shut, but permit a required minimum flow at all altitudes and when activated added
flow is directed. The valves are controlled by an altitude sensor which activates the
core compartment valve below 19,000 feet +5000 feet and the LPT case valve
above 19,000 feet +5000 feet.
Increased cooling airflow causes the cases to cool and shrink. This shrinkage
closes blade tip to case clearances producing improved efficiency.
Operation
At take-off and low altitude the valve is in its normal closed position allowing cooling
airflow to the core compartment. When an altitude of 19,000 feet +5000 feet is
reached, the altitude sensor switches to supply compressor discharge pressure to
the signal port of the valve, causing the valve piston to move to the open position,
thus allowing cooling airflow to the low pressure turbine cooling manifold.
During descent, at approximately 15,000 feet +1500 feet, the altitude sensor
switches back and cuts off the compressor discharge signal pressure to the valve
and the positioning spring in the valve returns the piston to its normal closed
position. Operation can be monitored by the electrical position indicator switch and
a disagree flightdeck light.
External Cooling.
Figure 12.11.
HP Air Powering a Jet Eductor to Draw Air Through a Generator at Low Speed.
Figure 12.12.
Generally on gas turbines the engine anti-icing system prevents the formation of ice
in the engine intake and on the aircraft structure by the circulation of hot air from the
engine. It is normally taken at a midway point along the HP compressor at an
approximate temperature of 300C and controlled by a switch on the flight deck. Air
is taken via the control valve mounted near the manifold on the HP compressor and
directed to an annular manifold around the air intake casing, then through hollow
intake guide vanes, tangential struts and nose cone exhausting into the airstream
or, as in the case of large fan engines, directly overboard.
Control of the nacelle anti-ice system is by means of flight deck switches. These
valves may fail safe, i.e. to the open position, if electrical power is lost. On some
systems a tapping of hot air also feeds the intake pressure probe.
On a large number of turbo fan engines there are no support struts to the spinner,
which rotates with the fan. Thermal anti-icing of the spinner is often provided by
using hot oil. Ice formation can also be minimised by the shape of the spinner and
a flexible rubber coating which tends to shed any ice which forms.
Intentionally Blank
An Air Starter
Figure 13.5.
Sprag clutches are used to provide the disconnect mechanism between the starter
motor and the engine. The clutch will transmit drive from the starter motor, but will
disconnect the drive when the engine speed exceeds the starter. The clutch
consists of two smooth concentric drive faces and between them a cage containing
many elongated figure of eight shaped cams called “sprags”. All the surfaces are
hardened to reduce wear, and are lubricated by oil. The sprag are spring loaded in
contact with the starter drive so that when the shaft starts to rotate the sprags stand
up and contact the engine drive due to the cam action of their shape. See Figure
13.6. As engine RPM accelerates its drive will be faster than the starter motor and
the clutch will automatically dis-engage as sprags get pushed back to their minimum
height position.
Sprag clutches are used on most types of starter motor or in drives where one way
drive is required such as helicopter gearboxes.
Sprag Clutch.
Figure 13.6.
13.2.4.3 Speed Switch
The speed switch can give warning of an over-speed of the starter (engine driving
starter) and/or an auto shut-down.
As the starter speeds up towards an over-speed, the ball weights centrifuge out
forcing up the bell housing breaking the micro-switch to give an over-speed signal.
115 VAC is used to energise the exciter and is controlled through the HP fuel shut
off valve lever, the ignition selector and the ignition relay.
The ignition relay is energised by 28 Vdc when the master switch is in the ARM
position and the start button is pushed.
Starting is achieved in the following manner:-
Set the ignition selector to A or B.
Set the master switch to “ARM”.
This arms the ignition circuit and closes the air conditioning system if it is open. The
amber lights in the push-to-start buttons will illuminate during this transit.
When the air conditioning valves are closed, the lights in the push-to-start buttons
extinguish and the operator can push the start button which will latch. This
increases the APU rpm to 100% to provide sufficient air for starting.
It also arms the ignition circuit and finally, provided that pneumatic power is
available, it opens the start valve and the blue OPEN light illuminates.
When engine N2 reaches 10% the HP Fuel Shut Off Valve must be opened.
This supplies fuel to the engine and energises the ignition exciters. The engine
should light up and EGT should increase.
Issue 2 – April 2003 Page 13-10
JAR 66 CATEGORY B1
MODULE 15
uk GAS TURBINE
engineering ENGINES
When N2 reaches 45% the engine will be self-sustaining so the ignition is switched
off, the push-to-start button pops out and the APU demand goes back to normal.
Engine rpm should now increase to Ground Idle, which is approximately 65% N 2
and 24% N1.
Transistor generator
The air gap type is similar in operation to the conventional reciprocating engine
spark plug, but has a larger air gap between the electrode and body for the spark to
cross. A potential difference of approximately 25,000 volts is required to ionise the
gap before a spark will occur. This high voltage requires very good insulation
throughout the circuit.
The surface discharge igniter plug has the end of the insulator formed by a semi-
conducting pellet which permits an electrical leakage from the central high tension
electrode to the body. This ionises the surface of the pellet to provide a low
resistance path for the energy stored in the capacitor. The discharge takes the form
of a high intensity flashover from the electrode to the body and only requires a
potential difference of approximately 2000 volts for operation.
The normal spark rate of a typical ignition system is between 60 and 100 sparks per
minute. Periodic replacement of the igniter plug is necessary due to the progressive
erosion of the igniter electrodes caused by each discharge.
The igniter plug tip protrudes approximately 0.1 inch into the flame tube. During
operation the spark penetrates a further 0.75 inch. The fuel mixture is ignited in the
relatively stable boundary layer which then propagates throughout the combustion
system.
Ignitor Plugs
Figure 13.15.
Engine indications are very important to the crew of a powered aircraft, as they
indicate one of the primary parameters needed for flight. There are three types of
indications:
1. Performance indications such as thrust (Engine Pressure Ratio EPR) and
Revolutions Per Minute (RPM).
2. Operation indications such as Turbine Temperature indications, fuel flow,
oil pressure and temperature.
3. Discrete indications which put ‘ON’ a warning annunciator such as low oil
pressure, fuel low pressure engine overspeed etc.
The engine instruments on most modern commercial aircraft will invariably be
located on the main instrument panel in the centre, so that they are visible to both
pilots. The instruments are laid out in a logical pattern so that the main thrust
indicator is at or near the top of the indications. The indicators will be in vertical
columns for each engine and like indicators in rows.
When a flight engineer is carried he will have a panel with some of the primary
indications and all of the secondary and discrete indicators. He may also have a
duplicate set of thrust levers so that he can trim engines when required.
Until fairly recently the majority of aircraft used analogue gauges (sometimes
referred to as clockwork gauges) These had moving pointers or strips which
indicated the parameter being monitored.
The modern trend is to replace the analogue instruments with electronic instruments
that use LED, liquid crystal or cathode ray screens to display the engine
parameters, often not displaying continuously all the information, but to highlight
when a fault has occurred or when asked for by the crew. These types of instrument
do not usually retain the last indication after an accident, however the electronic box
powering them will inform the flight data recorder and/or retain the information in its
own memory.
All engines have their rotational speed (R.P.M.) indicated. On a twin or triple-spool
engine, the high pressure assembly speed is always indicated; in most instances,
additional indicators show the speed of the low pressure and intermediate pressure
assemblies. Where Engine Pressure Ratio (EPR) is not indicated then Low
Pressure RPM is indicated as this can be corrected to give Thrust.
ROTOR
(SYNCHRONOUS
ROTOR WITH
(MAGNET) SQUIRREL
CAGE START)
N N
S
S
INDICATO
GENERATO
R
R
The speed probe can be positioned on the compressor casing in line with the
phonic wheel, which can be a machined part of the compressor shaft. A gear wheel
in an external gearbox can also be used. The teeth on the periphery of the wheel
pass the probe once each revolution and induce an electric current by varying the
magnetic flux across a coil in the probe. The magnitude of the current is governed
by the rate of change of the magnetic flux and is thus directly related to engine
speed.
On some engines one of the teeth is bigger than the others, and will give a bigger
response. This can be used for Fan blade balancing or synchronising and/or
synchrophasing.
MAXWELL TACHO
SQUARER GAUGE
BRIDGE CIRCUIT
DC N
Turboprop and turboshaft engines do not provide significant thrust through their jet
pipes, so EPR would not be of any use in determining the thrust being produced by
the engine. Engine torque is used to indicate the power that is developed by these
engines, and the indicator is known as a torquemeter. The engine torque or turning
moment is proportional to the horsepower and is transmitted through the propeller
or rotor reduction gear.
A torquemeter system is shown in fig. 14.9. In this system, the axial thrust
produced by the helical gears is opposed by oil pressure acting on a number of
pistons; the pressure required to resist the axial thrust is transmitted to the indicator.
Operation
The helical gear form used in the reduction gearbox develops an axial thrust in its
three layshaft assemblies. This thrust is proportional to the power which is being
transmitted through the reduction gearbox. The axial thrust is balanced by an
opposing oil pressure, which is therefore proportional to engine power. This oil
pressure is referred to as torquemeter pressure and is indicated on a flight deck
instrument. Each of the layshafts operates against a piston that is supplied with oil
pressure from a torquemeter pump. The torquemeter supply comes from the
pressure side of the engine lubricating system. To balance any changes in axial
thrust, or engine power changes, the oil pressure is regulated by a control valve that
is incorporated in the lower piston assembly.
The piston on the lower layshaft assembly is drilled centrally and operates over a
stationary control valve. Flats on the control valve align with radial drillings in the
piston. This is oil spill to the engine oil scavenge system as shown in Fig. 14.10.
With the engine running at a stabilised power setting the lower piston will be in a
sensitive position, allowing a constant spill of oil to engine scavenge. In this
situation oil pressure is balancing the axial thrust. With an increase in engine power
the layshaft pushes the piston further over the control valve. The oil spill is reduced,
the oil pressure then increases giving an increased thrust indication on the flight
deck instrument. With a decrease in engine power the oil pressure pushes the
piston and the layshaft rearwards. The control valve now increases the oil spill, and
the oil pressure decreases until it balances the axial thrust on the layshafts. If an
engine fails the torquemeter pressure rapidly decreases below its normal operating
range, this condition is referred to as a negative torque signal. The negative torque
signal activates a low torque switch, which will in turn could activate the automatic
feathering sequence.
The stagnation type is fitted to pure jet engines where the exhaust velocity is high,
allowing the larger inlet hole to let the gas circulate around the couple, with the
offset outlet hole reducing the outward velocity of the air. In this way the probe
receives a good sampling of the gas temperature.
Types of Thermocouple
Figure 14.14.
The rapid response type will be fitted mainly to turboprop engines where the gas
flow is not as high as the jet turbine flow. In this arrangement the inlet and outlet
holes are the same, creating no restriction, so a rapid response of EGT indication is
achieved.
Finally if we consider the EGT gauge (Fig. 14.15.) you will see that there are
similarities to the rpm indicator.
The indicator shown in Fig. 14.15. is a fairly modern type, although you may
experience older instruments with a pointer only. Normally EGT is expressed in
degrees centigrade. A red line limit indicates the maximum permissible temperature
the engine is allowed to run at. And on some a red dot shows the maximum
overswing allowed for a very short time. Finally, in addition to the maximum red line
limits, most engines have an engine start EGT limit that is much less than the max.
limit. this lower limit protects a cold engine from thermal shock (overtemping)
during initial engine start.
TGT Gauge.
Figure 14.15.
14.5 FUEL FLOW METERING
Fuel flowmeters are fitted in aircraft to give an accurate indication of the rate at
which fuel is being used and the total amount of fuel that has been used at any
point during the flight. From the rate of fuel consumption the pilot is able to
determine the performance of his engines, and from the indication of the total fuel
consumed, can calculate the total flying hours that the aircraft can remain in the air.
There are a number of different types of fuel flowmeters in use on various aircraft
and it is beyond the scope of this publication to describe them all. Some of these
flowmeters indicate only the total fuel consumed, but the majority give indications of
both rate of flow and total fuel consumed.
To indicate mass flow accurately a flowmeter that compensates for changes of S.G.
is required.
The mass flow type of flowmeter gives a reading of the mass flow rate in pounds or
kilograms per hour rather than a volumetric reading in gallons per hour. The mass
flow rate is a more useful indication for most types of aircraft. Refer to figure 14.17.
for a mass flowmeter. The mass flowmeter consists of a motor-driven impeller, a
turbine and a synchro system to transmit the data to a flightdeck gauge. In order to
give accurate readings, the impeller must be driven at a constant speed. This is
accomplished with an AC synchronous motor or a similar device. As the fuel flows
through the impeller, it is given a spin or rotation by the spinning impeller. When the
fuel leaves the impeller, it strikes the turbine, which is rotated against a restraining
spring by the spin energy of the fuel. Because a denser fuel would impart more
spin energy to the turbine the degree of rotation of the turbine is a measure of mass
flow rate. The turbine is connected to the transmitter rotor of a synchro system
which will cause the pointer on the flightdeck gauge to rotate to the proper position
to indicate the correct mass flow rate. The sensor for this and other types of
flowmeters is installed in the fuel system downstream of the fuel control device so
that the flow rate represents the fuel consumption rate for that engine.
There are other type of mass flow transmitters, that use swirl vanes to cause the
rotation and have a different type of detection system, or vane type with
complicated S.G. correction.
The flowmeter gauge will have a flow indicator and usually a fuel used indication.
The fuel used indicator is usually a digital read-out that is derived by integrating the
fuel used with time.
The gauge can be calibrated in pounds per hour of kilograms per hour.
14.6 OIL
14.6.1 THE OIL PRESSURE INDICATOR
The oil pressure indicator has a dial normally calibrated in pounds per square inch
(psi). The indicator may have max. limit markers, but will always show the minimum
pressure that the engine is allowed to run at. The reason that some engines have
an upper limit is dependant upon the type of oil supply system. Some systems may
be regulated, therefore needing an upper limit, or be based upon flow where an
upper limit is not required.
An example of an oil pressure indicating system
is given in Fig.14.19.; the pressure indicator has
no upper oil pressure limit, however, the low
pressure limit is shown as 15 psi. There is also a
precautionary band, normally yellow in colour,
that is set just above the lower limit in the case in
Fig. 14.19., an indication of between 15 and 25
psi in this yellow band during engine operation
Oil Pressure Gauge. may require corrective action.
Figure 14.19.
Any change in oil pressure introduced into the
synchro transmitter causes an electrical signal to be transmitted through the
interconnecting wiring to the synchro receiver. This signal causes the receiver rotor
and the indicator pointer to move a distance proportional to the amount of pressure
exerted by the oil.
Most oil pressure transmitters are composed of two main parts, a bellowsor
diaphragm mechanism for measuring pressure and a synchro assembly (Fig.
14.20.) The pressure of the oil causes linear displacement of the synchro rotor.
The amount of displacement is proportional to the pressure, and varying voltages
are set up in the synchro stator. These-voltages are transmitted to the synchro
indicator.
14.7 VIBRATION
A turbo-jet engine has an extremely low vibration level and a change of vibration,
due to an impending or partial failure, may pass without being noticed. Many
engines are therefore fitted with vibration indicators that continually monitor the
vibration level of the engine. The indicator is usually a milliammeter that receives
signals through an amplifier from engine mounted transmitters fig.14.25.
The vibration level recorded on the gauge is the sum total of vibration felt at the
pick-up. A more accurate method differentiates between the frequency ranges of
each rotating assembly and so enables the source of vibration to be isolated. This
is particularly important on multi-spool engines.(Figure 14.26. refers)
15 THRUST AUGMENTATION
15.1 INTRODUCTION
There are occasions when the maximum thrust from a basic gas turbine engine is
inadequate and some method of increasing the available thrust is required without
resorting to a larger engine with its concurrent penalties of increased frontal area,
weight and fuel consumption.
There are two recognised methods of augmenting this maximum thrust:
a. De-mineralised Water or water/Methanol injection to restore, or even boost, the
thrust from a gas turbine operating from hot and high altitude airfields.
b. Reheat (or afterburning) to boost the thrust at various altitudes, especially at
high speeds. This is normally for short periods only.
15.2 WATER INJECTION
15.2.1 EFFECTS ON ENGINE POWER
The power output from a gas turbine engine depends upon the weight (air density)
of the airflow and the amount that it is accelerated as it flows through the engine.
Therefore, it follows that any condition that reduces the air density will reduce also
the engine power output. The two main natural causes of reduced air pressure are:
Increased Altitude
Increased Temperature
When these two causes of reduced air density are combined at a high altitude/
tropical airfield, there is a possibility that engines may not produce sufficient power
for a safe take-off and climb out. However, in these circumstances, the engine
power can be restored and in some instances increased, by cooling the airflow to
increase its density. To date, the addition of water or a water/methanol mixture has
proved to be the cheapest practical means of restoring or increasing the power of
an engine. Methanol has anti-freezing properties and it is also a fuel; therefore
water/methanol increases the density of the airflow and provides the extra fuel
necessary to match the increased weight of air. Adjustments to the engine fuel
system are, therefore, unnecessary. The addition of water has two effects upon the
performance of the engine: the cooling effect of water increases the density of the
airflow to increase the thrust and, when the water is converted into steam, it
provides a high volumetric expansion that increases the thrust even further.
15.2.2 METHODS OF APPLYING WATER/METHANOL
The following notes describe two methods of using water/methanol as a means of
restoring lost engine power, or as a means of increasing the total useful power
obtainable from a gas turbine engine. The water/methanol mixture can be
Injecting as a spray into the compressor air intake.
Injecting direct into the combustion chamber.
Spraying the mixture into the air intake is more effective for engines with centrifugal
compressors than it is for axial compressors. With centrifugal compressors, an
even distribution of the mixture is obtained whereas, with an axial flow compressor,
even distribution is uncertain. (Turbo propeller engines use intake injection
regardless of the type of engine in use).
Water/methanol injection into the combustion chamber used to be carried out on
older engines where the combustion chambers were relatively long and the
methanol had time to separate and burn before entering the turbine. Later engines
use water only and increase the fuel flow to gain the extra thrust.
15.2.3 COMPRESSOR INTAKE INJECTION (TURBO PROP)
When water or water/methanol mixes with the air at the compressor intakes, the
temperature of the air is reduced and, as a result, the air density, mass airflow and
thrust are increased. If water alone were to be injected, it would reduce the turbine
inlet temperature and permit an increased fuel flow to be used. When methanol is
added, the turbine inlet temperature is partially restored by burning the methanol in
the combustion chamber; this restores the engine power without adjusting the fuel
flow.
Operation
When the system is switched ON, water/methanol mixture is pumped from the
aircraft-mounted tank to a control unit which meters the flow of mixture fed to the air
intakes ( figure 15.1.). The flow of water/methanol is controlled by a single metering
valve and a servo piston that is powered by engine oil. The flow of the engine oil to
the servo piston is controlled both by a shut-off cock and the position of a servo
valve which, in turn, is moved by a control mechanism. This control mechanism
balances propeller torque system oil pressure against atmospheric air pressure
upon a capsule assembly within the control. The oil cock is interconnected with the
throttle lever in such a manner that until the throttle is moved to the take-off position,
the oil cock remains closed and the water/methanol system is inoperative. Moving
the throttle lever to the “take-off” position opens the oil cock to motivate the
water/methanol system.
Fuel Control Unit Speed Governor Reset Device to Increase Fuel Flow
Figure 15.2.
Description
A ring of hinged master flaps is interleaved with a ring of hinged sealing flaps to
provide a variable area propelling nozzle. Each flap is hinged at its forward edge so
that the rear edge can move inwards to reduce the nozzle area, or outwards to
increase the nozzle area.
Actuation of the nozzle system can be hydraulic using oil or fuel as the fluid
medium, or an air motor driving screw jacks.
On selection of reheat the nozzle will move first to prevent back pressure on the
engine, when it has moved the fuel will be supplied. With any increase in reheat the
nozzle moves then the fuel follows. When reheat is reduced the opposite occurs
first the fuel reduces then the nozzle closes. This ensures the nozzle area is too
large rather than too small for any change in fuel flow.
The afterburning jet pipe is made from a heat resistant nickel alloy and requires
more insulation than the normal jet pipe to prevent the heat of combustion being
transferred to the aircraft structure. The jet pipe may be of a double skin
construction with the outer skin carrying the flight loads and the inner skin the
thermal stresses; a flow of cooling air is often induced between the inner and outer
skins. Provision is also made to accommodate expansion and contraction, and to
prevent gas leaks at the jet pipe joints.
A circular heatshield of similar material to the jet pipe is often fitted to the inner wall
of the jet pipe to improve cooling at the rear of the burner section. The heatshield
comprises a number of bands, linked by cooling corrugations, to form a single skin.
The rear of the heatshield is a series of overlapping 'tiles' riveted to the surrounding
skin. The shield also prevents combustion instability from creating excessive noise
and vibration, which in turn would cause rapid physical deterioration of the
afterburner equipment.
Reheat Burner
Figure 15.7.
Spark ignition
Figure 15.8.
Catalytic Ignition
Figure 15.10.
INTENTIONALLY BLANK
16 TURBO-PROP ENGINES
16.1 INTRODUCTION
The turbo-prop engine consists of a gas turbine engine driving a propeller. In the
turbo-jet engine the turbine extracts only sufficient energy from the gas flow to drive
the compressor and engine accessories, leaving the remaining energy to provide
the high velocity propulsive jet. By comparison, the turbine stages of the turbo-prop
engine absorb the majority of the gas energy because of the additional power
required to drive the propeller, leaving only a small residual jet thrust at the
propelling nozzle.
Turbo-shaft engines work on identical principles, except that all the useful gas
energy is absorbed by the turbine to produce rotary shaft power and the residual
thrust is negligible; such engines find particular applications in helicopters and
hovercraft. The lack of a significant propulsive jet means that these engines can be
mounted in any position in the airframe and this flexibility is increased by the very
compact design and layout of a modern turbo-shaft engine.
Because the propeller wastes less kinetic energy in its slipstream than a turbo-jet in
its exhaust, the turbo-prop is the most efficient method of using the gas turbine
cycle at low and medium altitudes and at speeds up to approximately 350 knots. At
higher speeds and altitudes, the efficiency of the propeller deteriorates rapidly
because of the development of shock waves on the blade tips.
16.2 TYPES OF TURBO-PROP ENGINES
Current turbo-prop engines can be categorised according to the method used to
achieve propeller drive; these categories are:
a. Coupled Power Turbine.
b. Free Power Turbine.
c. Compounded Engine.
16.2.1 COUPLED POWER TURBINE
The coupled power turbine engine is the simplest adaptation from the turbo-jet
engine. In this configuration, the gas flow is fully expanded across a turbine which
drives the compressor, the surplus power developed being transmitted to the
propeller by a common drive shaft via suitable reduction gearing. This arrangement
is shown diagrammatically in figure 16.1.
An Epicyclic Gear
TrainFigure 16.4.
If the annulus is fixed, rotation of the sun wheel causes the planet pinions to rotate
about their axes within the annulus gear, this causes the planet carrier to rotate in
the same direction as sun wheel but at a lower speed. With the propeller shaft
secured to the planet pinion carrier, a speed reduction is obtained with the turbine
shaft (input shaft) and propeller shaft (output shaft) in the same axis and rotating in
the same direction. (Fig.16.5.)
Garrett 331 Cut away Showing the Combined Epicyclic Gear Train.
Figure 16.7.
A propeller that overspeeds, even by the small amount of, say 5 or 10%, increases
the centrifugal forces on the hub by a huge amount. This could cause the blades to
separate from the hub with catastrophic results to the aircraft.
A gas turbine engine has its own fuel control system, which maintains the engine
within its operating speed range. With a turboprop engine it is normally the
propeller which acts as a governor by increasing or decreasing its pitch angle to add
or remove the loading on the rotating parts of the engine.
If a turboprop overspeeds, it is usually due to the fact that the propeller controls
have allowed the pitch angle of the propeller to decrease, so that the reduction of
load on the engine has caused it to overspeed. This reduction of pitch is as a result
of aerodynamic and centrifugal forces acting on the rotating propeller.
If the reduction of the propeller pitch has been caused by failure of the propeller
control unit, there may be a back-up method, built in to the control system, to drive
the propeller back to a coarser angle, thereby slowing it down to a safe value.
These back-up systems usually involve the use of centrifugal governors that sense
the overspeed.
If the propeller control system is damaged or it cannot drive the propeller to a safe,
coarser, blade angle, the fuel control of the engine may reduce the flow of fuel to
the engine, effectively acting as if the pilot had retarded the throttle. This should
bring the hub loading within a safe value.
As an example, the system shown is that fitted to the Pratt & Whitney 124 engines
on the ATR72 aircraft, which has a combined hydraulic/pneumatic overspeed
protection. If the propeller overspeeds above 102.5% NP, (NP = propeller speed),
The flyweights move outwards, opening the pilot valve and allowing metered oil
pressure to drive the propeller towards coarse.
In the event that the above system fails to operate, (propeller continues to
accelerate), the air bleed orifice opens at a slightly higher NP. This bleed biases
the fuel control system, (H.M.U.) to decrease the fuel flow, reducing the engine
speed.
Whilst the system previously described is rather complex, the engine of a modern,
'free power turbine' design has to have sophisticated protective measures fitted. By
comparison, the overspeed protection installed on the Rolls Royce Dart, a 'direct
coupled' drive engine designed in the 1940s, is a relatively simple system.
The pump case pressure is fed with fuel from radial tappings in the rotating pump
assembly. If the engine overspeeds, the fuel is 'centrifuged' into the pump case at a
higher pressure. This pressure is fed to a diaphragm in the overspeed governor,
which spills the servo pressure and reduces the fuel supply to the engine. This
limits the engine, which normally has a governed maximum of 15,000 R.P.M., to an
overspeed maximum of 16,400 R.P.M. The illustration below shows the basic
system showing how spilling the servo pressure reduces the pump output. Apart
from the protection mechanisms already mentioned, which have to react extremely
fast to prevent accidents, there are a number of flight deck indications which may be
in place of, or in addition to the automatic systems.
The simplest is the 'red line' on the tachometer, (revolution counter), or power,
(percentage), instrument, which must not be exceeded at any time. If the aircraft
has an electronic flight warning system, (F.W.S.) however, then warning lights,
captions and audio warnings may be used to get the attention of the flight crew.
Intentionally Blank
17 TURBOSHAFT ENGINES
17.1 INTRODUCTION.
Gas turbine engines that deliver power through a shaft to operate something other
than a propeller are referred to as turboshaft engines. In most cases the output
shaft (power takeoff), is driven by its own power turbine (free turbine), which
extracts the majority of the total power output from the engines gas generator.
Turboshaft engines with a reduction gear are used to power boats, ships,
hovercraft, trains and cars. They are also used to pump natural gas across country
and to drive various kinds of industrial equipment such as air compressors or large
electric generators (fig 17.1.)
In aviation turboshaft engines are used to power many of the modern helicopters in
service. They are similar in design to turboprop engines and in some instances will
use the same gas generator section design. The turboshaft power takeoff may be
coupled to, and driven directly by the turbine that drives the compressor, but is more
likely to be driven by a turbine of its own. Engines using a separate turbine for
power takeoff are called free power turbine engines, and it is this type of engine that
is most commonly used in today’s modern fixed wing and rotary wing aircraft.
Atypical example of a turboprop/turboshaft engine is the Pratt and Whitney PT 6.
(figure 17.2.)
The Pratt and Whitney (Canada) PT6 turboprop engine is a popular free turbine
engine that can be adapted to both turboprop and turboshaft applications.
Figure 17.2.
A free power turbine engine consists of two main units; the gas generator and the
free power turbine. In the example shown in Figure 17.2. air enters the engine and
is compressed, then heated in the combustion chamber . The resulting expansion
forces the gas at high velocity through the gas generator turbine that drives the
compressor. The remaining gas energy is then used to drive the power turbine,
which in turn drives the power output shaft.
The free power turbine is mechanically independent of the of the gas generator and
operates at virtually a constant speed. The power developed by the turbine is varied
to meet changing loads imposed on the rotor system, by increasing or decreasing
the fuel supplied to the gas generator, thus altering the gas generator speed and
the supply of gas energy to the power turbine.
The turboshaft engine and the helicopter are ideal companions. The engine is
required to respond to frequent and sudden changes in power demands to keep the
helicopter rotor revolving at a virtually constant speed (250-300 RPM being typical).
The power required to drive the rotor is determined by the pitch angle of the main
rotor blades, this angle is being controlled by the pilot using the collective pitch
lever. The pilot changes the flight path of the aircraft by using the cyclic pitch control
lever, by tilting the rotor head. Control of the tail rotor to compensate for the torque
produced by the main rotor is via foot pedals similar to rudder pedals (fig 17.3.).
Whenever a control is activated, the resultant force is sensed by the rotor gearbox
and in turn sensed by the power output shaft of the engine which means that the
engine power must be adjusted to suit.
The power output of a free power turbine engine can be changed rapidly because
its output speed is independent of the power produced, the latter being dependant
on the gas generator speed. The low inertia of the gas generator rotor allows its
speed to be changed very quickly, by adjusting the flow of fuel available for
combustion. This is achieved in the fuel control system invariably by a computer
(electronic or mechanical) controlling the throttling valve. The pilot selects the rotor
speed and the fuel control system automatically maintains that speed, within the
limits set by the governing characteristics of the system and the operating
limitations of the engine. As the fuel control system is automatic, the pilot is relieved
of the necessity to constantly manipulate the throttle control.
The control parameters being monitored and used for a typical turboshaft engine
would include:
Parameter Destination
Gas generator speed (N2) Computer and cockpit gauge
Free power turbine speed (N1) Computer and cockpit gauge
Power turbine inlet temperature (PTIT) Computer and cockpit gauge
Main rotor speed (Nr) Cockpit gauge
Throttle valve position Computer
Torque Cockpit gauge and computer (torque
matching engines)
The computer controls the fuel flow to the engine to maintain a constant rotor RPM.
During normal operation the optimum engine/rotor speed is selected by a speed
selector lever, and the varying power demands are met thereafter by the automatic
fuel computer. The computer varies the rates of fuel flow to the engines to suit the
changing power demands occasioned by alterations of rotor blade pitch.
The position of the throttle valve is set by an electric actuator controlled by the
computer. The speed select lever in the cockpit is directly connected to the
computer, and by operating this lever the pilot can select a power turbine speed that
is maintained by the computer within built in control laws.
Computer Signalling.
Figure 17.4.
17.3 ARRANGEMENTS
Because of the need for turboshaft engines to be installed in a variety of aircraft,
coupled with the requirement to fit two or more engines, giving more power and
adding safety. The turboshaft engine has to be able to output its drive from a variety
of different locations. Typical examples of this ability can be seen in Figure 17.5. to
17.9.
Figure 17.5. shows the different ways in which the Rolls Royce Gem engine can be
configured to suit different aircraft designs.
Different Ways Power can be Taken From the Rolls Royce Gem Engine.
Figure 17.5.
Finally there are a few other installations on helicopters, using turboshaft engines,
that show the flexibility in the way these engines can be mounted to suit the
designers needs. The little Hughes 500 series (fig 17.8.) has a small 400+ S.H.P.
engine, installed at an angle, driving upwards at 45° to the main gearbox.
The large E.H. 101 helicopter (fig 17.9.), however has not only three engines, each
of 2,000 S.H.P., installed above the decking and all feeding into the main gearbox,
but there is an Auxiliary Power unit installed alongside the No.2 engine as well.
17.5 COUPLINGS
Because of the requirement to make maintenance tasks such as engine
removal/refit, gearbox removal/refit easier, it is necessary to have a means of
coupling the turboshafts output shaft to the helicopter main rotor gearbox input shaft
together. This coupling must possess qualities which will allow movement of both
the engine and the rotor gearbox independently of each other i.e. it must be flexible.
It must also be finely balanced to reduce vibration.
One of the most common couplings in use is the ‘Thomas Coupling’, sometimes
referred to as the engine ‘high speed drive shaft’ (fig 17.12.). The engine is joined to
the main rotor gearbox by this high speed drive shaft. The shaft is belled at either
end , one end being attached to the power take off shaft by means of Thomas
flexible steel coupling. Each coupling consists of a number of steel discs, indexed
by flats to ensure correct alignment when assembled. Two different numbered discs
are used, each disc having a grain running either parallel to the flat or perpendicular
to the flat. The discs are assembled alternately with the grains at 90° to each other.
The bolts, nuts and washers securing the shaft to the engine are part of the fine
balancing of the assembly and must always be replaced in the same position.
Thomas Coupling.
Figure 17.12.
Yet another method of coupling the engines power output to the main gearbox is
shown in Figure 17.13.
The engine front mounting is bolted with the reduction gearbox to the hub of the
air-intake case; it supports the engine in the aircraft and serves as a torque reaction
point. The mounting, which is of the gimbal type, is bolted to a gimbal ring, which is
bolted to a similar mounting on the aircraft main gearbox, thus forming a gimbal
coupling.
The engine output drive is transmitted to the aircraft main gearbox by a flanged
coupling, which is secured via a flexible laminated disc coupling (Thomas Coupling)
to a drive assembly. The drive assembly consists of an engine coupling and an
aircraft main gearbox coupling bolted together, with a flexible laminated disc
coupling (Thomas Coupling) at each end.
Intentionally blank
An APU
Figure 18.1.
Although the APU is usually rated to run at the max cruise altitude of the aircraft it is
fitted to, its ability to take load diminishes with altitude. As the major load on any
APU is the air load it can be seen from Figure 18.2. that the APU’s ability to provide
sufficient air for the aircraft is limited to 15-20,000 ft. Above this height the APU will
only provide electrical power, this may also be limited to less than the max cruise
height. Most APU’s give shaft priority which means that if air and electric generators
are on the generators are given priority. Most Aircraft use constant frequency
generators, and their APU’s which run at a constant 100% do not therefore require
a constant speed drive unit to maintain a constant output. If the air loads become to
high the APU will reach its max EGT and the control system will back off the fuel to
prevent damage, this would bring the APU generator off frequency and take the
generator ‘off line’. Instead the air load is reduced to maintain a constant APU
speed.
18.2 GENERAL ARRANGEMENTS AND CONFIGURATION
With the configuration shown in figure 18.3. we can see that air is taken from the
compressor via the load control valve (LCV) when pneumatic power is required.
Although such an APU layout is acceptable on smaller aircraft where pneumatic
power demand is small, it is unacceptable on larger aircraft as the air being drawn
from the compressor for pneumatic purposes, reduces the air going to the turbines
for cooling purposes. This reduction of cooling air leads to an increase in exhaust
gas temperature and a reduction in the life of the turbine.
On larger models of APU this problem of reduced turbine life has been reduced by
the inclusion of a load compressor. See figure18.4.
A combination of the previous two examples can also be found, see figure18.6.
The location of the APU on the aircraft is generally dictated by the requirements of
the manufacturer. Because of the noise factor and the problem of hot exhaust
gases, it is located as far away from ground servicing areas as possible. The
normal place for it to be fitted is in the tail section of the aircraft, however, this may
be impracticable due to the location of a tail mounted engine or airstairs. On some
aircraft the APU may be fitted into landing gear bays, engine nacelles, forward
fuselage or wing structures. Examples of these are Hercules (U/C bay), Fokker F50
(rear of engine nacelle) and BAe ATP (wing fillet)
Light Alloy APU Intake Duct Without an Intake Door. (BAe 146)
Figure 18.8.
The variable intake door figure 18.11. is used to reduce the ram air entering the
APU intake ducting. This could effect the APU fuel system if intake pressure is not
taken into the calculation of engine fuel scheduling which is the case with most
APU’s .
In most cases there is a design compromise made between the ideal APU for an
aircraft i.e. its ability to provide air and electricity throughout the operational
envelope of the aircraft, and it weight and size. It is usual therefore to find that air
and electricity are limited to various altitudes dependant upon the parameter
required.
APU systems are very basic and the APU will shut down if a problem is sensed.
Most APU’s will shut down for the following faults:
Fault Comment
Low Oil Pressure
Engine Overspeed 110% Honeywell 108% Sundstrand
High EGT 849°C Honeywell
Loss of Speed Signal Electronically monitored APU’s need this signal to
control the APU.
Los of EGT Signal Electronically monitored APU’s need this signal to
control the APU.
Low Speed Some APU’s shutdown if they drop below 90%.
(Some will try and relight at 95%)
Electronic Unit Failure Loss of Control
The APU may also shut down on the ground (not in flight) for the following faults:
Fault Comment
Fire May cause a warning horn in the u/c bay to sound
Generator Drive Low Oil
Pressure or High Oil
Temperature
By adding a by-pass valve a method of controlling the fuel pressure and thus the
engine. If the by-pass valve is closed, all the fuel is directed to the nozzle. Opening
the by-pass valve will allow fuel back to the inlet of the pump, thus reducing the fuel
to the nozzle. By controlling the by-pass valve, the operator can vary the amount of
fuel to the nozzle.
Such control in fact is done automatically by the APU fuel control unit.
Figure 18.17 fuel pressure is applied to the lower part of the by-pass ball valve. An
air tapping which protrudes into the compressor airstream, applies pressure to the
upper part of the by-pass valve diaphragm, thus holding the valve on its seat.
Therefore fuel pressure is limited by the air pressure.
When initial ignition takes place within the APU, there is little air pressure, so fuel
pressure cannot rise very much without pushing the valve open and allowing the
excess fuel to go to the pump inlet. Because of the size of the diaphragm and
valve, the air pressure allows the fuel pressure to rise by a proportional amount,
thus fuel and air pressure stay in step with each other.
As engine speed increases:-
Compressor pressure rises.
Fuel pressure rises.
A minimum fuel pressure is required for good fuel atomisation at the fuel nozzle for
initial ignition. This is achieved by applying a spring pressure to the by-pass valve,
thus keeping it on its seat.
Figure 18.18. shows a solenoid operated shut-off valve fitted between the FCU and
the fuel nozzle. Normally spring-loaded closed; it receives its open and close
signals from the APU control unit at certain speeds. On a mechanical APU it is
signalled open by the low oil pressure switch when oil pressure is sensed. In an
electronic system it is open at speeds above 10%. On receiving a closed signal, the
solenoid de-energises and the valve closes, the flow to the combustor is blocked.
The build-up in pressure in the fuel line is relieved by the by-pass valve, acting as a
pressure relief valve.
In the flow divider, one nozzle is placed within the other and separated by a small
pressure relief valve. The flow divider is set for a slightly higher pressure than the
by-pass valve spring pressure, thus on initial light-up, fuel will only spray from the
primary nozzle.
After light-up, rising compressor pressure increases the by-pass valve setting and
the fuel pressure increases to force the flow divider off its seat. This allows fuel flow
through to the secondary nozzle as well as the primary nozzle.
During start and acceleration, the APU must produce temperatures that are within
certain limits, while at the same time allow the engine to accelerate.
Despite the fact that fuel pressure is kept in step with rising compressor pressure
(through the by-pass valve), turbine over temperature is possible during certain
acceleration phases. As a protection against over temperature, a thermostat
(known as acceleration thermostat) is connected to the air pressure line, leading to
the by-pass valve, this thermostat is normally closed (see figure 18.20).
Provided the EGT remains below the thermostat setting, it will remain fully closed.
If the EGT exceeds its setting, the thermostat will gradually open and bleed off air
pressure that is acting on top of the diaphragm of the by-pass valve.
This reduced air pressure against the by-pass valve diaphragm will allow the fuel
pressure to lift the by-pass valve and direct excessive fuel pressure back to the inlet
of the pump. As the fuel pressure drops across the nozzles, the turbine
temperature drops until the thermostat closes at a lower safe limit.
The acceleration thermostat provides a continuous monitor to prevent the APU
engine overtemping. A second pneumatic thermostat is fitted to control the air load
valve (see figure 18.29.) which is similar to the acceleration thermostat.
The thermostat can be adjusted in two ways, shimming or vernier adjuster.
Shimming requires careful calculations to set the correct pressure on the ball. The
vernier type adjuster has indications around the top of the thermostat, when it is
unlocked the top can be twisted to make the adjustment.
A Pneumatic Thermostat.
Figure 18.21
The speed governor is linked mechanically to the APU drive. As speed increases
above 95%, the bob weights start to move outwards and begin to by-pass the fuel
back to the inlet of the pump and as speed increases up to 100% rpm, it causes
sufficient fuel to be by-passed by the governor, to maintain this rpm. Increase or
decrease in the speed setting is achieved by adjustment of the governor spring.
Note that at speeds below 95% rpm the by-pass valve controls the acceleration up
to a maximum speed of 95% rpm.
Electronic fuel control emulates the mechanical system, however it provides control
in a slightly different way. The electronic Control Unit (ECU) monitors the APU
speed and EGT continuously and also the low oil pressure switch.
During start the ECU knows the engine speed so will signal the fuel shut off valve to
open at 8-10%. At the same time ignition is selected on and the light up will be
sensed by the EGT system. The ECU then enters a timed acceleration schedule
where EGT and speed are monitored by the ECU.
The ECU deselects the starter at 50% and the ignition at 95%. Once up to speed
the ECU keeps the engine at 100% and will monitor the EGT and speed to maintain
operation throughout the operating envelope of the APU.
The Fuel control unit mounted on the APU gearbox is much simpler than the
mechanical FCU. It contains a fuel pump, an electronic servo valve and a pressure
drop control valve ( [delta] P valve). The electrical shut of valve and the fuel flow
divider are retained and work as they did in the mechanical system.
The ECU has Built In Test Equipment (BITE) indicators which will indicate why the
APU shut down, however these do not retain the information if power is removed.
The start fuel valve and ignition are energised as soon as rotation (3%) is sensed by
an Electronic Sequence Unit (ESU). At 14% and with rising EGT the main fuel
valve is opened. The acceleration rate is controlled by the acceleration schedule
adjuster, however this is modified by the differential pressure regulator which uses
compressor discharge pressure to vary the fuel flow to the engine. At 50% the
starter cuts out. When the engine reaches 85% the start fuel valve closes and the
ignition is de-energised. The engine governor then takes over and controls the
engine to 100%. As the engine passes 95% plus 3 seconds, the max fuel valve
energises open and bypasses the acceleration adjuster and full control of the
engine is given to the governor. If the engine is shut down both the Main and Max
fuel valves are closed.
The ESU has indicators that indicate which step of the start sequence the APU is at
and the resets at 95% + 3sec to act as BITE indicators.
A sump at the bottom of the gearbox collects the returning oil, in some APU's the
rear face of the sump is finned and let into the intake plenum to act as the oil cooler.
The oil is drawn up by the oil pump and pressurised, it then passes through the oil
filter before being distributed to the bearings. The oil returns to the sump by gravity.
The oil system is monitored by a low oil pressure switch and a high oil temperature
switch, either of which can shut the engine down.
A Load valve (Figure 18.29) is switched on from the flightdeck, power for the switch
is available once the APU has achieved 95% + 3 sec. This energises the switcher
valve solenoid, which vents the lower chamber (B) of the control piston and
pressurises the top chamber (A). The piston will move down and open the butterfly
valve. The bleed air will flow and the EGT will rise, at a predetermined value the
Load Thermostat will start to open which will reduce the pressure acting on the top
of the piston. This will cause the piston to move up by spring pressure and thus
back off the butterfly valve. If the EGT rise is excessive then it could close the valve.
The valve will modulate under the control of EGT. The Load thermostat is set at a
lower setting than the acceleration thermostat setting to prevent hunting of the
system.
An electronically controlled APU uses the same principle, but the ECU controls a
servo valve in the load control valve instead of the load thermostat, see figure
18.30.
Some APU's do not use load valves, instead they have an air bleed valve which is a
simple on/off valve. A flow limiting venturi is used to limit the flow of air from the
APU
If the APU is fitted with a load compressor either of the previous two methods are
used, but instead of controlling a butterfly valve the piston operates a set of variable
intake guide vanes for the load compressor, see figure 18.31.
The cooling valve figure 18.33. is a spring-loaded closed butterfly valve with a
pneumatic actuator. When the APU is started, the compressor discharge pressure
is ported to the top of the diaphragm. The piston moves down with increasing air
pressure and opens the valve against the spring pressure. The cooling air then
flows to the compartment. On APU shutdown the air pressure is reduced and
spring pressure closes the valve.
Overboard Venting
Figure 18.35 represents a typical APU bay overboard vent arrangement. The
cooling air is directed into the compartment and also to the oil cooler, this air is then
vented overboard along a separate duct. Compartment cooling air is vented
overboard, through a louvered door at the rear of the compartment.
Vent System
Figure 18.35.
.
APU Mount.
Figure 18.36.
A Shrouded APU.
Figure 18.37.
Most APU’s are located in a fire proof box made of titanium. Some aircraft have the
APU shrouded in a close fitting Titanium case.
19 POWERPLANT INSTALLATION
19.1 NACELLES OR PODS
19.1.2 FIREWALLS
The firewall is a seal which separates the engine into two zones. Sometimes
referred as the “wet zone” and “dry zone”, but more commonly called zone one
(front) and zone two (rear). The firewall forms a barrier that prevents combustible
fumes that may form in the front section (zone 1), from passing into the rear section
(zone 2), and igniting on the hot exhaust section. Dependant upon aircraft/engine
design the fire walls design and location will differ, Figures 19.3. and 19.4. refer.
A Turbofan Firewall.
Figure 19.3.
Turboprop Firewall.
Figure 19.4.
JAR 66 CATEGORY B1
MODULE 15
uk GAS TURBINE
engineering ENGINES
19.1.3 COOLING
Turbine engines are designed to convert heat energy into mechanical energy. The
combustion process is continuous and, therefore, heat is produced. On turbine
engines, most of the cooling air must pass through the inside of the engine. If only
enough air were admitted into a turbine engine to support combustion, internal
engine temperatures would rise to more than 4,000 degrees Fahrenheit. In
practice, a typical turbine engine uses approximately 25 percent of the total inlet
airflow to support combustion. This airflow is often referred to as the engine's
primary airflow. The remaining 75 percent is used for cooling, and is referred to as
secondary airflow.
When the proper amount of air flows through a turbine engine, the outer case will
remain at a temperature between ambient and 1,000 degrees Fahrenheit depending
on the section of the engine. For example, at the compressor inlet, the outer case
temperature will remain at, or slightly above, the ambient air temperature. However,
at the front of the turbine section where internal temperatures are greatest, outer
case temperatures can easily reach 1,000 degrees Fahrenheit. (Figure 19.5.)
Cooling Requirements
To properly cool each section of an engine, all turbine engines must be constructed
with a fairly intricate internal air system. This system must take ram and/or bleed air
and route it to several internal components deep within the core of the engine. In
most engines, the compressor, combustion, and turbine sections all utilise cooling
air to some degree.
For the most part, an engine's nacelle is cooled by ram air as it enters the engine.
To do this, cooling air is typically directed between the engine case and nacelle. To
properly direct the cooling air, a typical engine compartment is divided into two
sections; forward and aft. The forward section is constructed around the engine
inlet duct while the aft section encircles the engine. A seal or firewall separates the
two sections.
In flight, ram air provides ample cooling for the two compartments. However, on the
ground, airflow is provided by the reduced pressure at the rear of the nacelle. The
low pressure area is created by the exhaust gases as they exit the exhaust nozzle.
The lower the pressure at the rear of the nozzle, the more air is drawn in through
the forward section.
Typical Nacelle Cooling Using Ram Air From the Intake Duct.
Figure 19.6.
Abradable Linings are usually made of a composite material which will be abraded
away should the tip of a rotating blade touch the material. In flight the casings of an
engine are subject to large changes in ambient temperature, so they will expand or
contract. As we know the air temperature at 30,000ft is close to –50°C this would
cause the casings to contract onto the rotor and the blades will then rub. To
overcome this problem abrasive materials where used on early engines to wear
down the tip of the blades, but this may cause balance problems. So most engines
now use abradable linings that maintain minimum tip clearance but do not affect
balance. They are usually found on the fan as this is the cold area of the rotating
assemblies.
Figure 19.12. shows a typical method of mounting an engine onto a wing pylon.
The engine is usually suspended on three attachment points. The two front points
are located at the lower end of a pylon mounted yoke and engage with the mounting
bracket assemblies on the left-hand and right-hand side of the fan casing. The
assemblies differ inboard and outboard. The inboard bracket assembly takes side,
vertical and thrust loads. The outboard bracket assembly takes vertical and thrust
loads.
The rear attachment point is an engine mounted lower link assembly bolted to a
pylon mounted upper link assembly. This attachment point carries vertical loads
only and allows for engine axial expansion.
3. 2 aft lateral shockmounts on the Left Hand and Right Hand sides.
A torque compensation system with a torque tube.
Two crane beams in the nacelle carry the weight of the engine. The crane beams
are connected to the frames of the fuselage. Vibration isolators are on the engine
mounting Points to absorb vibration. There are three mounting points:
the rear mount.
the trunnion
The trunnion transmits the engine thrust to the airframe. The Trunnion fits in the
trunnion housing on the forward crane bean attachment.
Between the trunnion housing and the aft beam attachment is a thrust strut, This
strut divides the engine thrust between the forward and aft beams attachment. The
shear shell between the crane beams makes the engine mounting more rigid.
When an engine stops, fuel from the fuel manifold and combustion chamber drains
either overboard, or as is more usual into an ’ecology drain tank’. This tank is
automatically emptied, (the fuel being fed back into the engine) next time the engine
is run. (figure 19.16.)
Engine driven accessory drive shaft require lubrication. This will be provided by the
engine lubrication system. To ensure proper lubrication, the drive shaft bearings are
sealed to prevent loss of oil. These bearing seals are monitored for leaks, by the
engine drain system which consists of a number of shrouds, enclosing the drive
shaft bearing, and pipes leading either an overboard series of drain pipes (figure
19.17.) or a collector tank (figure 19.18.). These drains are often referred to as
‘witness drains or dry drains’ as if they exhibit signs of leakage they bear witness to
a potential drive shaft failure.
To allow autothrottle functions the quadrants below the thrust levers can be moved
by an actuator which drive all four levers via clutches.
Figure 19.20. shows a typical mechanical control system for a turboprop engine. It
uses a double path system to transmit power requirements to the power unit,i.e. the
power lever controls engine power in the normal operating modes and both power
and propeller blade angle in the beta mode. A condition lever controls propeller
blade angles in the normal mode, and also controls the feathering of the propeller
and the HP shutoff cock.
Condition Lever:
1. Fuel “on” or “off”.
2. Feathering or unfeathering
the propeller.
3. NP from minimum to
maximum.
Intentionally Blank
When an engine is delivered from manufacturer or overhaul it will not have all the
equipment needed for its installation into the aircraft. This is because engines can
be fitted into different types of aircraft and the accessories will be type specific.
Hydraulic pumps, electrical generators, starters, drains and mounts will have to be
fitted during or prior to installation in the aircraft. Although the engines fitted to each
wing are the same, the accessories and their fittings may well be handed for the
different installations i.e. the BÆ 146 has a generator on the outboard engines and
a hydraulic pump on the inboard. These components are referred to as dress items,
an engine that is dressed is ready for fitment.
For some engines fitting the accessories prior to fit on the aircraft is impractical and
the accessories are fitted once the engine is installed.
Examples of engine build units are shown in Figures 19.24. to 19.27. together with a
list of items and components that must be fitted before the engine is considered
ready for release to service prior to installation into the aircraft.
19.5.1 TURBOFAN ENGINE
The manufacturer delivers the engine to fit the no-2 (right) position.
Conversion from the no.2 (right) to the no.1 (left) position requires re-position of:
The front engine mount adaptor.
The trunnion mount.
The HP compressor 7th and 12th stage bleed air ducts.
The electrical harness on the engine.
The external igniter leads on top of the engine.
The engine vibration transducer wiring.
Number Item
10 Front Mount Adapter
20 Anti-Icing System
30 Vibration Transducer
40 Hydraulic Lines
50 Inlet Cowling
60 Hydraulic Hoses
70 Hydraulic Pump No. 1
80 Hydraulic Pump No. 2
90 Integrated Drive Generator
100 Vent and Drain System
110 Starter System,
120 Air-Starter Duct,
120A Air-Starter Duct
130 After Cowling
140 Fuel Flow Transmitter
150 Fuel Line
160 Engine Control Rods
170 Power Lever Angle Transmitter
,
Number Item
10 Igniter Leads
20 Igniter Leads
30 Anti-Ice Electrical Harness
40 Anti-Ice Electrical Harness
50 Electrical Harness on the Hydraulic Pumps No. 1 and 2
60 Electrical Harness on IDG and IDG Oil Temperature Switch
70 Vibration Transducer Electrical Harness, LH-Engine
80 Vibration Transducer Electrical Harness, RH-Engine
90 Electrical Harness on Fuel Flow Transmitter
100 Electrical Harness on PLA-Transducer
110 Fire Detection Element
Number Item
10. Engine Mounts - Forward Isolators
20. Engine Mounts - Forward Frame Assy
30. IDG Assy
40. IDG Support Bracket
50. Pitch Control Unit and Control Rods
60. Lever Bracket and Interconnection Rods
70. Bleed Air - Low Pressure Check Valve
80. Electrical Harness
90 Bleed Air, High Pressure Bleed Valve
95. Heat Shield Installation
100 Back-up Firewall
110 Bleed Air - Low Pressure Off-Take
120. Female Flange - Exhaust
130. Main Fuel Supply Tube
140. Drain Hoses
150 Pipe Lines Installation for Oil Pressure Transducer & Oil Pressure
Switch
160 Oil-Pressure Transducer, Oil-Pressure Switch, Oil-Temperature
Detector and Fuel-Temperature Detector
170 Heat Exchanger
180 Airduct and LHS & A-Frame
190 Oil-Cooler Assy
200 Propeller
210 Spinner
Number Item
220 Vertical Firewall
230 Bleed Air - High Pressure and Low Pressure
240 Fire Extinguisher Tube
250 Starter Motor
260 Hydraulic Hose Assemblies and Hydraulic Pump
270 Feathering Pump
275 Brush Block
280 Drain Tubes
290 Torque Tube Isolator
300 Air Intake
310 Engine Seal Assy
320 Hydraulic Pump Seal Drain
330 Fuel Flow Transmitter
340 Oil Drains
350 Fuel Lines on the Engine
360 Spray Pipe for Air Intake
370 Engine Mounts
370A Engine Mounts - Rear Isolators
Fire Zones.
Figure 19.28.
All fire zones are sealed from adjacent areas. Fire resistant rubber seals are fitted to
the edges of all doors, panels and bulkhead fittings to prevent fire spreading. Each
of the zones will be ventilated to prevent the build up gases or pressure and to cool
the outer casing of the engine and accessories. Fire break in panels will be built in
to allow the use of external fire extinguishers, these may also operate as blow out
doors to prevent pressure build up in the zone.
19.7.1 REMOVAL
To prepare an aircraft for engine removal, check that the aircraft weight and balance
will not be adversely effected when the engine is removed. Most engines weigh
between 0.5 and 1 ton. Trestles may be required to stabilise the fore and aft axis of
the aircraft.
The aircraft fuel system does not have to be drained, but the LP fuel valve must
closed and a label attached to the LP Cock handle, in the flightdeck, to prevent
inadvertent operation. In addition, the aircraft should be made electrically safe
which will entail isolation of the engine starting and ignition system.
Planning is an essential part of any engine removal activity. The Supervisor and
personnel involved, should ensure that all necessary resources, such as sufficient
manpower, special tools, lifting equipment and an engine transit / storage stand, are
available.
The engine access doors and fairings will either have to be removed or supported
clear of the engine.
Due to restricted access of some engine accessories and components, it is, in some
cases, much easier to remove these items with the engine installed in the aircraft.
Once the engine has been initially prepared for removal (accessories removed etc)
the procedure of disconnecting the engine systems, at the engine/ aircraft interface,
can begin. Most engines employ quick release plugs and sockets for ease of
disconnection of the electrical systems, however some electrical systems, with
heavier duty cables, such as the starter and generator cables, may be bolted
connections. Disconnect any cable cleats going across the engine / airframe
interface.
The hydraulic pipes are usually quick release/self-sealing connections at both the
hydraulic pump and the engine / airframe interface. Air supply connections will
generally interface with a ‘vee band’ type of clamp or a bolted connection.
The engine LP fuel inlet pipe must be drained, before disconnection, into a suitable
container and the waste fuel disposed off in an approved manner. With the
exception of the main engine bearers, all mechanical links must be released and
either removed or tied back to prevent fouling during the removal operation.
Bae 146 Engine Lift Equipment. Note. The Nose Cowling is attached to the
Engine and is Removed Later.
Figure 19.29.
If the engine is not being replaced or refitted immediately, all open pipes must be
blanked off to prevent foreign particle ingress and all electrical plugs tied back and
protected.
Once satisfied that the engine is ready for removal the lifting equipment can be
fitted in accordance with the AMM. Jet engines are installed and removed utilising
gantry cranes, mobile cranes or in many cases by use of 2,3 or 4 mini hoists.
Whatever method is used the lifting equipment must be inspected before use.
Particular attention should be paid to ensuring that the equipment has approval
documentation and is of the correct ‘safe working load’ for the task. Cables should
not show evidence of twisting or fraying and end fittings should be free of damage,
corrosion etc. When mini hoists are used, the brake and clutch mechanisms of
each hoist should be functionally checked and that the correct hoist is being used
as similar units are rated at different settings.
Supervisors should double check that all the lifting equipment is serviceable and
correctly fitted prior to commencing the removal process. The supervisor should
also carry out a final check of the engine / airframe disconnect points to satisfy
himself/herself that the engine and equipment is safe for removal.
Each winch / hoist is to be manned at all times during the removal process and at
least one person who can check the engine to ensure it remains in a safe condition
during removal. The supervisor must ensure that all team members are fully aware
of the process and briefed on what is required of each individual. All instructions
should be given in a clear and unambiguous manner and where hand signals are
required, all members can see the supervisor and are aware of their meaning. Only
the supervisor of the task should issue instructions during the process and
unnecessary talk and noise (i.e. riveting operations in vicinity) minimised or
stopped.
Immediately prior to removing the engine and finally releasing the engine mounts /
attachments, the weight of the engine must be ‘taken’ by the lifting equipment. This
will ensure that there is no unnecessary ‘jerking’ or ‘snatching’ of the cables. With
mini hoists this is achieved by winching the cable in until the clutch in the handle
breaks (Always re-engage the handle before progressing further). At this point the
effectiveness of the brake unit in the mini hoist should be checked following the
relevant manufacturers procedures. Once the supervisor is satisfied that all
procedures have been followed correctly and that all resources are in place the
engine mountings / bearers can be disconnected and the engine removed / lowered
from its housing. At all stages of the removal procedure checks should be carried
out to ensure that the engine does not become caught on the airframe structure or
components.
WARNING
NEVER WALK UNDER A SUSPENDED LOAD. EVERY EFFORT SHOULD BE
TAKEN TO MINIMISE THE TIME NECESSARY TO CARRY OUT ANY
MAINTENANCE BENEATH A SUSPENDED LOAD
When lowering an engine using a mini hoist system, the weight of the engine should
always be taken by the winding handle and the brake should be released and held
off.
An engine stand should be positioned ready to accept the engine and any pins or
mounts, between the engine and its stand, connected prior to allowing the weight to
be removed from the winching system.
If the engine is to be replaced remove any further dress items that have not already
been removed. Complete and attach an equipment label to the engine detailing its
condition, life used, etc.
To avoid or minimise deformation on the aircraft structure due to removal of the
engine, it may be necessary to fit a component called a ‘jury strut’ This requirement
will be clearly stated in the relevant procedure of the AMM.
Once removed further inspections on the engine and the nacelle will be carried out.
If the engine is to be returned to the manufacturer these will entail blanking of
exposed pipes and protection of exposed cables and components. If the engine is
to be refitted to the same aircraft then these checks, often referred to as ‘bay
checks’ are more involved and are designed to ensure that the condition of the hard
to see areas of the engine and engine bay are thoroughly checked.
19.7.2 FITTING
Prior to fit remove the label from the engine and attach it to the paperwork for
safekeeping. Check the engine over to ensure it is complete and check the label for
any tasks required before fit. Fit any dress items that need to be fitted prior to fit.
Check round the bay to ensure it is clear to fit the engine and remove the jury strut if
fitted. Check the lift gear is correctly installed and that it is serviceable.
Position the engine and correctly attach it to the lift gear (double check this).
Lifting the engine in follows the same basic rule as lowering. If using mini hoists
there is no need to operate the brake when hoisting as it ratchets. When the engine
nears the installed position the person in charge and his assistant will align the
mounts and fit the pins or bolts, this is a critical time and may require very small
movements on the lifting gear to allow the mounts to be connected. Great care and
concentration is required to prevent damage or injury. Do not use your finger to
check alignment as a very small movement of the engine could trap or sever it.
Once the mounts are made, and locked the lifting gear can be removed and the
engine systems and accessories can be reconnected which is the reverse of the
removal. Remember to fit new seals to the components.
After engine fit the electrical systems can be reset. The LP fuel valve opened and
the engine fuel system bled to remove any air. The engine oil system is then
checked and followed by an engine ground run. During the ground run leak and
performance checks are carried out to ensure that the engine is satisfactory. After
the run the chip detectors are checked and duplicate inspection is required on the
engine controls.
19.7.3 TURBO PROP ENGINE REMOVAL/FIT.
With a turboprop engine the prop would have to be removed prior to removal and
fitted after the engine is mounted. The prop would also have to be bled and
functioned prior to running to prevent damage.
19.7.4 FLIGHT TRANSIT
To allow an aircraft to return to a suitable base for an engine change, some multi
engine aircraft can be flown with one engine shut down. In the case of the BAE 146
it has sufficient power to take off and fly on 3 engines. To prevent damage to the
engine rotor locks are fitted to the LP and HP systems to prevent rotation. The
starting and ignition systems must be inhibited for that engine to prevent damage by
inadvertent selection.
Intentionally Blank
Loop Mounting.
Figure 20.4.
20.5 EXTINGUISHERS
Extinguishers vary in construction but are normally comprised of two main
components: the steel or copper container and the discharge or operating head.
CARTRIDGE
Older aircraft use Methyl Bromide as the extinguishing agent, this has been replaced
by BCF (Bromochlorodifluoromethane) Halon 1301. Both of these chemicals are
CFC’s and are banned under the Montreal Protocol. A recent amendment to this
document has allowed their continued use in aircraft until a suitable alternative is
found or existing stocks run out. CO2 is sometimes used however it does form snow
when released which can cause hot metal components to explode so its use is
limited.
Fire Test.
Figure 20.18.
A fuse indicator has a pellet of coloured wax around heating element, when electrical
power is applied to the element the wax vaporises and spreads itself all over the
clear plastic indicator dome.
20.8 CARTRIDGES OR SQUIBS
These devices are the electrical detonators that ‘fire’ the bottles. These detonators
are explosive devices and special precautions apply when handling and transporting
them. Prior to fit a ‘No Volts Test’ must be carried out to the fire system wiring to
ensure that it will not go off when connected. When handling the cartridges do not
touch the pins as a static discharge could fire it, ensure that you are earthed and are
not wearing clothing that is generating large amounts of static. They should be
transported and stored in steel boxes and in a secure manner.
On some aircraft a ‘squib’ test is provided, when pressed provides a circuit through
the cartridge with a current flow low enough to prevent firing the squib, but sufficient
to illuminate a green light if the squib is serviceable. Do not press the fire button to
do this test!
20.8.1 LIFE CONTROL OF SQUIBS
The service life of fire extinguisher discharge cartridges is calculated from the
manufacturer’s date stamp, which is usually placed on the face of the cartridge. The
cartridge service life recommended by the manufacturer is usually in terms of hours
below a predetermined temperature limit. Cartridges are available with a service life
of approximately 5,000 hours.
INTENTIONALLY BLANK
Before starting and ground running any gas turbine powered aircraft, several
considerations must be taken into account. The first and most important is the
safety of personnel, aircraft and equipment involved in the run. Secondly the safety
of personnel, aircraft, equipment and buildings close to but not involved in the run,
and thirdly the safety of the engine itself.
The aircraft maintenance manual (AMM) will show the danger areas associated with
the aircraft (fig 21.1 & 21.2) and these must be observed at all times. To alert other
personnel of the need to take precautions safety signs should be positioned. Ideally
engine ground runs should be carried out in a designated area which will to a large
extent assist safety. There may however be occasions when these designated
areas are not available. Precautions to protect personnel, aircraft and equipment
must still be observed.
Diagram of Fokker 100 Aircraft showing the Engine running danger areas at idle
and full power.
Figure 21.1.
Particular attention should be paid to the positioning of the aircraft and its ground
support equipment (GSE). The aircraft should be facing into wind and securely
chocked (possibly with the front and rear chocks tied together). The visual and free
movement of both compressor and turbine should be checked, and the engine air
intake examined for loose articles. The areas to the front and rear of the aircraft
should be checked for loose articles and spilt fuel, which could cause a hazard to
the aircraft during the run.
The technical log must be checked to ensure that no outstanding entries will
jeopardise the operation or function of other aircraft systems. Other entries may
require functional checks to be carried during the ground run, which may also
require involvement in the run of other tradesmen. Ground support equipment
should be positioned to ensure their safe operation and movement, if required,
during the start and run.
21.2 STARTING
Prior to starting the engines all personnel involved must be made aware of their
responsibilities and role during the run. If hand signals are to be used (fig. 21.3.)
they should be agreed and understood by all concerned. All personnel outside the
aircraft must wear ear-defenders, if possible one or more of the external team
should have an intercom headset for direct communication with those inside.
The person(s) operating the controls during starting and running must be familiar
with the controls, instruments and limitations associated with the engines. In
particular they should be aware of the limitations imposed upon the engines turbine
temperature during start.
If the start is to be made from the aircraft batteries, ensure they are fully charged. If
a ground power unit is to be used, it must be appropriate for the aircraft and must
be correctly connected. If the starter requires air, then the APU will be required or a
suitable air-cart attached correctly to the aircraft.
Starting procedures will vary depending on aircraft type and installation hence, the
AMM must always be referred to. The example that follows (Fig. 21.4. refers) is
however typical and will serve as a general guide:
1. Set all controls and switches etc. as per AMM.
2. Switch ‘on’ electrical power.
3. Carry out relevant flightdeck safety checks i.e. Brakes ‘on’, Engine fire warning
tests etc.
4. Low pressure fuel valve (LP) [sometimes called the LP cock] check ‘open’.
5. Contact Air Traffic Control on the radio, giving location, type of run and number
of people on board.
6. Switch ‘on the aircraft booster pumps.
7. Confirm ‘clear to start’ from safety man.
8. Select start master switch to ‘on’, the aircraft systems will be put into starting
mode.
9. Select ‘start’
At this point the starting sequence becomes semi automatic.
10. The starter begins to rotate the compressor (HP if multi shaft) to provide a flow
of air through the engine.
11. The engine ignitors are energised.
Observing the engine’s RPM, when this reaches a speed of approximately 10 –
20%, advance the high pressure fuel valve to open either by moving the throttle or
the HP cock lever (on aircraft with a separate lever) to the ‘fuel on’ or ground idle
(GI) position. The engine speed will increase as the starter motor continues its
acceleration; fuel will be supplied to the atomisers and will be burnt in the
combustion chambers. ‘Light up’ will occur which will be indicated by a rapid rise in
Exhaust Gas Temperature (EGT).
12. The rise in gas temperature will cause the air within the combustion chamber to
expand which when passed through the turbine will assist the acceleration.
13. During this phase the oil pressure should start to rise.
14. As the engine accelerates it will reach a point called ‘the self-sustaining speed’;
this is the minimum speed at which the engine can run unassisted.
15. Once above self-sustaining speed the starter and ignition will cut out
automatically, and the engine will accelerate to ground idle under the control of
the fuel system.
It is during this phase of the acceleration when there is a great risk of exceeding the
maximum starting temperature of the engine, so vigilance is required to monitor the
EGT.
16. The engine should settle quickly at ground idle. At this point the other flight deck
indications should be checked to ensure the start was successful, i.e. the starter
and ignition should have cut out, oil pressure should be in range (fig. 21.5),
check N1,or propeller, or rotor speed.
17. If only one engine is to be started, the Start Master Switch should be switched
‘Off’ and electric fuel pumps switched ‘on’ to support the running engine.
21.3 UNSATISFACTORY STARTS
Overtemperature
Limits During Starting.
Figure 21.6.
2. Hung Start.
After light up the engine RPM does not increase to ground idle, but remains at some
lower value. The EGT may stabilise or continue to rise (sometimes rapidly). Again
EGT must be monitored closely and the engine shut down if limits are exceeded.
Hung starts are often caused by insufficient power to the starter motor, or the starter
cutting out too soon. It could also be caused by rotational stiffness within the
rotating system, which may be caused by the engine or one of its accessories.
3. No Start.
The engine does not ‘light up’ as indicated by no increase in RPM or EGT. This
could be the result of a faulty starter motor, insufficient power to the starter motor,
faulty ignition system or even a problem with the FCU, engine fuel system or
possibly the aircraft fuel system.
For any of the above, the limitations laid down in the AMM and Company
Procedures must be adhered to.
21.4 ENGINE STOPPING.
Normal shut down of a gas turbine engine is accomplished simply by closing the
throttle (and/or HP cock) to the ‘fuel off’ position. This should be followed by
switching ‘off’ the aircraft fuel booster pumps. There are however other factors to
consider which will depend upon the operation of the engine prior to shut down.
If the engine has been operating at high power for any length of time a three to five
minute cooling period at ground idle is usually recommended prior to shut down.
The shroud casing and turbine rotors do not cool down at the same rate after shut
down. The turbine shroud casing, cooling at a faster rate may shrink onto the still
rotating rotor and cause damage.
Run down time should be monitored in terms of the time taken to stop, the
manufacturers will give a recommended time, also check for unusual noises;
compressor rub, turbine rub and accessory drives. Assuming all is well, all controls
and switches should be positioned in accordance with the AMM and electrical
power selected ‘off’.
Remember to inform Air Traffic that the run has been completed.
There are two main types of engine fire that can occur when running gas turbine
engines and they are dealt with in different ways.
1. Fire in the engine nacelle.
This type of fire will usually cause the engine fire warning system to function,
although it may be spotted by the safety man outside. The engine should be shut
down immediately. The engine fire handle should be pulled to isolate the nacelle. A
fire extinguisher should be discharged into the nacelle, preferably the CO 2
extinguisher by the safety man, if not available then one of the aircraft
extinguishers. Inform the control tower, then shut down any other running engines,
switch off power and evacuate the aircraft.
2. Fire in the core engine or external to the engine nacelle.
Fire can occur within the core engine especially after a ‘wet start’ (a start which fails
after fuel has been selected on). If insufficient time is allowed for fuel to drain from
the engine or there is a fault in the drain system, fuel can pool inside the turbine
area. On the next start this fuel ignites and flame and black smoke are seen in the
exhaust. This may then be pushed out of the jet pipe by the airflow and spread onto
the ground as a burning pool. This type of fire is usually spotted by the safety man.
He should inform the engine operator, who should then cut off the fuel by shutting
the throttle and or hp cock. The starter motor should continue to run to cool the
engine and to push the fire out of the engine. The safety man should attempt to put
out the fire by discharging CO2 directly into the intake never up the exhaust (as CO 2
produces ice when discharged which can have an explosive reaction when directed
into very hot metal). If the fire has spread out of the jet pipe this fire should also be
tackled with the CO2 extinguisher. When the starter reaches its maximum running
time select the start master switch to ‘off’ to cancel the start signal, pull the fire
handle but do not fire any extinguishers. Make the aircraft safe i.e. shut down
running engines and electrical power and evacuate. Beware!! sometimes burning
fuel from this type of fire can run down inside the cowlings and cause damage to the
engine.
Engine Ratings.
An understanding of gas turbine ratings is necessary in order to be able to interpret
graphs published by the manufacturer in the AMM.
Gas turbine engines are rated by the number of pounds thrust they are designed to
produce for:
Take-off (T.O.)
Maximum Continuous Thrust (M.C.T.)
Maximum Climb (CLB.)
Maximum Cruise (CRZ)
Parameters
Turbojet and turbofan engines can be measured via Engine Pressure Ratio (EPR)
or Fan Speed (N1). Turboprop and turboshaft engine power is measured via Torque
produced.
In the majority of cases the Take-off (T.O.) rating will be a ‘part throttle’ rating. This
means that T.O. thrust will be obtained at throttle settings below the full throttle
position. The reason for establishing a rating for a particular engine is quite simply
to accommodate the various atmospheric conditions under which the engine will be
operating.
Engine Pressure Ratio (EPR).
Figure 21.7. shows the manufacturers published tables which must be used to
establish the engine is producing its certified T.O. thrust under varying temperature
and altitude conditions.
Take-off (wet) This is the maximum thrust available certified for engine
with thrust augmentation systems (water or
water/methanol injection or reheat). The rating is time
limited usually to around 5 minutes. And is only used
during take-off phase of flight.
Take-off (dry) This is the maximum thrust certified without thrust
augmentation. The rating is time limited usually to
around 5 minutes. And is only used during take-off phase
of flight.
Maximum Continuous This rating is the maximum thrust certified for continuous
Thrust (MCT) use. This rating is used at the pilots discretion, to ensure
continued, safe operation of the aircraft. MCT is used as
the maximum normal thrust available throughout the
majority of the flight, and is used when a rapid climb rate
is needed (see Figure 21.9.).
Maximum Cruise (MCZ) This is the maximum power certified for cruising.
Ground Idle (GI)/ Flight These are not rating as such, but throttle positions that
Idle (FI) are suitable positions for minimum power operations on
the ground or in flight. Ground idle which is usually a
fixed stop, provides a core engine RPM which will ensure
the driven accessories, electrical, hydraulic and
pneumatic, as well as providing a comfortable taxi thrust.
This applies to flight idle, but must also include the
effects of ram air and altitude as well. On approach the
engine must be capable of acceleration from flight idle to
full power within a maximum time limit of 5 seconds
without surging. The flight idle RPM is set to a value
where this requirement can be met. This can seriously
affect the airframe design, as there may be too much
thrust on the approach, so high drag devices may be
needed to keep the approach speed as low as possible.
Flight idle is a moveable stop which is usually activated
by the aircraft weight sensing system, it may also have
more than one position if the air bleed loads affect the
acceleration time.
Engine Trend Monitoring Sheet Filled Out on Each Flight by the Crew.
Figure 21.14.
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EPR
N1
N2
TGT
Fuel Flow
Oil Pressure/Temperature
Vibration
These figures can then be transferred onto a graph that will serve to identify the
normal/abnormal trends the engine may be developing. By utilising this method of
monitoring the operator will be better able to predict the rate of deterioration in
engine performance and to instigate some form of maintenance to correct and re-
establish normal performance. The graphic trend charts can of course be produced
be produced by a computer, and most modern turbine engined aircraft’s engine
performance is automatically recorded during flight. The recorded data is then
downloaded and processed and then analysed either manually using charts or
automatically by computer. The common term used for this type of monitoring
system is ‘Engine Condition Monitoring (ECM). Some airlines use this system to
monitor pilot performance when handling engines, as fuel burn and engine life are
two major costs, inappropriate operation can lead to further training and/or loss of
job! Figure 21.15. shows a trend monitoring graph for an ALF 502 engine using
data collected from the forms (fig. 21.14.)
Inspecting and monitoring the engine for deterioration or damage is a vital part of
aircraft maintenance. The inspections can be broken down into two main areas, ‘Air
washed’ and ‘Oil washed’. Many of the inspection techniques involved are ‘non
destructive’ of a component/system in order to determine its serviceability.
Techniques in common use include inspection and monitoring via:
Visual inspection
Boroscope inspection
Magnetic chip detectors (MCD) debris analysis
Oil filter debris analysis
Spectrometric oil analysis programme (SOAP)
Vibration analysis
Noise analysis
Visual inspection
There are three basic routine inspections to which gas turbine engines are
subjected:
Pre flight inspection
Cold section inspection
Hot section inspection (HSI)
Pre Flight inspection
Typical routine inspection before flight will include:
External inspection of engine cowlings
Inspection of intake, IGV’s, Fan blades and First stage compressor for signs of
damage.
Inspection of exhaust unit, rear turbine stage and thrust reversers (if fitted) for
signs of damage, cracks, and discoloration etc.
Inspect inside and out of the cowlings for fuel, oil and air leakage from the
engine and its accessories.
Oil level checks are carried out with defined times after shut down and form part of
the daily inspection which also includes a more detailed inspection covering the pre
flight inspection areas.
A Rigid Boroscope.
Figure 21.16.
In general the boroscope inspection technique saves many hours of work and can
reduce the down time of the aircraft in many cases, disassembly and reassemble of
the engine not being required. The boroscope is essentially an eyepiece connected
to a rigid or flexible tube. The tube contains fibre optic cables that carry light and
therefore visual images, even when the tube is made to bend through considerable
angles. A second fibre optic cable within the tube carries light from a bright light
source to illuminate the target. At the end of the tube there will be a viewing lens,
with a light source lens nearby. Most flexible probes have a steerable tip which
allows the operator to steer toward the target, and the lens is mounted in the tip to
view straight ahead. Rigid probes may have prisms behind the lens to allow the
probe to view at right angles or 45° to the probe.
The operator inserts the probe into the appropriate port to view the internal
components. Some techniques require the use of guide tubes to ensure that a
steerable probe is going in the right direction. Ports are usually designed into the
compressor, turbine and combustion sections of the engine. On the viewing end of
the boroscope there will be the controls for the steerable tip (flexible probe) and to
allow the operator to focus the probe. It is more usual these days to find a video
camera attached to the eyepiece so that a recording of the inspection can be made.
The video is presented on a television screen that allows a much bigger picture and
also more than one person to view the screen. The recording is useful as
sometimes it is very difficult to find or reproduce a view that may fleetingly pass and
which gives you concern, also should a problem be observed it can be dispatched
to the manufacturer for analysis by their experts. When turning the engine careful
counting of the blades or number of turns of the hand turning point is required to
ensure that all of the blades have been viewed.
Boroscope probes are very delicate and expensive pieces of equipment and great
care is needed when using them. It is very easy to damage a probe if it is inserted
between rotor and stator blades, even to the point of cutting the end off the probe! If
this is the technique you are using you may need to lock the rotor to prevent the risk
of damage. If the technique requires the engine to be rotated, i.e. to check the
turbine blades, then a port and probe which does not go through the blades is
required. Remember when outside very little wind can cause the rotor to move!
Interpretation of boroscope images is not always as easy as it might sound. The
viewer is very small which can make tiny cracks look like the Grand Canyon!
Equally relatively small distances can appear distant when viewed. These make it
difficult when assessing a component which is close to a limit, and may require you
to look at a similar object with the naked eye to make a proportional judgement.
Most companies require special approval for people to carry out boroscoping.
NH Compressor Inspection.
Figure 21.24.
Lubrication Systems
With oil washed components, any mechanical wear from contacting surfaces, gears,
bearings etc. will produce debris which will be carried within the oil circulating round
the engine. Analysis of this debris can provide a very useful method of assessing
any trends in wear from the internal engine components. Analysis can involve a
number of different methods.
Magnetic Detector Plug Debris Analysis
The magnetic chip detectors (MCDs), are small, permanent magnets installed in the
scavenge/return lines of the engine oil system. They will attract ferrous debris from
the oil. At specified intervals they are removed and visually inspected.
As a general rule, the presence of small, fuzzy particles or grey metallic paste is
considered satisfactory and the result of normal wear. Metallic chips or flakes
however are an indication of a more serious nature requiring more in depth
investigation.
Some organisations have specialised departments that, by examining debris under
a microscope can, by virtue of shape, size, colour and marks determine quite
accurately where the debris is from; ball bearing, roller bearing, gear teeth etc. They
may also utilise a ‘Debris Tester’ which will provide a means of measuring
(magnetically) the mass of the debris produced. The figure gleaned can then be
transferred to a graph which will indicate the normal /abnormal amounts of debris
the engine is generating. A sudden increase in the amount of debris observed either
visually or by graphs generated from debris tester figures may result in more
frequent inspections of MCDs, or , in extreme cases, engine removal for
subsequent strip examination.
An indicating type of chip detector may be used to give a warning in the flight deck if
and when excessive debris is present. Basically the detector has two probes which
if connected by the debris act as a switch to bring on a warning.
A much newer type of chip detector is the electric pulsed chip detector, which can
discriminate between wear debris particles considered non-failure related, and large
wear debris particles, which could be an indication of a more serious nature.
Operating in a similar way to the indicating type chip detector, if the warning light
illuminates, an electrical charge can be instigated either manually or automatically
across the gap. Small wear debris particles will be ‘burnt’ off and the light will
extinguish. Large wear debris particles will however not burn off and the warning
light will remain ‘on’.
(A) In line type scavenge magnetic oil chip detector (non-indicating). (B) Chip
accumulation of ferrous particles. (C) Comparison between standard, pulsed and
detector showing
detector
auto indicating chip
s. Magnetic Chip Detectors.
Figure 21.25.
Oil Spectrometer.
Figure 21.26.
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21.7.4 INSPECTIONS
Maintenance covers both the work that is required to maintain the engine and its
systems in an airworthy condition while installed in the aircraft, and the work
required to return the engine to an airworthy condition after removal from the aircraft
for overhaul. Comprehensive instructions covering the actual work to be done are
contained in the relevant sections of the aircraft’s maintenance manual (AMM) for
installed engines, frequently referred to as ‘on wing maintenance and the
component maintenance manual (CMM) for uninstalled engines. Both sources of
maintenance information are based on the manufacturers recommendations, which
in turn are approved by the appropriate airworthiness authority.
The maximum time an engine can remain ‘on wing’ is limited to a fixed period
agreed between the engine manufacturer and the airworthiness authority. This
period is often referred to as the Time Between Overhaul period (TBO) and on
reaching this limit the engine must be removed for overhaul. Because the TBO is
actually determined by the life of a few major more critical assemblies within the
engine this means that other assemblies can continue in service for much longer
periods based on an ‘on condition’ monitoring process. Basically this means that a
‘life’ is not declared for a total engine, but only for the more critical assemblies.
Less critical assemblies on reaching their ‘life’ limit are replaced ‘on wing’ or are
inspected to ascertain that they are in a condition, which will allow them to continue
in service. It is the ‘on condition ‘ items which concern the aircraft maintenance
engineer (AME) being the checks, inspections, and examinations that are required
on wing. On wing maintenance falls into two categories, scheduled maintenance
and unscheduled maintenance.
Scheduled Maintenance Checks.
These embrace the periodic and recurring checks that have to be carried out in
accordance with the maintenance schedule and an example is shown in figure
21.27
Unscheduled Maintenance Checks.
These cover work not normally related to scheduled maintenance or time limits. Bird
strikes, lightning strikes, heavy landings will result in unscheduled checks being
carried out. Defects, trouble shooting and even manufacturers specific requirements
regarding repair, and adjustments etc. will also require unscheduled maintenance.
Section of Maintenance Programme for BAe 146 for Oil System Components.
Figure 21.27.
AME’s will invariably find that for most inspections the engine is divided into two
main sections, the cold section (compressor, diffuser, fan, IGVs etc.) and the hot
section (combustion chambers, burners, turbines, NGVs, exhaust unit, etc.).
Cold Section Inspections.
Damage to fan blades, IGVs and compressor blades can cause engine failure and
possible loss of the aircraft. Much of the damage to this section of the engine is
brought about by the ingestion of Foreign Objects into the intakes, hence the term
Foreign Object Damage (FOD). The quality of air close to ground level or sea level
leaves a lot to be desired. It is filled with tiny particles of dirt, soot, sand salt, oil and
other foreign matter.
The large volume of air being drawn inwards, then centrifuged outwards can result
in a coating forming on the compressor casing and stators as well as the fan and
rotors. This accumulation of dirt reduces the aerodynamic efficiency of the
compressor resulting in a deterioration of engine efficiency. Repeated ingestion can
also result in erosion of the compressor blades. It can even cause erosion and
damage to the hot section assemblies, NGVs, turbine blades, etc. If inspection
reveals an accumulation of dirt on the compressor it must be cleared. Some
maintenance schedules will schedule regular periodicity’s for cleaning. An example
of this is shown in Figure 21.28.
Operating Nature of Recommended Recommended Remarks
Environment Wash Frequency Method
Continuously Desalination Daily Motoring Strongly recommended after
salt laden last flight of day
Occassionally Desalination Weekly Motoring Strongly recommended.
salt laden Adjust washing frequency to
suit condition.
All Performance 100 to 200 Motoring or Strongly recommended.
Recovery hours Running Performance recovery
required less frequently.
Adjust washing frequency to
suit engine operating
conditions as indicated by
engine condition monitoring
system. Motoring wash for
light soil and multiple
motoring or running wash
for heavy soil is
recommended.
Two Methods of combating the effect of dirty compressors are in use. The fluid
cleaning process and the abrasive grit cleaning process.
Fluid Cleaning.
This procedure involves spraying an emulsive type surface cleaning fluid into the
compressor whilst the engine is turning either on the starter motor or at low RPM.
This is followed by a rinsing solution being applied. This process would be used to
restore engine performance as is commonly referred to as a ‘performance recovery
wash’. To remove salt deposits a water wash only may be required. This process is
termed a ‘de-salination wash’. A schematic view of equipment that might be used is
shown in figure 21.29.
Fluid Cleaning.
Figure 21.29
Issue 2 – April 2003 Page 21-39
JAR 66 CATEGORY B1
MODULE 15
uk GAS TURBINE
engineering ENGINES
Abrasive Grit.
This method of compressor cleaning involves injecting an abrasive grit into the
engine at selected power settings ( Figure 21.30.)grit used may be ground walnut
shell or apricot pits. The type and amount of material and the operational
procedures will be described in the AMM. The main advantage of this procedure is
that allows the time between cleaning to be extended because it produces a better
result. However because the grit is mostly burned up in the combustion zone of the
engine, it will not give an effective cleaning of the turbine blades and vanes as the
fluid.
Compressor Damage.
Foreign objects often enter engine air intakes either accidentally or through
carelessness. Items such as pens, pencils cigarette lighters etc. can be drawn out
of pockets and ingested by the engine. The compressor could be damaged beyond
repair. Likewise, tools left in engine intakes could be drawn in causing damage.
Prior to starting an engine therefore, the AME should ensure that all tools used in
the vicinity of the intakes are free of any foreign objects and the area in front of
intakes should be cleared of any loose stones or rubbish . Examples of the typical
types of damage to be found on compressor blades is shown in Figure 21.31. and
possible causes of damage and the terminology used in Figure 21.32.
The majority of cold section inspections will require the use of a strong light source
and sometimes a small mirror. If however doubt exists as regard the extent of
damage, then a boroscope inspection would be instigated. Always observe the
safety precautions associated with working in the intake. Ensure that the flightdeck
is suitably placarded informing other personnel that you are in the intake. Tripping of
C/Bs may be required by the manufacturer in order to isolate the starting and
ignition circuits. A safety man may be required who’s job it will be to look after your
interest. Don’t get sucked in!!!
Hot Section Inspections (HSI’s)
The hot section includes all components in the combustion and turbine sections of
the engine. Scheduled inspections may involve visual inspection of hot section
components, and limited dimensional checks and fits and clearances as called up in
the maintenance schedule and described in the AMM. The term ‘hot section
inspection’ is usually interpreted to indicate a time related inspection of the hot
section components. It may also be required following an over-temperature
condition or hot start.
Some more in depth HSI’s will require the removal of major components of the hot
section. The modular construction of most modern gas turbine engine (Figure
21.34) will enable this removal element of the task to be carried out on the wing,
thus reducing the down time. To reduce this down time figure even more, some
operators maintain a stock of ‘hot section’ modules that are ready for immediate
replacement, the removed item being returned for inspection to the operators
overhaul facility.
An Exhaust System.
Figure 21.42.
Vibration Analysis
Gas turbine engines have extremely low levels of vibration compared to piston
engines. Changes in vibration levels could occur therefore without being noticed. To
assist the operator in identifying increasing vibration level, most engines are fitted
with vibration indicators that continually monitor the vibration level of the engine.
The indication is normally a milliammeter that receives its signals from an engine
mounted transmitter via an amplifier. Analysis of engine vibration signals is an
important tool for the detection of early failure in mechanical components.
Engine Vibration Monitoring (EVM) System.
This may take the form of a solid state circuit device utilising the piezoelectric effect.
The device consists of quartz discs with a metallic pattern deposited on them and,
arranged such that they serve as a flexible diaphragm. When subjected to pressure
changes the resultant flexing sets up an electrical polarisation in the discs, so that
electrical charges are produced relative to the amount of flexing. The electrical
charges are routed, via an amplifier to the flightdeck indicator. This is calibrated in
inches per second (IPS). On some engines there will be more than one sensor,
enabling switching if one fails. Yet another useful variation is the wide and narrow
band which means the readings can be either taken from over the whole range of
vibrations from the engine or by one or two major rotational assemblies such as N 1
and N2 spools. An example of this type is fitted to the RR Tay engine.
The EVM system shows vibration in inches/second (IPS) An amber limit shows the
maximum vibration level.
The EVM system has:
The vibration transducer has two internal vibration pick-ups, a pick-up A and B.
each pick-up gives a voltage proportional to the acceleration or deceleration of the
vibration.
The vibration transducer is on the IP compressor casing. This casing is the
housing for bearings of the HP and LP shaft.
The engine vibration signal conditioner is a single unit for both engines. It
processes the output of the engine vibration transducers for indication. The
engine vibration signal conditioner gives two modes of vibration indication,
tracked and broadband.
Tracked Indication
The tracked mode shows vibration of the N 1 and N2 shaft. The engine vibration
signal conditioner tunes two filters with an input of the N 1 and N2 RPM indicator
generators. Both filters connect to one pick-up of the vibration transducer, the
other is standby. The VIB pushswitch on the ENGINE panel controls the active
pick-up of the vibration transducer.
Broadband Indication
The broadband mode is an alternative mode. Vibration of the total power plan t is
shown. In this mode the output of both pick-ups in the vibration transducer goes
through broadband filters. A semi-guarded switch selects the tracked or
broadband mode.
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Some engines or components are packed into rigid containers of wood or metal
these will have a mounting frame within them. Wooden containers will require the
engine to be sealed in a moisture proof bag within the container however, metal
containers are usually sealed and pressurised to approx. 5 PSI and do not require a
bag.
Bags containing silica gel desiccant should be placed in the air intake and exhaust
unit and attached at convenient positions around the engine. Approximately 14 to
18 kg (30 to 40 lb) of desiccant will be required depending on the size of the engine
and the manufacturer may specify the use of VPI paper in addition (see Leaflet
BL/1-7). A humidity indicator should then be placed in the bag where it can be easily
seen and the bag sealed up. Where possible the humidity indicator should be
inspected at frequent intervals to ensure that the condition of the air inside the bag
is still `safe' (i.e. the colour of the indicator is blue). If an `unsafe' condition is shown
(i.e. the colour of the indicator is lilac or pink) the bag should be inspected and
repaired as necessary, and the desiccant renewed.
22.1.3 STORAGE.
With certain components (rubber seals, etc) the manufacturer may recommend that
the number of components in a stack is limited to a specific number to prevent
distortion.
Components that have a shelf life should be used in sequence, any that become
time expired being removed for overhaul, test and repacking.
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