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AGNEL POLYTECHNIC VASHI
INPLANT TRAINING REPORT
AIR-INDIA LTD (SANTACRUZ)
SUBMITTED BY
HONEY VISHWAKARMA
V ndash SEMESTER
ROLL NO - 075119
AGNEL POLYTECHNIC VASHI
DIPLOMA IN MECHANICAL ENGINEERING
01st JUN 2009 ndash 14th NOV 2009
1 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
SUBMISSION
I HONEY VISHWAKARMA Roll Number - 075119 a student
of FIFTH SEMESTER of diploma course in MECHANICAL
ENGINEERING humbly submit that I have completed from time to
time the inplant training work as described in the report by my own skills
and study from 01062009 to 14112009 as per the instructionguidance
of Mr_________________________
I certify that I have not copied the report or any of its appreciable
part from any other literature in contravention of academic ethics
Candidates seat No ____________
Date ____________
________________________
Signature of student
2 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Agnel Polytechnic
Sector 9-A Vashi Navi Mumbai ndash 400 703 Telephone 766 2949 766 1924 Telex 11-71109 AGNEL IN
Fax 7662949 7661924
Date - ______________
CERTIFICATE
This is to certify that Mr HONEY VISHWAKARMA Roll No075119 a student of V SEMESTER of Diploma Course in MECHANICAL ENGINEERING has submitted this report after satisfactory completion of INPLANT TRAINING from 1ST JUN 2009 to 14TH NOV 2009 as prescribed by Maharashtra Board of Technical Education Mumbai
I have instructed guided him for the said work from time to time and I found his progress satisfactory
The said work has been assessed by me and I am satisfied that the same is up to the standard envisaged for the level of the course
Candidate Seat No -
LECTURER-IN-CHARGE Signature
Name
Date
HEAD OF THE DEPT Signature
Name Mr R S Nehte
Date
TRAINING amp Signature
PLACEMENT OFFICER Name Mr Umesh Kantute
Date
EXAMINER Signature
Name
Date
3 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NO OBJECTION CERTIFICATE THIS IS CERTIFY THAT MrHONEY VISHAWAKARMA
ROLL NO075119 A STUDENT OF VTH SEMESTER OF DIPLOMA
COURSE IN MECHANICAL ENGINEERING HAS COMPLETED
HIS INPLANT TRAINING FROM 1ST JUN 2009 TO 14TH NOV 2009
IN THE ENGINE OVERHAUL DEPARTMENT (EOD) OF AIR-
INDIA LTD (SANTACRUZ)
4 5TH SEMESTER
WE HAVE NO OBJECTION IN USING CONTENTS OF THIS
PROJECT REPORT FOR ACADEMIC PURPOSE
AGNEL POLYTECHNIC VASHI
INDEX SR NO TOPIC PAGE
NO
1 INTRODUCTION TO THE COMPANY 8-17
2 INTRODUCTION TO EOD (ENGINE OVERHAUL DIVISION)
18-29
3 INTRODUCTION TO JET ENGINES amp ITS PARTS 30-47
4 DESCRIPTION OF GENERAL ELECTRICAL CF6 80C2 A2
48-53
5 INTRODUCTION TO GEARBOX 54-57
6 DESCRIPTION OF PW4056 58-64
7 DESCRIPTION OF GE 90 65-70
8 DESCRIPTION OF PLASMA COATING SECTION 72-78
9 CONCLUSION 79-80
10 REFERENCE 81
5 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACKNOWLEDGMENT
I take this opportunity to express my sincere thanks to the training
department of ldquoAIR INDIA LTDrdquo works for providing me with
training facility in the in the motor plant of their organization
I express my gratitude and thanks to MR T G RAJU (General
Manager) who gave me such a interesting department to carry out my
inplant training and also for allowing to utilize the various facilities
available in the plant MR _______________________ whose timely
guidance and help were invaluable in the completion of the project I am
thankful to PROF PRABHUDESAI the training supervisor who kept
me well linked with our college and gave valuable instruction and
advice needed I am thankful Mr BHAVSAR Mr NARULA Mr
SARDESAI Mr NARKHEDE Mr ASHIT SEN and Mr
SARDESAI
They are persons who had given detailed information and project
work and provide brief support
I am sincerely thankful to our Principal MR GHULE MR
UMESH KANTUTE the training and placement officer of Agnel
Polytechnic (Vashi) for their valuable teachings and guidance
Last but not least I would like to thank all my friends and
colleagues for their invaluable co - operation without which I would not
been able to complete my training
6 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABSTRACT
This report is a description of the maintenance and overhaul procedures
conducted in Air India at its Old Airport workshop in Santacruz Mumbai
in its Engine Overhaul Department (EOD) This report starts with an
introduction to the Company presents the aircraft that undergoes
maintenance at the EOD describes the maintenance procedures and
concludes with our contribution to improve these procedures
Today the field of avionics has gained a lot of importance both as
commercial Airliner as well as Cargo ships Thus it is clear that avionics
has played a vital point in the development and advancement of our
country
Air India boasts of a huge fleet of aircrafts and it not only connects the
cities internally in collaboration with Indian Airlines but also provides
vast linkage to various countries across the globe The two Indian
avionics giants Air India and Indian Airlines have recently merged to
form NACIL Air India possesses flights of Boeing as well as fleet of
Airbus aircrafts
7 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
8 5TH SEMESTER
AIR INDIA
AGNEL POLYTECHNIC VASHI
HISTORY OF AIR INDIA
In 1929 LATE Mr NEVILLE VINCENT a Royal Air Force Pilot realized that
there is immense potential for aviation in India after surveying no of possible
routes He met Mr JRD TATA a young Indian who was first to get his A-
licensing in India
Mr Vincent and J R D Tata worked out a scheme which was also
approved by Mr PETERSON (Director Tata Sons) and Mr DORABJI TATA (Chairman Tata Sons) and thus was born the TATA AIRLINES which later
became AIR INDIA According to the scheme on 15th October 1932 a light Single Engine
De-Havilland Puss Moth from Karachi on its flight to Mumbai via Ahmedabad
At control of tiny plane was J R D Tata This was First Scheduled Flight in
our country
Tata airlines consisted of One Puss Moth One Leopard Moth in there
fleet In 1933 in full year of operation TATA airlines flew 160000 miles carried
155 passengers and 1071 tons of mail A Tata airline was converted to a
public limited company on 29th July 1946 and was known as AIR INIDA Air India started its services from Bombay to London via Cairo and
Geneva with a constellation aircraft on 8th June 1948
9 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LAND MARKS IN HISTORY OF AIR INDIA
DATE LANDMARKS
15 Oct 1932
Tata sonrsquos ltd
Inaugurated the first scheduled service in India with a puss
month Pilot ndash Mr J R D Tata
29 July 1946 Tata airlines were converted to a public limited company And was named Air India
8 Mar 1948 Air India international was formed
16 Mar 1948 First constellation aircraft arrives
8 June 1948 First Bombay-London service inaugurated
21 Feb 1960 Arrival of first Boeing 707 aircraft
11 June 1962 Nine super constellation aircrafts were sold out Thus Air
India becomes worlds first all jet airliner
18 Apr 1971 First Boeing 747 aircraft arrives
8 Dec 1980 New international airport terminal inaugurated at Bombay
11 Aug 1982 First airbus VT-EHN ldquoGANGArdquo arrives at Bombay
10 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABOUT THE COMPANY
Air-India is Indias national flag carrier Although air transport was born
in India on February 18 1911 when Henri Piquet flying a Humber bi-
plane carried mail from Allahabad to Naini Junction some six miles
away the scheduled services in India in the real sense began on
October 15 1932 It was on this day that JRD Tata the father of Civil
Aviation in India and founder of Air-India took off from Drigh Road
Airport Karachi in a tiny light single-engined de Havilland Puss Moth
on his flight to Mumbai (then known as Bombay) via Ahmedabad He
landed with his precious load of mail on a grass strip at Juhu At
Mumbai Neville Vincent a former RAF pilot who had come to India from
Britain three years earlier on a barn-storming tour during which he had
surveyed a number of possible air routes took over from JRDTata and
flew the Puss Moth to Chennai (then Madras) via Bellary Air-India has
achieved several milestones in its history since it began operations on
October 15 1932 In the first full year of operations Tata Airlines flew
160000 miles carried 155 passengers and 1071 tonnes of mail Tata
Airlines was converted into a Public Company under the name of Air-
India in August 1946
11 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
More Aircraft Larger Network amp Higher Profitability
Air-India is Indias finest flying Ambassador Air-India has expanded its
fleet by inducting 10 aircraft (one Boeing 747-400 and nine Airbus 310s) on
dry lease in recent
months Air-India has also gifted three A300-B4 aircraft to Ariana
Afghan Airlines to help resurrect the civil aviation sector of Afghanistan
Expansion of fleet through the dry-leasing route pending acquisition of
aircraft has enabled Air-India to improve its ranking amongst world
airlines on the basis of revenue earned and number of passengers
carried According to a review published in September 2003 in Airline
Business an international magazine while Air-Indiarsquos ranking on the
basis of revenue in 2002 has gone up to 51 from 54 in the preceding
year Air-India stands at 54 amongst international airlines on the basis of
passengers carried - up from 61 in 2001
Air-Indiarsquos total issue and paid-up Capital is Rs1 5384 million The
airline has been profitable in most years since its inception In the financial
year ending March 31 2003 the Company carried 339 million passengers
and made a net profit of Rs13385 million on operating revenue of Rs5658
billion The success on the financial front was achieved despite the global
economic recession and the adverse impact of the September 11 incident in
New York on the aviation industry globally
12 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Achievements
Air-India which has won commendation from passengers for its
in-flight food was presented the Mercury Award Gold Shield for the
finest In-flight Meal Service Concept by the International Flight Catering
Association in Geneva in February 1994 The airline was adjudged
best among 52 entries in the annual competition open to all airlines and
catering agencies
Air-India has over the past 55 years come to the rescue of Indian Nationals
in various parts of the world in their hour of need on more than one occasion
13 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Network
In its ever-growing quest for providing direct services from various points in
India Air-India currently operates flights from Mumbai and 11 other Indian
cities viz Ahmedabad Bangalore Chennai Delhi Goa
Hyderabad Kochi Kolkata Kozhikode Lucknow and Thiruvananthapuram
Commencement of international operations from these cities has
obviated to a very large extent the need for passengers from these
regions to necessarily travel to Mumbai and Delhi the traditional main
gateways for taking international flights Passengers boarding or
deplaning in these cities can now complete their immigration and
custom formalities at their city airport
both at the time of departure and arrival Air-India has simultaneously
introduced fixed time departures for flights to the Gulf from Mumbai
Delhi and Kochi In the past two years the number of flights operated to
the Gulf has increased from 75 to 104
14 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Air indiarsquos worldwide network today covers 44 destinations by operating
services with its own aircrafts and through code-shared flightsSignificant
improvements introduced in all areas of Air-Indias Operations on an on-
going basis reinforces the airlines commitment to quality and insistence
on high standards Air-India has in tune with the times emerged as a
progressive forward looking airline eager to satiate the growing needs and
expectations of the discerning jet-age traveller of today
15 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
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ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
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The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
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AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
SUBMISSION
I HONEY VISHWAKARMA Roll Number - 075119 a student
of FIFTH SEMESTER of diploma course in MECHANICAL
ENGINEERING humbly submit that I have completed from time to
time the inplant training work as described in the report by my own skills
and study from 01062009 to 14112009 as per the instructionguidance
of Mr_________________________
I certify that I have not copied the report or any of its appreciable
part from any other literature in contravention of academic ethics
Candidates seat No ____________
Date ____________
________________________
Signature of student
2 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Agnel Polytechnic
Sector 9-A Vashi Navi Mumbai ndash 400 703 Telephone 766 2949 766 1924 Telex 11-71109 AGNEL IN
Fax 7662949 7661924
Date - ______________
CERTIFICATE
This is to certify that Mr HONEY VISHWAKARMA Roll No075119 a student of V SEMESTER of Diploma Course in MECHANICAL ENGINEERING has submitted this report after satisfactory completion of INPLANT TRAINING from 1ST JUN 2009 to 14TH NOV 2009 as prescribed by Maharashtra Board of Technical Education Mumbai
I have instructed guided him for the said work from time to time and I found his progress satisfactory
The said work has been assessed by me and I am satisfied that the same is up to the standard envisaged for the level of the course
Candidate Seat No -
LECTURER-IN-CHARGE Signature
Name
Date
HEAD OF THE DEPT Signature
Name Mr R S Nehte
Date
TRAINING amp Signature
PLACEMENT OFFICER Name Mr Umesh Kantute
Date
EXAMINER Signature
Name
Date
3 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NO OBJECTION CERTIFICATE THIS IS CERTIFY THAT MrHONEY VISHAWAKARMA
ROLL NO075119 A STUDENT OF VTH SEMESTER OF DIPLOMA
COURSE IN MECHANICAL ENGINEERING HAS COMPLETED
HIS INPLANT TRAINING FROM 1ST JUN 2009 TO 14TH NOV 2009
IN THE ENGINE OVERHAUL DEPARTMENT (EOD) OF AIR-
INDIA LTD (SANTACRUZ)
4 5TH SEMESTER
WE HAVE NO OBJECTION IN USING CONTENTS OF THIS
PROJECT REPORT FOR ACADEMIC PURPOSE
AGNEL POLYTECHNIC VASHI
INDEX SR NO TOPIC PAGE
NO
1 INTRODUCTION TO THE COMPANY 8-17
2 INTRODUCTION TO EOD (ENGINE OVERHAUL DIVISION)
18-29
3 INTRODUCTION TO JET ENGINES amp ITS PARTS 30-47
4 DESCRIPTION OF GENERAL ELECTRICAL CF6 80C2 A2
48-53
5 INTRODUCTION TO GEARBOX 54-57
6 DESCRIPTION OF PW4056 58-64
7 DESCRIPTION OF GE 90 65-70
8 DESCRIPTION OF PLASMA COATING SECTION 72-78
9 CONCLUSION 79-80
10 REFERENCE 81
5 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACKNOWLEDGMENT
I take this opportunity to express my sincere thanks to the training
department of ldquoAIR INDIA LTDrdquo works for providing me with
training facility in the in the motor plant of their organization
I express my gratitude and thanks to MR T G RAJU (General
Manager) who gave me such a interesting department to carry out my
inplant training and also for allowing to utilize the various facilities
available in the plant MR _______________________ whose timely
guidance and help were invaluable in the completion of the project I am
thankful to PROF PRABHUDESAI the training supervisor who kept
me well linked with our college and gave valuable instruction and
advice needed I am thankful Mr BHAVSAR Mr NARULA Mr
SARDESAI Mr NARKHEDE Mr ASHIT SEN and Mr
SARDESAI
They are persons who had given detailed information and project
work and provide brief support
I am sincerely thankful to our Principal MR GHULE MR
UMESH KANTUTE the training and placement officer of Agnel
Polytechnic (Vashi) for their valuable teachings and guidance
Last but not least I would like to thank all my friends and
colleagues for their invaluable co - operation without which I would not
been able to complete my training
6 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABSTRACT
This report is a description of the maintenance and overhaul procedures
conducted in Air India at its Old Airport workshop in Santacruz Mumbai
in its Engine Overhaul Department (EOD) This report starts with an
introduction to the Company presents the aircraft that undergoes
maintenance at the EOD describes the maintenance procedures and
concludes with our contribution to improve these procedures
Today the field of avionics has gained a lot of importance both as
commercial Airliner as well as Cargo ships Thus it is clear that avionics
has played a vital point in the development and advancement of our
country
Air India boasts of a huge fleet of aircrafts and it not only connects the
cities internally in collaboration with Indian Airlines but also provides
vast linkage to various countries across the globe The two Indian
avionics giants Air India and Indian Airlines have recently merged to
form NACIL Air India possesses flights of Boeing as well as fleet of
Airbus aircrafts
7 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
8 5TH SEMESTER
AIR INDIA
AGNEL POLYTECHNIC VASHI
HISTORY OF AIR INDIA
In 1929 LATE Mr NEVILLE VINCENT a Royal Air Force Pilot realized that
there is immense potential for aviation in India after surveying no of possible
routes He met Mr JRD TATA a young Indian who was first to get his A-
licensing in India
Mr Vincent and J R D Tata worked out a scheme which was also
approved by Mr PETERSON (Director Tata Sons) and Mr DORABJI TATA (Chairman Tata Sons) and thus was born the TATA AIRLINES which later
became AIR INDIA According to the scheme on 15th October 1932 a light Single Engine
De-Havilland Puss Moth from Karachi on its flight to Mumbai via Ahmedabad
At control of tiny plane was J R D Tata This was First Scheduled Flight in
our country
Tata airlines consisted of One Puss Moth One Leopard Moth in there
fleet In 1933 in full year of operation TATA airlines flew 160000 miles carried
155 passengers and 1071 tons of mail A Tata airline was converted to a
public limited company on 29th July 1946 and was known as AIR INIDA Air India started its services from Bombay to London via Cairo and
Geneva with a constellation aircraft on 8th June 1948
9 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LAND MARKS IN HISTORY OF AIR INDIA
DATE LANDMARKS
15 Oct 1932
Tata sonrsquos ltd
Inaugurated the first scheduled service in India with a puss
month Pilot ndash Mr J R D Tata
29 July 1946 Tata airlines were converted to a public limited company And was named Air India
8 Mar 1948 Air India international was formed
16 Mar 1948 First constellation aircraft arrives
8 June 1948 First Bombay-London service inaugurated
21 Feb 1960 Arrival of first Boeing 707 aircraft
11 June 1962 Nine super constellation aircrafts were sold out Thus Air
India becomes worlds first all jet airliner
18 Apr 1971 First Boeing 747 aircraft arrives
8 Dec 1980 New international airport terminal inaugurated at Bombay
11 Aug 1982 First airbus VT-EHN ldquoGANGArdquo arrives at Bombay
10 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABOUT THE COMPANY
Air-India is Indias national flag carrier Although air transport was born
in India on February 18 1911 when Henri Piquet flying a Humber bi-
plane carried mail from Allahabad to Naini Junction some six miles
away the scheduled services in India in the real sense began on
October 15 1932 It was on this day that JRD Tata the father of Civil
Aviation in India and founder of Air-India took off from Drigh Road
Airport Karachi in a tiny light single-engined de Havilland Puss Moth
on his flight to Mumbai (then known as Bombay) via Ahmedabad He
landed with his precious load of mail on a grass strip at Juhu At
Mumbai Neville Vincent a former RAF pilot who had come to India from
Britain three years earlier on a barn-storming tour during which he had
surveyed a number of possible air routes took over from JRDTata and
flew the Puss Moth to Chennai (then Madras) via Bellary Air-India has
achieved several milestones in its history since it began operations on
October 15 1932 In the first full year of operations Tata Airlines flew
160000 miles carried 155 passengers and 1071 tonnes of mail Tata
Airlines was converted into a Public Company under the name of Air-
India in August 1946
11 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
More Aircraft Larger Network amp Higher Profitability
Air-India is Indias finest flying Ambassador Air-India has expanded its
fleet by inducting 10 aircraft (one Boeing 747-400 and nine Airbus 310s) on
dry lease in recent
months Air-India has also gifted three A300-B4 aircraft to Ariana
Afghan Airlines to help resurrect the civil aviation sector of Afghanistan
Expansion of fleet through the dry-leasing route pending acquisition of
aircraft has enabled Air-India to improve its ranking amongst world
airlines on the basis of revenue earned and number of passengers
carried According to a review published in September 2003 in Airline
Business an international magazine while Air-Indiarsquos ranking on the
basis of revenue in 2002 has gone up to 51 from 54 in the preceding
year Air-India stands at 54 amongst international airlines on the basis of
passengers carried - up from 61 in 2001
Air-Indiarsquos total issue and paid-up Capital is Rs1 5384 million The
airline has been profitable in most years since its inception In the financial
year ending March 31 2003 the Company carried 339 million passengers
and made a net profit of Rs13385 million on operating revenue of Rs5658
billion The success on the financial front was achieved despite the global
economic recession and the adverse impact of the September 11 incident in
New York on the aviation industry globally
12 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Achievements
Air-India which has won commendation from passengers for its
in-flight food was presented the Mercury Award Gold Shield for the
finest In-flight Meal Service Concept by the International Flight Catering
Association in Geneva in February 1994 The airline was adjudged
best among 52 entries in the annual competition open to all airlines and
catering agencies
Air-India has over the past 55 years come to the rescue of Indian Nationals
in various parts of the world in their hour of need on more than one occasion
13 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Network
In its ever-growing quest for providing direct services from various points in
India Air-India currently operates flights from Mumbai and 11 other Indian
cities viz Ahmedabad Bangalore Chennai Delhi Goa
Hyderabad Kochi Kolkata Kozhikode Lucknow and Thiruvananthapuram
Commencement of international operations from these cities has
obviated to a very large extent the need for passengers from these
regions to necessarily travel to Mumbai and Delhi the traditional main
gateways for taking international flights Passengers boarding or
deplaning in these cities can now complete their immigration and
custom formalities at their city airport
both at the time of departure and arrival Air-India has simultaneously
introduced fixed time departures for flights to the Gulf from Mumbai
Delhi and Kochi In the past two years the number of flights operated to
the Gulf has increased from 75 to 104
14 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Air indiarsquos worldwide network today covers 44 destinations by operating
services with its own aircrafts and through code-shared flightsSignificant
improvements introduced in all areas of Air-Indias Operations on an on-
going basis reinforces the airlines commitment to quality and insistence
on high standards Air-India has in tune with the times emerged as a
progressive forward looking airline eager to satiate the growing needs and
expectations of the discerning jet-age traveller of today
15 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
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THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
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FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
Agnel Polytechnic
Sector 9-A Vashi Navi Mumbai ndash 400 703 Telephone 766 2949 766 1924 Telex 11-71109 AGNEL IN
Fax 7662949 7661924
Date - ______________
CERTIFICATE
This is to certify that Mr HONEY VISHWAKARMA Roll No075119 a student of V SEMESTER of Diploma Course in MECHANICAL ENGINEERING has submitted this report after satisfactory completion of INPLANT TRAINING from 1ST JUN 2009 to 14TH NOV 2009 as prescribed by Maharashtra Board of Technical Education Mumbai
I have instructed guided him for the said work from time to time and I found his progress satisfactory
The said work has been assessed by me and I am satisfied that the same is up to the standard envisaged for the level of the course
Candidate Seat No -
LECTURER-IN-CHARGE Signature
Name
Date
HEAD OF THE DEPT Signature
Name Mr R S Nehte
Date
TRAINING amp Signature
PLACEMENT OFFICER Name Mr Umesh Kantute
Date
EXAMINER Signature
Name
Date
3 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NO OBJECTION CERTIFICATE THIS IS CERTIFY THAT MrHONEY VISHAWAKARMA
ROLL NO075119 A STUDENT OF VTH SEMESTER OF DIPLOMA
COURSE IN MECHANICAL ENGINEERING HAS COMPLETED
HIS INPLANT TRAINING FROM 1ST JUN 2009 TO 14TH NOV 2009
IN THE ENGINE OVERHAUL DEPARTMENT (EOD) OF AIR-
INDIA LTD (SANTACRUZ)
4 5TH SEMESTER
WE HAVE NO OBJECTION IN USING CONTENTS OF THIS
PROJECT REPORT FOR ACADEMIC PURPOSE
AGNEL POLYTECHNIC VASHI
INDEX SR NO TOPIC PAGE
NO
1 INTRODUCTION TO THE COMPANY 8-17
2 INTRODUCTION TO EOD (ENGINE OVERHAUL DIVISION)
18-29
3 INTRODUCTION TO JET ENGINES amp ITS PARTS 30-47
4 DESCRIPTION OF GENERAL ELECTRICAL CF6 80C2 A2
48-53
5 INTRODUCTION TO GEARBOX 54-57
6 DESCRIPTION OF PW4056 58-64
7 DESCRIPTION OF GE 90 65-70
8 DESCRIPTION OF PLASMA COATING SECTION 72-78
9 CONCLUSION 79-80
10 REFERENCE 81
5 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACKNOWLEDGMENT
I take this opportunity to express my sincere thanks to the training
department of ldquoAIR INDIA LTDrdquo works for providing me with
training facility in the in the motor plant of their organization
I express my gratitude and thanks to MR T G RAJU (General
Manager) who gave me such a interesting department to carry out my
inplant training and also for allowing to utilize the various facilities
available in the plant MR _______________________ whose timely
guidance and help were invaluable in the completion of the project I am
thankful to PROF PRABHUDESAI the training supervisor who kept
me well linked with our college and gave valuable instruction and
advice needed I am thankful Mr BHAVSAR Mr NARULA Mr
SARDESAI Mr NARKHEDE Mr ASHIT SEN and Mr
SARDESAI
They are persons who had given detailed information and project
work and provide brief support
I am sincerely thankful to our Principal MR GHULE MR
UMESH KANTUTE the training and placement officer of Agnel
Polytechnic (Vashi) for their valuable teachings and guidance
Last but not least I would like to thank all my friends and
colleagues for their invaluable co - operation without which I would not
been able to complete my training
6 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABSTRACT
This report is a description of the maintenance and overhaul procedures
conducted in Air India at its Old Airport workshop in Santacruz Mumbai
in its Engine Overhaul Department (EOD) This report starts with an
introduction to the Company presents the aircraft that undergoes
maintenance at the EOD describes the maintenance procedures and
concludes with our contribution to improve these procedures
Today the field of avionics has gained a lot of importance both as
commercial Airliner as well as Cargo ships Thus it is clear that avionics
has played a vital point in the development and advancement of our
country
Air India boasts of a huge fleet of aircrafts and it not only connects the
cities internally in collaboration with Indian Airlines but also provides
vast linkage to various countries across the globe The two Indian
avionics giants Air India and Indian Airlines have recently merged to
form NACIL Air India possesses flights of Boeing as well as fleet of
Airbus aircrafts
7 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
8 5TH SEMESTER
AIR INDIA
AGNEL POLYTECHNIC VASHI
HISTORY OF AIR INDIA
In 1929 LATE Mr NEVILLE VINCENT a Royal Air Force Pilot realized that
there is immense potential for aviation in India after surveying no of possible
routes He met Mr JRD TATA a young Indian who was first to get his A-
licensing in India
Mr Vincent and J R D Tata worked out a scheme which was also
approved by Mr PETERSON (Director Tata Sons) and Mr DORABJI TATA (Chairman Tata Sons) and thus was born the TATA AIRLINES which later
became AIR INDIA According to the scheme on 15th October 1932 a light Single Engine
De-Havilland Puss Moth from Karachi on its flight to Mumbai via Ahmedabad
At control of tiny plane was J R D Tata This was First Scheduled Flight in
our country
Tata airlines consisted of One Puss Moth One Leopard Moth in there
fleet In 1933 in full year of operation TATA airlines flew 160000 miles carried
155 passengers and 1071 tons of mail A Tata airline was converted to a
public limited company on 29th July 1946 and was known as AIR INIDA Air India started its services from Bombay to London via Cairo and
Geneva with a constellation aircraft on 8th June 1948
9 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LAND MARKS IN HISTORY OF AIR INDIA
DATE LANDMARKS
15 Oct 1932
Tata sonrsquos ltd
Inaugurated the first scheduled service in India with a puss
month Pilot ndash Mr J R D Tata
29 July 1946 Tata airlines were converted to a public limited company And was named Air India
8 Mar 1948 Air India international was formed
16 Mar 1948 First constellation aircraft arrives
8 June 1948 First Bombay-London service inaugurated
21 Feb 1960 Arrival of first Boeing 707 aircraft
11 June 1962 Nine super constellation aircrafts were sold out Thus Air
India becomes worlds first all jet airliner
18 Apr 1971 First Boeing 747 aircraft arrives
8 Dec 1980 New international airport terminal inaugurated at Bombay
11 Aug 1982 First airbus VT-EHN ldquoGANGArdquo arrives at Bombay
10 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABOUT THE COMPANY
Air-India is Indias national flag carrier Although air transport was born
in India on February 18 1911 when Henri Piquet flying a Humber bi-
plane carried mail from Allahabad to Naini Junction some six miles
away the scheduled services in India in the real sense began on
October 15 1932 It was on this day that JRD Tata the father of Civil
Aviation in India and founder of Air-India took off from Drigh Road
Airport Karachi in a tiny light single-engined de Havilland Puss Moth
on his flight to Mumbai (then known as Bombay) via Ahmedabad He
landed with his precious load of mail on a grass strip at Juhu At
Mumbai Neville Vincent a former RAF pilot who had come to India from
Britain three years earlier on a barn-storming tour during which he had
surveyed a number of possible air routes took over from JRDTata and
flew the Puss Moth to Chennai (then Madras) via Bellary Air-India has
achieved several milestones in its history since it began operations on
October 15 1932 In the first full year of operations Tata Airlines flew
160000 miles carried 155 passengers and 1071 tonnes of mail Tata
Airlines was converted into a Public Company under the name of Air-
India in August 1946
11 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
More Aircraft Larger Network amp Higher Profitability
Air-India is Indias finest flying Ambassador Air-India has expanded its
fleet by inducting 10 aircraft (one Boeing 747-400 and nine Airbus 310s) on
dry lease in recent
months Air-India has also gifted three A300-B4 aircraft to Ariana
Afghan Airlines to help resurrect the civil aviation sector of Afghanistan
Expansion of fleet through the dry-leasing route pending acquisition of
aircraft has enabled Air-India to improve its ranking amongst world
airlines on the basis of revenue earned and number of passengers
carried According to a review published in September 2003 in Airline
Business an international magazine while Air-Indiarsquos ranking on the
basis of revenue in 2002 has gone up to 51 from 54 in the preceding
year Air-India stands at 54 amongst international airlines on the basis of
passengers carried - up from 61 in 2001
Air-Indiarsquos total issue and paid-up Capital is Rs1 5384 million The
airline has been profitable in most years since its inception In the financial
year ending March 31 2003 the Company carried 339 million passengers
and made a net profit of Rs13385 million on operating revenue of Rs5658
billion The success on the financial front was achieved despite the global
economic recession and the adverse impact of the September 11 incident in
New York on the aviation industry globally
12 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Achievements
Air-India which has won commendation from passengers for its
in-flight food was presented the Mercury Award Gold Shield for the
finest In-flight Meal Service Concept by the International Flight Catering
Association in Geneva in February 1994 The airline was adjudged
best among 52 entries in the annual competition open to all airlines and
catering agencies
Air-India has over the past 55 years come to the rescue of Indian Nationals
in various parts of the world in their hour of need on more than one occasion
13 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Network
In its ever-growing quest for providing direct services from various points in
India Air-India currently operates flights from Mumbai and 11 other Indian
cities viz Ahmedabad Bangalore Chennai Delhi Goa
Hyderabad Kochi Kolkata Kozhikode Lucknow and Thiruvananthapuram
Commencement of international operations from these cities has
obviated to a very large extent the need for passengers from these
regions to necessarily travel to Mumbai and Delhi the traditional main
gateways for taking international flights Passengers boarding or
deplaning in these cities can now complete their immigration and
custom formalities at their city airport
both at the time of departure and arrival Air-India has simultaneously
introduced fixed time departures for flights to the Gulf from Mumbai
Delhi and Kochi In the past two years the number of flights operated to
the Gulf has increased from 75 to 104
14 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Air indiarsquos worldwide network today covers 44 destinations by operating
services with its own aircrafts and through code-shared flightsSignificant
improvements introduced in all areas of Air-Indias Operations on an on-
going basis reinforces the airlines commitment to quality and insistence
on high standards Air-India has in tune with the times emerged as a
progressive forward looking airline eager to satiate the growing needs and
expectations of the discerning jet-age traveller of today
15 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
NO OBJECTION CERTIFICATE THIS IS CERTIFY THAT MrHONEY VISHAWAKARMA
ROLL NO075119 A STUDENT OF VTH SEMESTER OF DIPLOMA
COURSE IN MECHANICAL ENGINEERING HAS COMPLETED
HIS INPLANT TRAINING FROM 1ST JUN 2009 TO 14TH NOV 2009
IN THE ENGINE OVERHAUL DEPARTMENT (EOD) OF AIR-
INDIA LTD (SANTACRUZ)
4 5TH SEMESTER
WE HAVE NO OBJECTION IN USING CONTENTS OF THIS
PROJECT REPORT FOR ACADEMIC PURPOSE
AGNEL POLYTECHNIC VASHI
INDEX SR NO TOPIC PAGE
NO
1 INTRODUCTION TO THE COMPANY 8-17
2 INTRODUCTION TO EOD (ENGINE OVERHAUL DIVISION)
18-29
3 INTRODUCTION TO JET ENGINES amp ITS PARTS 30-47
4 DESCRIPTION OF GENERAL ELECTRICAL CF6 80C2 A2
48-53
5 INTRODUCTION TO GEARBOX 54-57
6 DESCRIPTION OF PW4056 58-64
7 DESCRIPTION OF GE 90 65-70
8 DESCRIPTION OF PLASMA COATING SECTION 72-78
9 CONCLUSION 79-80
10 REFERENCE 81
5 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACKNOWLEDGMENT
I take this opportunity to express my sincere thanks to the training
department of ldquoAIR INDIA LTDrdquo works for providing me with
training facility in the in the motor plant of their organization
I express my gratitude and thanks to MR T G RAJU (General
Manager) who gave me such a interesting department to carry out my
inplant training and also for allowing to utilize the various facilities
available in the plant MR _______________________ whose timely
guidance and help were invaluable in the completion of the project I am
thankful to PROF PRABHUDESAI the training supervisor who kept
me well linked with our college and gave valuable instruction and
advice needed I am thankful Mr BHAVSAR Mr NARULA Mr
SARDESAI Mr NARKHEDE Mr ASHIT SEN and Mr
SARDESAI
They are persons who had given detailed information and project
work and provide brief support
I am sincerely thankful to our Principal MR GHULE MR
UMESH KANTUTE the training and placement officer of Agnel
Polytechnic (Vashi) for their valuable teachings and guidance
Last but not least I would like to thank all my friends and
colleagues for their invaluable co - operation without which I would not
been able to complete my training
6 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABSTRACT
This report is a description of the maintenance and overhaul procedures
conducted in Air India at its Old Airport workshop in Santacruz Mumbai
in its Engine Overhaul Department (EOD) This report starts with an
introduction to the Company presents the aircraft that undergoes
maintenance at the EOD describes the maintenance procedures and
concludes with our contribution to improve these procedures
Today the field of avionics has gained a lot of importance both as
commercial Airliner as well as Cargo ships Thus it is clear that avionics
has played a vital point in the development and advancement of our
country
Air India boasts of a huge fleet of aircrafts and it not only connects the
cities internally in collaboration with Indian Airlines but also provides
vast linkage to various countries across the globe The two Indian
avionics giants Air India and Indian Airlines have recently merged to
form NACIL Air India possesses flights of Boeing as well as fleet of
Airbus aircrafts
7 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
8 5TH SEMESTER
AIR INDIA
AGNEL POLYTECHNIC VASHI
HISTORY OF AIR INDIA
In 1929 LATE Mr NEVILLE VINCENT a Royal Air Force Pilot realized that
there is immense potential for aviation in India after surveying no of possible
routes He met Mr JRD TATA a young Indian who was first to get his A-
licensing in India
Mr Vincent and J R D Tata worked out a scheme which was also
approved by Mr PETERSON (Director Tata Sons) and Mr DORABJI TATA (Chairman Tata Sons) and thus was born the TATA AIRLINES which later
became AIR INDIA According to the scheme on 15th October 1932 a light Single Engine
De-Havilland Puss Moth from Karachi on its flight to Mumbai via Ahmedabad
At control of tiny plane was J R D Tata This was First Scheduled Flight in
our country
Tata airlines consisted of One Puss Moth One Leopard Moth in there
fleet In 1933 in full year of operation TATA airlines flew 160000 miles carried
155 passengers and 1071 tons of mail A Tata airline was converted to a
public limited company on 29th July 1946 and was known as AIR INIDA Air India started its services from Bombay to London via Cairo and
Geneva with a constellation aircraft on 8th June 1948
9 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LAND MARKS IN HISTORY OF AIR INDIA
DATE LANDMARKS
15 Oct 1932
Tata sonrsquos ltd
Inaugurated the first scheduled service in India with a puss
month Pilot ndash Mr J R D Tata
29 July 1946 Tata airlines were converted to a public limited company And was named Air India
8 Mar 1948 Air India international was formed
16 Mar 1948 First constellation aircraft arrives
8 June 1948 First Bombay-London service inaugurated
21 Feb 1960 Arrival of first Boeing 707 aircraft
11 June 1962 Nine super constellation aircrafts were sold out Thus Air
India becomes worlds first all jet airliner
18 Apr 1971 First Boeing 747 aircraft arrives
8 Dec 1980 New international airport terminal inaugurated at Bombay
11 Aug 1982 First airbus VT-EHN ldquoGANGArdquo arrives at Bombay
10 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABOUT THE COMPANY
Air-India is Indias national flag carrier Although air transport was born
in India on February 18 1911 when Henri Piquet flying a Humber bi-
plane carried mail from Allahabad to Naini Junction some six miles
away the scheduled services in India in the real sense began on
October 15 1932 It was on this day that JRD Tata the father of Civil
Aviation in India and founder of Air-India took off from Drigh Road
Airport Karachi in a tiny light single-engined de Havilland Puss Moth
on his flight to Mumbai (then known as Bombay) via Ahmedabad He
landed with his precious load of mail on a grass strip at Juhu At
Mumbai Neville Vincent a former RAF pilot who had come to India from
Britain three years earlier on a barn-storming tour during which he had
surveyed a number of possible air routes took over from JRDTata and
flew the Puss Moth to Chennai (then Madras) via Bellary Air-India has
achieved several milestones in its history since it began operations on
October 15 1932 In the first full year of operations Tata Airlines flew
160000 miles carried 155 passengers and 1071 tonnes of mail Tata
Airlines was converted into a Public Company under the name of Air-
India in August 1946
11 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
More Aircraft Larger Network amp Higher Profitability
Air-India is Indias finest flying Ambassador Air-India has expanded its
fleet by inducting 10 aircraft (one Boeing 747-400 and nine Airbus 310s) on
dry lease in recent
months Air-India has also gifted three A300-B4 aircraft to Ariana
Afghan Airlines to help resurrect the civil aviation sector of Afghanistan
Expansion of fleet through the dry-leasing route pending acquisition of
aircraft has enabled Air-India to improve its ranking amongst world
airlines on the basis of revenue earned and number of passengers
carried According to a review published in September 2003 in Airline
Business an international magazine while Air-Indiarsquos ranking on the
basis of revenue in 2002 has gone up to 51 from 54 in the preceding
year Air-India stands at 54 amongst international airlines on the basis of
passengers carried - up from 61 in 2001
Air-Indiarsquos total issue and paid-up Capital is Rs1 5384 million The
airline has been profitable in most years since its inception In the financial
year ending March 31 2003 the Company carried 339 million passengers
and made a net profit of Rs13385 million on operating revenue of Rs5658
billion The success on the financial front was achieved despite the global
economic recession and the adverse impact of the September 11 incident in
New York on the aviation industry globally
12 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Achievements
Air-India which has won commendation from passengers for its
in-flight food was presented the Mercury Award Gold Shield for the
finest In-flight Meal Service Concept by the International Flight Catering
Association in Geneva in February 1994 The airline was adjudged
best among 52 entries in the annual competition open to all airlines and
catering agencies
Air-India has over the past 55 years come to the rescue of Indian Nationals
in various parts of the world in their hour of need on more than one occasion
13 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Network
In its ever-growing quest for providing direct services from various points in
India Air-India currently operates flights from Mumbai and 11 other Indian
cities viz Ahmedabad Bangalore Chennai Delhi Goa
Hyderabad Kochi Kolkata Kozhikode Lucknow and Thiruvananthapuram
Commencement of international operations from these cities has
obviated to a very large extent the need for passengers from these
regions to necessarily travel to Mumbai and Delhi the traditional main
gateways for taking international flights Passengers boarding or
deplaning in these cities can now complete their immigration and
custom formalities at their city airport
both at the time of departure and arrival Air-India has simultaneously
introduced fixed time departures for flights to the Gulf from Mumbai
Delhi and Kochi In the past two years the number of flights operated to
the Gulf has increased from 75 to 104
14 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Air indiarsquos worldwide network today covers 44 destinations by operating
services with its own aircrafts and through code-shared flightsSignificant
improvements introduced in all areas of Air-Indias Operations on an on-
going basis reinforces the airlines commitment to quality and insistence
on high standards Air-India has in tune with the times emerged as a
progressive forward looking airline eager to satiate the growing needs and
expectations of the discerning jet-age traveller of today
15 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
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American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
INDEX SR NO TOPIC PAGE
NO
1 INTRODUCTION TO THE COMPANY 8-17
2 INTRODUCTION TO EOD (ENGINE OVERHAUL DIVISION)
18-29
3 INTRODUCTION TO JET ENGINES amp ITS PARTS 30-47
4 DESCRIPTION OF GENERAL ELECTRICAL CF6 80C2 A2
48-53
5 INTRODUCTION TO GEARBOX 54-57
6 DESCRIPTION OF PW4056 58-64
7 DESCRIPTION OF GE 90 65-70
8 DESCRIPTION OF PLASMA COATING SECTION 72-78
9 CONCLUSION 79-80
10 REFERENCE 81
5 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACKNOWLEDGMENT
I take this opportunity to express my sincere thanks to the training
department of ldquoAIR INDIA LTDrdquo works for providing me with
training facility in the in the motor plant of their organization
I express my gratitude and thanks to MR T G RAJU (General
Manager) who gave me such a interesting department to carry out my
inplant training and also for allowing to utilize the various facilities
available in the plant MR _______________________ whose timely
guidance and help were invaluable in the completion of the project I am
thankful to PROF PRABHUDESAI the training supervisor who kept
me well linked with our college and gave valuable instruction and
advice needed I am thankful Mr BHAVSAR Mr NARULA Mr
SARDESAI Mr NARKHEDE Mr ASHIT SEN and Mr
SARDESAI
They are persons who had given detailed information and project
work and provide brief support
I am sincerely thankful to our Principal MR GHULE MR
UMESH KANTUTE the training and placement officer of Agnel
Polytechnic (Vashi) for their valuable teachings and guidance
Last but not least I would like to thank all my friends and
colleagues for their invaluable co - operation without which I would not
been able to complete my training
6 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABSTRACT
This report is a description of the maintenance and overhaul procedures
conducted in Air India at its Old Airport workshop in Santacruz Mumbai
in its Engine Overhaul Department (EOD) This report starts with an
introduction to the Company presents the aircraft that undergoes
maintenance at the EOD describes the maintenance procedures and
concludes with our contribution to improve these procedures
Today the field of avionics has gained a lot of importance both as
commercial Airliner as well as Cargo ships Thus it is clear that avionics
has played a vital point in the development and advancement of our
country
Air India boasts of a huge fleet of aircrafts and it not only connects the
cities internally in collaboration with Indian Airlines but also provides
vast linkage to various countries across the globe The two Indian
avionics giants Air India and Indian Airlines have recently merged to
form NACIL Air India possesses flights of Boeing as well as fleet of
Airbus aircrafts
7 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
8 5TH SEMESTER
AIR INDIA
AGNEL POLYTECHNIC VASHI
HISTORY OF AIR INDIA
In 1929 LATE Mr NEVILLE VINCENT a Royal Air Force Pilot realized that
there is immense potential for aviation in India after surveying no of possible
routes He met Mr JRD TATA a young Indian who was first to get his A-
licensing in India
Mr Vincent and J R D Tata worked out a scheme which was also
approved by Mr PETERSON (Director Tata Sons) and Mr DORABJI TATA (Chairman Tata Sons) and thus was born the TATA AIRLINES which later
became AIR INDIA According to the scheme on 15th October 1932 a light Single Engine
De-Havilland Puss Moth from Karachi on its flight to Mumbai via Ahmedabad
At control of tiny plane was J R D Tata This was First Scheduled Flight in
our country
Tata airlines consisted of One Puss Moth One Leopard Moth in there
fleet In 1933 in full year of operation TATA airlines flew 160000 miles carried
155 passengers and 1071 tons of mail A Tata airline was converted to a
public limited company on 29th July 1946 and was known as AIR INIDA Air India started its services from Bombay to London via Cairo and
Geneva with a constellation aircraft on 8th June 1948
9 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LAND MARKS IN HISTORY OF AIR INDIA
DATE LANDMARKS
15 Oct 1932
Tata sonrsquos ltd
Inaugurated the first scheduled service in India with a puss
month Pilot ndash Mr J R D Tata
29 July 1946 Tata airlines were converted to a public limited company And was named Air India
8 Mar 1948 Air India international was formed
16 Mar 1948 First constellation aircraft arrives
8 June 1948 First Bombay-London service inaugurated
21 Feb 1960 Arrival of first Boeing 707 aircraft
11 June 1962 Nine super constellation aircrafts were sold out Thus Air
India becomes worlds first all jet airliner
18 Apr 1971 First Boeing 747 aircraft arrives
8 Dec 1980 New international airport terminal inaugurated at Bombay
11 Aug 1982 First airbus VT-EHN ldquoGANGArdquo arrives at Bombay
10 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABOUT THE COMPANY
Air-India is Indias national flag carrier Although air transport was born
in India on February 18 1911 when Henri Piquet flying a Humber bi-
plane carried mail from Allahabad to Naini Junction some six miles
away the scheduled services in India in the real sense began on
October 15 1932 It was on this day that JRD Tata the father of Civil
Aviation in India and founder of Air-India took off from Drigh Road
Airport Karachi in a tiny light single-engined de Havilland Puss Moth
on his flight to Mumbai (then known as Bombay) via Ahmedabad He
landed with his precious load of mail on a grass strip at Juhu At
Mumbai Neville Vincent a former RAF pilot who had come to India from
Britain three years earlier on a barn-storming tour during which he had
surveyed a number of possible air routes took over from JRDTata and
flew the Puss Moth to Chennai (then Madras) via Bellary Air-India has
achieved several milestones in its history since it began operations on
October 15 1932 In the first full year of operations Tata Airlines flew
160000 miles carried 155 passengers and 1071 tonnes of mail Tata
Airlines was converted into a Public Company under the name of Air-
India in August 1946
11 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
More Aircraft Larger Network amp Higher Profitability
Air-India is Indias finest flying Ambassador Air-India has expanded its
fleet by inducting 10 aircraft (one Boeing 747-400 and nine Airbus 310s) on
dry lease in recent
months Air-India has also gifted three A300-B4 aircraft to Ariana
Afghan Airlines to help resurrect the civil aviation sector of Afghanistan
Expansion of fleet through the dry-leasing route pending acquisition of
aircraft has enabled Air-India to improve its ranking amongst world
airlines on the basis of revenue earned and number of passengers
carried According to a review published in September 2003 in Airline
Business an international magazine while Air-Indiarsquos ranking on the
basis of revenue in 2002 has gone up to 51 from 54 in the preceding
year Air-India stands at 54 amongst international airlines on the basis of
passengers carried - up from 61 in 2001
Air-Indiarsquos total issue and paid-up Capital is Rs1 5384 million The
airline has been profitable in most years since its inception In the financial
year ending March 31 2003 the Company carried 339 million passengers
and made a net profit of Rs13385 million on operating revenue of Rs5658
billion The success on the financial front was achieved despite the global
economic recession and the adverse impact of the September 11 incident in
New York on the aviation industry globally
12 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Achievements
Air-India which has won commendation from passengers for its
in-flight food was presented the Mercury Award Gold Shield for the
finest In-flight Meal Service Concept by the International Flight Catering
Association in Geneva in February 1994 The airline was adjudged
best among 52 entries in the annual competition open to all airlines and
catering agencies
Air-India has over the past 55 years come to the rescue of Indian Nationals
in various parts of the world in their hour of need on more than one occasion
13 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Network
In its ever-growing quest for providing direct services from various points in
India Air-India currently operates flights from Mumbai and 11 other Indian
cities viz Ahmedabad Bangalore Chennai Delhi Goa
Hyderabad Kochi Kolkata Kozhikode Lucknow and Thiruvananthapuram
Commencement of international operations from these cities has
obviated to a very large extent the need for passengers from these
regions to necessarily travel to Mumbai and Delhi the traditional main
gateways for taking international flights Passengers boarding or
deplaning in these cities can now complete their immigration and
custom formalities at their city airport
both at the time of departure and arrival Air-India has simultaneously
introduced fixed time departures for flights to the Gulf from Mumbai
Delhi and Kochi In the past two years the number of flights operated to
the Gulf has increased from 75 to 104
14 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Air indiarsquos worldwide network today covers 44 destinations by operating
services with its own aircrafts and through code-shared flightsSignificant
improvements introduced in all areas of Air-Indias Operations on an on-
going basis reinforces the airlines commitment to quality and insistence
on high standards Air-India has in tune with the times emerged as a
progressive forward looking airline eager to satiate the growing needs and
expectations of the discerning jet-age traveller of today
15 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
ACKNOWLEDGMENT
I take this opportunity to express my sincere thanks to the training
department of ldquoAIR INDIA LTDrdquo works for providing me with
training facility in the in the motor plant of their organization
I express my gratitude and thanks to MR T G RAJU (General
Manager) who gave me such a interesting department to carry out my
inplant training and also for allowing to utilize the various facilities
available in the plant MR _______________________ whose timely
guidance and help were invaluable in the completion of the project I am
thankful to PROF PRABHUDESAI the training supervisor who kept
me well linked with our college and gave valuable instruction and
advice needed I am thankful Mr BHAVSAR Mr NARULA Mr
SARDESAI Mr NARKHEDE Mr ASHIT SEN and Mr
SARDESAI
They are persons who had given detailed information and project
work and provide brief support
I am sincerely thankful to our Principal MR GHULE MR
UMESH KANTUTE the training and placement officer of Agnel
Polytechnic (Vashi) for their valuable teachings and guidance
Last but not least I would like to thank all my friends and
colleagues for their invaluable co - operation without which I would not
been able to complete my training
6 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABSTRACT
This report is a description of the maintenance and overhaul procedures
conducted in Air India at its Old Airport workshop in Santacruz Mumbai
in its Engine Overhaul Department (EOD) This report starts with an
introduction to the Company presents the aircraft that undergoes
maintenance at the EOD describes the maintenance procedures and
concludes with our contribution to improve these procedures
Today the field of avionics has gained a lot of importance both as
commercial Airliner as well as Cargo ships Thus it is clear that avionics
has played a vital point in the development and advancement of our
country
Air India boasts of a huge fleet of aircrafts and it not only connects the
cities internally in collaboration with Indian Airlines but also provides
vast linkage to various countries across the globe The two Indian
avionics giants Air India and Indian Airlines have recently merged to
form NACIL Air India possesses flights of Boeing as well as fleet of
Airbus aircrafts
7 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
8 5TH SEMESTER
AIR INDIA
AGNEL POLYTECHNIC VASHI
HISTORY OF AIR INDIA
In 1929 LATE Mr NEVILLE VINCENT a Royal Air Force Pilot realized that
there is immense potential for aviation in India after surveying no of possible
routes He met Mr JRD TATA a young Indian who was first to get his A-
licensing in India
Mr Vincent and J R D Tata worked out a scheme which was also
approved by Mr PETERSON (Director Tata Sons) and Mr DORABJI TATA (Chairman Tata Sons) and thus was born the TATA AIRLINES which later
became AIR INDIA According to the scheme on 15th October 1932 a light Single Engine
De-Havilland Puss Moth from Karachi on its flight to Mumbai via Ahmedabad
At control of tiny plane was J R D Tata This was First Scheduled Flight in
our country
Tata airlines consisted of One Puss Moth One Leopard Moth in there
fleet In 1933 in full year of operation TATA airlines flew 160000 miles carried
155 passengers and 1071 tons of mail A Tata airline was converted to a
public limited company on 29th July 1946 and was known as AIR INIDA Air India started its services from Bombay to London via Cairo and
Geneva with a constellation aircraft on 8th June 1948
9 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LAND MARKS IN HISTORY OF AIR INDIA
DATE LANDMARKS
15 Oct 1932
Tata sonrsquos ltd
Inaugurated the first scheduled service in India with a puss
month Pilot ndash Mr J R D Tata
29 July 1946 Tata airlines were converted to a public limited company And was named Air India
8 Mar 1948 Air India international was formed
16 Mar 1948 First constellation aircraft arrives
8 June 1948 First Bombay-London service inaugurated
21 Feb 1960 Arrival of first Boeing 707 aircraft
11 June 1962 Nine super constellation aircrafts were sold out Thus Air
India becomes worlds first all jet airliner
18 Apr 1971 First Boeing 747 aircraft arrives
8 Dec 1980 New international airport terminal inaugurated at Bombay
11 Aug 1982 First airbus VT-EHN ldquoGANGArdquo arrives at Bombay
10 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABOUT THE COMPANY
Air-India is Indias national flag carrier Although air transport was born
in India on February 18 1911 when Henri Piquet flying a Humber bi-
plane carried mail from Allahabad to Naini Junction some six miles
away the scheduled services in India in the real sense began on
October 15 1932 It was on this day that JRD Tata the father of Civil
Aviation in India and founder of Air-India took off from Drigh Road
Airport Karachi in a tiny light single-engined de Havilland Puss Moth
on his flight to Mumbai (then known as Bombay) via Ahmedabad He
landed with his precious load of mail on a grass strip at Juhu At
Mumbai Neville Vincent a former RAF pilot who had come to India from
Britain three years earlier on a barn-storming tour during which he had
surveyed a number of possible air routes took over from JRDTata and
flew the Puss Moth to Chennai (then Madras) via Bellary Air-India has
achieved several milestones in its history since it began operations on
October 15 1932 In the first full year of operations Tata Airlines flew
160000 miles carried 155 passengers and 1071 tonnes of mail Tata
Airlines was converted into a Public Company under the name of Air-
India in August 1946
11 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
More Aircraft Larger Network amp Higher Profitability
Air-India is Indias finest flying Ambassador Air-India has expanded its
fleet by inducting 10 aircraft (one Boeing 747-400 and nine Airbus 310s) on
dry lease in recent
months Air-India has also gifted three A300-B4 aircraft to Ariana
Afghan Airlines to help resurrect the civil aviation sector of Afghanistan
Expansion of fleet through the dry-leasing route pending acquisition of
aircraft has enabled Air-India to improve its ranking amongst world
airlines on the basis of revenue earned and number of passengers
carried According to a review published in September 2003 in Airline
Business an international magazine while Air-Indiarsquos ranking on the
basis of revenue in 2002 has gone up to 51 from 54 in the preceding
year Air-India stands at 54 amongst international airlines on the basis of
passengers carried - up from 61 in 2001
Air-Indiarsquos total issue and paid-up Capital is Rs1 5384 million The
airline has been profitable in most years since its inception In the financial
year ending March 31 2003 the Company carried 339 million passengers
and made a net profit of Rs13385 million on operating revenue of Rs5658
billion The success on the financial front was achieved despite the global
economic recession and the adverse impact of the September 11 incident in
New York on the aviation industry globally
12 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Achievements
Air-India which has won commendation from passengers for its
in-flight food was presented the Mercury Award Gold Shield for the
finest In-flight Meal Service Concept by the International Flight Catering
Association in Geneva in February 1994 The airline was adjudged
best among 52 entries in the annual competition open to all airlines and
catering agencies
Air-India has over the past 55 years come to the rescue of Indian Nationals
in various parts of the world in their hour of need on more than one occasion
13 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Network
In its ever-growing quest for providing direct services from various points in
India Air-India currently operates flights from Mumbai and 11 other Indian
cities viz Ahmedabad Bangalore Chennai Delhi Goa
Hyderabad Kochi Kolkata Kozhikode Lucknow and Thiruvananthapuram
Commencement of international operations from these cities has
obviated to a very large extent the need for passengers from these
regions to necessarily travel to Mumbai and Delhi the traditional main
gateways for taking international flights Passengers boarding or
deplaning in these cities can now complete their immigration and
custom formalities at their city airport
both at the time of departure and arrival Air-India has simultaneously
introduced fixed time departures for flights to the Gulf from Mumbai
Delhi and Kochi In the past two years the number of flights operated to
the Gulf has increased from 75 to 104
14 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Air indiarsquos worldwide network today covers 44 destinations by operating
services with its own aircrafts and through code-shared flightsSignificant
improvements introduced in all areas of Air-Indias Operations on an on-
going basis reinforces the airlines commitment to quality and insistence
on high standards Air-India has in tune with the times emerged as a
progressive forward looking airline eager to satiate the growing needs and
expectations of the discerning jet-age traveller of today
15 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
ABSTRACT
This report is a description of the maintenance and overhaul procedures
conducted in Air India at its Old Airport workshop in Santacruz Mumbai
in its Engine Overhaul Department (EOD) This report starts with an
introduction to the Company presents the aircraft that undergoes
maintenance at the EOD describes the maintenance procedures and
concludes with our contribution to improve these procedures
Today the field of avionics has gained a lot of importance both as
commercial Airliner as well as Cargo ships Thus it is clear that avionics
has played a vital point in the development and advancement of our
country
Air India boasts of a huge fleet of aircrafts and it not only connects the
cities internally in collaboration with Indian Airlines but also provides
vast linkage to various countries across the globe The two Indian
avionics giants Air India and Indian Airlines have recently merged to
form NACIL Air India possesses flights of Boeing as well as fleet of
Airbus aircrafts
7 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
8 5TH SEMESTER
AIR INDIA
AGNEL POLYTECHNIC VASHI
HISTORY OF AIR INDIA
In 1929 LATE Mr NEVILLE VINCENT a Royal Air Force Pilot realized that
there is immense potential for aviation in India after surveying no of possible
routes He met Mr JRD TATA a young Indian who was first to get his A-
licensing in India
Mr Vincent and J R D Tata worked out a scheme which was also
approved by Mr PETERSON (Director Tata Sons) and Mr DORABJI TATA (Chairman Tata Sons) and thus was born the TATA AIRLINES which later
became AIR INDIA According to the scheme on 15th October 1932 a light Single Engine
De-Havilland Puss Moth from Karachi on its flight to Mumbai via Ahmedabad
At control of tiny plane was J R D Tata This was First Scheduled Flight in
our country
Tata airlines consisted of One Puss Moth One Leopard Moth in there
fleet In 1933 in full year of operation TATA airlines flew 160000 miles carried
155 passengers and 1071 tons of mail A Tata airline was converted to a
public limited company on 29th July 1946 and was known as AIR INIDA Air India started its services from Bombay to London via Cairo and
Geneva with a constellation aircraft on 8th June 1948
9 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LAND MARKS IN HISTORY OF AIR INDIA
DATE LANDMARKS
15 Oct 1932
Tata sonrsquos ltd
Inaugurated the first scheduled service in India with a puss
month Pilot ndash Mr J R D Tata
29 July 1946 Tata airlines were converted to a public limited company And was named Air India
8 Mar 1948 Air India international was formed
16 Mar 1948 First constellation aircraft arrives
8 June 1948 First Bombay-London service inaugurated
21 Feb 1960 Arrival of first Boeing 707 aircraft
11 June 1962 Nine super constellation aircrafts were sold out Thus Air
India becomes worlds first all jet airliner
18 Apr 1971 First Boeing 747 aircraft arrives
8 Dec 1980 New international airport terminal inaugurated at Bombay
11 Aug 1982 First airbus VT-EHN ldquoGANGArdquo arrives at Bombay
10 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABOUT THE COMPANY
Air-India is Indias national flag carrier Although air transport was born
in India on February 18 1911 when Henri Piquet flying a Humber bi-
plane carried mail from Allahabad to Naini Junction some six miles
away the scheduled services in India in the real sense began on
October 15 1932 It was on this day that JRD Tata the father of Civil
Aviation in India and founder of Air-India took off from Drigh Road
Airport Karachi in a tiny light single-engined de Havilland Puss Moth
on his flight to Mumbai (then known as Bombay) via Ahmedabad He
landed with his precious load of mail on a grass strip at Juhu At
Mumbai Neville Vincent a former RAF pilot who had come to India from
Britain three years earlier on a barn-storming tour during which he had
surveyed a number of possible air routes took over from JRDTata and
flew the Puss Moth to Chennai (then Madras) via Bellary Air-India has
achieved several milestones in its history since it began operations on
October 15 1932 In the first full year of operations Tata Airlines flew
160000 miles carried 155 passengers and 1071 tonnes of mail Tata
Airlines was converted into a Public Company under the name of Air-
India in August 1946
11 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
More Aircraft Larger Network amp Higher Profitability
Air-India is Indias finest flying Ambassador Air-India has expanded its
fleet by inducting 10 aircraft (one Boeing 747-400 and nine Airbus 310s) on
dry lease in recent
months Air-India has also gifted three A300-B4 aircraft to Ariana
Afghan Airlines to help resurrect the civil aviation sector of Afghanistan
Expansion of fleet through the dry-leasing route pending acquisition of
aircraft has enabled Air-India to improve its ranking amongst world
airlines on the basis of revenue earned and number of passengers
carried According to a review published in September 2003 in Airline
Business an international magazine while Air-Indiarsquos ranking on the
basis of revenue in 2002 has gone up to 51 from 54 in the preceding
year Air-India stands at 54 amongst international airlines on the basis of
passengers carried - up from 61 in 2001
Air-Indiarsquos total issue and paid-up Capital is Rs1 5384 million The
airline has been profitable in most years since its inception In the financial
year ending March 31 2003 the Company carried 339 million passengers
and made a net profit of Rs13385 million on operating revenue of Rs5658
billion The success on the financial front was achieved despite the global
economic recession and the adverse impact of the September 11 incident in
New York on the aviation industry globally
12 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Achievements
Air-India which has won commendation from passengers for its
in-flight food was presented the Mercury Award Gold Shield for the
finest In-flight Meal Service Concept by the International Flight Catering
Association in Geneva in February 1994 The airline was adjudged
best among 52 entries in the annual competition open to all airlines and
catering agencies
Air-India has over the past 55 years come to the rescue of Indian Nationals
in various parts of the world in their hour of need on more than one occasion
13 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Network
In its ever-growing quest for providing direct services from various points in
India Air-India currently operates flights from Mumbai and 11 other Indian
cities viz Ahmedabad Bangalore Chennai Delhi Goa
Hyderabad Kochi Kolkata Kozhikode Lucknow and Thiruvananthapuram
Commencement of international operations from these cities has
obviated to a very large extent the need for passengers from these
regions to necessarily travel to Mumbai and Delhi the traditional main
gateways for taking international flights Passengers boarding or
deplaning in these cities can now complete their immigration and
custom formalities at their city airport
both at the time of departure and arrival Air-India has simultaneously
introduced fixed time departures for flights to the Gulf from Mumbai
Delhi and Kochi In the past two years the number of flights operated to
the Gulf has increased from 75 to 104
14 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Air indiarsquos worldwide network today covers 44 destinations by operating
services with its own aircrafts and through code-shared flightsSignificant
improvements introduced in all areas of Air-Indias Operations on an on-
going basis reinforces the airlines commitment to quality and insistence
on high standards Air-India has in tune with the times emerged as a
progressive forward looking airline eager to satiate the growing needs and
expectations of the discerning jet-age traveller of today
15 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
8 5TH SEMESTER
AIR INDIA
AGNEL POLYTECHNIC VASHI
HISTORY OF AIR INDIA
In 1929 LATE Mr NEVILLE VINCENT a Royal Air Force Pilot realized that
there is immense potential for aviation in India after surveying no of possible
routes He met Mr JRD TATA a young Indian who was first to get his A-
licensing in India
Mr Vincent and J R D Tata worked out a scheme which was also
approved by Mr PETERSON (Director Tata Sons) and Mr DORABJI TATA (Chairman Tata Sons) and thus was born the TATA AIRLINES which later
became AIR INDIA According to the scheme on 15th October 1932 a light Single Engine
De-Havilland Puss Moth from Karachi on its flight to Mumbai via Ahmedabad
At control of tiny plane was J R D Tata This was First Scheduled Flight in
our country
Tata airlines consisted of One Puss Moth One Leopard Moth in there
fleet In 1933 in full year of operation TATA airlines flew 160000 miles carried
155 passengers and 1071 tons of mail A Tata airline was converted to a
public limited company on 29th July 1946 and was known as AIR INIDA Air India started its services from Bombay to London via Cairo and
Geneva with a constellation aircraft on 8th June 1948
9 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LAND MARKS IN HISTORY OF AIR INDIA
DATE LANDMARKS
15 Oct 1932
Tata sonrsquos ltd
Inaugurated the first scheduled service in India with a puss
month Pilot ndash Mr J R D Tata
29 July 1946 Tata airlines were converted to a public limited company And was named Air India
8 Mar 1948 Air India international was formed
16 Mar 1948 First constellation aircraft arrives
8 June 1948 First Bombay-London service inaugurated
21 Feb 1960 Arrival of first Boeing 707 aircraft
11 June 1962 Nine super constellation aircrafts were sold out Thus Air
India becomes worlds first all jet airliner
18 Apr 1971 First Boeing 747 aircraft arrives
8 Dec 1980 New international airport terminal inaugurated at Bombay
11 Aug 1982 First airbus VT-EHN ldquoGANGArdquo arrives at Bombay
10 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABOUT THE COMPANY
Air-India is Indias national flag carrier Although air transport was born
in India on February 18 1911 when Henri Piquet flying a Humber bi-
plane carried mail from Allahabad to Naini Junction some six miles
away the scheduled services in India in the real sense began on
October 15 1932 It was on this day that JRD Tata the father of Civil
Aviation in India and founder of Air-India took off from Drigh Road
Airport Karachi in a tiny light single-engined de Havilland Puss Moth
on his flight to Mumbai (then known as Bombay) via Ahmedabad He
landed with his precious load of mail on a grass strip at Juhu At
Mumbai Neville Vincent a former RAF pilot who had come to India from
Britain three years earlier on a barn-storming tour during which he had
surveyed a number of possible air routes took over from JRDTata and
flew the Puss Moth to Chennai (then Madras) via Bellary Air-India has
achieved several milestones in its history since it began operations on
October 15 1932 In the first full year of operations Tata Airlines flew
160000 miles carried 155 passengers and 1071 tonnes of mail Tata
Airlines was converted into a Public Company under the name of Air-
India in August 1946
11 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
More Aircraft Larger Network amp Higher Profitability
Air-India is Indias finest flying Ambassador Air-India has expanded its
fleet by inducting 10 aircraft (one Boeing 747-400 and nine Airbus 310s) on
dry lease in recent
months Air-India has also gifted three A300-B4 aircraft to Ariana
Afghan Airlines to help resurrect the civil aviation sector of Afghanistan
Expansion of fleet through the dry-leasing route pending acquisition of
aircraft has enabled Air-India to improve its ranking amongst world
airlines on the basis of revenue earned and number of passengers
carried According to a review published in September 2003 in Airline
Business an international magazine while Air-Indiarsquos ranking on the
basis of revenue in 2002 has gone up to 51 from 54 in the preceding
year Air-India stands at 54 amongst international airlines on the basis of
passengers carried - up from 61 in 2001
Air-Indiarsquos total issue and paid-up Capital is Rs1 5384 million The
airline has been profitable in most years since its inception In the financial
year ending March 31 2003 the Company carried 339 million passengers
and made a net profit of Rs13385 million on operating revenue of Rs5658
billion The success on the financial front was achieved despite the global
economic recession and the adverse impact of the September 11 incident in
New York on the aviation industry globally
12 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Achievements
Air-India which has won commendation from passengers for its
in-flight food was presented the Mercury Award Gold Shield for the
finest In-flight Meal Service Concept by the International Flight Catering
Association in Geneva in February 1994 The airline was adjudged
best among 52 entries in the annual competition open to all airlines and
catering agencies
Air-India has over the past 55 years come to the rescue of Indian Nationals
in various parts of the world in their hour of need on more than one occasion
13 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Network
In its ever-growing quest for providing direct services from various points in
India Air-India currently operates flights from Mumbai and 11 other Indian
cities viz Ahmedabad Bangalore Chennai Delhi Goa
Hyderabad Kochi Kolkata Kozhikode Lucknow and Thiruvananthapuram
Commencement of international operations from these cities has
obviated to a very large extent the need for passengers from these
regions to necessarily travel to Mumbai and Delhi the traditional main
gateways for taking international flights Passengers boarding or
deplaning in these cities can now complete their immigration and
custom formalities at their city airport
both at the time of departure and arrival Air-India has simultaneously
introduced fixed time departures for flights to the Gulf from Mumbai
Delhi and Kochi In the past two years the number of flights operated to
the Gulf has increased from 75 to 104
14 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Air indiarsquos worldwide network today covers 44 destinations by operating
services with its own aircrafts and through code-shared flightsSignificant
improvements introduced in all areas of Air-Indias Operations on an on-
going basis reinforces the airlines commitment to quality and insistence
on high standards Air-India has in tune with the times emerged as a
progressive forward looking airline eager to satiate the growing needs and
expectations of the discerning jet-age traveller of today
15 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
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AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
HISTORY OF AIR INDIA
In 1929 LATE Mr NEVILLE VINCENT a Royal Air Force Pilot realized that
there is immense potential for aviation in India after surveying no of possible
routes He met Mr JRD TATA a young Indian who was first to get his A-
licensing in India
Mr Vincent and J R D Tata worked out a scheme which was also
approved by Mr PETERSON (Director Tata Sons) and Mr DORABJI TATA (Chairman Tata Sons) and thus was born the TATA AIRLINES which later
became AIR INDIA According to the scheme on 15th October 1932 a light Single Engine
De-Havilland Puss Moth from Karachi on its flight to Mumbai via Ahmedabad
At control of tiny plane was J R D Tata This was First Scheduled Flight in
our country
Tata airlines consisted of One Puss Moth One Leopard Moth in there
fleet In 1933 in full year of operation TATA airlines flew 160000 miles carried
155 passengers and 1071 tons of mail A Tata airline was converted to a
public limited company on 29th July 1946 and was known as AIR INIDA Air India started its services from Bombay to London via Cairo and
Geneva with a constellation aircraft on 8th June 1948
9 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LAND MARKS IN HISTORY OF AIR INDIA
DATE LANDMARKS
15 Oct 1932
Tata sonrsquos ltd
Inaugurated the first scheduled service in India with a puss
month Pilot ndash Mr J R D Tata
29 July 1946 Tata airlines were converted to a public limited company And was named Air India
8 Mar 1948 Air India international was formed
16 Mar 1948 First constellation aircraft arrives
8 June 1948 First Bombay-London service inaugurated
21 Feb 1960 Arrival of first Boeing 707 aircraft
11 June 1962 Nine super constellation aircrafts were sold out Thus Air
India becomes worlds first all jet airliner
18 Apr 1971 First Boeing 747 aircraft arrives
8 Dec 1980 New international airport terminal inaugurated at Bombay
11 Aug 1982 First airbus VT-EHN ldquoGANGArdquo arrives at Bombay
10 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABOUT THE COMPANY
Air-India is Indias national flag carrier Although air transport was born
in India on February 18 1911 when Henri Piquet flying a Humber bi-
plane carried mail from Allahabad to Naini Junction some six miles
away the scheduled services in India in the real sense began on
October 15 1932 It was on this day that JRD Tata the father of Civil
Aviation in India and founder of Air-India took off from Drigh Road
Airport Karachi in a tiny light single-engined de Havilland Puss Moth
on his flight to Mumbai (then known as Bombay) via Ahmedabad He
landed with his precious load of mail on a grass strip at Juhu At
Mumbai Neville Vincent a former RAF pilot who had come to India from
Britain three years earlier on a barn-storming tour during which he had
surveyed a number of possible air routes took over from JRDTata and
flew the Puss Moth to Chennai (then Madras) via Bellary Air-India has
achieved several milestones in its history since it began operations on
October 15 1932 In the first full year of operations Tata Airlines flew
160000 miles carried 155 passengers and 1071 tonnes of mail Tata
Airlines was converted into a Public Company under the name of Air-
India in August 1946
11 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
More Aircraft Larger Network amp Higher Profitability
Air-India is Indias finest flying Ambassador Air-India has expanded its
fleet by inducting 10 aircraft (one Boeing 747-400 and nine Airbus 310s) on
dry lease in recent
months Air-India has also gifted three A300-B4 aircraft to Ariana
Afghan Airlines to help resurrect the civil aviation sector of Afghanistan
Expansion of fleet through the dry-leasing route pending acquisition of
aircraft has enabled Air-India to improve its ranking amongst world
airlines on the basis of revenue earned and number of passengers
carried According to a review published in September 2003 in Airline
Business an international magazine while Air-Indiarsquos ranking on the
basis of revenue in 2002 has gone up to 51 from 54 in the preceding
year Air-India stands at 54 amongst international airlines on the basis of
passengers carried - up from 61 in 2001
Air-Indiarsquos total issue and paid-up Capital is Rs1 5384 million The
airline has been profitable in most years since its inception In the financial
year ending March 31 2003 the Company carried 339 million passengers
and made a net profit of Rs13385 million on operating revenue of Rs5658
billion The success on the financial front was achieved despite the global
economic recession and the adverse impact of the September 11 incident in
New York on the aviation industry globally
12 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Achievements
Air-India which has won commendation from passengers for its
in-flight food was presented the Mercury Award Gold Shield for the
finest In-flight Meal Service Concept by the International Flight Catering
Association in Geneva in February 1994 The airline was adjudged
best among 52 entries in the annual competition open to all airlines and
catering agencies
Air-India has over the past 55 years come to the rescue of Indian Nationals
in various parts of the world in their hour of need on more than one occasion
13 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Network
In its ever-growing quest for providing direct services from various points in
India Air-India currently operates flights from Mumbai and 11 other Indian
cities viz Ahmedabad Bangalore Chennai Delhi Goa
Hyderabad Kochi Kolkata Kozhikode Lucknow and Thiruvananthapuram
Commencement of international operations from these cities has
obviated to a very large extent the need for passengers from these
regions to necessarily travel to Mumbai and Delhi the traditional main
gateways for taking international flights Passengers boarding or
deplaning in these cities can now complete their immigration and
custom formalities at their city airport
both at the time of departure and arrival Air-India has simultaneously
introduced fixed time departures for flights to the Gulf from Mumbai
Delhi and Kochi In the past two years the number of flights operated to
the Gulf has increased from 75 to 104
14 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Air indiarsquos worldwide network today covers 44 destinations by operating
services with its own aircrafts and through code-shared flightsSignificant
improvements introduced in all areas of Air-Indias Operations on an on-
going basis reinforces the airlines commitment to quality and insistence
on high standards Air-India has in tune with the times emerged as a
progressive forward looking airline eager to satiate the growing needs and
expectations of the discerning jet-age traveller of today
15 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
LAND MARKS IN HISTORY OF AIR INDIA
DATE LANDMARKS
15 Oct 1932
Tata sonrsquos ltd
Inaugurated the first scheduled service in India with a puss
month Pilot ndash Mr J R D Tata
29 July 1946 Tata airlines were converted to a public limited company And was named Air India
8 Mar 1948 Air India international was formed
16 Mar 1948 First constellation aircraft arrives
8 June 1948 First Bombay-London service inaugurated
21 Feb 1960 Arrival of first Boeing 707 aircraft
11 June 1962 Nine super constellation aircrafts were sold out Thus Air
India becomes worlds first all jet airliner
18 Apr 1971 First Boeing 747 aircraft arrives
8 Dec 1980 New international airport terminal inaugurated at Bombay
11 Aug 1982 First airbus VT-EHN ldquoGANGArdquo arrives at Bombay
10 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ABOUT THE COMPANY
Air-India is Indias national flag carrier Although air transport was born
in India on February 18 1911 when Henri Piquet flying a Humber bi-
plane carried mail from Allahabad to Naini Junction some six miles
away the scheduled services in India in the real sense began on
October 15 1932 It was on this day that JRD Tata the father of Civil
Aviation in India and founder of Air-India took off from Drigh Road
Airport Karachi in a tiny light single-engined de Havilland Puss Moth
on his flight to Mumbai (then known as Bombay) via Ahmedabad He
landed with his precious load of mail on a grass strip at Juhu At
Mumbai Neville Vincent a former RAF pilot who had come to India from
Britain three years earlier on a barn-storming tour during which he had
surveyed a number of possible air routes took over from JRDTata and
flew the Puss Moth to Chennai (then Madras) via Bellary Air-India has
achieved several milestones in its history since it began operations on
October 15 1932 In the first full year of operations Tata Airlines flew
160000 miles carried 155 passengers and 1071 tonnes of mail Tata
Airlines was converted into a Public Company under the name of Air-
India in August 1946
11 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
More Aircraft Larger Network amp Higher Profitability
Air-India is Indias finest flying Ambassador Air-India has expanded its
fleet by inducting 10 aircraft (one Boeing 747-400 and nine Airbus 310s) on
dry lease in recent
months Air-India has also gifted three A300-B4 aircraft to Ariana
Afghan Airlines to help resurrect the civil aviation sector of Afghanistan
Expansion of fleet through the dry-leasing route pending acquisition of
aircraft has enabled Air-India to improve its ranking amongst world
airlines on the basis of revenue earned and number of passengers
carried According to a review published in September 2003 in Airline
Business an international magazine while Air-Indiarsquos ranking on the
basis of revenue in 2002 has gone up to 51 from 54 in the preceding
year Air-India stands at 54 amongst international airlines on the basis of
passengers carried - up from 61 in 2001
Air-Indiarsquos total issue and paid-up Capital is Rs1 5384 million The
airline has been profitable in most years since its inception In the financial
year ending March 31 2003 the Company carried 339 million passengers
and made a net profit of Rs13385 million on operating revenue of Rs5658
billion The success on the financial front was achieved despite the global
economic recession and the adverse impact of the September 11 incident in
New York on the aviation industry globally
12 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Achievements
Air-India which has won commendation from passengers for its
in-flight food was presented the Mercury Award Gold Shield for the
finest In-flight Meal Service Concept by the International Flight Catering
Association in Geneva in February 1994 The airline was adjudged
best among 52 entries in the annual competition open to all airlines and
catering agencies
Air-India has over the past 55 years come to the rescue of Indian Nationals
in various parts of the world in their hour of need on more than one occasion
13 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Network
In its ever-growing quest for providing direct services from various points in
India Air-India currently operates flights from Mumbai and 11 other Indian
cities viz Ahmedabad Bangalore Chennai Delhi Goa
Hyderabad Kochi Kolkata Kozhikode Lucknow and Thiruvananthapuram
Commencement of international operations from these cities has
obviated to a very large extent the need for passengers from these
regions to necessarily travel to Mumbai and Delhi the traditional main
gateways for taking international flights Passengers boarding or
deplaning in these cities can now complete their immigration and
custom formalities at their city airport
both at the time of departure and arrival Air-India has simultaneously
introduced fixed time departures for flights to the Gulf from Mumbai
Delhi and Kochi In the past two years the number of flights operated to
the Gulf has increased from 75 to 104
14 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Air indiarsquos worldwide network today covers 44 destinations by operating
services with its own aircrafts and through code-shared flightsSignificant
improvements introduced in all areas of Air-Indias Operations on an on-
going basis reinforces the airlines commitment to quality and insistence
on high standards Air-India has in tune with the times emerged as a
progressive forward looking airline eager to satiate the growing needs and
expectations of the discerning jet-age traveller of today
15 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
ABOUT THE COMPANY
Air-India is Indias national flag carrier Although air transport was born
in India on February 18 1911 when Henri Piquet flying a Humber bi-
plane carried mail from Allahabad to Naini Junction some six miles
away the scheduled services in India in the real sense began on
October 15 1932 It was on this day that JRD Tata the father of Civil
Aviation in India and founder of Air-India took off from Drigh Road
Airport Karachi in a tiny light single-engined de Havilland Puss Moth
on his flight to Mumbai (then known as Bombay) via Ahmedabad He
landed with his precious load of mail on a grass strip at Juhu At
Mumbai Neville Vincent a former RAF pilot who had come to India from
Britain three years earlier on a barn-storming tour during which he had
surveyed a number of possible air routes took over from JRDTata and
flew the Puss Moth to Chennai (then Madras) via Bellary Air-India has
achieved several milestones in its history since it began operations on
October 15 1932 In the first full year of operations Tata Airlines flew
160000 miles carried 155 passengers and 1071 tonnes of mail Tata
Airlines was converted into a Public Company under the name of Air-
India in August 1946
11 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
More Aircraft Larger Network amp Higher Profitability
Air-India is Indias finest flying Ambassador Air-India has expanded its
fleet by inducting 10 aircraft (one Boeing 747-400 and nine Airbus 310s) on
dry lease in recent
months Air-India has also gifted three A300-B4 aircraft to Ariana
Afghan Airlines to help resurrect the civil aviation sector of Afghanistan
Expansion of fleet through the dry-leasing route pending acquisition of
aircraft has enabled Air-India to improve its ranking amongst world
airlines on the basis of revenue earned and number of passengers
carried According to a review published in September 2003 in Airline
Business an international magazine while Air-Indiarsquos ranking on the
basis of revenue in 2002 has gone up to 51 from 54 in the preceding
year Air-India stands at 54 amongst international airlines on the basis of
passengers carried - up from 61 in 2001
Air-Indiarsquos total issue and paid-up Capital is Rs1 5384 million The
airline has been profitable in most years since its inception In the financial
year ending March 31 2003 the Company carried 339 million passengers
and made a net profit of Rs13385 million on operating revenue of Rs5658
billion The success on the financial front was achieved despite the global
economic recession and the adverse impact of the September 11 incident in
New York on the aviation industry globally
12 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Achievements
Air-India which has won commendation from passengers for its
in-flight food was presented the Mercury Award Gold Shield for the
finest In-flight Meal Service Concept by the International Flight Catering
Association in Geneva in February 1994 The airline was adjudged
best among 52 entries in the annual competition open to all airlines and
catering agencies
Air-India has over the past 55 years come to the rescue of Indian Nationals
in various parts of the world in their hour of need on more than one occasion
13 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Network
In its ever-growing quest for providing direct services from various points in
India Air-India currently operates flights from Mumbai and 11 other Indian
cities viz Ahmedabad Bangalore Chennai Delhi Goa
Hyderabad Kochi Kolkata Kozhikode Lucknow and Thiruvananthapuram
Commencement of international operations from these cities has
obviated to a very large extent the need for passengers from these
regions to necessarily travel to Mumbai and Delhi the traditional main
gateways for taking international flights Passengers boarding or
deplaning in these cities can now complete their immigration and
custom formalities at their city airport
both at the time of departure and arrival Air-India has simultaneously
introduced fixed time departures for flights to the Gulf from Mumbai
Delhi and Kochi In the past two years the number of flights operated to
the Gulf has increased from 75 to 104
14 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Air indiarsquos worldwide network today covers 44 destinations by operating
services with its own aircrafts and through code-shared flightsSignificant
improvements introduced in all areas of Air-Indias Operations on an on-
going basis reinforces the airlines commitment to quality and insistence
on high standards Air-India has in tune with the times emerged as a
progressive forward looking airline eager to satiate the growing needs and
expectations of the discerning jet-age traveller of today
15 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
More Aircraft Larger Network amp Higher Profitability
Air-India is Indias finest flying Ambassador Air-India has expanded its
fleet by inducting 10 aircraft (one Boeing 747-400 and nine Airbus 310s) on
dry lease in recent
months Air-India has also gifted three A300-B4 aircraft to Ariana
Afghan Airlines to help resurrect the civil aviation sector of Afghanistan
Expansion of fleet through the dry-leasing route pending acquisition of
aircraft has enabled Air-India to improve its ranking amongst world
airlines on the basis of revenue earned and number of passengers
carried According to a review published in September 2003 in Airline
Business an international magazine while Air-Indiarsquos ranking on the
basis of revenue in 2002 has gone up to 51 from 54 in the preceding
year Air-India stands at 54 amongst international airlines on the basis of
passengers carried - up from 61 in 2001
Air-Indiarsquos total issue and paid-up Capital is Rs1 5384 million The
airline has been profitable in most years since its inception In the financial
year ending March 31 2003 the Company carried 339 million passengers
and made a net profit of Rs13385 million on operating revenue of Rs5658
billion The success on the financial front was achieved despite the global
economic recession and the adverse impact of the September 11 incident in
New York on the aviation industry globally
12 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Achievements
Air-India which has won commendation from passengers for its
in-flight food was presented the Mercury Award Gold Shield for the
finest In-flight Meal Service Concept by the International Flight Catering
Association in Geneva in February 1994 The airline was adjudged
best among 52 entries in the annual competition open to all airlines and
catering agencies
Air-India has over the past 55 years come to the rescue of Indian Nationals
in various parts of the world in their hour of need on more than one occasion
13 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Network
In its ever-growing quest for providing direct services from various points in
India Air-India currently operates flights from Mumbai and 11 other Indian
cities viz Ahmedabad Bangalore Chennai Delhi Goa
Hyderabad Kochi Kolkata Kozhikode Lucknow and Thiruvananthapuram
Commencement of international operations from these cities has
obviated to a very large extent the need for passengers from these
regions to necessarily travel to Mumbai and Delhi the traditional main
gateways for taking international flights Passengers boarding or
deplaning in these cities can now complete their immigration and
custom formalities at their city airport
both at the time of departure and arrival Air-India has simultaneously
introduced fixed time departures for flights to the Gulf from Mumbai
Delhi and Kochi In the past two years the number of flights operated to
the Gulf has increased from 75 to 104
14 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Air indiarsquos worldwide network today covers 44 destinations by operating
services with its own aircrafts and through code-shared flightsSignificant
improvements introduced in all areas of Air-Indias Operations on an on-
going basis reinforces the airlines commitment to quality and insistence
on high standards Air-India has in tune with the times emerged as a
progressive forward looking airline eager to satiate the growing needs and
expectations of the discerning jet-age traveller of today
15 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
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C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
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American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
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FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
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AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
Achievements
Air-India which has won commendation from passengers for its
in-flight food was presented the Mercury Award Gold Shield for the
finest In-flight Meal Service Concept by the International Flight Catering
Association in Geneva in February 1994 The airline was adjudged
best among 52 entries in the annual competition open to all airlines and
catering agencies
Air-India has over the past 55 years come to the rescue of Indian Nationals
in various parts of the world in their hour of need on more than one occasion
13 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Network
In its ever-growing quest for providing direct services from various points in
India Air-India currently operates flights from Mumbai and 11 other Indian
cities viz Ahmedabad Bangalore Chennai Delhi Goa
Hyderabad Kochi Kolkata Kozhikode Lucknow and Thiruvananthapuram
Commencement of international operations from these cities has
obviated to a very large extent the need for passengers from these
regions to necessarily travel to Mumbai and Delhi the traditional main
gateways for taking international flights Passengers boarding or
deplaning in these cities can now complete their immigration and
custom formalities at their city airport
both at the time of departure and arrival Air-India has simultaneously
introduced fixed time departures for flights to the Gulf from Mumbai
Delhi and Kochi In the past two years the number of flights operated to
the Gulf has increased from 75 to 104
14 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Air indiarsquos worldwide network today covers 44 destinations by operating
services with its own aircrafts and through code-shared flightsSignificant
improvements introduced in all areas of Air-Indias Operations on an on-
going basis reinforces the airlines commitment to quality and insistence
on high standards Air-India has in tune with the times emerged as a
progressive forward looking airline eager to satiate the growing needs and
expectations of the discerning jet-age traveller of today
15 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
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NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
Network
In its ever-growing quest for providing direct services from various points in
India Air-India currently operates flights from Mumbai and 11 other Indian
cities viz Ahmedabad Bangalore Chennai Delhi Goa
Hyderabad Kochi Kolkata Kozhikode Lucknow and Thiruvananthapuram
Commencement of international operations from these cities has
obviated to a very large extent the need for passengers from these
regions to necessarily travel to Mumbai and Delhi the traditional main
gateways for taking international flights Passengers boarding or
deplaning in these cities can now complete their immigration and
custom formalities at their city airport
both at the time of departure and arrival Air-India has simultaneously
introduced fixed time departures for flights to the Gulf from Mumbai
Delhi and Kochi In the past two years the number of flights operated to
the Gulf has increased from 75 to 104
14 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Air indiarsquos worldwide network today covers 44 destinations by operating
services with its own aircrafts and through code-shared flightsSignificant
improvements introduced in all areas of Air-Indias Operations on an on-
going basis reinforces the airlines commitment to quality and insistence
on high standards Air-India has in tune with the times emerged as a
progressive forward looking airline eager to satiate the growing needs and
expectations of the discerning jet-age traveller of today
15 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
Air indiarsquos worldwide network today covers 44 destinations by operating
services with its own aircrafts and through code-shared flightsSignificant
improvements introduced in all areas of Air-Indias Operations on an on-
going basis reinforces the airlines commitment to quality and insistence
on high standards Air-India has in tune with the times emerged as a
progressive forward looking airline eager to satiate the growing needs and
expectations of the discerning jet-age traveller of today
15 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
DEPARTMENTS IN AIR INDIA
1 Air Safety Department
2 Commercial Department
3 Department Of Information And Technology
Department
4 Engine Overhaul Department
5 Engineering Department
6 Finance Department
7 Electronics Overhaul Department
8 Ground Service amp Maintenance Department
9 Human Resources Development Department
10 In-Flight Service Department
11 Internal Audit Department
12 Medical Service Department
13 Material Management Department
14 Operations Department
15 Planning And Foreign Relations Department
16 Public Relations Department
17 Properties And Facilities Department
18 Security Department
19 Vigilance Department
20 Accessories Overhaul Department
21 Components Overhaul Department
16 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
ORGANISATIONAL CHART
MANAGEMENT
MANAGING DIRECTOR DEPUTY MANAGING DIRECTOR
DIRECTOR OF ENGINEERING
DEPUTY DIRECTOR OF ENGINEERING
GENERAL MANAGER DEPUTY GENERAL MANAGER
ASSISTANT GENERAL MANAGER
CHIEF AIRCRAFT ENGINEER DEPUTY AIRCRAFT ENGINEER
SENIOR AIRCRAFT ENGINEER
AIRCRAFT ENGINEER ASSISTANT AIRCRAFT ENGINEER
SENIOR FOREMAN
ASSISTANT FOREMAN
SENIOR AIRCRAFT TECHNICIAN
AIRCRAFT TECHNICIAN
17 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
ENGINE
OVERHAUL
DEPARTMENT
18 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
LIST OF ENGINES USED IN DIFFERENT
AIRCRAFT MODELS
ENGINES AIRCRAFT MODELS
1 CF6 - 80E1 ------------------------------------------------------ A330
2 CF6 - 80C2 ----------------------------------------------------- A310-200 ADV300
A300 ndash 600 B747 ndash
200300400 B767 ndash
200 ER300300ER
McDonnell Douglas
3 CF6 ndash 80A ----------------------------------------------------- B767 ndash 200 A310 ndash
200
4 CF6 ndash 50 ------------------------------------------------------ A300 B2B4 McDonnell
Douglas DC 10
series15
B 747 ndash 200300SR
5 CF6 ----------------------------------------------------------- McDonnell Douglas
DC10
19 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
Series 10
6 CFM 56 ndash 5 -------------------------------------------------- A320 A321 A340
7 CFM 56 -3 ---------------------------------------------------- B737 ndash 300 B737 ndash
400
B737 ndash 500
8 CFM 56 ndash 2 -------------------------------------------------- McDonnell Douglas DC8
Super 70
9 CF 34 -------------------------------------------------------- Canadair challenger
CL ndash 601 Canadair
Regional jet
10 CF 700 ------------------------------------------------------ Dassault falcon 20F
Sabre 75 A
11 CJ6 ndash 10 --------------------------------------------------- IAI West wind Learjet
Hansa jet
12 CT 58 -------------------------------------------------------- B107 Sikorsky S-61
Sikorsky S-62
13 CT7 (Turbo prop) ---------------------------------------- Saab 340 CASA ndash IPTN
20 5TH SEMESTER
LET L610 CN ndash 235
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
14 CT7 (Turbo shaft) ----------------------------------------- Bell 214 ST
West land W30-300
EH 101
Sikorsky S70-C
EOD
Air Indiarsquos engine overhaul department provides facilities for overhauls and
Repair of Jet Engines and Auxiliary Power Units (APU) It is one of the
most comprehensive engine maintenance organizations It is the part of Air
Indiarsquos engineering complex at Mumbai airport where the airlines fleet of 13-
boeing 747rsquosand 17-airbus a-310-300rsquos is maintained and overhauled The
engine overhaul department can overhaul 12 engines of three different types
every month This facility is approved by
DIRECTOR GENERAL OF CIVIL AVIATION FEDERAL AVIATION ADMINISTRATION
(FAA) USA JOINT AVIATION AUTHORITY (JAA)
EUROPE ISO
The types of engines overhauled includes JT-9D series JT-8D series CF-650C2 series CF-6 80C2 series and APUrsquos GTCP 660 TSCP 700 GTCP 331
21 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
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The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
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American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
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ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
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THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
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FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
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To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
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must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
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While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
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JET ENGINE
AND
ITS PARTS
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BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
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Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
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CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
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NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
HISTORY OF ENGINE OVERHAUL DEPARTMENT
A separate dedicated engine overhaul department was established in 1987
to give special thrust on engine overhaul activities which was also carried
before
As newer and modern aircrafts were introduced in Air Indiarsquos fleet the
engine overhaul capabilities were also extended to fulfill needs of overhaul of
modern Aircraft engines Air India overhauled aircraft engines piston engines
of Dakotas thru Lockheed Dehavilland to present dayrsquos large jet engines for
Boeing 747-400 aircraftrsquos for last 40 years
bull The JET CENTRE was built in 1963 to service Rolce Royce Convay
engines of Boeing 707-200 aircraft and Rolce Royce Avon engines of
Indian airlines A test house was also built to test these engines
bull This was followed by capabilities to overhaul PW JT-3D engines of
Boeing 707-400 aircraft
bull In 1969 overhaul of PW JT-9D engines and Honeywell GTCP 660
APUrsquos of Boeing 747-200 aircraft was started A new
test house to test engines up to 100000 lbs thrust was established
in 1972
bull Capability of overhaul of GE CF-6 50 C2 engines installed on Airbus
A-300-B4 Aircraft was started in 1977
bull In 1982 the CENTRAL REPAIR FACILITY (CRF) was established to
repair engine and aircraft parts
22 5TH SEMESTER
bull Capability to overhaul GE CF-6 80C2 GTCP 331 TSCP 700 APUrsquos
was established in1986
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
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AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
bull In 1986 the test house was fully computerized
bull Capability to overhaul PW 4056-3 engines and PW 901 APUrsquos was
established in 1999 Engine overhaul department not only overhauls Air Indiarsquos and Indian Airlines
engines but also renders services in
1) Engine maintenance
2) Engine overhaul
3) Testing and repairing of engines and aircraft components of other
operator also
CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
bull AAR Corporation
bull CS aviation services
bull Indian Airlines Corporation
bull Kuwait airways
bull Air lanka
bull Sahara air ways
bull Blue dart express
bull Transmediterenian airway
bull ONGC
The engine overhaul department is divided in three main wings
1 The Jet Center
2 The Central Repair Facility
3 The Test House
A) JET CENTRE
23 5TH SEMESTER
The jet centre is housed in a spacious building with 3 wings The main
wing with an area of 6500 sqmts consisting of engine striping and assembly
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
area stores and office accommodation and other amenities such as rest room
and canteens for staff In addition to this on one side of building annex with
approximately 1115 sqmts area is used for power plant built up area and
modular maintenance of PW JT 9D engines A similar annex ion other side
has facilities for maintenance and power plant built up of GE CF6 50C2 and
GE CF 6 80C2 engines
Jet Centre is divided in following sections
1) DRESSING SECTIONS The engine to be overhauled is brought to respective dressing sections There the engine is disassembled in various modules viz Low Pressure Compressor High Pressure Compressor High Pressure Turbine Low Pressure Turbine Gearbox Module etc These modules are sent to respective module sections The assembly of all modules is done in these sections The assembled modules from respective module sections come here and are assembled here thus a complete power plant build up
2) MODULE SECTIONS Here the various modules are completely stripped off Then they are cleaned according to specifications of manufacturers These parts are inspected thoroughly for cracks dents etc The dimensional and visual checks are done here The unserviceable parts are sent for repairs or replaced
After the cleaning crack test repair the parts are again assembled into a
module and is sent to respective engine dressing sections
3) CLEANING SECTIONS The parts of the engine modules are thoroughly cleaned according to the cleaning procedures specified by the manufacturers and DGCA etc
24 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
4) CRACK TEST
The striped engine parts are thoroughly inspected for cracks These cracks can be detected by FPI FMPI Radiographic method Ultrasonic method Ultrasonic crack detection method is specially used for sub-surface cracks The defective and unserviceable parts are sent for repairs such as welding planting etc
5) VIEW ROOMS
Here every engine part is thoroughly inspected before assembly The repaired unserviceable parts are made serviceable To make them serviceable some visual and dimensional checks are carried out
6) STORES
The spares of engines are stored here which are procured from the manufacturer These parts are sent to the section that requires it
7) CAPABILITIES a) Engine Assembly ndash Disassembly -
1) PW JT-9Dndash7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
25 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
b) Modular Overhaul ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
c) Cleaning Processes - 1) According to P and W Specifications
2) According to GE Specifications
3) Sweco Cleaning
4) Ultrasonic Cleaning
5) Special Cleaning Processes
d) CRACK TEST - 1) FPI
2) FMPI
3) According to PW GE and Honeywell and allied specifications
e) BALANCING -
1) Static Balancing
2) Dynamic Balancing
B) THE CENTRAL REPAIR FACILITY ndash
A separate building of an area of 6970 sqmts accommodates the central repair facility for repair of engine and aircraft components This facility has sophisticated machine tools and equipments including a plating shop required for all types of repairs It also has a state of art of plasma spray machines and fully computerized shot peening and glass beed peening machines A vacuum furnace is also available for heat treating of engine parts
26 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
It contains the various sections ndash
1) Gearbox Section
2) Bearing Section
3) Rework Section
4) Blade Section
5) Plasma Section
6) Planting Section
7) Welding Section
8) Shot Peening Section
CAPABALITIES OF CRF-
1) GEARBOX SECTION ndash
To repair and overhaul of gearboxes of the following types of engines ndash
1) PW JT-9D-7J7Q
2) PW JT-8D-9A17A
3) PW 4056-3
4) GE CF6-50 C2
5) GE CF6-80 C2
6) PW JT-3D
2) MACHINE SHOP ndash It has the following types of machines ndash
1) Vertical Turret Lathes
2) Vertical Boring Machines
3) Lathes
4) Milling Machines
5) Jig Boring Machines
6) NC Milling Machines
27 5TH SEMESTER
7) Universal Milling Machines
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
3) PLASMA COATING -
1) Zinc Phosphate Coating
2) Black Oxide Coatings
3) Alodine Coatings
4) Phosphate Coating
5) Other Special Types of Coatings
4) PLATING SECTION -
a) Platings
1) Nickel Coating
2) Cadmium Coatings
3) Nickel-Cadmium Coatings
4) Cr-Coatings
5) Silver Plating
6) Titanium-Cadmium Plating
7) Electro Less Nickel Plating
b) Heat Treatment Processes
1) Vacuum Heat Treatment
2) Air Furnace Heat Treatment
3) Baking Processes
6) SHOT PEENING SECTION ndash
1) Shot Peening
2) Glass Bead Peening
3) Plc Controlled Shot Peening
4) Dry Glass Bead Peening
5) Wet Glass Beed Peening
28 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
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NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
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AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
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AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
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ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
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The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
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AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
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AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
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What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
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The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
C) TEST HOUSE ndash
There are two test houses in engine overhaul department The Small Test House was built in 1953 capable of handling engines up to 30000 Ibs thrust The Large Test House is built in 1973 which is capable of handling engines
up to 100000 lbs thrust
29 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom
AGNEL POLYTECHNIC VASHI
INTRODUCTION
TO
JET ENGINES
30 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The First Jet Engine ndash
A Short History of Early Engine
Sir Isaac Newton in the 18th century
was the first to theorize that a Rear
ward-channel explosion could propel a
machine forward at a great rate of speed This theory was based on his
third law of motion As the hot air blasts backwards through the nozzle
the plane moves forward
Henri Giffard built an airship which was powered by the first aircraft
engine a three-horse power steam engine It was very heavy too heavy
to fly
In 1874 Felix de Temple built a monoplane that flew just a short hop
down a hill with the help of a coal fired steam engine
Otto Daimler in the late 1800s invented the first gasoline engine
In 1894 American Hiram Maxim tried to power his triple biplane with
two coal fired steam engines It only flew for a few seconds The early
steam engines were powered by heated coal and were generally much
too heavy for flight
31 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
American Samuel Langley made a model airplanes that were powered
by steam engines In 1896 he was successful in flying an unmanned
airplane with before it ran out of steam He then tried to build a full
sized plane the Aerodrome A with a gas powered engine In 1903 it
crashed immediately after being launched from a house boat
In 1903 the Wright Brothers flew The Flyer with a 12 horse power
gas powered engineFrom 1903 the year of
the Wright Brothers first
flight to the late 1930s the gas powered
reciprocating internal-
combustion engine with a propeller was the
sole means used to propel aircraft
It was Frank Whittle a British pilot who designed the first turbo jet
engine in 1930 The first Whittle engine successfully flew in April
1937 This engine featured a multistage compressor and a combustion
chamber a single stage turbine and a nozzle The first jet airplane to
successfully use this type of engine was the German Heinkel He 178 It
was the worlds first turbojet powered flight General Electric for the US
Army Air Force built the first American jet plane It was the
XP-59A experimental aircraft
32 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ROLE OF ENGINES ndash Engine which forms energy generating center in any moving vehicle most of
the two wheeler use IC engines in two stroke execution The energy
generated by the engine is used to drive the vehicle in most economical
manner Bigger automobiles use petrol or diesel engines in four stroke
execution and they try to maintain the economic feasibility at best of its level
Still larger vehicles use giant size IC engines like in the railway locomotives
ships etc In all the vehicles energy generated by engine is used to drive the
gearbox which ultimately is connected to wheels of the vehicles which enable
the vehicles to move from place to place However these engines have certain
deficiencies in them The main out of the many is the dead weightpower
developed ratio which runs in fractions in most of these designs Obviously for
aviation purposes these engines could not do much of help Consequently
man looked upon further development of engines suitable for aviation
purposes which should be light in weight but highly fuel efficient The main
differences in a reciprocating and rotary engines are as follows
ROTARY ENGINE RECIPROCATING ENGINES
Dead weight per kilowatt is less Dead weight per kilowatt is more
Efficiency is more than reciprocating engine (70)
Efficiency is as low as 40
Lubrication is very simple Lubrication system is complicated
It can be driven at very high speeds
It is driven at low speeds
Pressure of the air at the end of compression is less
Pressure of air after compression is more up to 35 bar
Cooling system is very simple Cooling system is complicated
33 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
THEORY OF JET PROPULTION ndash
The principle of jet propulsion is obtained from the application of
Newtonrsquos second and third law of motion laws of thermodynamics and the Bernoullirsquos theorem We know when the fluid is accelerated a force is required to produce this acceleration in fluid and at the same time there is equal and opposite reaction This equal and opposite reaction is known as thrust and thus jet propulsion theory is based on action reaction principle
Jet Engines Are Mainly Classified In Two Types -
1) AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) 2) ROCKET ENGINES (NON AIR BREATHING ENGINES)
AIR BREATHING ENGINES (ATMOSPHERIC JET ENGINES) In this engine the hot compressed air is mixed with energy rich fuel and combusted These combustion gases are used for propulsion Therefore these are known as air breathing or atmospheric jet engines
ROCKET ENGINES (NON AIR BREATHING ENGINES) These jet propulsion engines use a jet of gas produced by chemical reaction of fuel and oxidizer each of which is carried in the propelled body Atmospheric air is not used in formation of jet The equipment producing jet is known as rocket motor
34 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
The jet engines are mainly classified as follows ndash
TURBOJET
The original jet engine discussed in the History section became known
as the turbojet This engine completely changed air transportation It
greatly reduced the expense of air travel and improved aircraft safety
The turbojet also allowed faster speeds even supersonic speeds It had a
much higher thrust per unit weight ratio than the piston-driven engines
which led directly to longer ranges (flight distances) and higher
payloads (more passengers and baggage) As it happened it also has
lower maintenance costs The typical turbojet engine has all 5 of the
components described in the previous section an inlet a compressor a
combustor a turbine and a nozzle The figure below shows a basic
turbojet schematic with the 5 components clearly identified
35 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
To get an increased thrust an afterburner can be added to the turbojet
The figure below is the turbojet with an afterburner Most aircraft do not
use an afterburner because they use so much fuel Fighter aircraft with
afterburners only use them when absolutely necessary If a pilot runs
too long with afterburner on he or she risks running low on fuel
before the mission is completed
Remember from the components section that
temperature is a very important factor when designing the turbine The
exhaust cannot be too hot or it will melt parts (such as the blades) in the
turbine However the hotter the exhaust the more thrust there will be
The engineers use a technique called turbine blade cooling This
allows hotter than normal exhaust from the combustor to enter the
turbine engine Cool air from the compressor is fed into hollow turbine
blades so they wont become overheated and warp or break The cooling
36 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
must be controlled very carefully to get maximum thrust The turbojet
engine is the most popular engine for most high-speed aircraft in spite
of the higher fuel consumption When high speed and performance are
important the cost of fuel is less important Military fighters and fast
business jets use turbojet engines
TURBOPROP
Soon after the first turbojets were in the air the turboprop engine was
developed This engine design produces two thrusts one with the
propeller and the other through exhaust A large gear box makes it
possible for the turbine to turn a large propeller at high speed producing
the first thrust The large gear box has many moving parts (that could
break) and can get in the way of the air stream going into the engine As
the propeller speed increases the tips of the blades may approach
supersonic speeds If this happens the flow may separate and shocks
may form decreasing the air flow into the engine For these reasons this
type of engine is still restricted to slower speeds because of the large
propeller and the gear box The sketch below shows the basic
components of a turboprop engine The propeller precedes the inlet and
the compressor but it serves the same purpose It provides a large
volume of high pressure air to the engine exhaust streams An inlet and a
compressor are used to send a part of the air flow to the burner A
37 5TH SEMESTER
turbine is used to power the propeller and the compressor and the hot
AGNEL POLYTECHNIC VASHI
exhaust gases are accelerated out through the nozzle (This is the second
thrust after the propeller) Because only a small part of the air flow is
actually burned inside the engine the turboprop engine can generate alot of thrust with a low fuel consumption compared to a turbojet engine
When an airplane is designed to fly at lower speeds the turboprop is usually the engine chosen
38 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
TURBOFAN
As engineers struggled to overcome the limitations of the turboprop
engine for airplanes at higher speeds a new design emerged the
turbofan It can be described as a compromise between the turboprop
and the turbojet engines It includes a large internal propeller
(sometimes called a ducted fan) and 2 streams of air flowing through the
engine The primary stream travels through all of the components like a
turbojet engine while the secondary stream is usually accelerated
through a nozzle to mix with the primary exhaust stream The figure
below illustrates the design of a turbofan engine There are several
advantages to the turbofan over the other 2 engines The fan is not as
large as a propeller so the increase of speeds along the blades is less
Also by enclosing the fan inside a duct or cowling the aerodynamics
are better controlled There is less flow separation at the higher speeds
and less trouble with shocks developing A turbofan engine can fly at
transonic speeds up to Mach 09 While the fan is smaller than the
propeller it does suck in much more air flow than the turbojet engine so
it gets more thrust Like the turboprop engine the turbofan has low fuel
consumption compared to a turbojet The turbofan engine is the engine
of choice for high-speed subsonic commercial airplanes
39 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
While it is possible to put afterburners into one or both streams the
slight additional thrust gained is at the expense of a large increase in fuel
consumption The cost is so high in fact that they are rarely ever built
into turbofan engines
40 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
JET ENGINE
AND
ITS PARTS
41 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
BASIC COMPONENTS OF JET ENGINE
The basic components of an air-breathing (jet) engine are the inlet a
compressor or fan the combustor (burner) a turbine and an exit nozzle
Different engines will use these components in various combinations
Some engine designs even leave out one or more of these components
(see next section) But these are the basic building blocks of an engine
The figure below shows a typical jet engine design and its components
42 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Inlet The design of the inlet or air intake helps determine the amount of air
flow into an engine After deciding the cruise speed of the aircraft
engineers design the inlet to suck in as much of the air coming toward it
as needed Subsonic supersonic and hypersonic cruise speeds each
require a different inlet design Inside the engine the next component
the compressor works much much better when the air enters fairly
the inlet are designed slowly (usually much slower than cruise
velocity) so the inner walls of to slow the velocity of the air stream as it
comes to the compressor
43 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Compressor The compressor is used to squeeze the air or to increase the pressure of
the air flow This is vital to creating thrust Using a balloon as an
example as more air is blown into the balloon the pressure increases
Increased pressure will produce increased thrust To increase the
pressure you must use power (your lungs) The purpose of the
compressor is to increase the pressure of the incoming air (power)
Typical compressors increase the pressure of the air by 15 to 30 times
the original pressure Usually an engine designer will choose among
different compressors to find the compression ratio that fits the
specifications of the airplane being built
44 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Combustor The slow moving high pressure air from the compressor is fed into the
combustor or burner where it is mixed with a highly flammable fuel and
ignited The very hot high pressure air leaving the burner will be used
to generate the thrust These gases are very very hot and the engineer
must be careful designing the components that come after the burner so
they are not melted or destroyed The combustion engineer works with
the mixture of fuel and air to get just the right combination for a good
hot burn Too little fuel and the mixture doesnt burn hot enough and the
resulting thrust is lower Too much fuel and the mixture doesnt burn
completely you may be getting enough thrust but the engine is wasting
fuel Sometimes a second burner is used after the turbine The second
burner reheats the gases to a higher temperature just as they increase
generating more thrust
45 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Turbine The very high temperature high pressure gases are released from the
burner and passed into the turbine (engine) where the local pressures are
much lower The high pressure gases begin to drop in pressure As the
pressure drops the velocity of the flow of exhaust gases increases As
these gases leave the engine (turbine) they generate thrust Part of this
flow may also be used to power (run) the compressor Although this
decreases overall thrust it is more efficient than having a separate power
source for the compressor An engineer must be very careful in the
design of a turbine because ofthe high temperature of the gases coming
from the burner If the materials in the turbine blades are not chosen
well the blades can melt and deform and be less efficient or even break
off and destroy the rest of the turbine Some engines use an
afterburner
Remember the afterburner does a second burn on the lower pressure
gases coming from the turbine Some of the gas flow is used to run
the
compressor the afterburner reheats the gases which increases their velocity thereby increasing thrust Without the afterburner the additional thrust would not be there
46 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
Nozzle The inside walls of the exit nozzle are shaped so that the exhaust gases
continue to increase their velocity as they travel out of the engine The
higher the exit velocity of the gases the more thrust that can be
generated Some fighter aircraft have adjustable nozzles allowing the
pilot to adjust thrust as needed
Other nozzles are of a fixed design
because conditions do not change
enough to need an adjustable
nozzle
Again the engineer must be
concerned with the temperatures
of the exhaust gases in the exit
nozzle especially if there is an afterburner
If the walls on the inside of the nozzle melt and change then the exhaust
velocities and thrust may not be correct There are four basic types of
air-breathing engines (turbines) the turbojet the turboprop the
turbofan and the ramjet Each has its advantages and disadvantages for
specific cruise speeds Engineers look for two things when designing a
jet engine thrust to weight ratio and fuel consumption Most aircraft are
designed for low fuel consumption even though it means lower thrust
capabilitiy Some aircraft such as fighter jets need a lot of thrust and are
not as concerned about the amount of fuel used if the mission requires
it Engineers recommend which engine would work best
47 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
GENERAL
ELECTRICAL
CF 6 - 80 C2 A2
48 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
49 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
GENERAL ELECTRICAL CF6-80C2A2
ENGINE ndash DESCRIPTION AND OPERATION bull GENERAL DESCRIPTION A The CF6-80C2 engine is a high bypass ratio dual-rotor axial-flow turbofan power plant The 14-stage high pressure compressor is driven by a 2-stage high pressure turbine and the integrated front fan and 4-stage booster is driven by a 5-stage low pressure turbine An annular combustor converts fuel and compressor discharge air into energy to drive the high and low pressure turbines The engine features direct fan speed control and clearance control for both low pressure and high pressure turbines B The accessory drive system transmits torque from the high pressure rotor
system to the engine mounted accessories
C Reverse thrust for braking the aircraft after landing is supplied by an
integrated system that uses the fan discharge airflow
bull ENGINE DATA A The axial length of the engine is marked by station numbers (STA) given in
inches The height in terms of water level (WL) with 100 inches (2540 mm)
being the horizontal center line The width is determined by the buttress line
(BL) with 100 inches (2540 mm) on the vertical axis
B The following data applies to the typical CF6-80C2 engine less optional
and additional equipment
Nominal Thrust Class ndash 57000 lbs (2537 kN)
Nominal Engine Length (Without Turbine Nozzle) ndash 170 inches (4318 mm)
Nominal Engine Width (Overall) ndash 100 inches (2540 mm)
Nominal Engine Weight (Dry) ndash 9000 lbs (4050 kg)
50 5TH SEMESTER
Direction of Rotation (Both Rotors) Clockwise
AGNEL POLYTECHNIC VASHI
bull ENGINE MODULES
Special attention is given to disassemblyassembly of the engine by major modules to permit the changing of a module without completely disassemblingassembling the engine Major modules of the engine are fan core engine high pressure turbine (HPT) low pressure turbine (LPT) and accessory drive
THE FAN MODULE (1) The fan module contains a single stage high bypass ratio front-mounted fan and a 4-stage axial flow compressor booster driven by the low pressure turbine (2) The fan frame is the major support structure It supports the front of the compressor the fan rotor fan stator inlet gearbox radial drive shaft transfer gearbox and the forward engine mount It also provides a variable bypass valve system that consists of 12 variable bleed valves (VBV) located between the struts (3) The fan rotor has a large diameter (93 inches ndash 2362 mm) first stage and reduced diameter stages 2 3 4 and 5 that supercharge the inner portion of the fan flow entering the compressor (4) The fan mid-shaft connects the fan rotor to the low pressure turbine rotor The shaft transmits torque from the turbine rotor to the fan rotor (5) The fan stator contains fixed stator vanes mounted behind all stages of the rotor Acoustic panels line the fan casing to reduce sound levels (6) A hydro-mechanical fan speed sensor provides a fan speed single to the man engine control (7) Booster discharge air is piped to inlet of these identical bore cooling valves (BCV) located on the fan frame Discharge of each BCV is piped to the bore of the compressor Air cools the compressor bore when engine is at high power levels
51 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CORE ENGINE MODULE (1) The core engine module consists of a 14-stage compressor rotor and stator compressor rear frame (CRF) and combustion liner and stage 1 high pressure turbine nozzle assemblies contained in the compressor rear frame The front of the compressor stator is supported by the fan frame and the rotor by a bearing in the fan frame The rear of the compressor stator is supported by the compressor rear frame and the rotor by two bearings within this frame (2) The inlet guide vanes and the first five stator stages of the compressor use variable angel vanes whose angular position is changed as a function of core engine speed (N2) and compressor inlet temperature (CIT) the variability of angle vanes optimizes compressor efficiency and stall margin at all engine speeds (3) Part of the fan discharge airflow is passed through the compressor and is progressively compressed as the air moves from stage-to-stage The stage 14 discharge air output is compressed by a ratio of approximately 30 to 1 (4) The combustion liner assembly in the compressor rear frame is a rolled-ring annular combustor consisting of a cowl assembly inner and outer liners and a dome assembly that contains swirler cups for the 30 fuel nozzles The stage 1 high pressure turbine nozzle assembly mounts behind the combustor on an inner support of the compressor rear frame The fuel nozzles and two igniters mount in ports of the compressor rear frame and extend into the combustor
HIGH PRESSURE TURBINE MODULE
(1) The high pressure turbine module consists of stage 2 HPT nozzle assembly and rotor The nozzles are supported by the compressor rear frame The high pressure turbine rotor is attached to the high pressure compressor rotor
52 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
LOW PRESSURE TURBINE MODULE
(1) The low pressure turbine module consists of a 5-stage turbine rotor nozzles stator case and rear frame Surrounding the stator case is a clearance control manifold system The low pressure turbine rotor is connected to the fan rotor by the fan mid-shaft
bull ACCESSORY DRIVE MODULE (1) The accessory drive module consists of the inlet gearbox radial drive shaft and transfer gearbox supported in the fan frame plus the horizontal drive shaft accessory gearbox engine accessories and accessory heat shield supported by core engine The function of this module is to transmit torque from the high pressure rotor system to the engine-mounted accessories and provide the core engine speed singal (2) The inlet gearbox is located in the fan frame and connects to the forward shaft of the high pressure compressor rotor The inlet gearbox transmits torque to the radial drive shaft (3) The radial drive shaft is located within the No 7 strut of the fan frame The shaft transmits torque from the inlet gearbox to the transfer gearbox (4) The transfer gearbox mounted on the fan frame consists of an enclosed 45-degree bevel gear train The transfer gearbox diverts the torque from the radial drive shaft to the horizontal drive shaft that powers the accessory gearbox (5) The accessory gearbox is mounted to the underside of engine compressor stator Engine and aircraft accessory mounting and drive pads and provided on both the forward and rear faces of the gearbox The engine accessories mounted on the gearbox are starter main fuel pump main engine control lube and scavenge pump and control alternator Pads are also provided for mounting the aircraft hydraulic pumps and integrated drive generator
53 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION TO GEARBOXES bull INLET GEARBOX ASSEMBLY ndash DESCRIPTION AND
OPERATION The inlet gearbox assembly is located in the A sump of the engine and bolted to a support flange in the fan frame hub The inlet gearbox extracts energy from core engine rotor and transmits energy to the transfer gearbox through the radial drive shaft It also provides a speed input from the fan rotor to the N1 indicator DESCRIPTION
A The gearbox assembly consists of a cast titanium housing an adapter two pairs of bevel gears bearings and oil jets The main horizontal bevel gear is driven by a splined adapter in the compressor rotor forward shaft and the forward end is supported by a ball bearing The horizontal gear mates with the radial bevel gear which rotates on an inclined axis The radial gear is supported by a ball bearing and roller bearing The lower end of the radial gear is splined to mate with the radial drive shaft B The horizontal N1 gear shaft contains a bevel gear and spur gear The spur gear is driven by a gear on the fan shaft and the bevel gear mates with the radial N1 bevel gear The radial N1 bevel gear is splined to mate with a
54 5TH SEMESTER
radial shaft to the N1 indicator Both N1 gear shafts are mounted on two ball bearings
AGNEL POLYTECHNIC VASHI
bull RADIAL DRIVE SHAFT ndash DESCRIPTION AND OPERATION
A The radial drive shaft (Figure 1) transmits torque drive between the engine internal inlet gearbox and the externally-mounted transfer
aft is made of steel alloy and is hollow It measures pproximately 15 in (381 mm) long and 12 in (305 mm) in diameter Both
evel
TRANSFER GERABOX ASSEMBLY ndash DESCRIPTION AND
A The transfer gearbox assembly (Figure 1) is bolted to a flange on the fan frame aft end at the number 7 shrut The gearbox transmits torque form
rbox assembly consists of a cast aluminum main housing
dapters a set of bevel gears and associated bearings and oil jets
oil jets to rovide lubrication for the gears and bearings Each of the two bevel gears is
gearbox It is mounted within a pressure compartment in the fan frame No 7 strut
DESCRIPTION A The radial drive shaends are externally splined to mate with the transfer and inlet gearboxes bgears A retaining ring installed inside the lower end of the shaft provides an oil dam to maintain a supply of oil for the upper spline
bull
OPERATION
the radial drive shaft to the horizontal drive shaft
DESCRIPTION
A The transfer geaa B The main housing and upper adapter have internal passages and psupported by a ball bearing and a roller bearing The upper bevel gear is splined to the radial drive shaft and the gear that rotates on the horizontal axisis splined to the horizontal drive shaft
55 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull HORIZONTAL DRIVE SHAFT ndash DESCRIPTION AND
he horizontal drive shaft assembly (Figure 1) is mounted between the
ESCRIPTION
ive shaft components consist of a one-piece machined
The shaft is splined at the forward end to the transfer gearbox and at the
t
The housing is slip fitted into the gearboxes and held in axial position by
h
OPERATION Ttransfer and accessory gearboxes Its function is to transmit torque drive between the transfer gearbox and the accessory gearbox D
The horizontal drAtubular steel shaft an aluminium alloy housing and retaining ring Baft end to the accessory gearbox Forward and aft movement of the shaft is limited by an internal flange in the transfer gearbox gear and by the starter output shaft in the accessory gearbox The retaining ring installed in the shafforward inner diameter creates an oil dam to keep oil in the aft spline area
Ctwo mounting arms attached to the accessory gearbox The mounting arms also react overturning moments from the accessory gearbox Grooves in eacend of the housing are for preformed packing to prevent oil leakage from the drive shaft housing
56 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ACCESSORY GEARBOX ASSEMBLY ndash DESCRIPTION
he accessory gearbox assembly (Figure 1) is installed on the bottom of the ore engine The gearbox receives torque from the horizontal drive shaft and
ESCRIPTION
mbly consists of a one-piece cast aluminium alloy main ousing aluminium pad adapters spur gears and associated bearings seals
and replacement of these parts without otherwise
retained from outside of the gearbox and can be
Tcdistributes torque through spur gears to drive gearbox mounted accessories
D A The gearbox assehand oil nozzles B The plug-in adapter feature used to install the gears bearings and seals
ermits removal pdisassembling the gearbox C Internal tubes and oil nozzles provide lubrication of the gears and bearings
ll gearbox carbon seals areAreplaced without disassembly of the gearbox
57 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PW 4056
58 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
INTRODUCTION
Pratt amp Whitneys PW4000 94-inch fan model is the first in a family of high-
ine
Since entering revenue service in 1987 the PW4000 has offered airlines en
Todays PW4000 meets all current and anticipated emissions and noise
y
t
The PW4000s exceptional service experience performance and modern as
In addition to low noise and emissions it offers far greater fuel economy and
thrust aircraft engines With certified thrust ranging from 52000 to 62000 pounds it powers the Airbus A310-300 and A300-600 aircraft and Boeing 747-400 767-200300 and MD-11 aircraft For twin-engine aircraft the PW4000 is approved for 180-minute ETOPS (Extended-range Twin-engOperations) giving airlines excellent operational flexibility
excellent operating economics and high reliability Advanced service-provtechnologies such as single-crystal superalloy materials and its Full-AuthorityDigital Electronic Control (FADEC) contribute to superior fuel economy and reliability The engines attractiveness is further enhanced by excellent performance retention long on-wing times and low maintenance costs
regulations with margin For a further reduction in emissions mdash especiallyNOx mdash TALON (Technology for Advanced Low NOx) combustor technologis now available as an option Derived from the 112-inch fan model TALON has segmented replaceable liner panels for easy maintainability and air blasfuel nozzles for excellent fuel atomization and mixing
technologies make it attractive for a future military tanker application such the 767
59 5TH SEMESTER
maintainability than engines powering existing tankers
AGNEL POLYTECHNIC VASHI
GENERAL Bypass Ratio Turbofan
- Fan produces 78 of total thrust
bull Mounted Angle and Main Gearbox bull Engine Inlet Diameter
bull Axial Flow High
- 97 in (24638cm) - 93 in (2362cm)fan
bull En
in (39116 cm - frac34 in (19 cm) takeoff growth
bull En
cal non-QEC dry
(4175 kg)
- Typical QE
00 lb (5216 kg)
bull Takeoff Specifications
052 PW 4056 PW 4158 PW 4060
4460
gine Length
- 154
gine Weight
- Typi
9200 lb
C wet
115
PW 4050 PW 4
PW 4251 PW 4056 PW
Thrust 50000 52000 56000 58000 60000
TSFC (lbhrlb)
032 033 034 035 035
p Bypass Ratio 48 1 5 1 5 1 5 1 5 1 Compressor Pressure Ratio
60 5TH SEMESTER
27 1 27 1 29 1 30 1 30
1
AGNEL POLYTECHNIC VASHI
ngine Characteristics
1327 in
75 to 323
EFan tip diameter 94 in
Length flange to flange
Takeoff thrust 52000 - 62000 lb
Flat rated temperature 86 or 92deg F
Bypass ratio 48 to 51
Overall pressure ratio 2
61 5TH SEMESTER
Fan pressure ratio 165 - 180
AGNEL POLYTECHNIC VASHI
HISTORY
The Pratt amp Whitney Company 60
was founded in 18 by Francis Pratt and Amos Whitney with headquarters in Hartford Connecticut The company manufactured machine tools tools for the makers of sewing machines and gun-making machinery for use by the Union Army during the American Civil War
In 1925 Frederick Brant Rentschler approached Pratt amp Whitney looking for nds and a location to build his new aircraft engine Pratt amp Whitney loaned
the Pratt amp Whitney name and space in their fuhim $250000 the use of building This was the beginning of the Pratt amp Whitney Aircraft Company Pratt amp Whitneys first engine the Wasp was completed on Christmas Eve 1925 The Wasp developed 425 horsepower (317 kW) on its third test run It easily passed the Navy qualification test in March 1926 and by October theNavy had ordered 200 engines The Wasp exhibited speed climb performance and reliability that revolutionized American aviation
In 1929
Frederick Rentschler ended his association with Pratt amp Whitney Machine Tool and formed United Aircraft and Transport Corporation the
or to todays United Technologiespredecess His agreement allowed Rentschler to carry the name with him to his new corporation
Pratt amp Whitney is a business unit of industrial conglomerate United Technologies making it a sister company to Pratt amp Whitney Canada (PWC
Sikorskyoriginally United Aircraft of Canada) Helicopters Hamilton Sundstrand Otis Elevator Company and refrigeration giant Carrier Corporation PWC designs and builds the smaller aircraft engines while PampW manufactures the larger engines
Pratt amp Whitney is headquarted in East Hartford Connecticut and also has lants in Middletownp CT Cheshire CT West Palm Beach FL and North
Berwick ME
62 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
NGINE GENERAL a two-spool axial flow high bypass n and construction
rive HPC
bull Full Authority Digital Electronic Control (FADEC) amp EEC
bull Supplemental Control Unit (SCU)
bull Engine Air System
bull Engine Fuel System
bull Engine Ignition System
ower plant systems and their associated components located on the left side
bull Engine Fuel System
bull Engine Oil System
bull Engine Indicating System
E The PW 4056 series engine isratio turbo fan engine of modular desig
Two separate airflow paths primary and secondary provide thrust The primary (core) airflow accounts for approx 20 of the total thrust The
condary (fan) airflow bypasses the engine core and accounts for approx se80 of the total thrust The PW 4056 is flat rated at 92 F with a 5 1 bypass ratio The engine dry weight is approx 9290 pounds (4216 KGS) The combustion section generates the hot exhaust gases that dthe turbines The LPT drives the fan and LPC (N1) The HPT drives the
2) N2 drives the main gearbox by way of the angle gearbox (N PW 4056 power plant systems and their associated components located on the right side of the engine includes -
bull Engine Control System
Pof the engine ndash
bull Engine Air System
63 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
bull EEC Speed (N1) Transducer
bull Other Air Plane System ndash Electrical
ower plant system and components and other air plane system components
bull Engine Fuel System Fuel Pump Drive
bull Engine Ignition System Ignition Exciters
bull Engine Oil System
G
acelle The cowls provide a smooth w into out of and around the
on the e r
th
pletely removing these cowls
Pmounted on the main gearbox includes ndash
bull Engine Control System EEC Alternator
ENGINE COWLIN Fixed and hinged cowls make up the nair floengine The also protect the engine ndashmounted components The fixed cowls include the inlet cowl and exhaust sleeve and
ug which are mountedplforward and aft flanges of the engin Hinged cowls include the fanhinge on the strut and latch on the undersidengine and its components by opening or com
esp
rust reverser and core cowls They the crew can gain access to the
e Two engine mounts forward and aft secure the engine to the strut
64 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
(GENERAL
ELECTRIC)
GE 90
65 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
ENGINE OVERVIEW-
Built by General Electric in conjunction with SNECMA of France IHI of Japan
and FiatAvio of Italy and first commissioned by the British Airways for its new fleet
of Boeing 777s recently (September 1995) it is the most powerful commercial
aircraft engine today Certified at a Take-Off Thrust of 380 kN (85000 lb) only two
engines suffice for a huge aircraft like the 777 with a seating capacity of 375 (weight
approx 230 tonnes) A derivative of the GENASA Energy Efficient Engine (E3)
program it is also the most fuel efficient silent and environment friendly engine of today In addition to the highest thrust to be offered the GE90 is expected to provide
airlines with a 5-6 improvement in fuel burn lower noise pollution and NOX
emissions 33 lower than todayrsquos high bypass ratio engines
This seminar attempts at highlighting the various aspects of the engine by presenting a brief insight into its features
66 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The GE90 combines the best proven technology from these engine programs NASA and military programs with advanced technology to provide a highly reliable fuel-efficient powerplant for the next generation of wide-body aircraft
Originally certified in 1995 at 84700 pounds of thrust todays GE90 engines power newer more advanced Boeing 777 aircraft capable of flying farther faster and more efficiently than their predecessors
The most powerful derivative of the GE90 the GE90-115B is the sole powerplant for Boeings longer-range 777-300ER The GE90-115B certified at 115000 lbs of thrust and has broken a number of aviation records
The GE90-115B derated to 110 lbs of thrust (GE90-110B) powers the Boeing 777-200LR and the worlds largest most capable twin-engine freighter -- Boeings 777 Freighter The 777 Freighter will offer unsurpassed efficiency to
67 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
long-haul markets and provide more capacity than any other twin-engine freighter
The Guinness Book of World Records recognized the engine as the Worlds Most Powerful Commercial Jet Engine in 2001 after it recorded an amazing 123000 lbs of
steady-state thrust while undergoing initial ground testing In late 2002 the engine shattered its original record by reaching 127900 lbs of thrust during required certification testing
Since the introduction of Boeings longer-range 777 in early 2000 the GE90 has been the best-selling engine for that aircraft family
Snecma of France Avio of Italy and IHI of Japan are participants in the GE90 development program
HISTORY OF GE90-
NASA GE90 airflow simulation
The GE90 was launched in 1990 by General Electric (USA) associated with Snecma (France) IHI (Japan) and Avio (Italy) Developed from the 1970s NASA Energy Efficient Engine the 10-stage high pressure compressor develops a pressure ratio of 231 an industry record The GE90-115B fan is an advanced design made from composite materials and is the first production engine to feature swept rotor blades
At least one technical paper presented on behalf of one of GEs project partners indicates that further thrust improvement programs will be promoted should a market for higher thrusts arise For comparison purposes the Boeing 747-400s largest engines produce 63300 lbf (289 kN) of thrust It is therefore likely that the next version or successor of the Boeing 777 will be powered with a later version or derivation of this engine and will produce twice the thrust of the most powerful fitted to the venerable 747
68 5TH SEMESTER
They can only be airfreighted in assembled form by outsize cargo aircraft such as the Antonov An-124 Condor presenting unique problems if due to emergency diversions a 777 was stranded in a place without the proper spare parts If the fan is removed from the core then they may be shipped on a 747 Freighter On December 17 2005 a GE90-94B failed on an Air France
AGNEL POLYTECHNIC VASHI
777 flying from Seoul to Paris resulting in an unscheduled landing in Irkutsk Siberia A replacement engine was flown via an An-124 and the engines were exchanged The cause of the failure is still under investigation[1]
The GEnx engine that has been developed for the Boeing 787 747-8 and certain versions of the Airbus A350 is derived from the GE90 Engine Alliance a cooperative venture between GE Aircraft Engines and Pratt amp Whitney developed a separate GE90 derivative engine for the Airbus A380 called the GP7000
Worlds largest jet engine
The GE90 series are physically the largest engines in aviation history the fan diameter of the original series being 312 cm (123 in) The latest variant the GE90-115B has a fan diameter of 325 cm (128 in) This means that the GE90 has a larger diameter than most cabins in business aircraft as well as smaller airliners such as the Bombardier CRJ family and is only slightly smaller than the 37-metre cabin width of the Boeing 737
Holder of the thrust world record
According to the Guinness Book of Records at 127900 lbf (569 kN) it holds the record for the highest thrust (though it is rated at 115300 lbf (513 kN)) This thrust record was accomplished inadvertently as part of a one hour triple red-line engine stress test In order to accommodate the increase in torsional stresses an entirely new steel alloy GE1014 had to be created and then machined to extreme tolerances
Holder of the range world record
On November 10 2005 the GE90 entered the Guinness World Records for a second time It powered a 777-200LR during the worlds longest flight by a commercial airliner though there were no fare-paying passengers on the flight only journalists and invited guests The 777-200LR flew 13422 miles (21601 km) in 22 hours 42 minutes flying from Hong Kong to London the long way over the Pacific over the continental US then over the Atlantic to London[2] (The longest flight by a commercial airliner with passengers was 18 hours flown by an Airbus A340-500 aircraft)
69 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
AGNEL POLYTECHNIC VASHI
70 5TH SEMESTER
70 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
DESCRIPTION
OF
PLASMA
COATING
SECTION
71 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is Plasma coating and why is it used
instead of Welding
Plasma coating is a process in which the fine metal powder to be used is
induced on the object to be coated
The object to be coated is fixed on a turn table and the table is rotated at a
particular RPM irrespective of the type of coating and the powdered metal to
be used (all electrically amp hydraulically operated)
The meal powder being at a temperature of 1100 degree Celsius is sprayed
at a pressure according to the parametric specification for each type of
powder at a particular distance ranging fro various values (100 500 cm)
Due to this method of spraying the hot powder from a distance the
temperature of the fused metal particles is around 200 degree Celsius
72 5TH SEMESTER
Hence there is least possible distortion of meant at that particular point or
area Whereas in case of welding arc of 3200 degree Celsius is directly
induced on the metal as a result there is a lot amount of distortion caused To
have the least possible distortion we use plasma coating
AGNEL POLYTECHNIC VASHI
What is wire flame spraying
This is the oldest process of applying sprayed coating on a substrate
It uses heat from a chemical reaction as the melting source Common fuel
gases are acetylene methyl-acetylene-propadiene (MAPP) propane
propylene and natural gas each combined with oxygen
However acetylene is the most widely used because of the higher
temperature s it produces
Any material available in the form of wire and capable of being melted below
2480 degree Celsius can be flame sprayed
73 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The gas flame is used only to melt the material Spraying is accomplished by
surrounding this flame with a co axial stream of compressed gas or air to
atomize the molten material and to propel it on to the work piece
74 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
What is plasma arc spraying
Plasma spray process uses coating materials in the form of powders which
are melted a plasma heat source
Plasma is an excited gas often considered to be a fourth state of matter
consisting of an equal ratio of free electrons and positive ions
This forms an electrically neutral flame
A plasma arc gun is a water cooled device which has an open ended chamber
in which the plasma is formed
The primary arc gas usually argon or nitrogen is introduced into the
chamber and is ionized by the electrical discharge from a high frequency arc
starter
Once discharge is initiated the plasma can conduct currently as high as 2000
amperes direct current with voltage potential ranging from approximately
75 5TH SEMESTER
30 to 80 volts direct current
AGNEL POLYTECHNIC VASHI
METALLURGICAL COATING FAILIURES
I I
I I
I I
UNMELTED OVER HEATED
PARTICLES COATINGS
I I
I I
COATING TOO SOFT COATINGS TOO
OR SPRAYED COLD HARD
76 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
The failures are mostly caused because of the dwell time ie the span
of the time the material is in the flame or the amount of time the material has
to reach its melting point
he variables which govern the dwell time are-
pray distance -
T
S Distance between the nozzle and work piece
rimary pressure and flow -
P Flow of gas to the gun
Spray rate - The amount of material measured in lbshour introduced
the flame in the gun in
77 5TH SEMESTER
AGNEL POLYTECHNIC VASHI
CONCLUSION
It was a great experience to work with AIR INDIA LTD and to get
myself coped with the industrial environment During my training I
noticed that there is a good scope in the Mechanical Industry (AirCraft
Industry - AIR INDIA LTD) It gave me the opportunity to work on
AirCrafts and thoroughly professional Aircraft Maintenance Engineers
and Supervisors with whose co-operation I could increase my
knowledge About the company I can say that AIR INDIA who
maintains Aircrafts are maintained to comply with international
standards and complete satisfaction of travelers The engineers at AIR
INDIA LTD are known for their innovative approach and extensive
industrial experience
While undergoing training in assembly shop and dressing sections helped me
to know about the various fitment processes and the assembly
processes carried out I got an opportunity to work with various tool kit
instruments such as rachet-sockets speed handles open end spanners ring
spanners ring rachets etc I also learnt about various locking procedures
such as wire locking tab washers spring washers etc
78 5TH SEMESTER
I got knowledge about various inspection procedures such as visual
inspection dimensional checks etc I also got an opportunity to learn about
various crack detection methods I also learnt about torque wrenches and dial
type indicators
AGNEL POLYTECHNIC VASHI
79 5TH SEMESTER
Thus at the end of my training I can say that it was the most
constructive period of my budding career in the engineering field I am
highly obliged to all those who help me make the best use of this
opportunity
AGNEL POLYTECHNIC VASHI
80 5TH SEMESTER
REFERENCE
1 Aircraft Manual
2 Encyclopedia
3 wwwgooglecom
4 GE 90 CF6 ndash 80 C2 A2 B1 50 C2 PW 4056 Engine dressing
Manual
5 wwwairlinersnet
6 wwwwikipediacom