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AGNEL POLYTECHNIC, VASHI INPLANT TRAINING REPORT AIR-INDIA LTD. (SANTACRUZ) SUBMITTED BY HONEY VISHWAKARMA V – SEMESTER ROLL. NO. - 075119 AGNEL POLYTECHNIC, VASHI DIPLOMA IN MECHANICAL ENGINEERING 01 st JUN 2009 – 14 th NOV 2009 1 5 TH SEMESTER

INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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Page 1: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

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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

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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)

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 2: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

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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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 3: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 4: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 5: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 6: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

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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

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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

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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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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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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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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

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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

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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

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

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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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 7: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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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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

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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

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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

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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

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 8: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

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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

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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

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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

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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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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

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 9: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

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

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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

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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

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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

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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

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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

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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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 10: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

36 5TH SEMESTER

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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

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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

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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

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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

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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

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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

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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

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DESCRIPTION

OF

PW 4056

58 5TH SEMESTER

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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

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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

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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

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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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 11: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

36 5TH SEMESTER

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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

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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

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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

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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

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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

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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

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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

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DESCRIPTION

OF

PW 4056

58 5TH SEMESTER

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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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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

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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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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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 12: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

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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

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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

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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

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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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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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 13: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

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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

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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

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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

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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

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

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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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 14: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 15: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 16: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 17: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 18: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

36 5TH SEMESTER

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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

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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

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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

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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

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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

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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

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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

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DESCRIPTION

OF

PW 4056

58 5TH SEMESTER

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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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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

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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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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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 19: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

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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

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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

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 20: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 21: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

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

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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

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

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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

40 5TH SEMESTER

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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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 22: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

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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

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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

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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

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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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 23: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 24: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

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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

32 5TH SEMESTER

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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

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

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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

40 5TH SEMESTER

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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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 25: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

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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

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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

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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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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

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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

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 26: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 27: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

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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

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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

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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

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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

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DESCRIPTION

OF

PW 4056

58 5TH SEMESTER

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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

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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

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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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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

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 28: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 29: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

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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

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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

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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

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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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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

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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

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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

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

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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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
Page 30: INPLANT TRAINING REPORT AIR-INDIA LTD....time the inplant training work as described in the report by my own skills and study, from 01/06/2009 to 14/11/2009 as per the instruction/guidance

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

  • CERTIFICATE
  • ACKNOWLEDGMENT
  • Network
    • MANAGEMENT
    • MANAGING DIRECTOR
    • DEPUTY MANAGING DIRECTOR
    • DIRECTOR OF ENGINEERING
    • EOD
      • CUSTOMERS OF ENGINE OVERHAUL DEPARTMENT
        • 7) CAPABILITIES
        • a) Engine Assembly ndash Disassembly -
        • B) THE CENTRAL REPAIR FACILITY ndash
        • 2) MACHINE SHOP ndash
        • 3) PLASMA COATING -
        • 4) PLATING SECTION -
        • a) Platings
        • b) Heat Treatment Processes
        • 6) SHOT PEENING SECTION ndash
        • C) TEST HOUSE ndash
        • INTRODUCTION
        • TO
        • JET ENGINES
        • The First Jet Engine ndash
        • A Short History of Early Engine
        • ROLE OF ENGINES ndash
        • ROTARY ENGINE
        • THEORY OF JET PROPULTION ndash
        • ROCKET ENGINES (NON AIR BREATHING ENGINES)
        • FURTHER CLASSIFICATION OF AIR BREATHING JET ENGINES
        • JET ENGINE
        • AND
        • ITS PARTS
        • OF
        • GENERAL ELECTRICAL
        • CF 6 - 80 C2 A2
          • GENERAL ELECTRICAL CF6-80C2A2
          • ENGINE ndash DESCRIPTION AND OPERATION
          • INTRODUCTION
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