January 11, 2017 | Author: Bruno Alonso Pacheco | Category: N/A
ARRIEL 1
Training manual December 2000 Ref.: X 292 87 960 2
TURBOSHAFT ENGINE
ARRIEL 1
Training Manual
FOREWORD This document provides, in a teaching form, all the information required for the operation and the maintenance of the ARRIEL 1 Turboshaft engine for training purposes only. It will not be updated, and if required, modifications will be included in a new issue.
TURBOMECA Training Centre This document is the property of TURBOMECA and it may not be copied without the express authority of TURBOMECA. For training purposes only © Copyright - TURBOMECA - 2000
0.1 Edition : December 2000
FOREWORD
Training Manual
ARRIEL 1
SUMMARY 0 - Foreword
9 - Starting
1 - Introduction
10 - Electrical system
2 - Power plant
11 - Engine installation
3 - Engine 4 - Oil system
12 - Operating limitations and procedures
5 - Air system
13 - Various aspects of maintenance
6 - Fuel system
14 - Maintenance procedures
7 - Control system
15 - Fault analysis and trouble shooting
8 - Control and indication For training purposes only © Copyright - TURBOMECA - 2000
16 - Checking of knowledge 0.2 Edition : December 2000
SUMMARY
ARRIEL 1
Training Manual
TABLE OF CONTENTS 3 - ENGINE
0 - FOREWORD -
Summary ............................................ Table of contents ................................ List of abbreviations .......................... Conversion table ................................
0.2 0.3 0.7 0.10
1 - INTRODUCTION -
General information ........................... Training method ................................. Training aids ...................................... Training programme .........................
1.2 1.4 1.6 1.8 to 1.12
2 - POWER PLANT -
General presentation ......................... General description ........................... General operation .............................. Principle of adaptation to helicopter .. Main characteristics ........................... Design and development ...................
For training purposes only © Copyright - TURBOMECA - 2000
2.2 2.4 2.8 2.12 2.14 2.22 to 2.27
- Engine ................................................ - Axial compressor ............................... - Gas generator HP section ................... • Centrifugal compressor ................... • Combustion chamber....................... • Gas generator turbine ...................... - Power turbine ..................................... - Exhaust pipe ....................................... - Reduction gearbox ............................. - Transmission shaft and accessory gearbox ....................... • Transmission shaft - twin-engine version ............................................. • Transmission shaft - single engine version ............................................. • Accessory box .................................
3.2 3.8 3.14 3.16 3.22 3.28 3.34 3.40 3.42 3.48 3.50 3.52 3.54 to 3.61
4 - OIL SYSTEM - Oil system ......................................... 4.2 - Lubrication ........................................ 4.8
0.3 Edition : December 2000
TABLE OF CONTENTS
Training Manual
ARRIEL 1
TABLE OF CONTENTS (CONTINUED) 6 - FUEL SYSTEM
4 - OIL SYSTEM (CONTINUED) -
Oil tank ............................................. Oil pumps ........................................... Electrical magnetic plugs ................... Oil filter.............................................. Filter pre-blockage indicator .............. Oil cooler ........................................... Centrifugal breather ........................... Magnetic plugs ................................... Strainers ............................................. Indicating devices .............................. Oil pipes and ducts .............................
4.12 4.14 4.20 4.24 4.30 4.34 4.36 4.40 4.42 4.44 4.50 to 4.51
5 - AIR SYSTEM -
Air system ......................................... Internal air system ............................. Air tappings........................................ Compressor bleed valve ..................... Air tapping unions ............................. Air pipes .............................................
For training purposes only © Copyright - TURBOMECA - 2000
5.2 5.4 5.8 5.10 5.18 5.20 to 5.21
- Fuel system ....................................... - Fuel Control Unit ............................... • Fuel pump ........................................ • Fuel filter ......................................... • Manual control ................................ • Metering unit ................................... - Overspeed and drain valve ................ - Start injector electro-valve ................. - Main injection system ........................ - Start injectors ..................................... - Combustion chamber drain valve ...... - Fuel pipes ...........................................
6.2 6.12 6.14 6.18 6.24 6.28 6.30 6.36 6.42 6.46 6.50 6.54 to 6.55
7 - CONTROL SYSTEM - Control system ................................... • General ............................................ • Description ...................................... • Operation .........................................
7.2 7.2 7.4 7.6 to 7.33
0.4 Edition : December 2000
TABLE OF CONTENTS
ARRIEL 1
Training Manual
TABLE OF CONTENTS (CONTINUED) 8 - CONTROL AND INDICATION -
Manual control system ....................... Indicating system ............................... Speed indication ................................. Tachometer transmitters ..................... Speed probes (1E, 1K, 1S versions) .. Gas temperature indication ................ Thermocouple probes ........................ Thermocouple junction box (1S version) ........................................ Torque indication ............................... Torquemeter ....................................... Torque transmitter .............................. Miscellaneous indications ..................
10 - ELECTRICAL SYSTEM 8.2 8.6 8.8 8.10 8.14 8.16 8.18
- Electrical system ................................ - Electrical accessories ......................... - Power turbine overspeed safety system ................................................ - Power turbine overspeed sensor ........ - Tachometer box .................................. - Super contingency power system ...... - Electrical harnesses ............................
8.20 8.22 8.24 8.26 8.28 to 8.35
9 - STARTING -
Starting system ................................... Starter ................................................. Ignition system ................................... Ignition units ...................................... Igniter plugs ....................................... Ignition cables ....................................
For training purposes only © Copyright - TURBOMECA - 2000
9.2 9.10 9.16 9.18 9.22 9.26 to 9.27
10.2 10.4 10.6 10.10 10.14 10.24 10.28 to 10.29
11 - ENGINE INSTALLATION -
Engine compartment .......................... Engine mounting ................................ Power drive ........................................ Air intake ........................................... Exhaust system .................................. Engine system interfaces ................... • Oil system ........................................ • Aircraft LP fuel system ................... • Manual controls ............................... • Air system ....................................... - Drain system ...................................... - Fire protection ....................................
11.2 11.4 11.8 11.10 11.12 11.14 11.14 11.16 11.18 11.20 11.22 11.24 to 11.25
0.5 Edition : December 2000
TABLE OF CONTENTS
ARRIEL 1
Training Manual
TABLE OF CONTENTS (CONTINUED) - Deep maintenance .............................. 14.62 - Repair and overhaul ........................... 14.64 to 14.65
12 - OPERATING LIMITATIONS AND PROCEDURES - Operating limitations ......................... 12.2 - Operating procedures ........................ 12.6 to 12.9
13 - VARIOUS ASPECTS OF MAINTENANCE -
Maintenance concept ......................... TBOs and life limits ........................... Preventive maintenance ..................... "On-condition" monitoring ................ Corrective maintenance ..................... Lubricants - Fuels - Materials ............ Tooling ............................................... Technical publications ....................... Product support ..................................
13.2 13.4 13.6 13.8 13.10 13.12 13.14 13.16 13.22 to 13.23
14 - MAINTENANCE PROCEDURES - General ............................................... 14.2 - Inspection and check procedures ....... 14.4 - Removal and installation procedures . 14.52 For training purposes only © Copyright - TURBOMECA - 2000
15 - FAULT ANALYSIS AND TROUBLE SHOOTING - Fault analysis ..................................... 15.2 - Trouble shooting ................................ 15.32 to 15.47
16 - CHECKING OF KNOWLEDGE -
Introduction ........................................ Questionnaire 1 ................................. Questionnaire 2 ................................. Questionnaire 3 ................................. Questionnaire 4 ..................................
16.2 16.3 16.6 16.12 16.15 to 16.30
OBSERVATIONS ................................... Last page This training manual is established to meet training requirements and takes into consideration, to a certain extent, ATA 104 specifications. This document has 562 pages. It was produced using a desktop publishing system.
0.6 Edition : December 2000
TABLE OF CONTENTS
Training Manual
ARRIEL 1
LIST OF ABBREVIATIONS The abbreviations / symbols shown below may be used during training : A/C ............... AC ................. ACMS ........... ACW ............. AEO .............. ATA .............. BITE ............. Tq (C) ........... cc/h ............... FCV .............. CH ................. cSt ................. CW ................ daN ............... dB ................. DC ................. DGAC ........... Ec .................. EGT ..............
Aircraft Alternating Current Automatic Control Monitoring System Anti-clockwise All Engines Operating Air Transport Association Built In Test Equipment Torque Cubic centimetres per hour Frequency/Voltage Converter Hourly Fuel consumption Centistoke Clockwise DecaNewton Decibel Direct Current Direction Générale de l'Aviation Civile Kinetic energy Exhaust Gas Temperature
For training purposes only © Copyright - TURBOMECA - 2000
FAA .............. FCU .............. FMU ............. FOD .............. ft .................... FWD ............. G ................... g .................... HE ................. HP ................. HP ................. HUMS........... Hz ................. ICP ................ ID .................. IFDS ............. ILS ................ ISA ................ ISV ................
Federal Aviation Administration Fuel Control Unit Fuel Metering Unit Foreign Object Damage Feet Forward Mass air flow Gram High Energy Horse Power High Pressure Health and Usage Monitoring System Hertz Intermediate Contingency Power Identification Integrated Flight Display System Integrated Logistic Support International Standard Atmosphere Servo-valve intensity
0.7 Edition : December 2000
LIST OF ABBREVIATIONS
Training Manual
ARRIEL 1
LIST OF ABBREVIATIONS (CONTINUED) kHz ............... kPa ................ kW ................ l/h .................. lb ................... lb/HP.hr ........ lb/hr ............... lb/sec. ............ LRU .............. LTT ............... LVDT ........... m ................... mA ................ MAX ............. MCP .............. MCQ ............. MGB ............. MHz .............. MIN .............. mm ................ mP .................
Kilohertz Kilopascal Kilowatt Litre per hour Pound Pounds per Horse Power per hour Pounds per hour Pounds per second Line Replaceable Unit Learning Through Teaching Linear Voltage Differential Transducer Metre Milliampere Maximum Max Continuous Power Multi Choice Questionnaire Main gearbox Mega Hertz Minimum Millimetre Micro-processor
For training purposes only © Copyright - TURBOMECA - 2000
MTBF ........... MTBUR ........ MTCP ........... MTTR ........... mV ................ N ................... N1 ................. N2 ................. NMD ............. NOVRAM .... NR ................. ω ................... O/S ................ OEI ............... P .................... P2 .................. POS ............... PPM .............. PSI ................ PSIA ............. PSID .............
Mean Time Between Failure Mean Time Between Unscheduled Removal Maintenance Test Control Panel Mean Time to Repair Millivolt Rotation speed Gas generator rotation speed Power turbine rotation speed Navigation and Mission Display Non Volatile Random Access Memory Rotor rotation speed Angular Velocity Overspeed One Engine Inoperative Pressure Compressor outlet pressure Position Parts per million Pounds per Square Inch Pounds per Square Inch Absolute Pounds per Square Inch Differential
0.8 Edition : December 2000
LIST OF ABBREVIATIONS
ARRIEL 1
Training Manual
LIST OF ABBREVIATIONS (CONTINUED) PSIG ............. PT ................. Q ................... RAM ............. ROM ............. RPM .............. RTD .............. SCP ............... SFC ............... Shp ................ SI ................... SRU .............. t ..................... T/O ................ TBO .............. TET ............... TM ................ t° ................... t4 ...................
Pounds per Square Inch Gauge Power Turbine Fuel flow Random Access Memory Read Only Memory Revolutions Per Minute Resistive Temperature Device Super Contingency power Specific Fuel Consumption Shaft horse power International System Shop replaceable unit Time Take-Off Time Between Overhauls Turbine Entry Temperature Turbomeca Temperature Gas temperature
For training purposes only © Copyright - TURBOMECA - 2000
US G ............. VAC .............. VDC .............. W .................. XTL .............. XCP .............. Z .................... Zp .................. °C .................. °F .................. °K .................. ± .................... Ω ................... ∆ .................... ∆P ................. % ................... < .................... > ....................
US Gallon Volt, Alternating Current Volt, Direct Current Power Throttle position signal Collective Pitch Signal Altitude Pressure altitude Degrees Celsius Degrees Fahrenheit Degrees Kelvin Plus or Minus Ohm Difference (delta) Pressure difference Percent Is lower than Is higher than
0.9 Edition : December 2000
LIST OF ABBREVIATIONS
ARRIEL 1
Training Manual
CONVERSION TABLE UNIT
International System
Length
1 mm 1m
= =
0.039 inch 3.28 ft = 1.09 yard
Volume
1 dm3 = 1 litre
=
0.26 US gallon
Mass
1 kg
=
2.2 lbs
Power
1 kW
=
1.34 HP
Temperature
°C °K
= =
(°F-32). 5/9 [(°F-32)5/9] + 273
Pressure
1 kPa = 0.01 bar
=
0.145 PSI
Flow (air, oil, fuel)
1 kg/s
=
2.2 lbs/sec.
Specific Fuel Consumption
1 g/kW.h
=
0.00164 lb/HP.hr
For training purposes only © Copyright - TURBOMECA - 2000
British or American Systems
0.10 Edition : December 2000
CONVERSION TABLE
Training Manual
ARRIEL 1
1 - INTRODUCTION - General information ...................................................... 1.2 - Training method ............................................................ 1.4 - Training aids .................................................................. 1.6 - Training programme .................................................... 1.8 to 1.12
For training purposes only © Copyright - TURBOMECA - 2000
1.1 Edition : December 2000
INTRODUCTION
ARRIEL 1
Training Manual
Training Centre
GENERAL INFORMATION
The Training Centre is located in one of the buildings of TURBOMECA's TARNOS factory.
«The power of knowledge» Adequate training is essential for obvious safety reasons, but also to reduce additional maintenance costs incurred by unjustified removals and excessive downtime.
TARNOS ....
5 kms north of the BAYONNE ANGLET - BIARRITZ district - Access by train (BAYONNE station), by plane (BIARRITZ-PARME airport), by road (A63 highway, TARNOS exit).
Address ......
TURBOMECA - 40220 TARNOS FRANCE
Telex ...........
570 042
Telephone ..
(33) 5 59 74 40 07 or 05 59 74 40 07
Fax ..............
(33) 5 59 74 45 15 or 05 59 74 45 15
E-mail .........
[email protected]
"Greater knowledge leads to greater efficiency".
Objectives of training The main objective is the acquisition of the knowledge required for the tasks to be achieved (know and know how). Further information is also communicated to widen the skill and the experience of the trainee.
Training approach - Performance based training according to task analysis, with classroom sessions, student involvement, practical work and troubleshooting techniques - Advanced training aids : training manual, Computer Aided Presentation (or overhead projection), multimedia courseware and demonstration mock-ups - Experienced and formally trained instructors - Courses are taught in English and French and, in special circumstances, in German and Spanish. For training purposes only © Copyright - TURBOMECA - 2000
The training centre is organized in order to answer to training demands (administration, training aids, instructors).
Training sites Training courses are also conducted in subsidiaries, in approved training centres and on site : - by a TURBOMECA qualified instructor, in certain subsidiaries and approved training centres - or by an instructor detached from TURBOMECA France, in our subsidiaries and in the clients' premises.
1.2 Edition : December 2000
INTRODUCTION
ARRIEL 1
Training Manual
TRAINING OBJECTIVES OF TRAINING
«The power of knowledge» Adequate training is essential for obvious safety reasons, but also to reduce additional maintenance costs incurred by unjustified removals and excessive downtime.
TRAINING APPROACH
"Greater knowledge leads to greater efficiency".
TRAINING CENTRE, TURBOMECA Tarnos (FRANCE)
FRANCE ATLANTIC OCEAN
TARNOS BAYONNE BORDES
SPAIN
PARIS
TRAINING SITES Training courses are also conducted in subsidiaries, in approved training centres and on site.
GENERAL INFORMATION For training purposes only © Copyright - TURBOMECA - 2000
1.3 Edition : December 2000
INTRODUCTION
Training Manual
ARRIEL 1
TRAINING METHOD Knowledge transmission process
Training method
The required knowledge is transmitted in such a manner that the student may use it efficiently in various circumstances.
The training method is a carefully balanced combination of : - Lecture
The training is conducted in accordance with a process which considers :
- Discussions
- A phase of explanation for understanding
- Exercises
- A phase of assimilation leading to the complete acquisition and long-term retention of the knowledge.
- Practical work.
Continuous checking of knowledge helps to ensure the information is assimilated. It is more a method of work than a testing in the traditional sense (refer to chapter 16).
For training purposes only © Copyright - TURBOMECA - 2000
1.4 Edition : December 2000
INTRODUCTION
ARRIEL 1
Training Manual
EXPLANATION
ASSIMILATION
1 KNOWLEDGE TRANSMISSION, PHASES :
2
MEDIA
3
4
- Explanation - Assimilation CHECKING OF KNOWLEDGE : - Continuous checking, treated in
1 - LECTURE
chapter 16
2 - EXERCISES 3 - DISCUSSIONS 4 - PRACTICAL WORK
INSTRUCTOR
STUDENT
KNOWLEDGE TRANSMISSION PROCESS
TRAINING METHOD
TRAINING METHOD For training purposes only © Copyright - TURBOMECA - 2000
1.5 Edition : December 2000
INTRODUCTION
Training Manual
ARRIEL 1
TRAINING AIDS Training manual
Multimedia courseware
The training manual is the basic source of information.
Interactive courseware is used to transmit information during a course.
It contains, in a teaching form, all required information and explanations, following a layout derived from the ATA 104 standard. Thus each subject is treated following a plan which allows the material to be adapted to different levels of training.
This multimedia system uses text, photos, illustrations, animation and video. Certain courses are available for sale on CD-ROM. This system with quick and easy access can be very efficient for maintaining knowledge levels in the workplace.
Typical plan : - General (function, position, main characteristics, main components) - Description (general and detailed)
However, only a course delivered by a TURBOMECA instructor or TURBOMECA qualified instructor would allow the issue of an engine maintenance authorisation card.
- Operation (phases, synthesis). Other technical publications are also used during a course.
Demonstration mock-ups are also used for component identification and maintenance procedures.
Computer Aided Presentation or overhead projection Computer Aided Presentation or overhead projection is used to display the illustrations contained in the training manual (the instructor's explanations follow the manual).
For training purposes only © Copyright - TURBOMECA - 2000
Demonstration mock-ups
Note : The information contained in the Training Aids must be considered for training purposes only.
1.6 Edition : December 2000
INTRODUCTION
Training Manual
ARRIEL 1
TRAINING MANUAL Note : The information contained in the Training Aids must be considered for training purposes only.
MULTIMEDIA COURSEWARE
COMPUTER AIDED PRESENTATION OR OVERHEAD PROJECTION
DEMONSTRATION MOCK-UPS
TRAINING AIDS For training purposes only © Copyright - TURBOMECA - 2000
1.7 Edition : December 2000
INTRODUCTION
Training Manual
ARRIEL 1
TRAINING PROGRAMME The course programme follows the manual. However, it should be noted that the "classroom sessions" alternate with periods devoted to demonstrations and practical work.
Examples of programme :
According to the contents, each session is mainly devoted to description and operation.
- Familiarization course
The engine maintenance aspect is mainly covered by the last part of the manual, which also deals with various elements related to maintenance (standard practices, technical publications, logistics and mainly fault analysis and fault finding).
The following pages provide examples of training programme :
- 1st line maintenance (O level) : preventive and corrective maintenance - 2nd line maintenance (I level) : modules, SRU - 3rd line maintenance (H level) : deep maintenance - 4th line maintenance (D level) : repair or overhaul.
For training purposes only © Copyright - TURBOMECA - 2000
1.8 Edition : December 2000
INTRODUCTION
Training Manual
ARRIEL 1
FAMILIARIZATION COURSE Objective : At the end of this course, the student will be able to describe the engine, to explain its principle of operation and to identify the main components of the engine and systems. Programme :
- Introduction
FIRST DAY
- General presentation of the engine - Engine description - Engine systems
- Engine systems (continued)
SECOND DAY
- Main aspects of maintenance - Revision - Checking of knowledge
For training purposes only © Copyright - TURBOMECA - 2000
1.9 Edition : December 2000
INTRODUCTION
Training Manual
ARRIEL 1
1st LINE MAINTENANCE COURSE (O LEVEL) : PREVENTIVE AND CORRECTIVE MAINTENANCE Objective : At the end of this course, the student will be able to identify the engine components, to describe and to explain the operation of the engine and its systems, to carry out 1st line maintenance procedures and to diagnose operating failures. Programme :
- Introduction - General
FIRST DAY - Engine presentation - Engine description - Oil system
SECOND DAY
- Air system - Fuel system - Control system - Measurement and indicating systems - Starting
THIRD DAY - Electrical system - Engine installation - Operating limitations and procedures - Various aspects of maintenance
FOURTH DAY - Maintenance procedures - Trouble shooting - Visits - Revision
FIFTH DAY - Examination - Miscellaneous questions
For training purposes only © Copyright - TURBOMECA - 2000
1.10 Edition : December 2000
INTRODUCTION
Training Manual
ARRIEL 1
2nd LINE MAINTENANCE COURSE (I LEVEL) : MODULES, SRU Objective : At the end of this course, the student will be able to identify the engine components, to carry out all the 2nd line maintenance procedures (mainly the removal/installation of modules and shop replaceable unit). Programme : The programme mainly includes practical work. This programme can be carried out after the 1st line maintenance programme.
- Introduction
FIRST DAY
- Revision (if this course is not conducted directly after the 1st line course) - Removal of modules - Removal of modules
SECOND DAY
- Inspection and check of modules - Installation of modules
THIRD DAY
For training purposes only © Copyright - TURBOMECA - 2000
- Inspection and checks after installation
1.11 Edition : December 2000
INTRODUCTION
Training Manual
ARRIEL 1
3rd LINE MAINTENANCE COURSE (H LEVEL) : DEEP MAINTENANCE Objective : At the end of the course, the trainee will be able to carry out the 3rd line maintenance procedures (deep maintenance). Programme :
- Introduction FROM 3 DAYS TO 3 WEEKS
- Definition of procedures - Practical work
4th LINE MAINTENANCE COURSE (D LEVEL) : REPAIR OR OVERHAUL Objective : At the end of the course, the trainee will be able to carry out the specific tasks regarding the engine and related to his skills (eg : control system, assembly, machining procedures...). Programme :
- Introduction SEVERAL WEEKS
- Definition of procedures - Practical work
For training purposes only © Copyright - TURBOMECA - 2000
1.12 Edition : December 2000
INTRODUCTION
Training Manual
ARRIEL 1
2 - POWER PLANT - General presentation .................................................... 2.2 - General description ...................................................... 2.4 - General operation ........................................................ 2.8 - Principle of adaptation to helicopter ........................... 2.12 - Main characteristics ..................................................... 2.14 - Design and development .............................................. 2.22 to 2.27
For training purposes only © Copyright - TURBOMECA - 2000
2.1 Edition : December 2000
POWER PLANT
Training Manual
ARRIEL 1
GENERAL PRESENTATION Function The power plant provides power by transforming the energy contained in the air and fuel into shaft power.
Main characteristics - Type : free turbine turboshaft engine, front power drive, external power transmission shaft - Concept : modular - Output shaft speed: 6000 RPM (at 100 %) (except the 1S1) - Mass ≈ 126 kg (277 lbs). The mass may vary according to the engine versions.
For training purposes only © Copyright - TURBOMECA - 2000
2.2 Edition : December 2000
POWER PLANT
ARRIEL 1
Training Manual
GAS
AIR
POWER FUEL
6000 RPM at 100 % (except 1S1)
POWER PLANT - Free turbine type - Modular - Mass ≈ 126 kg (277 lbs)
GENERAL PRESENTATION For training purposes only © Copyright - TURBOMECA - 2000
2.3 Edition : December 2000
POWER PLANT
Training Manual
ARRIEL 1
ENGINE GENERAL DESCRIPTION This description considers the main functional components of the engine.
Transmission shaft
Gas generator
- External shaft located in a protecting tube which connects the reduction gearbox to the accessory gearbox.
- Single stage axial compressor
Accessory gearbox
- Centrifugal compressor
- Gearbox containing the accessory drive train and the main power drive.
- Annular combustion chamber with centrifugal fuel injection - Two stage axial turbine.
Power turbine - Single stage axial turbine.
Exhaust pipe - Elliptical, axial exhaust pipe.
Reduction gearbox - Reduction gearbox comprising three helical toothed gears.
For training purposes only © Copyright - TURBOMECA - 2000
2.4 Edition : December 2000
POWER PLANT
ARRIEL 1
Training Manual
GAS GENERATOR Axial compressor
Centrifugal compressor
POWER TURBINE
Combustion chamber
EXHAUST PIPE
Turbine
ACCESSORY GEARBOX
MAIN POWER DRIVE
TRANSMISSION SHAFT
REDUCTION GEARBOX
ENGINE GENERAL DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
2.5 Edition : December 2000
POWER PLANT
Training Manual
ARRIEL 1
ENGINE SYSTEMS - GENERAL DESCRIPTION This part deals with the systems and functions of the engine.
Engine handling procedure Entirely automatic. Control lever to start, stop and for emergency control.
Oil system The oil system lubricates and cools the engine components.
Engine indicating
Dry sump system, synthetic oil, tank and cooling unit installed on the aircraft. Pressure, temperature and magnetic particles indications.
Rotation speeds. Gas temperature. Engine torque. Oil temperature and pressure. Miscellaneous indications.
Starting Air system Internal system to pressurise and cool engine internal parts. Accessory air supply system (ventilation of start injectors, engine control). Compressor bleed valve. Air supply to the aircraft.
Cranking by an electric starter. Ignition by High Energy. Manual control.
Electrical system Starting system. Indicating system. Overspeed system. Harness with two or three connectors according to version.
Fuel system Fuel supply through a gear type pump. Delivery through a metering unit and a valve. Start injection through 2 simple injectors. Main injection by a centrifugal wheel.
Control system
Engine installation - Interfaces designed for quick removal and installation of engine - Front and rear supports. Lifting rings
Constant power turbine rotation speed. Acceleration control. Miscellaneous protection systems.
- Miscellaneous equipment (air intake, exhaust, firewalls, transmission shaft, air bleeds, drains, fire protection).
Hydro-mechanical control system (with a mechanical back-up manual control) using fuel as hydraulic fluid.
For training purposes only © Copyright - TURBOMECA - 2000
2.6 Edition : December 2000
POWER PLANT
ARRIEL 1
Training Manual
AIR SYSTEM
FUEL SYSTEM
OIL SYSTEM
CONTROL SYSTEM
ENGINE INSTALLATION
FWD
ENGINE HANDLING PROCEDURE
ELECTRICAL SYSTEM ENGINE INDICATING STARTING
ENGINE SYSTEMS - GENERAL DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
2.7 Edition : December 2000
POWER PLANT
Training Manual
ARRIEL 1
GENERAL OPERATION This part deals with the basic operation of the engine.
Transmission shaft
Gas generator
- Transmission of the power from the reduction gearbox to the output shaft.
- Compression of the air in the axial and centrifugal compressors - Combustion of the fuel/air mixture in the annular combustion chamber - Gas expansion in the gas generator turbine which drives the compressors and engine accessories.
Accessory gearbox - Power take-off to drive the helicopter main gearbox - Drive of the accessories by the gas generator through a bevel gear, a vertical drive shaft and a gear train.
Power turbine - Expansion of the gas in the single stage turbine which drives the output shaft through the reduction gearbox.
Exhaust - Discharge overboard of the gas.
Reduction gearbox - Drive, at reduced speed, to the transmission shaft.
For training purposes only © Copyright - TURBOMECA - 2000
2.8 Edition : December 2000
POWER PLANT
ARRIEL 1
Training Manual
GAS GENERATOR COMPRESSION
COMBUSTION
POWER TURBINE EXPANSION
EXPANSION
GAS EXHAUST
AIR INLET
ACCESSORY GEARBOX ACCESSORY DRIVE
POWER DRIVE
FUEL
TRANSMISSION SHAFT
REDUCTION GEARBOX
FORWARD POWER TRANSMISSION
DRIVE SPEED REDUCTION
GENERAL OPERATION For training purposes only © Copyright - TURBOMECA - 2000
2.9 Edition : December 2000
POWER PLANT
Training Manual
ARRIEL 1
OPERATION - ADAPTATION This part deals with the parameters and the adaptation of the gas generator and power turbine.
Component adaptation For the engine operation, two functional assemblies can be considered :
Power turbine The power turbine operation is defined by the balance between the power received from the gas generator and the torque applied on the shaft, that is the torque C and the rotation speed N2.
Operation
- The gas generator which provides kinetic energy - The power turbine which transforms the kinetic energy into mechanical power on a shaft.
The operation is represented by the diagram which shows the power W, the rotation speeds N1 and N2 and the max torque limit C imposed by the mechanical transmission :
The two assemblies have different rotation speeds.
- The torque C is a function of the N2 rotation speed
Gas generator
- The power W is equal to the torque C multiplied by the angular velocity ω
The gas generator operation is defined by : - The air mass flow G (air flow which enters the engine)
- At constant N2 speed, the power is only a function of the torque
- The air pressure P2 and air temperature t2 at the centrifugal compressor outlet
- The engine parameters can be represented as a function of a reference parameter ; N1 for example.
- The fuel flow Q injected into the combustion chamber - The gas temperature TET at the turbine entry - The rotation speed N1 of the gas generator - The kinetic energy Ec supplied to the turbine.
For training purposes only © Copyright - TURBOMECA - 2000
2.10 Edition : December 2000
POWER PLANT
ARRIEL 1
Training Manual GAS GENERATOR
POWER TURBINE C (shaft torque)
N1 (rotation speed) Ec (kinetic energy)
G (air mass flow)
N2 rotation speed (constant) W (shaft power)
P2, t2 (compressor outlet pressure and temperature)
TET (turbine entry temperature) Q (fuel flow) ENGINE PARAMETERS
W
C
e qu
or xt
Isospeeds N1
Ma
W=C.ω ω=2 πN 60
G
0 /P P2 W
CH T TE
SFC
N2 Power W and speeds N1, N2
N2 Torque as a function of N2
N1
P2/P0: Compression ratio CH : Hourly fuel consumption SFC : Specific fuel consumption
COMPONENT ADAPTATION
OPERATION - ADAPTATION For training purposes only © Copyright - TURBOMECA - 2000
2.11 Edition : December 2000
POWER PLANT
Training Manual
ARRIEL 1
PRINCIPLE OF ADAPTATION TO HELICOPTER Power transmission
Installation requirements
The mechanical power supplied by the engine, is used to drive the helicopter rotors through a mechanical transmission.
The main functional requirements of the installation are : - Constant rotor rotation speed NR in all operating conditions
This power drives : - Max torque limit C (usually imposed by the aircraft transmission)
- The main rotor (approximately 82 %) - The tail rotor (approximately 10 %)
- Complete engine protection (N1 and N2 speeds, TET temperature, compressor surge ∆Q/∆t…)
- The main gearbox (approximately 8 %).
- Good load sharing (in the case of a multi-engine configuration).
Twin engine configuration In a twin engine configuration, the engines are installed at the rear of the main gearbox. The power turbines of the two engines are mechanically connected to the main gearbox which drives the rotors (main and tail rotors).
For training purposes only © Copyright - TURBOMECA - 2000
Adaptation to requirements To have a constant rotation speed of the power turbine N2, the power supplied by the engine is automatically adapted to the demand. This adaptation is ensured by the control system which meters the fuel flow injected into the combustion chamber so as to deliver the required power (variation of the gas generator N1 rotation speed) while keeping the engine within its operational limits.
2.12 Edition : December 2000
POWER PLANT
ARRIEL 1
Training Manual MAIN ROTOR 82%
MAIN GEARBOX
ENGINE 2
ENGINE 100%
TAIL ROTOR
ENGINE 1 MAIN GEARBOX 8%
TAIL ROTOR 10%
MAIN ROTOR
POWER TRANSMISSION
TWIN ENGINE CONFIGURATION
N2
W - Power
NR (constant) N1, N2, TET,
W
Q/ t N2 N2
time Max torque C
t
INSTALLATION REQUIREMENTS
ADAPTATION TO REQUIREMENTS
PRINCIPLE OF ADAPTATION TO HELICOPTER For training purposes only © Copyright - TURBOMECA - 2000
2.13 Edition : December 2000
POWER PLANT
Training Manual
ARRIEL 1
MAIN CHARACTERISTICS (1) Mass, dimensions and identification Mass (dry) - Engine with specific equipment and without fluid : ≈ 126 kg (277 lbs) it may vary according to the engine version. Dimensions - Engine : • Length : 1166 mm (45.5 inches) • Width : 465.5 mm (18.2 inches) • Height : 609 mm (23.8 inches) Identification - Each module has an identification plate. - The identification plate of the complete engine is located on the module 1 protection tube.
For training purposes only © Copyright - TURBOMECA - 2000
2.14 Edition : December 2000
POWER PLANT
ARRIEL 1
Training Manual
609 mm (23.8 inches)
1166 mm (45.5 inches)
POWER PLANT MASS (dry and with specific equipment) ≈ 126 kg (277 lbs)
465,5 mm (18.2 inches)
TURBOMECA
64320 BORDES - FRANCE Brevets SZYDLOWSKI
ARRIEL
Module référence
TURBOMECA
64320 BORDES - FRANCE Brevets SZYDLOWSKI
ARRIEL Date Contrôles Certificat
P
kW
MASS, DIMENSIONS AND IDENTIFICATION
MAIN CHARACTERISTICS (1) For training purposes only © Copyright - TURBOMECA - 2000
2.15 Edition : December 2000
POWER PLANT
Training Manual
ARRIEL 1
MAIN CHARACTERISTICS (2) Operational ratings The operational ratings correspond to given conditions of helicopter operation. The ratings are generally defined under determined speed and temperature conditions.
• Super contingency power (SCP or 1 min) : extreme rating used in place of max. contingency on some versions. Its limited use requires particular maintenance practices.
The following operational ratings are considered : - AEO ratings (All Engines Operating) : • Max take-off power (T/O) : max rating which can be used during take-off. This rating has a limited duration (5 minutes continuous) • Max continuous power (MCP) : rating which can be used without time limitation (this does not imply that it is used permanently) - OEI ratings (One Engine Inoperative) : • Max contingency power (MCP) : rating which can be used in the case of one engine failure during take-off or landing. This rating is usually limited to a period of continuous operation : 2 minutes 30 seconds. • Intermediate contingency power (ICP) : rating which can be used in the case of one engine failure in flight. This rating is usually limited to 30 minutes or unlimited
For training purposes only © Copyright - TURBOMECA - 2000
2.16 Edition : December 2000
POWER PLANT
ARRIEL 1
Training Manual
W
A.E.O. RATINGS
O.E.I. RATINGS MAX CONTINGENCY POWER (MCP)
T/O
5 minutes
MAX CONTINUOUS POWER (MCP)
2 minutes 30 seconds
SCP
INTER CONTINGENCY POWER (ICP)
unlimited
1 minute
OPERATIONAL RATINGS
MAIN CHARACTERISTICS (2) For training purposes only © Copyright - TURBOMECA - 2000
2.17 Edition : December 2000
POWER PLANT
Training Manual
ARRIEL 1
MAIN CHARACTERISTICS (3) Factors which affect performance
Evolution of specific fuel consumption (SFC)
The engine performance is affected by flight and atmospheric conditions. The effects of these conditions are usually indicated by graphs which show the evolution of performance as a function of parameters likely to modify it (example : atmospheric temperature t0 and pressure altitude Z).
The specific fuel consumption varies with the operating conditions.
Power evolution (W)
The specific fuel consumption decreases, when the power (W) increases (better thermal efficiency). For this type of installation, the specific fuel consumption which is mostly considered is that at the cruise rating.
The power delivered by the engine decreases when the altitude (Z) and the temperature (t0) increase (this is due to the air mass flow decrease through the engine). The conditions of the engine installation on the aircraft should also be noted (miscellaneous losses due to installation) as well as the flight conditions (essentially the aircraft speed). Evolution of fuel consumption (CH) The fuel consumption decreases at a given rating, when the altitude (Z) and the temperature (t0) increase.
For training purposes only © Copyright - TURBOMECA - 2000
2.18 Edition : December 2000
POWER PLANT
ARRIEL 1
Training Manual
W (kW)
CH
Z=
Z=
600 0m
0m
Z=
(0
Z=
(19
680
-
+ 15 °C (59 °F)
0m
ft)
ft)
60 00
m
(0
ft)
(19 68 0f t)
t0
t0
EVOLUTION OF POWER (W)
EVOLUTION OF FUEL CONSUMPTION (CH)
SFC (g/kW.h) A = Cruise condition A
W (kW)
EVOLUTION OF SPECIFIC FUEL CONSUMPTION (SFC)
FACTORS WHICH AFFECT PERFORMANCE
MAIN CHARACTERISTICS (3) For training purposes only © Copyright - TURBOMECA - 2000
2.19 Edition : December 2000
POWER PLANT
Training Manual
ARRIEL 1
MAIN CHARACTERISTICS (4) Engine operating envelope
Limitations
The engine is designed to operate within a given climatic envelope.
The engine operates within various limitations : rotation speeds, temperatures, pressures…
The envelope is defined by :
Refer to corresponding chapters and official publications.
- The atmospheric temperature t0 - The pressure altitude Zp - And lines of standard atmosphere. Flight envelope The flight envelope is illustrated by the t0/Zp diagram and the lines of standard atmosphere, with the max tropical zone and the min arctic zone. Engine starting envelope The starting and relight envelope is defined in the same way, but it is also affected by the specifications of oil and fuel used, and sometimes by particular procedures.
For training purposes only © Copyright - TURBOMECA - 2000
2.20 Edition : December 2000
POWER PLANT
ARRIEL 1
Training Manual
ISA - International standard atmosphere
*
Max - Tropical zone t0
Min - Arctic zone
°C
+50°
t0
Depending on oil and fuel specifications. Can also require special operating procedures.
°C
+50°
Max
+15°
Max
ISA Min
-50°
-500 0
ISA
* -50°
Min
Zp
FLIGHT ENVELOPE
Zp
STARTING ENVELOPE
ENGINE OPERATING ENVELOPE
MAIN CHARACTERISTICS (4) For training purposes only © Copyright - TURBOMECA - 2000
2.21 Edition : December 2000
POWER PLANT
Training Manual
ARRIEL 1
DESIGN AND DEVELOPMENT (1) Principles of design
Development steps
The engine is designed to meet the aircraft propulsion requirements and particularly for the new generation of helicopters.
- Certification in 1977 by the French Authorities. - The first production engine was delivered in January 1978.
The engine design is based on : - ARRIEL engines will be in service far beyond 2000. - An optimised thermodynamic cycle which gives high performance - Simple and reliable components giving a good supportability, and a good maintainability to reduce the costs.
Engine development
- Example : ARRIEL 1A2. ARRIEL - According to TURBOMECA tradition : name of a Pyrenean lake. - 1 : Type
The ARRIEL engine is based on research and experience of other engines : - First generation engines : ASTAZOU, ARTOUSTE and TURMO
For training purposes only © Copyright - TURBOMECA - 2000
Engine designation
- A : Variant - 2 : Version.
2.22 Edition : December 2000
POWER PLANT
ARRIEL 1
Training Manual
Engine design
Optimised thermodynamic cycle
ARRIEL 1 650 - 700 Shp
Simple and reliable components
Supportability Maintainability
ASTAZOU 500 - 1000 Shp ARTOUSTE 400 - 850 Shp
High performance
Cost reduction
TURMO 1500 - 1600 Shp
ENGINE DEVELOPMENT
PRINCIPLES OF DISIGN In service far beyond 2000
STEPS 1978
ARRIEL lake
First production
1977 Certification
TIME
Example : ARRIEL 1A2 ARRIEL : Name of a Pyrenean lake for the turboshaft engines 1 : Type A : Variant 2 : Version
ENGINE DESIGNATION
DEVELOPMENT STEPS
DESIGN AND DEVELOPMENT (1) For training purposes only © Copyright - TURBOMECA - 2000
2.23 Edition : December 2000
POWER PLANT
Training Manual
ARRIEL 1
DESIGN AND DEVELOPMENT (2) Application
Engine fleet status
The ARRIEL 1 is presently destined for the following helicopters : Squirrel and Dolphin (EUROCOPTER), A 109 K2 (Agusta), S 76 (Sikorsky), BK 117 (MBB).
At the beginning of ..., we can note : - Number of ARRIEL 1 engines produced : ................ - Number of ARRIEL 1 engines in operation : ...........
Maintenance concept
- Operating hours : .......................................................
The ARRIEL is designed to provide a high availability rate with reduced maintenance costs. The main aspects of the maintenance concept are the following : - Full modularity - Good accessibility - Reduced removal and installation times - "On condition" monitoring - High initial TBO - Low cost of ownership : • Low production costs • Durability (TBO, defined and proven life limits) • High reliability • Low fuel consumption.
For training purposes only © Copyright - TURBOMECA - 2000
2.24 Edition : December 2000
POWER PLANT
ARRIEL 1
Training Manual
PT-HALB
S 76 (SIKORSKY)
SQUIRREL (EUROCOPTER)
CONOCO
G-BKXD SA 365 N
Management Aviation
BK 117 (MBB)
DOLPHIN (EUROCOPTER)
MAINTENANCE CONCEPT REGA I-RAIE
- Actual modularity
A 109 K2 (AGUSTA)
- Good accessibility - Reduced time of removal and installation
FLEET STATUS
- Condition monitoring
- Arriel 1 engines produced
- High initial TBO
- Arriel 1 engines in service
- Low cost of ownership
- Operating hours
DESIGN AND DEVELOPMENT (2) For training purposes only © Copyright - TURBOMECA - 2000
2.25 Edition : December 2000
POWER PLANT
Training Manual
ARRIEL 1
DESIGN AND DEVELOPMENT (3) ARRIEL family The great diversity of ARRIEL 1 operation is represented in the table below including : - Certification year - Version - Helicopter type - Engine power - Differences
For training purposes only © Copyright - TURBOMECA - 2000
2.26 Edition : December 2000
POWER PLANT
ARRIEL 1
Training Manual
ARRIEL 1A
DOLPHIN 365 C
651 shp (2' 30")
ARRIEL 1B
SQUIRREL AS 350 B
640 shp (5')
ARRIEL 1A1
DOLPHIN 365 C1
667 shp (2' 30")
max N1, W and flight envelope increased
ARRIEL 1A2
DOLPHIN 365 C2
670 shp (2' 30")
New centrifugal compressor
1980 ARRIEL 1C
DOLPHIN 365 N DOLPHIN 365 C3
700 shp (2' 30")
Gas generator turbine with fir-tree mounted blades, new combustion chamber, increased N2
1982 ARRIEL 1C1
DOLPHIN 365 N1
723 shp (2' 30")
1983 ARRIEL 1M
DOLPHIN 365 F
777 shp (2' 30")
ARRIEL 1K
AGUSTA A 109 K
723 shp (2' 30")
ARRIEL 1D
SQUIRREL AS 350 B1/L1
683 shp (5')
ARRIEL 1S
SIKORSKY S 76 A
772 shp (2' 30")
1977
1979
1985
1986
ARRIEL 1 MN DOLPHIN 365 F ARRIEL 1 D1 SQUIRREL AS 350 B2/L2 1988 ARRIEL 1 M1 PANTHER 365 K ARRIEL 1 C2 DOLPHIN 365 N2
777 shp (2' 30")
1991 ARRIEL 1E
760 shp (2' 30")
BK 117
Free wheel, long exhaust pipe
Turbine materials, power turbine bearing modified 1 minute rating Adaptation to Agusta aircraft Max fuel flow limit Free wheel, power turbine support and exhaust pipe of the 1B Sealed turbine blades Adaptation to Sikorsky aircraft (support, transmission, systems...).
1S standard. Adaptation to the BK 117
ARRIEL FAMILY
DESIGN AND DEVELOPMENT (3) For training purposes only © Copyright - TURBOMECA - 2000
2.27 Edition : December 2000
POWER PLANT
Training Manual
ARRIEL 1
3 - ENGINE - Engine ............................................................................. - Axial compressor ........................................................... - Gas generator HP section.............................................. • Centrifugal compressor ............................................................. • Combustion chamber ................................................................. • Gas generator turbine ................................................................ - Power turbine................................................................. - Exhaust pipe................................................................... - Reduction gearbox......................................................... - Transmission shaft and accessory gearbox ................. • Twin-engine transmission shaft................................................. • Single engine transmission shaft ............................................... • Accessory gearbox ......................................................................
For training purposes only © Copyright - TURBOMECA - 2000
3.2 3.8 3.14 3.16 3.22 3.28 3.34 3.40 3.42 3.48 3.50 3.52 3.54 to 3.61 3.1
Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
ENGINE - GENERAL Function
Main components
The engine transforms the energy in the air and fuel into mechanical power on a shaft.
- Gas generator
Main characteristics - Type : Free turbine with forward drive via an external shaft - Power class : from 480 to 560 kW (650 to 760 Shp) according to version - Specific fuel consumption : according to version (see maintenance manual) - Gas generator speed (N1) : approximately 52000 RPM at 100 % • Direction of rotation : anti-clockwise
• Axial compressor (module M02) • HP section (module M03) - Centrifugal compressor - Annular combustion chamber - Two stage turbine - Single stage power turbine (module M04) - Exhaust pipe - Reduction gearbox (module M05) - Transmission shaft and accessory gearbox (module M01).
- Power turbine speed (N2) : 41586 RPM at 100 % • Direction of rotation : clockwise - Output shaft speed : 6000 RPM at 100 % (except the 1S1) • Direction of rotation : clockwise
Note : Direction of rotation given viewed from the rear.
For training purposes only © Copyright - TURBOMECA - 2000
3.2 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
AXIAL COMPRESSOR
CENTRIFUGAL COMPRESSOR
COMBUSTION CHAMBER
TURBINE
POWER TURBINE
EXHAUST PIPE
Type : Free turbine Power class : From 480 to 560 kW (650 to 760 Shp) Specific fuel consumption : According to version Gas generator speed (N1) : Approximately 52000 RPM at 100% (ACW) Power turbine (N2) : 41586 RPM at 100% (CW) Output shaft : 6000 RPM at 100% (CW) except 1S1 TRANSMISSION SHAFT AND ACCESSORY GEARBOX
REDUCTION GEARBOX
ENGINE - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
3.3 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
ENGINE - DESCRIPTION Main components
Modular layout
- Gas generator • Axial compressor • Centrifugal compressor • Combustion chamber • Two stage turbine
The engine comprises 5 modules : - Module M01 : Transmission shaft and accessory gearbox - Module M02 : Axial compressor - Module M03 : Gas generator HP section
- Single stage power turbine
- Module M04 : Power turbine
- Exhaust pipe
- Module M05 : Reduction gearbox.
- Reduction gearbox - Transmission shaft
Note : A module is a sub-assembly which can be replaced on-site (2nd line maintenance) without complex tooling or adaptation work.
- Accessory gearbox.
Note : Some accessories are provided with each module.
Each module has an identification plate. The engine identification plate is fitted on the right hand side of the M01 protection tube.
In this manual, those components are dealt with in the chapters corresponding to the main systems.
For training purposes only © Copyright - TURBOMECA - 2000
3.4 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
MODULE M02 AXIAL COMPRESSOR
MODULE M04 POWER TURBINE MODULE M03 GAS GENERATOR HIGH PRESSURE SECTION
MODULE M01 TRANSMISSION SHAFT AND ACCESSORY GEARBOX
MODULE M05 REDUCTION GEARBOX
ENGINE - DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
3.5 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
ENGINE - OPERATION The engine provides power by transforming the energy in the air and fuel into mechanical energy on a shaft. The process comprises compression, combustion, expansion and the transmission of the power.
Expansion - The gas expands in the gas generator turbine which extracts the energy required to drive the compressor and accessories (N1 rotation : 52000 RPM ACW) During this phase the pressure and temperature of the gas drop, whilst the velocity increases.
Compression The ambient air is compressed by an axial supercharging compressor and a centrifugal compressor. This phase is essentially characterised by the air flow (approx. 2.5 kg/s ; 5.5 lbs/sec.) and the compression ratio (approx. 8.2).
Combustion
- There is a further expansion in the power turbine which extracts most of the remaining energy to drive the output shaft (N2 rotation : 41586 RPM CW) After the power turbine the gas is discharged overboard via the exhaust pipe, giving a slight residual thrust.
Power transmission
The compressed air is admitted into the combustion chamber, mixed with the fuel and burnt in a continuous process.
The power is transmitted forward by a reduction gearbox and an external transmission shaft.
The air is divided into two flows : Note : The engine reference stations are :
- A primary flow for combustion - A secondary flow for cooling the gas. This phase is essentially characterised by the temperature rise, flame temperature approx. 2500 °C and turbine entry temperature of approx. 1100 °C, and a pressure drop of about 4 %.
For training purposes only © Copyright - TURBOMECA - 2000
0 1 1' 2 3 4 5
-
Air intake Axial compressor inlet Axial compressor outlet Centrifugal compressor outlet Turbine inlet Gas generator turbine outlet Power turbine outlet.
3.6 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
Primary air Residual thrust ≈ 15 daN (33 lbs)
Gas Secondary air
AIR FLOW 2.5 kg/s (5.5 lbs/s)
EXHAUST
2500 (4532) 0
1
1'
2
3
101,3 P kPa (14.7) (PSI) t °C (°F) V
800 (116)
600 (1080)
POWER TRANSMISSION (power transmitted forward by a reduction gearbox and an external shaft)
300 (43.5)
320 (608) 108 (15.7)
65 (149)
15 (59)
AIR INLET
5
1125 (2057) 880 (1616)
820 (118.9) 160 (23.2)
4
Values given for information at a given reference rating COMPRESSOR
COMBUSTION CHAMBER
COMPRESSION
COMBUSTION
TURBINES EXPANSION
ENGINE - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
3.7 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
AXIAL COMPRESSOR - GENERAL Function
Main components
The axial compressor ensures a first stage of compression to supercharge the centrifugal compressor.
- Rotating components
Position - At the front of the engine (the axial compressor assembly forms the module M02).
• Air inlet cone • Axial wheel, shaft, bearing and accessory drive shaft - Stationary components • Diffuser • Casing.
Main characteristics - Type : axial transonic supercharging compressor - Air flow : 2.5 kg/sec (5.5 lbs/sec.) - Outlet pressure : 160 kPa (23.2 PSI) - Outlet temperature : 65 °C (149 °F)
For training purposes only © Copyright - TURBOMECA - 2000
3.8 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
WHEEL
DIFFUSER
SHAFT
Type : Axial transonic supercharging compressor Air flow : 2.5 kg/s (5.5 lbs/sec.) Outlet pressure : 160 kPa (23.2 PSI) Outlet temperature : 65 °C (149 °F)
AIR INLET CONE
BEARING
CASING
ACCESSORY DRIVE SHAFT
AXIAL COMPRESSOR - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
3.9 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
AXIAL COMPRESSOR - DESCRIPTION The axial compressor module (module M02) includes rotating and stationary components.
Stationary components The stationary assembly includes the diffuser and the casing.
Rotating components The rotating assembly comprises the shaft, the inlet cone, the axial wheel and the accessory drive gear. The inlet cone, made of light alloy, is screwed into the front of the shaft. The compressor wheel is fitted to the shaft. It is a disc made of titanium alloy with blades cut from the solid. The shaft connects the centrifugal compressor to the axial compressor. The shaft is secured by a nut onto the tie-bolt. This assembly is supported by two bearings : a ball bearing at the rear of the axial compressor and a ball bearing in a flexible cage at the front of the centrifugal compressor.
The diffuser (diffuser-straightener) welded inside the casing has two rows of steel stator vanes which form a divergent passage for the air. The casing, made of steel, houses all the compressor components. It has a front flange for the mounting of the air inlet duct and a rear flange for the attachment to the module M03. The inner hub of the casing provides the location for the bearings. The casing has a boss for the mounting of the compressor bleed valve. The module identification plate is located at the front of the casing.
The accessory drive consists of a bevel gear on the shaft which drives a vertical drive shaft.
For training purposes only © Copyright - TURBOMECA - 2000
3.10 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual WHEEL
BEARING
DIFFUSER
NUT
TIE-BOLT IDENTIFICATION PLATE
SHAFT
ACCESSORY DRIVE GEAR INLET CONE
CASING CASING DIFFUSER WHEEL SHAFT
INLET CONE
AXIAL COMPRESSOR - DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
3.11 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
AXIAL COMPRESSOR - OPERATION The axial compressor ensures a first stage of compression in order to supercharge the centrifugal compressor.
Compressor air flow The ambient air, admitted through the air intake duct and guided by the inlet cone, flows between the blades of the axial compressor. The air is discharged rearwards with an increased axial velocity. The air then flows through the vanes of the diffuser. Due to the divergent passage, the air velocity is reduced and the pressure increased.
Operating parameters In standard conditions, the air flow is 2.5 kg/s (5.5 lbs/ sec.), the outlet pressure 160 kPa (23.2 PSI) and the outlet temperature 65 °C (149 °F). The rotation speed of the axial compressor wheel is obviously the gas generator speed. In order to avoid compressor surge, a valve discharges overboard a certain amount of air in certain operating conditions (refer to "AIR SYSTEM" chapter for further details on the compressor bleed valve).
The flow is straightened by the stator vanes before being admitted, through an annular duct, to the centrifugal compressor.
For training purposes only © Copyright - TURBOMECA - 2000
3.12 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
ACCELERATION OF THE AIR
COMPRESSION AND STRAIGHTENING OF THE AIR
P1' : AIR DISCHARGED THROUGH THE COMPRESSOR BLEED VALVE
ADMISSION OF AMBIENT AIR (2.5 kg/s / 5.5 lbs/sec.)
SUPERCHARGING OF THE CENTRIFUGAL COMPRESSOR (160 kPa / 23.2 PSI ; 6 °C / 149 °F)
AXIAL COMPRESSOR - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
3.13 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
GAS GENERATOR HP SECTION Function
Main components
The HP section of the gas generator ensures the phases of compression (second stage), combustion and expansion (first stage).
- Centrifugal compressor
It provides the energy necessary to drive the power turbine.
- Turbine.
Position - It forms the module M03 and is mounted between the module M02 (axial compressor) and the module M04 (power turbine).
- Combustion chamber
Note : The power turbine nozzle guide vane belongs to the module M03.
Main characteristics - Identification plate on the turbine casing. For further information, refer to following pages.
For training purposes only © Copyright - TURBOMECA - 2000
3.14 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
COMBUSTION CHAMBER
TURBINE
IDENTIFICATION PLATE
CENTRIFUGAL COMPRESSOR
GAS GENERATOR HP SECTION For training purposes only © Copyright - TURBOMECA - 2000
3.15 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
CENTRIFUGAL COMPRESSOR - GENERAL Function
Main components
The compressor supplies the compressed air required for combustion.
- Rotating components (wheel, shaft, bearing) - Stationary components (diffusers, casings).
Supercharged by the axial compressor, it ensures the second stage of compression.
Position - At the front of the module M03.
Main characteristics - Type : centrifugal, high efficiency - Air flow : 2.5 kg/s (5.5 lbs/sec.) - Compression ratio : 5.4/1 (global : 8.2/1) - Outlet temperature : 320 °C (608 °F)
For training purposes only © Copyright - TURBOMECA - 2000
3.16 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
CASINGS
DIFFUSERS
BEARING
Type : Centrifugal, high efficiency TIE-BOLT
Air flow : 2.5 kg/s (5.5 lbs/sec.) Compression ratio : 5.4 / 1 (global : 8.2 / 1) Outlet temperature : 320 °C (608 °F) CENTRIFUGAL WHEEL
CENTRIFUGAL COMPRESSOR - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
3.17 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
CENTRIFUGAL COMPRESSOR DESCRIPTION The centrifugal compressor assembly includes rotating and stationary components.
Rotating components The main rotating component is the centrifugal wheel. The wheel has blades which are cut from the solid in a disc of titanium alloy and has a labyrinth seal on the rear shaft. The front part of the wheel connects to the axial compressor shaft. The rear part has a curvic-coupling for the mounting of the centrifugal fuel injection wheel. The rotating components are secured by a tie-bolt.
For training purposes only © Copyright - TURBOMECA - 2000
Stationary components The stationary assembly includes the diffusers and the casings. The compressor front cover is mounted inside the external casing by means of a ring of bolts which also secure the axial compressor casing, the front cover and the diffuser assembly. The external casing of the centrifugal compressor is bolted to the turbine casing. It is provided with several bosses for air bleeds. The diffuser assembly comprises the first stage diffuser (radial stator vanes) and the second stage diffuser (axial stator vanes). The diffuser back-plate forms a partition between the compressor and the combustion chamber. The fuel injection system is mounted on its inner hub.
3.18 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
1st STAGE DIFFUSER WHEEL
2nd STAGE DIFFUSER
DIFFUSER ASSEMBLY LABYRINTH SEAL
COMPRESSOR FRONT COVER
BEARING TIE-BOLT
CURVIC COUPLING WHEEL FUEL INJECTION SYSTEM EXTERNAL CASING
EXTERNAL CASING
COMPRESSOR FRONT COVER
CENTRIFUGAL COMPRESSOR - DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
3.19 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
CENTRIFUGAL COMPRESSOR OPERATION The centrifugal compressor ensures the main stage of compression.
Compressor air flow The air supplied by the axial compressor flows between the blades of the centrifugal compressor. The air pressure increases due to the divergent passage between the blades and the air velocity increases due to the centrifugal flow.
Operating parameters In standard conditions, the air flow is 2.5 kg/s (5.5 lbs/ sec.), the compression ratio 5.4 (total 8.2), the outlet pressure 820 kPa (118.9 PSI) and the outlet temperature 320 °C (608 °F). The compressor wheel rotation speed is obviously the gas generator speed.
The air leaves the tips of the blades at very high velocity and then flows through the first stage diffuser vanes where the velocity is decreased and the pressure is increased. The air then passes through an elbow and the flow becomes axial. In the second stage diffuser, the velocity is again decreased and the pressure increased. The air is then admitted into the combustion chamber.
For training purposes only © Copyright - TURBOMECA - 2000
3.20 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
COMPRESSION OF THE AIR IN THE DIFFUSERS ACCELERATION AND COMPRESSION OF THE AIR
AIR ADMITTED INTO THE COMBUSTION CHAMBER (820 kPa / 118.9 PSI ; 320 °C / 608 °F)
SUPERCHARGING BY THE AXIAL COMPRESSOR (2.5 kg/s / 5.5 lbs/sec. ; 160 kPa / 23.2 PSI)
CENTRIFUGAL COMPRESSOR - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
3.21 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
COMBUSTION CHAMBER - GENERAL Function
Main components
The combustion chamber forms an enclosure in which the air-fuel mixture is burnt.
- Outer part (front swirl plate and mixer unit) - Inner part (rear swirl plate and shroud)
Position
- Fuel injection system
- Central section of the gas generator.
- Turbine casing.
Main characteristics - Type : annular with centrifugal fuel injection - Overall fuel-air ratio : 1/45 - Turbine inlet temperature : 1125 °C (2057 °F).
For training purposes only © Copyright - TURBOMECA - 2000
3.22 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
OUTER PART Front swirl plate
Mixer unit
INNER PART Rear swirl plate
Shroud
Type : Annular with centrifugal fuel injection Overall fuel-air ratio : 1/45 Turbine inlet temperature : 1125 °C (2057 °F)
FUEL INJECTION SYSTEM
TURBINE CASING
COMBUSTION CHAMBER - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
3.23 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
COMBUSTION CHAMBER - DESCRIPTION The combustion chamber assembly includes the outer part, the inner part, the turbine casing and the fuel injection system.
Outer part The outer part includes the front swirl plate and the mixer unit. The front swirl plate is provided with calibrated orifices for the passage of primary air ; it is secured to the mixer unit with special rivets. The mixer unit is provided with calibrated orifices for the passage of dilution air ; it is bolted to the rear flange of the turbine casing. It includes the dilution tubes.
Inner part
Turbine casing The casing houses the combustion chamber and the turbine. It has various bosses and, particularly the boss for the combustion chamber drain valve at the bottom of the casing.
Fuel injection system The main fuel injection system includes : the fuel inlet union, the inner fuel tube, the fuel distributor and the centrifugal injection wheel. The injection wheel is mounted by means of curvic couplings between the compressor and the turbine shaft (refer to "FUEL SYSTEM" chapter for further details on the fuel injection system).
The inner part includes the rear swirl plate and the shroud. The rear swirl plate is provided with calibrated orifices for the passage of primary air. The shroud, integral with the rear swirl plate surrounds the shaft ; it is bolted to the turbine nozzle guide vane.
Note : The two parts are made of special alloy. The calibrated orifices are drilled using the electron beam process.
For training purposes only © Copyright - TURBOMECA - 2000
3.24 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
FRONT SWIRL PLATE
TURBINE CASING
DILUTION TUBE MIXER UNIT REAR SWIRL PLATE
REAR SWIRL PLATE SHROUD
SHROUD
MIXER UNIT
Curvic-coupling
Drain valve
FRONT SWIRL PLATE FUEL INJECTION SYSTEM
TURBINE CASING
INJECTION WHEEL
COMBUSTION CHAMBER - DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
3.25 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
COMBUSTION CHAMBER - OPERATION The combustion chamber forms an enclosure in which the fuel - air mixture is burnt.
Combustion chamber flow In the combustion chamber, the compressed air is divided into two flows : a primary air flow mixed with the fuel for combustion and a secondary air flow (or dilution air flow) for cooling of the burnt gases.
Secondary air The secondary air (or dilution air) flows through the orifices of the mixer unit and the dilution tubes. It is calibrated to obtain flame stability, cooling of the burnt gases, and distribution of temperature on the turbine. Gas
Primary air
The gas produced by the combustion is directed into the turbine nozzle guide vane.
One part flows through the orifices of the front swirl plate.
Operating parameters
A second part flows through the hollow vanes of the turbine nozzle guide vane (cooling of the vanes) and through the orifices of the rear swirl plate.
The fuel-air ratio for combustion is approximately 1/15 ; the total ratio is approximately 1/45.
The primary air is mixed with the fuel sprayed by the injection wheel. The combustion occurs between the two swirl plates. The flame temperature reaches approximately 2500 °C (4532 °F).
For training purposes only © Copyright - TURBOMECA - 2000
The pressure drop in the combustion chamber is approximately 4 %. The turbine inlet temperature (at design point) is approximately 1125 °C (2057 °F).
3.26 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual COMPRESSED AIR (820 kPa / 118.9 PSI ; 320 °C / 608 °F)
Primary air (combustion) Secondary air (cooling of burnt gases) Burnt gases
GAS FLOW TO THE TURBINE (1125 °C / 2057 °F)
FUEL INJECTION
COMBUSTION (2500 °C / 4532 °F) (pressure loss : 4 %)
COMBUSTION CHAMBER - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
3.27 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
GAS GENERATOR TURBINE - GENERAL Function
Main components
The turbine extracts sufficient energy from the gas flow to drive the compressors and the accessories.
- Rotating components (wheels, shafts, bearing)
Position
- Stationary components (nozzle guide vanes, containment shield, casing).
- At the rear of the gas generator.
Main characteristics - Type : two stage axial - Turbine inlet temperature : 1125 °C (2057 °F) - Turbine outlet temperature : 880 °C (1616 °F) - N1 speed ≈ 52000 RPM (100 %) ACW
For training purposes only © Copyright - TURBOMECA - 2000
3.28 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
NOZZLE GUIDE VANES
WHEELS
BEARING
Type : Two stage axial Turbine inlet temperature : 1125 °C (2057 °F) Turbine outlet temperature : 880 °C (1616 °F) N1 speed 52000 RPM (100%) ACW
CONTAINMENT SHIELD
CASING
SHAFTS
GAS GENERATOR TURBINE - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
3.29 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
GAS GENERATOR TURBINE DESCRIPTION The gas generator turbine assembly includes rotating components and stationary components.
The stationary components are the turbine nozzle guide vanes, the containment shield, the turbine casing and the diffuser casing.
Rotating components The main rotating components are the turbine wheels. The wheels consist of either a disc and fir-tree mounted blades or blades cut from the solid. The front wheel is coupled by curvic-couplings to the turbine shaft and to the second stage wheel. The rear wheel is coupled to a stub shaft by a curvic-coupling. The stub shaft is supported by a roller bearing. Rotating labyrinths provide sealing. A tie-bolt secures the rotating assembly.
For training purposes only © Copyright - TURBOMECA - 2000
Stationary components
The first stage nozzle guide vane includes a row of hollow vanes. It is mounted on the combustion chamber. The second stage nozzle guide vane includes a row of vanes mounted in a ring. The containment shield provides containment in case of blade failure. The turbine casing forms the housing of turbines and combustion chamber. The diffuser casing connects the gas generator and the power turbine and its hub contains the housing for the gas generator rear bearing. At the rear it houses the power turbine nozzle guide vane.
3.30 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual NOZZLE GUIDE VANES
TURBINE SHROUD
TURBINE WHEELS
DIFFUSER CASING
TURBINE CONTAINMENT SHIELD 2nd STAGE TURBINE WHEEL
BEARING (roller)
1st STAGE TURBINE WHEEL TURBINE SHROUD
TIE-BOLT
DIFFUSER CASING 2nd STAGE NOZZLE GUIDE VANE
REAR SHAFT 1st STAGE NOZZLE GUIDE VANE FRONT SHAFT FRONT SHAFT
TURBINE CASING
CONTAINMENT SHIELD
Curvic-coupling
GAS GENERATOR TURBINE - DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
3.31 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
GAS GENERATOR TURBINE - OPERATION The gas generator turbine transforms the gas energy into mechanical power to drive the compressors and various accessories.
Operating parameters
The operation is characterized by the first phase of expansion.
- Turbine inlet temperature : 1125 °C (2057 °F)
The operation is characterised by the following parameters :
- Turbine outlet temperature : 880 °C (1616 °F)
Turbine gas flow The burnt gases first flow through the nozzle guide vanes. The gas velocity increases due to the convergent passage. The flow on the blades results in aerodynamic forces whose resultant causes the rotation of the wheel. The gases, still containing energy, are directed to the power turbine.
For training purposes only © Copyright - TURBOMECA - 2000
3.32 Edition : December 2000
ENGINE
Training Manual
GAS FROM THE COMBUSTION CHAMBER (1125 °C / 2057 °F)
ARRIEL 1
GAS EXPANSION IN THE NOZZLE GUIDE VANE (convergent passage)
ROTATION Rotation
Nozzle guide vane
COMPRESSOR DRIVE (52000 RPM ; ACW 800 kW ; 1072 Shp)
Turbine wheel
GAS TO THE POWER TURBINE (880 °C / 1616 °F)
GAS GENERATOR TURBINE - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
3.33 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
POWER TURBINE - GENERAL Function
Main components
The turbine extracts the energy from the gas to drive the power shaft through the reduction gearbox.
- Rotating components (wheel, shaft, bearings) - Stationary components (nozzle guide vane, containment shield, casing).
Position - Between the gas generator and the reduction gearbox. It forms the module M04.
Main characteristics - Type : axial, single-stage - Turbine inlet temperature : 880 °C (1616 °F) - Turbine outlet temperature : 600 °C (1080 °F) - N2 speed at 100 % ≈ 41586 RPM, CW
For training purposes only © Copyright - TURBOMECA - 2000
3.34 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual NOZZLE GUIDE VANE
WHEEL
BEARINGS
Type : Axial, single stage Turbine inlet temperature : 880 °C (1616 °F) Turbine outlet temperature : 600 °C (1080 °F) N2 speed at 100% ≈ 41586 RPM (CW)
CONTAINMENT SHIELD
POWER TURBINE CASING
SHAFT
POWER TURBINE - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
3.35 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
POWER TURBINE - DESCRIPTION The power turbine assembly forms the module M04. It includes rotating components and stationary components.
Stationary components The main stationary components are the turbine nozzle guide vane, the power turbine casing and the bearing housing.
Rotating components The main rotating component is the power turbine with its shaft. The wheel includes a disc (integral with the shaft) and firtree mounted blades. The shaft is supported by two bearings : a front roller bearing and two rear ball bearings. It is fitted with two phonic wheels The front bearing sealing is ensured by a pressurised labyrinth seal (pressurisation with compressor air directed to the power turbine through an external pipe and inner ducts).
The nozzle guide vane includes a row of hollow vanes. It is part of the module M03. The power turbine casing engages over the gas generator outlet diffuser and is bolted to the module M03. It comprises an outer casing and an inner hub supported by three struts. The bearing housing is installed in the inner hub of the casing. Its rear part engages in the reduction gearbox. The identification plate is located on the power turbine casing. A containment shield is fitted around the rear of the casing.
The power is transmitted to the reduction gear by a muff coupling.
For training purposes only © Copyright - TURBOMECA - 2000
3.36 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
WHEEL
CONTAINMENT PRESSURISED FRONT LABYRINTH SHIELD BEARING SEAL
Identification plate REAR BEARING BEARING HOUSING SHAFT
LABYRINTH Muff coupling
POWER TURBINE CASING PHONIC WHEELS
BEARING HOUSING NOZZLE GUIDE POWER TURBINE VANE CASING
PHONIC WHEELS
WHEEL
POWER TURBINE - DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
3.37 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
POWER TURBINE - OPERATION The power turbine transforms the gas energy into mechanical power to drive the reduction gearbox.
Operating parameters The operation is characterised by the following parameters :
The operation is characterised by the second phase of expansion.
- Rotation : CW - Turbine inlet temperature : 880 °C (1616 °F)
Turbine flow The gas supplied by the gas generator flows through the nozzle guide vane. In the nozzle guide vane, the gas velocity increases due to the convergent passage.
- Power extracted : depending on the version
The gases are directed onto the turbine wheel and the resultant of the aerodynamic forces on the blades causes the wheel to rotate. The gases are then expelled overboard through the exhaust pipe.
For training purposes only © Copyright - TURBOMECA - 2000
3.38 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
ROTATION OF THE POWER TURBINE
GAS FROM THE GAS GENERATOR TURBINE (880 °C / 1616 °F)
REDUCTION GEARBOX DRIVE (CW)
Rotation
Nozzle guide vane
Turbine wheel
EXPANSION IN THE NOZZLE GUIDE VANE
GAS EXHAUST
POWER TURBINE - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
3.39 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
EXHAUST PIPE Function
Description
The exhaust pipe continues the expansion phase and expels the gas overboard.
The exhaust pipe, which has an elliptical outlet, is made from stainless steel. It is bolted to the rear flange of the power turbine casing with the containment shield.
Position - Behind the power turbine, around the reduction gear.
A heat shield is fitted between the exhaust pipe and the reduction gearbox to protect the gearbox from the exhaust heat.
Main characteristics
The exhaust pipe has a drain at the bottom.
- Type : Elliptical
Operation
- Non-modular part
Functionally it should be noted that the exhaust gas still contains a certain amount of energy which produces a small residual thrust of about 15 daN (33 lbs).
- Gas temperature : 600 °C (1080 °F) - Residual thrust : ≈ 15 daN (33 lbs).
Main components - Exhaust pipe - Heat shield.
Note : The exhaust pipe is considered to be an SRU.
For training purposes only © Copyright - TURBOMECA - 2000
3.40 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
RESIDUAL THRUST (15 daN / 33 lbs)
EXHAUST PIPE
GAS FROM POWER TURBINE
GAS EXHAUST (600 °C ; 1080 °F)
HEAT SHIELD
REDUCTION GEARBOX
DRAIN
DESCRIPTION
OPERATION
EXHAUST PIPE For training purposes only © Copyright - TURBOMECA - 2000
3.41 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
REDUCTION GEARBOX - GENERAL Function
Main components
The reduction gearbox provides a reduced speed output and transmits the drive forwards.
- Drive gear - Intermediate gear
Position
- Output gear
- At the rear of the engine
- Casings
- It forms the module M05.
- Hydraulic torquemeter.
Main characteristics - Type : 3 stages, helical gears - Output gear speed : 6000 RPM at 100 %.
For training purposes only © Copyright - TURBOMECA - 2000
3.42 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
DRIVE GEAR
INTERMEDIATE GEAR MUFF COUPLING
HYDRAULIC TORQUEMETER
Type : 3 stages, helical gears OUTPUT GEAR
Output gear speed : 6000 RPM at 100%
CASINGS
REDUCTION GEARBOX - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
3.43 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
REDUCTION GEARBOX - DESCRIPTION The reduction gearbox module mainly includes three gears contained in two half casings.
Drive gear The drive gear is linked to the power turbine by a muff coupling. It is supported by two roller bearings.
Intermediate gear
Reduction gearbox casing The gears are housed in a light alloy gearbox formed by two half casings. A fork shaped steel plate is mounted on the front face of the casing to prevent rearward movement of the power turbine in the event of overspeed. The module identification plate is located at the bottom of the casing.
It is a double helical type gear : one gear meshes with the drive gear, the other one with the output gear. The torquemeter piston is fitted in its hub. The intermediate gear is supported by two roller bearings.
Output gear It is supported by a ball bearing at the front and a roller bearing at the rear. The hub is internally splined to receive the transmission shaft.
For training purposes only © Copyright - TURBOMECA - 2000
3.44 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
Muff coupling
DRIVE GEAR
DRIVE GEAR
INTERMEDIATE GEAR
FRONT CASING INTERMEDIATE GEAR
TORQUEMETER PISTON
OUTPUT GEAR
FORK SHAPED PLATE
IDENTIFICATION PLATE
OUTPUT GEAR
REAR CASING
REDUCTION GEARBOX - DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
3.45 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
REDUCTION GEARBOX - OPERATION The reduction gear provides a forward output drive at a reduced speed.
Operation of the reduction gear The drive gear is directly driven by the power turbine shaft (muff coupling drive). It transmits the movement to the intermediate gear which contains the hydraulic torquemeter. The intermediate gear drives the output gear which provides the power drive at a speed of approximately 6000 RPM, clockwise.
For training purposes only © Copyright - TURBOMECA - 2000
3.46 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
DRIVE GEAR DRIVEN BY THE POWER TURBINE TORQUEMETER PISTON
DOUBLE INTERMEDIATE GEAR
TRANSMISSION SHAFT
OUTPUT GEAR
REDUCTION GEARBOX - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
3.47 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
TRANSMISSION SHAFT AND ACCESSORY GEARBOX Function The shaft transmits the power to the helicopter via the power off-take at the front of the engine. The accessory gearbox provides the drive for the engine accessories.
Position - Shaft beneath the engine - Accessory gearbox at the front of the engine - This assembly forms the module M01.
For training purposes only © Copyright - TURBOMECA - 2000
3.48 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
ACCESSORY DRIVE SHAFT
CASINGS
TRANSMISSION SHAFT
POWER OFF-TAKE
TRANSMISSION SHAFT AND ACCESSORY GEARBOX For training purposes only © Copyright - TURBOMECA - 2000
3.49 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
POWER TRANSMISSION SHAFT TWIN-ENGINE CONFIGURATION GENERAL - DESCRIPTION Function The shaft transmits the power to the front power off-take.
Position : - Lower part of the engine.
The front of the shaft is supported by a ball bearing in the accessory gearbox front casing. The triangular flange which forms the power off-take is splined onto the front of the transmission shaft and is secured by a nut. Sealing of the oil which lubricates the bearing is ensured by a carbon seal. Three oil tubes are located between the shaft and the protection tube.
Main characteristics
The rear of the shaft is splined into the hub of the output gear of the reduction gear.
Hollow steel shaft.
Main components - Transmission shaft - Protection tube - Accessory drive gear - Power off-take.
Description The shaft transmits the power to the power off-take and accessory gearbox. The shaft is located in a protection tube bolted to the reduction gearbox at the rear and to the accessory gearbox at the front.
For training purposes only © Copyright - TURBOMECA - 2000
3.50 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
SHAFT
POWER OFF-TAKE (triangular flange)
CARBON SEAL
BEARING
BEARING
OUTPUT GEAR
ACCESSORY DRIVE GEAR
OIL TUBE
PROTECTION TUBE
POWER TRANSMISSION SHAFT - TWIN-ENGINE CONFIGURATION GENERAL - DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
3.51 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
POWER TRANSMISSION SHAFT SINGLE ENGINE CONFIGURATION GENERAL - DESCRIPTION Function The shaft transmits the power to the front and to the rear of the engine.
Position :
The front of the transmission shaft is supported by a ball bearing in the accessory gearbox front casing. A triangular flange is splined onto the front of the transmission shaft. Sealing of the oil which lubricates the bearing is ensured by a carbon seal. Three oil pipes are located within the protection tube.
- Lower part of the engine.
A free wheel is mounted on the triangular flange to drive the power drive shaft which drives the main gearbox and the tail rotor.
Main characteristics - Hollow steel shaft with coaxial drive shaft.
Lubrication of the free wheel and its bearing is by the oil contained in the free wheel housing, or by the oil system of the engine, according to the version.
Main components - Transmission shaft
The rear of the transmission shaft is splined into the hub of the output gear of the reduction gear.
- Protection tube - Accessory drive gear
The rear of the tail rotor drive shaft is supported by a ball bearing in the hub of the output gear. A carbon seal is fitted in the rear cover of the gearbox.
- Drive shaft - Free wheel.
Description The shaft transmits the power to the power drive shaft. The transmission shaft is located in a protection tube bolted to the reduction gearbox at the rear and to the accessory gearbox at the front. For training purposes only © Copyright - TURBOMECA - 2000
3.52 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
SEAL
BEARING
TRIANGULAR FLANGE
BEARING
SHAFT
TAIL ROTOR DRIVE
ACCESSORY DRIVE GEAR
POWER DRIVE SHAFT
FREE WHEEL
CARBON SEAL
CARBON SEAL
OIL TUBE
FRONT PART
REAR PART
POWER TRANSMISSION SHAFT - SINGLE ENGINE CONFIGURATION GENERAL - DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
3.53 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
ACCESSORY GEARBOX - GENERAL Function
Main components
To provide the drive for the engine accessories.
- Accessory drive shaft
Position
- Accessory drive train
- At the front of the engine.
- Casings.
Main characteristics - Type of gears : • spur gear • bevel gear.
For training purposes only © Copyright - TURBOMECA - 2000
3.54 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
ACCESSORY DRIVE SHAFT (N1)
FRONT CASING
ACCESSORY DRIVE TRAIN
REAR CASING Type of gears : Spur gear Bevel gear
ACCESSORY DRIVE GEAR (N2)
ACCESSORY GEARBOX - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
3.55 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
ACCESSORY GEARBOX DESCRIPTION (1) The accessory gearbox has four drives on the front face : • starter generator • fuel control unit N1 • fuel control unit N2 • main power shaft. and four mounting bolts on the upper part for attachment of the M02. It has 3 power drives on the rear face : • oil pump • N1 tachometer generator • N2 tachometer generator. and the protection tube mounting flange, and the accessory drive shaft passage on the upper part.
For training purposes only © Copyright - TURBOMECA - 2000
3.56 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
MOUNTING BOLTS (4) ACCESSORY DRIVE SHAFT PASSAGE (N1)
N1 TACHOMETER GENERATOR
FUEL CONTROL UNIT N1 DRIVE
OIL PUMP
STARTER GENERATOR DRIVE
POWER DRIVE
FUEL CONTROL UNIT N2 DRIVE
PROTECTION TUBE MOUNTING FLANGE
N2 TACHOMETER GENERATOR
REAR VIEW
FRONT VIEW
ACCESSORY GEARBOX - DESCRIPTION (1) For training purposes only © Copyright - TURBOMECA - 2000
3.57 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
ACCESSORY GEARBOX DESCRIPTION (2) The transmission shaft and the accessory box assembly constitutes the module M01 located at the engine lower part. The accessory gearbox includes a train of gears housed in a gearbox formed by two half casings made of light alloy. The gearbox is installed at the bottom of the axial compressor by means of four bolts. The starter-generator gear forms the engine breather. The fuel control unit N1 gear drives the oil pump at the rear. The fuel control unit N2 gear is driven by the gear on the transmission shaft. The engine front support casing is bolted onto the front face of the accessory gearbox. The module identification plate is fitted on the front face of the gearbox.
For training purposes only © Copyright - TURBOMECA - 2000
3.58 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
DRIVE SHAFT (N1) BREATHER GEAR TRANSMISSION SHAFT GEAR (N2) FRONT CASING
REAR CASING
N1 FUEL CONTROL UNIT AND OIL PUMP DRIVE
STARTER GENERATOR DRIVE
N2 FUEL CONTROL UNIT
Identification plate FRONT SUPPORT CASING
ACCESSORY GEARBOX - DESCRIPTION (2) For training purposes only © Copyright - TURBOMECA - 2000
3.59 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
ACCESSORY GEARBOX - OPERATION The operation is considered during engine starting and in normal running.
The gas generator drives the accessory gear train through the bevel gear located on the axial compressor shaft.
Operation during engine starting During starting, the starter motor drives the accessory gearbox and thus the gas generator rotating assembly. The compressors supply air to the combustion chamber and the starting sequence continues. At self-sustaining speed (approximately 45 % N1) the electrical supply to the starter motor is cut. The starter motor is then mechanically driven by the engine and operates as a generator to provide DC current to the aircraft electrical system.
For training purposes only © Copyright - TURBOMECA - 2000
Operation in normal running
The following accessories are driven : - Starter-generator - FCU : N1 and N2 - Oil pumps - Tachometer generator : N1 and N2.
3.60 Edition : December 2000
ENGINE
ARRIEL 1
Training Manual
FWD STARTER MOTOR
FWD DRIVE SHAFT
DIRECT CURRENT GENERATOR
OPERATION DURING ENGINE STARTING
DRIVE SHAFT
OPERATION IN NORMAL RUNNING (N1 50 %)
ACCESSORY GEARBOX - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
3.61 Edition : December 2000
ENGINE
Training Manual
ARRIEL 1
4 - OIL SYSTEM - Oil system ...................................................................... - Lubrication .................................................................... - Oil tank .......................................................................... - Oil pumps ...................................................................... - Electrical magnetic plugs .............................................. - Oil filter ......................................................................... - Filter pre-blockage indicator ........................................ - Oil cooler ....................................................................... - Centrifugal breather ..................................................... - Magnetic plugs ............................................................... - Strainers ........................................................................ - Indicating devices .......................................................... - Oil pipes and ducts ........................................................
For training purposes only © Copyright - TURBOMECA - 2000
4.2 4.8 4.12 4.14 4.20 4.24 4.30 4.34 4.36 4.40 4.42 4.44 4.50 to 4.51
4.1 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
OIL SYSTEM - GENERAL Function
Lubrication requirements
The oil system ensures lubrication and cooling of the engine.
Lubrication is required for the following components :
Position All the components are fitted on the engine except the tank and cooler.
- Gas generator front bearings • Axial compressor bearing • Centrifugal compressor bearing • Accessory drive bearing - Gas generator rear bearing
Main characteristics
- Power turbine bearings - System type : variable pressure, full flow, dry sump, synthetic oil
- Reduction gearbox
- Max oil temperature : 115 °C (239 °F)
- Accessory drive gearbox.
- Min oil pressure : 90 or 130 kPa (13 or 18.85 PSIG) according to version - Max oil pressure : 800 kPa (116 PSIG) - Oil pressure : ≈ 300 kPa (43.5 PSIG) - Max oil consumption : 0.3 l/h or 0.15 l/h according to version.
For training purposes only © Copyright - TURBOMECA - 2000
4.2 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
GAS GENERATOR
OIL SYSTEM
POWER TURBINE REAR BEARING
FRONT BEARINGS
FRONT BEARING
REAR BEARINGS
Engine lubrication and cooling
Type : Variable pressure, full flow, dry sump, synthetic oil Max temperature : 115 °C (239 °F) Min pressure : 90 or 130 kPa (13 or 18.85 PSIG) according to version Max pressure : 800 kPa (116 PSIG) Max consumption : 0.3 l/h or 0.15 l/h according to version
BEARINGS
GEARS
ACCESSORY DRIVE GEARBOX
BEARINGS
GEARS REDUCTION GEARBOX
OIL SYSTEM - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
4.3 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
OIL SYSTEM - DESCRIPTION The system contains all the components necessary for engine lubrication : tank, pumps, filter, strainers, cooler, breather and indicating devices.
Oil tank
Cooler The oil cooler cools the oil. It is supplied by the aircraft manufacturer.
Breather
The tank contains the volume of oil required to lubricate the engine. It is supplied by the aircraft manufacturer.
Oil pumps
The centrifugal breather separates the oil from the air/oil mist and vents the system.
Indicating devices
The pump pack contains one pressure pump and three scavenge pumps. The gear type pumps are driven by the accessory gearbox. The pressure pump is equipped with a pressure relief valve and in some versions a check valve.
- Oil temperature probe (aircraft manufacturer supply) - Pre-blockage indicator - Low oil pressure switch
Oil filter The filter retains any particles which may be present in the oil. It is provided with a by-pass valve and a pre-blockage indicator.
- Pressure transmitter - Magnetic plugs - Electrical magnetic plugs.
Strainers The strainers protect the scavenge pumps from debris in the system.
For training purposes only © Copyright - TURBOMECA - 2000
4.4 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
AIRFRAME
Oil temperature probe
TANK
Low oil pressure switch
ENGINE
Pressure Relief valve
Pre-blockage indicator Check valve (some versions)
Check valve
CENTRIFUGAL BREATHER
By-pass valve
COOLER
Electrical magnetic plug
Pressure transmitter
Scavenge pumps
Pressure pump
Magnetic plug
FILTER
Electrical magnetic plug
Magnetic plug
STRAINERS
OIL PUMPS
OIL SYSTEM - DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
4.5 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
OIL SYSTEM - OPERATION The main functions of the oil system are : supply, scavenge, breathing and indicating.
Supply The pressure pump draws the oil from the tank and supplies the system. A pressure relief valve limits maximum pressure by returning oil to the pump inlet.
Scavenge After lubrication, the oil falls by gravity to the bottom of the sumps. The oil is then immediately drawn away by the scavenge pumps and returned to the tank through the oil cooler (dry sump system). The strainers protect the scavenge pumps against any particles which may be held in the oil.
The oil is then delivered through a check valve, the oil filter and a calibrated orifice to the engine sections which require lubrication :
Breathing
- Gas generator front bearings
The oil mist which results from lubrication is returned to the accessory gearbox, where the oil is separated from the air by a centrifugal breather which vents overboard.
- Gas generator rear bearing The gas generator rear bearing has a direct air vent. - Power turbine bearings
Indicating
- Reduction gearbox - Accessory gearbox and torquemeter (supply upstream of the calibrated orifice).
The system ensures the following indications : pressure, temperature, low pressure, electrical magnetic plug and filter pre-blockage.
The oil is sprayed by jets onto the parts to be lubricated.
For training purposes only © Copyright - TURBOMECA - 2000
4.6 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
AIRFRAME
ENGINE
Low oil pressure switch
Pressure transmitter
CENTRIFUGAL BREATHER Temperature probe PRESSURE PUMP
FILTER
TANK COOLER
Check valve
Electrical magnetic plug
Check valve
Magnetic plug
Electrical magnetic plug
SCAVENGE PUMPS
SUPPLY
Magnetic plug
Calibrated orifice
STRAINERS SCAVENGE
BREATHING
AIR VENT
OIL SYSTEM - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
4.7 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
LUBRICATION (1) This section describes the lubrication of the engine parts : gas generator, power turbine, reduction gear and accessory drive train.
Scavenge. The oil falls by gravity to the bottom of the housing, through a tube in the bottom of the housing and is returned to the tank by a scavenge pump.
Gas generator front bearings
Breathing. The air/oil mist which results from lubrication passes out through a tube screwed into the top of the housing and is vented overboard.
Supply. The oil is taken by external pipe to the upper part of the axial compressor casing. It is supplied to a jet which sprays the oil onto the two compressor bearings and the accessory drive bevel gear.
Accessory gearbox Supply. The oil is supplied by an internal duct. It passes through ducts and jets to the accessory gearbox gears and bearings.
The bearing housing is sealed by labyrinth seals. Scavenge. The oil falls by gravity into the accessory gearbox from where it is drawn by a scavenge pump and returned to the tank. Breathing. The air/oil mist which results from lubrication passes into the accessory gearbox and is vented through the centrifugal breather.
Scavenge. The oil falls by gravity to the bottom of the gearbox casing. It is immediately drawn by the scavenge pump and returned to the tank via the oil cooler. Breathing. The oil/air vapours resulting from the lubrication pass to the centrifugal breather. Then, the deoiled vapours are vented overboard.
Gas generator rear bearing Torquemeter pressure Supply. The oil, taken by external pipe, passes through a restrictor and a tube screwed into the bearing housing and is sprayed onto the bearing.
Supply. The torque indicating system receives a supply of oil from the pump outlet via a restrictor and through a tube in the protection tube. This system is described in chapter 8.
The bearing housing is sealed by pressurised labyrinth seals.
For training purposes only © Copyright - TURBOMECA - 2000
4.8 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
AXIAL COMPRESSOR BEARING
CENTRIFUGAL COMPRESSOR BEARING DIRECT AIR VENT
GAS GENERATOR REAR BEARING
AIR VENT
TORQUEMETER PRESSURE ACCESSORY GEARBOX
SCAVENGE
Supply
Torquemeter pressure
Scavenge
Air vent
LUBRICATION (1) For training purposes only © Copyright - TURBOMECA - 2000
4.9 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
LUBRICATION (2) Power turbine bearings and reduction gearbox Supply. The oil is supplied via a tube located inside the transmission shaft protection tube. The bearings and gears are lubricated by jets via internal drillings in the casings. A labyrinth seal is fitted in front of the power turbine front bearing to seal the housing. Scavenge. The oil which has lubricated the power turbine bearings is returned to the reduction gearbox. The oil in the reduction gearbox falls to the bottom of the casing and is drawn by a scavenge pump, through a tube in the transmission shaft protection tube, and is returned to the tank.
For training purposes only © Copyright - TURBOMECA - 2000
Breathing. The air/oil mist resulting from lubrication passes through the protection tube, into the accessory gearbox where it passes through the centrifugal breather.
Torquemeter A tube in the protecting tube, connects the torque transmitter to the torquemeter piston in the intermediate gear of the reduction gearbox.
4.10 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
POWER TURBINE BEARINGS
LUBRICATION OF THE REDUCTION GEARBOX (gears and bearings)
TORQUEMETER SUPPLY
BREATHING
SCAVENGE Supply Torquemeter pressure Scavenge Breathing
LUBRICATION (2) For training purposes only © Copyright - TURBOMECA - 2000
4.11 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
OIL TANK Function
Main components
The tank contains the oil required for engine lubrication.
- Filler cap
Position
- Level indicator
- On the aircraft : it is installed with the oil cooler above the plenum chamber, between the main gearbox and the front firewall.
- Drain plug (with magnetic plug) - Temperature probe - Unions (supply, return and vent).
Main characteristics - Aircraft manufacturer supply - Max capacity : 6 litres (1.56 US G)
For training purposes only © Copyright - TURBOMECA - 2000
Note : Refer to the aircraft manual for the description and operation.
4.12 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual FILLER CAP (provided with a dip stick)
Air vent
OIL COOLER
Aircraft supply
LEVEL INDICATOR
Oil return (from engine)
Max capacity : 6 litres (1.56 US G) TEMPERATURE PROBE DRAIN PLUG (with magnetic plug)
Tank drain
Engine oil supply
OIL TANK For training purposes only © Copyright - TURBOMECA - 2000
4.13 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
OIL PUMPS - GENERAL Function
Main components
The pumps ensure oil circulation.
- Drive shaft
Position
- Pump body (with one pressure pump, three scavenge pumps and valves).
- On the engine : the pump pack is mounted on the rear face of the accessory gearbox.
Main characteristics - Gear type - Pressure pump outlet pressure : ≈ 300 kPa (43.5 PSI) (variable pressure system) - Pressure relief valve setting : 800 kPa (116 PSI) - Check valve : according to version.
For training purposes only © Copyright - TURBOMECA - 2000
4.14 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
PACK OF PUMPS
- Gas generator rear bearing scavenge pump - Reduction gearbox scavenge pump - Accessory gearbox scavenge pump - Pressure pump
Type : Gear Pressure pump outlet pressure : ≈ 300 kPa (43.5 PSI) (variable pressure system) Pressure relief valve setting : 800 kPa (116 PSI) Check valve : According to version
DRIVE SHAFT
PUMP BODY
OIL PUMPS - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
4.15 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
OIL PUMPS - DESCRIPTION The oil pump pack is mounted on the rear left face of the accessory gearbox and is driven at a speed proportional to N1. It consists of : - 4 gear type pumps : • Pressure pump • Gas generator rear bearing scavenge pump • Reduction gearbox scavenge pump • Accessory gearbox scavenge pump - The pump casing provided with inlet and outlet orifices - The pressure relief valve - The check valve (according to version).
For training purposes only © Copyright - TURBOMECA - 2000
4.16 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
ACCESSORY GEARBOX SCAVENGE PUMP
REDUCTION GEARBOX SCAVENGE PUMP
GAS GENERATOR REAR BEARING SCAVENGE PUMP PRESSURE PUMP
CHECK VALVE DRIVE SHAFT
PUMP BODY
PRESSURE RELIEF VALVE
PUMP BODY
OIL PUMPS - DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
4.17 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
OIL PUMPS - OPERATION General The pressure pump draws the oil from the tank and pumps it to the filter. The scavenge pumps draw the oil from the casings and pump it to the cooler. Pressure relief valve operation If the oil pressure exceeds the valve setting the valve opens and allows the oil to return to the pump inlet. In normal operation the valve is closed and only opens in exceptional circumstances, e.g. starting with very low temperature. Pressure pump outlet check valve operation When the oil pressure is very low, e.g. engine stopped or at the beginning of start, the valve is closed in order to prevent flow between the pump and system.
For training purposes only © Copyright - TURBOMECA - 2000
4.18 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
GAS GENERATOR REAR BEARING SCAVENGE PUMP Normal running condition (valve closed)
Overpressure (valve open)
REDUCTION GEARBOX SCAVENGE PUMP
ACCESSORY GEARBOX SCAVENGE PUMP
OPERATION OF THE PRESSURE RELIEF VALVE
Normal running condition (valve open) PRESSURE PUMP Engine stopped and initial phase of starting (valve closed)
PRESSURE RELIEF VALVE Suction - Overpressure
OPERATION OF THE CHECK VALVE
Pressure
Scavenge
OIL PUMPS - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
4.19 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
ELECTRICAL MAGNETIC PLUGS GENERAL Function
Main components
The electrical magnetic plugs provide a cockpit indication of metal particles in the oil system.
- Magnetic plug body - Electrical connector
Position
- Housing (strainer).
- In the system : • one downstream of the scavenge pumps • one upstream of the rear bearing scavenge pump - On the engine : • one near the pump assembly (scavenge pumps) • one on the left side of the accessory gearbox (rear bearing).
Note : The oil system also has two mechanical magnetic plugs located on the lower part of the accessory gearbox and on the lower part of the reduction gearbox.
Main characteristics - Type : • Magnetic with electrical indication • Self-sealing housing.
For training purposes only © Copyright - TURBOMECA - 2000
4.20 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
HOUSING
MAGNETIC PLUG BODY
Type : Electrical magnetic plug Housing : Self-sealing ELECTRICAL CONNECTOR
ELECTRICAL MAGNETIC PLUGS - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
4.21 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
ELECTRICAL MAGNETIC PLUGS DESCRIPTION - OPERATION Description
Operation
The electrical magnetic plugs comprise a magnetic probe which has two parts which are electrically insulated from one another and have a small gap between them.
The magnetic probe attracts magnetic particles present in the oil.
A resistor is connected across the gap. The plugs are connected, via the engine electrical harness, to the aircraft instrument panel with an optional test system.
If it attracts sufficient particles to form a bridge across the gap, this will complete the electrical circuit between the two magnetic parts and thus illuminate an indicator on the instrument panel.
The plugs are fitted into a housing which is provided with a self-sealing valve.
The resistor is fitted to allow the installation of a test circuit.
The scavenge oil flows across the magnetic probe. Note : Refer to aircraft documents for further details.
For training purposes only © Copyright - TURBOMECA - 2000
4.22 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
Firewall
AIRCRAFT
ELECTRICAL CONNECTOR
Gap
+
44
GAP
2 3 1
26
60 KΩ
PLUG BODY
ENGINE
P003 O'RING SEAL MAGNETIC PLUG
+
44
SELF SEALING VALVE
2 3 1
26
60 KΩ
HOUSING
Resistor
P003 LIGHT "ON" BRIDGE OF PARTICLES
DESCRIPTION
OPERATION
ELECTRICAL MAGNETIC PLUGS - DESCRIPTION - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
4.23 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
OIL FILTER - GENERAL Function
Main components
The filter retains particles that may be in the oil.
- Filter base
Position
- Pre-blockage indicator
- In the system : downstream of the pressure pump
- Cover
- On the engine : on the left rear face of the accessory gearbox.
- By-pass valve.
Main characteristics - Type : metal cartridge - Filtering ability : 30 microns - Mechanical pre-blockage indicator : ∆P 150 kPa (21.7 PSID) - By-pass valve : • Setting : ∆P 200 kPa (29 PSID).
For training purposes only © Copyright - TURBOMECA - 2000
4.24 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
COVER
FILTER BASE
Type : Metal cartridge Filtering ability : 30 microns
BY-PASS VALVE
PRE-BLOCKAGE INDICATOR
Mechanical pre-blockage indicator : ∆P 150 kPa (21.7 PSID) By-pass valve : ∆P 200 kPa (29 PSID)
OIL FILTER - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
4.25 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
OIL FILTER - DESCRIPTION Description The main components of the filtering unit are the following : - Filter base - Filter cover - Metal cartridge (filtering element) - By-pass valve (fitted inside the filter base) - Drain valve. The filter base incorporates mounting points for the following : - Pre-blockage indicator - Low oil pressure switch - Oil pressure transmitter.
For training purposes only © Copyright - TURBOMECA - 2000
4.26 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
FILTERING ELEMENT
FILTER COVER
BY-PASS VALVE
LOW OIL PRESSURE SWITCH
DRAIN VALVE
FILTER BASE
OIL PRESSURE TRANSMITTER
PRE-BLOCKAGE INDICATOR
OIL FILTER - DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
4.27 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
OIL FILTER - OPERATION Operation Filtering (normal condition) The oil supplied by the pressure pump passes through the filter from outside to inside. The filtered oil then passes to the engine for lubrication. Pre-blockage If the filter begins to become blocked the pressure difference across the filter increases. At a given difference (150 kPa ⁄ 21.7 PSID) a red mechanical indicator pops out. The oil continues to flow through the filter. Blockage If the pressure difference exceeds 200 kPa (29 PSID), the by-pass valve opens and unfiltered oil passes to the system.
For training purposes only © Copyright - TURBOMECA - 2000
4.28 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
OPERATION OF THE MECHANICAL PRE-BLOCKAGE INDICATOR (∆P 150 kPa / 21.7 PSID)
OIL FILTER ASSEMBLY
PRE-BLOCKAGE
FILTERING (30 microns)
NORMAL CONDITION
BLOCKAGE
OPERATION OF THE BY-PASS VALVE (∆P 200 kPa / 29 PSID)
OIL FILTER - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
4.29 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
FILTER PRE-BLOCKAGE INDICATOR GENERAL Function
Main components
The indicator indicates the onset of filter blockage.
- Indicator body
Position
- Indicator
On the left face of the filter housing.
- O'ring seals.
Main characteristics - Type : differential - Setting : ∆P 150 kPa (21.7 PSID) - Indication : red indicator - Manual rearming.
For training purposes only © Copyright - TURBOMECA - 2000
4.30 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
INDICATOR BODY
O'RING SEALS
Type : Differential Setting : ∆P 150 kPa (21.7 PSID) Indication : Red indicator Manual rearming
INDICATOR
FILTER PRE-BLOCKAGE INDICATOR - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
4.31 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
FILTER PRE-BLOCKAGE INDICATOR DESCRIPTION - OPERATION Description
Operation
The pre-blockage indicator comprises the following parts :
Normal position
- Indicator body including : • Filter upstream pressure inlet • Filter downstream pressure inlet
Filter downstream pressure plus spring pressure is greater than upstream pressure. The two pistons are held together by magnetic force. The indicator is not visible.
- Red indicator piston
Pre-blockage
- ∆P piston
Filter upstream pressure exceeds downstream plus spring pressure and the ∆P piston displaces.
- Transparent cover
This breaks the magnetic hold and the indicator piston is pushed out by its spring. The indicator is visible.
- Thermal lock - O'ring seals ensure the filter pre-blockage indicator sealing.
The bi-metallic thermal lock ensures that the indicator doesn't operate when a large ∆P is caused by low temperature (locked below 50 °C (122 °F)). It is rearmed by removing the cover and pushing in the indicator.
For training purposes only © Copyright - TURBOMECA - 2000
4.32 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
INDICATOR BODY
O RING SEALS
TRANSPARENT COVER
< 50°C (122°F)
Downstream pressure > 50°C (122°F)
RED INDICATOR
Upstream pressure NORMAL CONDITION
FILTER DOWNSTREAM PRESSURE
Red indicator "out" FILTER UPSTREAM PRESSURE
∆P PISTON
Downstream pressure
THERMAL LOCK Upstream pressure
∆P > 150 kPa (21.7 PSID)
PRE-BLOCKAGE CONDITION
DESCRIPTION
OPERATION
FILTER PRE-BLOCKAGE INDICATOR - DESCRIPTION - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
4.33 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
OIL COOLER Function
Main components
The oil cooler cools the oil after it has passed through the engine.
- Oil cooler - By-pass thermostatic valve
Position
- Unions (oil inlet and outlet).
- In the system : between the scavenge pumps and the tank - On the aircraft : it is installed on the oil tank above the plenum chamber between the main gearbox and the front firewall.
Main characteristics - Type : air-oil cooler - By-pass thermostatic valve : 276 kPa (40 PSI) : • Full open when t° < 57 °C (135 °F) • Full closed when t° > 67 °C (153 °F) - Supplied by aircraft manufacturer.
For training purposes only © Copyright - TURBOMECA - 2000
4.34 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
OIL TANK
BY-PASS THERMOSTATIC VALVE
Oil inlet (from scavenge pumps)
OIL COOLER Aircraft component Type : Air/oil cooler By-pass Thermostatic valve : 276 kPa (40 PSI) - Full open when : t° < 57 °C (135 °F) - Full closed when : t° > 67 °C (153 °F) FAN
Ambient air
OIL COOLER For training purposes only © Copyright - TURBOMECA - 2000
4.35 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
CENTRIFUGAL BREATHER - GENERAL Function
Main components
The centrifugal breather separates the oil from the air/oil mist created by the oil system.
- Gear wheel with air passage holes - Splines for the starter generator drive.
Position It is formed by the starter/generator drive gear in the accessory gearbox.
Main characteristics - Type : centrifugal - De-oiled air : through the rear of the hollow shaft.
For training purposes only © Copyright - TURBOMECA - 2000
4.36 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
DE-OILED AIR
OIL MIST
Type : Centrifugal De-oiled air : Through the rear of the hollow shaft SPLINES FOR THE STARTER GENERATOR DRIVE GEAR PROVIDED WITH BREATHER HOLES
CENTRIFUGAL BREATHER - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
4.37 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
CENTRIFUGAL BREATHER - DESCRIPTION OPERATION Description
Operation
The centrifugal breather is formed by the starter generator drive gear. This gear is formed in one piece with a hollow shaft and has holes which provide a passage between the gearbox and the air vent.
The centrifugal breather is driven by the intermediate gear of the accessory drive.
The gear is supported by two ball bearings and has a magnetic carbon seal at each end. The breather air outlet is at the rear end of the shaft, where the air passes into the gearbox outlet.
For training purposes only © Copyright - TURBOMECA - 2000
When the engine is running, the air/oil mist passes through the breather : - Centrifugal force throws the oil droplets out into the gearbox where they fall to the bottom of the casing - The de-oiled air passes out through the shaft, via a gearbox passage, into an external pipe which discharges into the exhaust.
4.38 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
OIL MIST - from accessory gearbox - from gas generator bearings - from power turbine bearings - from reduction gearbox
AIR VENT
DE-OILED AIR MAGNETIC CARBON SEAL
STARTER GENERATOR DRIVE
MAGNETIC CARBON SEAL
BEARING
BEARING OIL DROPLETS
CENTRIFUGAL BREATHER - DESCRIPTION - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
4.39 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
MAGNETIC PLUGS Function
Main components
The magnetic plugs retain magnetic particles contained in the oil to provide a rapid and frequent check of the internal condition of the engine.
- Self sealing housing : • Housing • O'ring seal • Valve • Spring
Position In the system :
- Magnetic plug : • Magnet • O'ring seals • Locating pins.
- One on the reduction gearbox scavenge return - One on the accessory gearbox scavenge return. On the engine : - One at the bottom of the reduction gearbox - One at the bottom of the accessory gearbox. They are mounted on the left or the right side according to the position of the engine in the helicopter.
Main characteristics - Type : single magnetic pole. Self-sealing housing.
For training purposes only © Copyright - TURBOMECA - 2000
4.40 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
VALVE
O'RING SEAL HOUSING
LOCATING PINS
O'RING SEALS
NORMAL POSITION SPRING
MAGNET
Type : Single magnetic pole Self-sealing housing MAGNET
LOCATING PIN
O'RING SEALS
MAGNETIC PLUG
REMOVED POSITION
MAGNETIC PLUGS For training purposes only © Copyright - TURBOMECA - 2000
4.41 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
STRAINERS Function
Main components
The strainers protect the scavenge pumps against large particles which might be in the oil.
- Strainer body - Wide mesh filter
Position
- Mounting flange
- In the system : they are fitted in each scavenge line upstream of the scavenge pump
- O'ring seal.
- On the engine : • Two strainers are located on the accessory gearbox casing (reduction gearbox and accessory gearbox scavenge) • One strainer is located on the oil pump assembly (gas generator rear bearing scavenge)
Functional description A strainer is a wide mesh filter which retains any large particles which may be present in the oil in order to protect the scavenge pumps.
Main characteristics - Type : wide mesh filter.
Note : The rear bearing strainer is fitted in the electrical magnetic plug housing (TU 208).
For training purposes only © Copyright - TURBOMECA - 2000
4.42 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual
Gas generator rear bearing scavenge strainer Type : Wide mesh filter
Accessory gearbox scavenge strainer ACCESSORY GEARBOX STRAINER
GAS GENERATOR REAR BEARING STRAINER (After Mod. TU 208)
Reduction gearbox scavenge strainer
GAS GENERATOR REAR BEARING STRAINER
REDUCTION GEARBOX STRAINER
ACCESSORY GEARBOX AND REDUCTION GEARBOX STRAINERS
GAS GENERATOR REAR BEARING STRAINER (Before Mod. TU 208)
STRAINERS For training purposes only © Copyright - TURBOMECA - 2000
4.43 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
LOW OIL PRESSURE SWITCH - GENERAL Function
Main components
The low oil pressure switch detects low oil system pressure and provides cockpit indication.
- Pressure switch body - Electrical connector
Position
- Mounting flange.
- In the system : downstream of the filter - On the engine : mounted on the filter base.
Main characteristics - Type : diaphragm pressure switch - Setting : 90 or 130 kPa (13 or 18.9 PSI) (according to version) - Indication : warning light on instrument panel.
For training purposes only © Copyright - TURBOMECA - 2000
4.44 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
ELECTRICAL CONNECTOR
PRESSURE SWITCH BODY
MOUNTING FLANGE
Type : Diaphragm pressure switch Setting : 90 or 130 kPa (13 or 18.9 PSI) according to version Indication : Light on instrument panel
LOW OIL PRESSURE SWITCH - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
4.45 Edition : December 2000
OIL SYSTEM
Training Manual
ARRIEL 1
LOW OIL PRESSURE SWITCH DESCRIPTION - OPERATION Description
Operation
The pressure switch comprises the following components :
The pressure switch microswitch is open during normal engine operation.
- A diaphragm, subjected to the oil pressure downstream of the filter - A plunger, fixed to the diaphragm, to operate a microswitch - An electrical contact connected to a warning light on the instrument panel
If the oil pressure downstream of the filter reduces to less than 90 or 130 kPa (13 or 18.9 PSI) according to version, the diaphragm moves down. This causes the electrical contact to close, completing the circuit of the low oil pressure warning light.
The pressure switch is secured by means of three screws on the filter base. An O'ring seal ensures the sealing between the pressure switch and the filter base.
For training purposes only © Copyright - TURBOMECA - 2000
4.46 Edition : December 2000
OIL SYSTEM
ARRIEL 1
Training Manual Firewall
AIRCRAFT
ENGINE CONTACT OPEN (normal oil pressure)
ELECTRICAL CONTACT
WARNING LIGHT (instrument panel)
+28 VDC
+28 VDC
2 1 3
LOW OIL PRESSURE SWITCH
PLUNGER DIAPHRAGM +28 VDC
From filter
2 1 3
To lubrication LIGHT "ON" (instrument panel)
DESCRIPTION
CONTACT CLOSED (low oil pressure, min 45 % N1 - Purge valve setting : • opening at 5 kPa (0.725 PSI) • closing at 120 kPa (17.4 PSI).
For training purposes only © Copyright - TURBOMECA - 2000
6.36 Edition : December 2000
FUEL SYSTEM
ARRIEL 1
Training Manual
P2 BALL VALVE
START INJECTOR ELECTRO-VALVE AND REINJECTION PROHIBIT SWITCH
PURGE VALVE
PUMP PRESSURE PURGE TO TANK
P2
FUEL OUTLET TO INJECTORS
FUEL INLET
START INJECTOR ELECTRO-VALVE - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
6.37 Edition : December 2000
FUEL SYSTEM
Training Manual
ARRIEL 1
START INJECTOR ELECTRO-VALVE DESCRIPTION The assembly includes the electro-valve, the P2 ball valve, the reinjection prohibit switch and the purge valve.
Purge valve It ensures a pre-start purge by returning a certain quantity of fuel to the tank. As soon as start is selected, the pump pressure acts on the diaphragm to stop the purge. The auxiliary valve relieves the pressure under the diaphragm after the engine has stopped.
Electro-valve It opens when energised during starting.
P2 ball valve The valve admits P2 air pressure to ventilate the injectors after the starting phase.
Reinjection prohibit switch It prevents any electrical supply to the electro-valve when the P2 pressure reaches a certain value obtained at the end of starting and thus any reinjection.
For training purposes only © Copyright - TURBOMECA - 2000
6.38 Edition : December 2000
FUEL SYSTEM
ARRIEL 1
Training Manual
RE-INJECTION PROHIBIT SWITCH
ELECTRO-VALVE
RETURN TO TANK
AUXILIARY VALVE
FUEL INLET
BALL VALVE
P2
PUMP PRESSURE
DIAPHRAGM AND VALVE
START INJECTOR ELECTRO-VALVE
PURGE VALVE
START INJECTOR ELECTRO-VALVE - DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
6.39 Edition : December 2000
FUEL SYSTEM
Training Manual
ARRIEL 1
START INJECTOR ELECTRO-VALVE OPERATION Three main operating phases can be considered : purge before start, injection during start and ventilation in normal operation.
Purge of the system before starting During the initial phase of starting, the fuel supplied from the aircraft system flows into the F.C.U., through the nonreturn valve and to the purge valve which opens and returns the fuel to the tank. The purpose of this phase is to expel any air which may be in the system.
Ventilation of the injectors At the end of starting, the supply to the electro-valve is cut and the valve closes. The air under compressor pressure P2 (which has increased in the meantime) lifts the ball of the valve and flows to ventilate the injectors. This ventilation continues as long as the engine operates to prevent blockage of the injectors by carbonization of the remaining fuel. The P2 pressure actuates the pressure switch to prevent any reinjection which could cause a flame-out by suddenly reducing fuel flow to the injection wheel.
Fuel injection When starting is selected, the engine pump pressure increases rapidly and closes the purge valve, the electrovalve is energised open and the fuel supplied by the engine pump flows to the 2 injectors which spray it into the combustion chamber. The fuel is then ignited by the sparks of the igniter plugs.
For training purposes only © Copyright - TURBOMECA - 2000
6.40 Edition : December 2000
FUEL SYSTEM
ARRIEL 1
Training Manual
PUMP PRESSURE
PURGING OF THE SYSTEM BEFORE STARTING
FUEL INJECTION
PUMP PRESSURE
VENTILATION OF THE INJECTORS
START INJECTOR ELECTRO-VALVE - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
6.41 Edition : December 2000
FUEL SYSTEM
Training Manual
ARRIEL 1
MAIN INJECTION SYSTEM - GENERAL Function
Main components
The injection system sprays fuel into the combustion chamber to give stable and efficient combustion.
- Inlet union
Position
- Supply pipe - Distributor
- On the engine : inside the combustion chamber. The injection wheel is mounted between the centrifugal compressor and the turbine shaft. The distributor is bolted to the diffuser backplate.
- Wheel with spraying jets.
Main characteristics - Type : centrifugal injection - Radial fuel supply.
For training purposes only © Copyright - TURBOMECA - 2000
6.42 Edition : December 2000
FUEL SYSTEM
Training Manual
ARRIEL 1
CENTRIFUGAL INJECTION WHEEL (with spraying jets) DISTRIBUTOR
Type : Centrifugal injection, radial fuel supply
FUEL INLET UNION
SUPPLY PIPE
MAIN INJECTION SYSTEM - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
6.43 Edition : December 2000
FUEL SYSTEM
Training Manual
ARRIEL 1
MAIN INJECTION SYSTEM - DESCRIPTION OPERATION Description
Operation
The injection system comprises the fuel inlet union, the internal supply pipe and the centrifugal injection assemblydistributor and wheel.
The fuel is delivered to the distributor by the internal supply pipe. It passes through the distributor's axial holes into the chamber in the injection wheel.
Fuel inlet union Fitted at the lower right front face of the compressor casing, it has a plug to test the sealing of the union.
As the injection wheel is rotating at high speed (N1) the fuel is centrifuged out through the radial holes and is sprayed between the two swirl plates.
Internal supply pipe
It should be noted that the injection pressure is supplied by the centrifugal force and therefore the fuel system does not require very high pressures.
This pipe connects the inlet union to the fuel distributor. It is fitted between the front swirl plate and the diffuser backplate.
Centrifugal injection assembly
The injection wheel fuel chamber is sealed by pressurised labyrinth seals. There is a small air flow into the fuel chamber. During shut-down the fuel remaining in the system is purged via the overspeed and drain valve.
This assembly consists of a stationary distributor and a wheel. The distributor, fitted onto the diffuser back-plate, is drilled with axial holes which deliver the fuel to the wheel. The injection wheel, mounted by curvic couplings between the compressor and the turbine shaft, is drilled with radial holes which form the fuel spraying jets. Sealing between the distributor and the wheel is achieved by pressurised labyrinth seals.
For training purposes only © Copyright - TURBOMECA - 2000
6.44 Edition : December 2000
FUEL SYSTEM
ARRIEL 1
Training Manual
FUEL SPRAYING INTO THE COMBUSTION CHAMBER
CENTRIFUGAL WHEEL
DISTRIBUTOR
FUEL INLET UNION
INTERNAL SUPPLY PIPE
FUEL INLET LEAK CHECK PLUG
MAIN INJECTION SYSTEM - DESCRIPTION - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
6.45 Edition : December 2000
FUEL SYSTEM
Training Manual
ARRIEL 1
START INJECTORS - GENERAL Function
Main components
The two start injectors spray fuel into the combustion chamber during engine starting.
- Mounting flange - Fuel inlet union
Position
- Injector body
- On the upper part of the turbine casing at 2 o'clock and 10 o'clock
- Spraying jet.
- They penetrate into the mixer unit.
Main characteristics - Type : simple injector - Quantity : 2 - Ventilation : by air flow.
For training purposes only © Copyright - TURBOMECA - 2000
6.46 Edition : December 2000
FUEL SYSTEM
ARRIEL 1
Training Manual
INJECTOR IGNITER PLUG
Type : Simple injector Quantity : 2 Ventilation : By air flow
START INJECTORS - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
6.47 Edition : December 2000
FUEL SYSTEM
Training Manual
ARRIEL 1
START INJECTORS - DESCRIPTION OPERATION Description
Operation
The injectors are mounted on the upper part of the turbine casing. They penetrate into the combustion chamber through holes in the mixer unit.
Starting
They are secured by two bolts onto bosses with seals and spacers to prevent leaks and adjust the depth of penetration into the combustion chamber.
The fuel is atomised and is ignited by the sparks from the igniter plugs. The flame thus produced, ignites the fuel sprayed by the centrifugal injection wheel.
Injector components
Normal running
- Injector body with mounting flange
When the engine reaches self sustaining speed (approx. 45 % N1) the fuel supply to the injectors is shut off.
- Fuel inlet (threaded to receive a union) - Filter manifold - Spacer and seals - Nut
During starting the injectors are supplied with fuel.
P2 air is then blown through the injectors to avoid carbonisation of the residual fuel. It should be noted that ventilation is continuous during engine running.
- Jet - Shroud.
For training purposes only © Copyright - TURBOMECA - 2000
6.48 Edition : December 2000
FUEL SYSTEM
ARRIEL 1
Training Manual
INJECTOR
START INJECTOR SUPPLY
FUEL INLET MOUNTING FLANGE (mounting with two bolts)
Starting SPACERS AND SEALS
FILTER MANIFOLD
START INJECTOR VENTILATION
SHROUD JET
P2
NUT
Normal running
DESCRIPTION
OPERATION
START INJECTORS - DESCRIPTION - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
6.49 Edition : December 2000
FUEL SYSTEM
Training Manual
ARRIEL 1
COMBUSTION CHAMBER DRAIN VALVE GENERAL Function
Main components
The valve drains overboard any unburnt fuel remaining in the combustion chamber.
- Valve body - Outlet union.
Position - On the engine : screwed into the turbine casing lower part.
Main characteristics - Type : half-ball valve - Setting : Closing obtained at about 40 % N1.
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6.50 Edition : December 2000
FUEL SYSTEM
Training Manual
ARRIEL 1
VALVE BODY Type : Half-ball valve Setting : Closing obtained at about ≈ 40 % N1
OUTLET UNION
COMBUSTION CHAMBER DRAIN VALVE - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
6.51 Edition : December 2000
FUEL SYSTEM
Training Manual
ARRIEL 1
COMBUSTION CHAMBER DRAIN VALVE DESCRIPTION - OPERATION Description
Operation
The drain valve includes the following components :
The valve has two positions : open and closed.
- A threaded part to fix the valve on the combustion chamber
Open position
- A half ball valve mounted on a tension spring
When the engine is not running and at the beginning of start, the valve is held open by the action of the tension spring.
- An outlet union which connects to the drain system - A circlip which retains the valve in the body.
Any unburnt fuel in the combustion chamber will drain through the valve overboard to the drain system. This ensures that no fuel accumulates in the combustion chamber which could cause starting problems (e.g. : overtemperature) . Closed position As the engine starts the combustion chamber pressure increases. This pressure is felt on the upper surface of the half ball which moves down to close the drain. The valve closes during the initial phase of starting for a speed of about 40 % N1.
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6.52 Edition : December 2000
FUEL SYSTEM
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Training Manual
Unburnt fuel
CIRCLIP
P2 air pressure
THREADS
SEAL
SPRING
To drain system HALF-BALL VALVE
OUTLET UNION
"OPEN" position
DESCRIPTION
"CLOSED" position
OPERATION
COMBUSTION CHAMBER DRAIN VALVE - DESCRIPTION - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
6.53 Edition : December 2000
FUEL SYSTEM
Training Manual
ARRIEL 1
FUEL PIPES Description
Note : The pipes may be different according to version.
The fuel pipes ensure the circulation of fuel between the components of the system.
Main characteristics - Type : rigid, stainless steel - Unions : with integral olives.
Main pipes - Fuel inlet union - From FCU to overspeed and drain valve and to injector electro-valve - From electro-valve to the two injectors - From overspeed and drain valve to fuel inlet union - From union to the wheel (internal pipe) - From the pump to the overspeed and drain valve and the purge valve (control system) - Drains.
For training purposes only © Copyright - TURBOMECA - 2000
6.54 Edition : December 2000
FUEL SYSTEM
ARRIEL 1
Training Manual
FCU TO OVERSPEED AND DRAIN VALVE AND TO START INJECTOR ELECTRO-VALVE
PUMP PRESSURE TO OVERSPEED AND DRAIN VALVE AND PURGE VALVE
RETURN TO TANK
ELECTRO-VALVE TO INJECTORS
P2 P2
FUEL INLET UNION
DRAINS
OVERSPEED AND DRAIN VALVE TO FUEL INLET UNION
FUEL PIPES For training purposes only © Copyright - TURBOMECA - 2000
6.55 Edition : December 2000
FUEL SYSTEM
ARRIEL 1
Training Manual
7 - CONTROL SYSTEM - Control system ............................................................... 7.2 • General ...................................................................... 7.2 • Description .................................................................................. 7.4 • Operation ................................................................... 7.6 à 7.33
For training purposes only © Copyright - TURBOMECA - 2000
7.1 Edition : December 2000
CONTROL SYSTEM
Training Manual
ARRIEL 1
CONTROL SYSTEM - GENERAL Functions
Main components
The system is designed to adapt the engine to the aircraft power requirements whilst remaining within defined limits.
- Fuel control unit - Engine and systems
The main functions are : - Aircraft : various systems (control, indication, supply) - Manual control - Tachometer box - according to version. - Speed control - Various limits - Acceleration control - Overspeed protection.
Main characteristics - Hydromechanical control - Manual control.
For training purposes only © Copyright - TURBOMECA - 2000
7.2 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual
CONOCO
G-BKXD SA 365 N
Management Aviation
AIRCRAFT (various systems)
TEST
F.C.U.
MAIN FUNCTIONS
TACHOMETER BOX (according to version)
- Manual control - Speed control - Various limits - Acceleration control - Overspeed protection
ENGINE (engine and systems)
CONTROL SYSTEM - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
7.3 Edition : December 2000
CONTROL SYSTEM
Training Manual
ARRIEL 1
CONTROL SYSTEM - DESCRIPTION The complete system includes aircraft components, engine components and the FCU.
Aircraft components - Control devices (control lever and anticipator)
- FCU components : • Power turbine speed governor • Gas generator speed governor • Acceleration control unit • Metering unit.
- Indicating devices (indicators, lights...)
Engine components - Hydromechanical components : • Overspeed and drain valve • Purge valve • Start injector electro-valve • Pressurising valve • Start injectors • Main injection system
For training purposes only © Copyright - TURBOMECA - 2000
7.4 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual
START INJECTOR ELECTRO-VALVE
ANTICIPATOR
START INJECTORS
POWER TURBINE SPEED GOVERNOR
PURGE VALVE CONTROL LEVER
GAS GENERATOR SPEED GOVERNOR
OVERSPEED AND DRAIN VALVE
ACCELERATION CONTROL UNIT
METERING UNIT
PRESSURIZING VALVE
INJECTION WHEEL
CONTROL SYSTEM - DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
7.5 Edition : December 2000
CONTROL SYSTEM
Training Manual
ARRIEL 1
CONTROL SYSTEM - OPERATION (1) Control - General
Adaptation to requirements
Installation configuration
The control system ensures the engine adaptation to the requirements by metering the fuel flow CH sprayed into the combustion chamber.
The gas generator supplies power to the power turbine which is connected to the helicopter main rotor. Installation requirements - Aircraft rotor speed (NR) almost constant in all operating conditions (because of the rotor efficiency) whatever the load applied - Max torque limitation (imposed by the mechanical transmission and the helicopter main gearbox) - Power turbine rotation speed (N2) within given limits (in fact almost constant, as it is connected to the rotor)
Thus, the gas generator adapts automatically to the requirements (N1 demand) to maintain constant power turbine rotation speed N2 whilst keeping all the other parameters within determined limits. This adaptation is illustrated by : - The diagram W/N2 which illustrates the power W, the max torque C and the rotation speeds N1 and N2 - The diagram N1/N2 which illustrates the N1/N2 relationship.
- Limitation of the gas generator rotation speed N1 : • Max N1 (maximum engine power) • Min N1 (to avoid critical speeds) - Load sharing (equal sharing of loads between the 2 engines) - Protection against surge, flame-out, overtemp…
For training purposes only © Copyright - TURBOMECA - 2000
7.6 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual NR W
N2
N1
x
Ma
W
Max N1
e qu tor
N1 isospeeds
C
TET Min N1
CH
N2
Control system
POWER W / N1, N2 REQUIREMENTS
N1
- NR - N2 - Max torque - N1 - W eng 1 = W eng 2 - Protections
Max Nominal N2
Operating range Min
INSTALLATION CONFIGURATION AND REQUIREMENTS N1 / N2
N2
ADAPTATION TO REQUIREMENTS
CONTROL - GENERAL
CONTROL SYSTEM - OPERATION (1) For training purposes only © Copyright - TURBOMECA - 2000
7.7 Edition : December 2000
CONTROL SYSTEM
Training Manual
ARRIEL 1
CONTROL SYSTEM - OPERATION (2) Principle of the control loop
Static droop
The system meters the fuel flow in order to match the engine power to the requirements thus keeping power turbine rotation speed constant. The control components are contained in the hydromechanical unit mounted on the front face of the accessory gearbox.
In this type of control, the speed N1 is made inversely proportional to N2. The relation N1/N2 illustrates this proportionality and the N2 variation is called "static droop".
Operation of the control loop The power turbine governor compares the actual speed N2 with a speed datum which varies with the collective pitch. It determines a speed datum (N1*) which is a function of the difference measured.
This droop ensures the stability of the system but it cannot be tolerated as the helicopter rotor requires a given speed. As the load mainly results from the collective pitch, a linkage with the governor is provided to compensate the static droop. Moreover, this linkage advances the phase of detection (this is why it is called anticipator) to reduce the response time.
The gas generator governor compares the datum speed (N1*) and the actual speed (N1) and meters the fuel to maintain the datum speed, thus matching the gas generator to the conditions.
The diagram illustrates the static droop line for different collective pitch angles (anticipator effect).
The acceleration control unit limits the transient fuel flow variations in relation to P2 pressure so as to prevent compressor surge while permitting quick response times.
In operation, the points 1, 2 and 3 are obtained and the droop is slighthy overcompensated ; ie : power turbine speed (and therefore rotor speed) maintained almost constant in all operating conditions.
In the diagram : θ1 = low pitch, θ2 = medium pitch, θ3 = high pitch.
In transient conditions, the power turbine speed varies, but the governing system responds to regain the nominal speed very quickly. Note : the static droop is slightly overcompensated.
For training purposes only © Copyright - TURBOMECA - 2000
7.8 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual N1 POWER TURBINE
GAS GENERATOR
N2
N1
N2
N1
WITHOUT ANTICIPATOR
MAIN GEARBOX
P2
Static droop
Q
COLLECTIVE PITCH CONTROL θ
ACCELERATION CONTROL UNIT
N1
+
Static droop line without anticipator for different θ θ3
N1
GAS GENERATOR SPEED GOVERNOR
N2
θ2
WITH ANTICIPATOR
θ1
N1* +
3
Apparent static droop line
N2
POWER TURBINE SPEED GOVERNOR
2 +
N2*
1
Apparent static droop
N2
PRINCIPLE OF THE CONTROL LOOP
CONTROL SYSTEM - OPERATION (2) For training purposes only © Copyright - TURBOMECA - 2000
7.9 Edition : December 2000
CONTROL SYSTEM
Training Manual
ARRIEL 1
CONTROL SYSTEM - OPERATION (3) Hydraulics of the FCU The hydromechanical control unit operates with the fuel as hydraulic fluid and lubricant. The illustration shows the entire fuel system.
For training purposes only © Copyright - TURBOMECA - 2000
7.10 Edition : December 2000
CONTROL SYSTEM
Training Manual
ARRIEL 1
HYDRAULICS OF THE FCU
CONTROL SYSTEM - OPERATION (3) For training purposes only © Copyright - TURBOMECA - 2000
7.11 Edition : December 2000
CONTROL SYSTEM
Training Manual
ARRIEL 1
CONTROL SYSTEM - OPERATION (4) Power turbine governor
Operating envelope of control
This proportional type governor determines a datum signal according to the anticipator signal and the actual speed.
The graph illustrates the N2 speed between max and min N1 ; the static droop is compensated, and slightly overcompensated, by the action of the anticipator.
In stabilized conditions, the flyweight centrifugal force balances the datum spring force. The articulated lever is in a fixed position in front of the potentiometric jet. The reduced pressure flows to the low pressure and a modulated pressure is established in the chamber. The amplifier piston (subjected to a reference pressure on one side and to the modulated pressure on the other side) determines the N1 datum transmitted to the gas generator governor by a lever and a plunger. Transient conditions, the anticipator modifies the spring tension while the centrifugal force changes. The articulated lever pivots and moves in front of the potentiometric jet thus altering the leak and therefore changing the modulated pressure. The amplifier piston then moves and, by means of the lever and plunger, sets a new datum on the gas generator governor. The gas generator adapts itself to the new condition until the balance is regained.
For training purposes only © Copyright - TURBOMECA - 2000
7.12 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual
ANTICIPATOR
N2 DATUM SPRING
N2 SPEED DETECTOR (flyweight)
N1 Max 100% Power turbine nominal speed 90 Static droop lines for different collective pitch positions 80
MAX N1 STOP
ARTICULATED LEVER
POTENTIOMETRIC JET
70 Min
MIN N1 STOP
100% N1 DATUM PLUNGER
Low pressure (≈ 1 b)
AMPLIFIER PISTON
Modulated pressure N2 (≈ 2.8 b)
N2
Operating envelope of control
Reduced pressure (≈ 4 b)
POWER TURBINE GOVERNOR
CONTROL SYSTEM - OPERATION (4) For training purposes only © Copyright - TURBOMECA - 2000
7.13 Edition : December 2000
CONTROL SYSTEM
Training Manual
ARRIEL 1
CONTROL SYSTEM - OPERATION (5) Gas generator governor This integral type governor controls the datum speed demanded by the power turbine governor. It achieves this control by metering the fuel flow. In stabilized conditions, the flyweight centrifugal force balances the force of the datum spring. The lever is in a fixed position and the valve determines a given modulated pressure. The working piston controls a given position of the metering needle which meters the fuel flow to obtain the required rotation speed. The system is "in balance". In transient conditions, we have seen that the power turbine governor determines a new datum which upsets the balance. The lever moves, the leak varies and consequently the modulated pressure. The working piston moves the metering needle until the new N1 datum is obtained. The gas generator speed increases or decreases, thus regulating engine output power to match the load and obtain a constant power turbine speed.
For training purposes only © Copyright - TURBOMECA - 2000
7.14 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual
C LOAD C (Eg : collective pitch) N1 DATUM SPRING
ARTICULATED LEVER
N1 SPEED DETECTOR (flyweight)
t N2 N2 SPEED (Transient variation and quick return to nominal speed)
DAMPING DEVICE
t
Q FUEL FLOW Q (Variation controlled by the governor) t
N1 POTENTIOMETRIC JET
WORKING PISTON
METERING NEEDLE
N1 SPEED (Increase or decrease to match the load variations)
THERMAL COMPENSATOR Low pressure (≈ 1 b)
Modulated pressure N1 (≈ 3 b)
Reduced pressure (≈ 4 b)
t VARIATION OF THE MAIN PARAMETERS IN TIME
GAS GENERATOR GOVERNOR
CONTROL SYSTEM - OPERATION (5) For training purposes only © Copyright - TURBOMECA - 2000
7.15 Edition : December 2000
CONTROL SYSTEM
Training Manual
ARRIEL 1
CONTROL SYSTEM - OPERATION (6) Acceleration control unit It limits fuel flow increase in transient conditions, in order to prevent compressor surge during acceleration. In stabilized conditions, there is a gap between the fork and the metering valve. The position of the metering valve is determined by the working piston. In load increase transient conditions, the governor "responds" and the working piston moves rapidly. Under the action of its spring, the metering needle opens until it stops against the fork. This displacement represents what is called "instant flow increase" initiating the acceleration. Then the subsequent increase in P2 pressure causes the deformation of the capsule which permits further opening of the metering needle until it comes into contact with the working piston.
For training purposes only © Copyright - TURBOMECA - 2000
7.16 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual
Q
Max flow for a determined P2 pressure (lever mechanism position) Max flow stop of the acceleration control unit
Maxi X WORKING PISTON
CAM
"X" instant flow increase = distance between the metering valve position and fork position Min flow stop of the acceleration control unit
Mini
P0 ACCELERATION CAPSULE
P2 ACCELERATION CURVE (Fuel flow Q as a function of compressor pressure P2) WORKING PISTON
GAP (x)
CAM
FUEL METERING NEEDLE
x
P0
P2
BAROSTATIC DEVICE
METERING NEEDLE
ACCELERATION CAPSULE
LEVER MECHANISM LEVER MECHANISM DIAGRAM OF THE MECHANISM
ACCELERATION CONTROL UNIT
CONTROL SYSTEM - OPERATION (6) For training purposes only © Copyright - TURBOMECA - 2000
7.17 Edition : December 2000
CONTROL SYSTEM
Training Manual
ARRIEL 1
CONTROL SYSTEM - OPERATION (7) Deceleration control unit In some versions, a deceleration control unit (or min flow limiter) is included in the metering unit to prevent flameout during deceleration. In load decrease transient conditions, the closing of the metering needle is limited by a mechanical stop. This mechanical stop is controlled by a diaphragm subjected to P2 pressure. The stop withdraws as the P2 pressure decreases in order to prevent engine flame-out during rapid deceleration.
For training purposes only © Copyright - TURBOMECA - 2000
7.18 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual
DECELERATION CONTROL UNIT
Q P2 P0
Min flow curve as a function of P2 pressure
P2 DECELERATION CURVE (Q as a function of P2)
P2
DECELERATION CONTROL UNIT
CONTROL SYSTEM - OPERATION (7) For training purposes only © Copyright - TURBOMECA - 2000
7.19 Edition : December 2000
CONTROL SYSTEM
Training Manual
ARRIEL 1
CONTROL SYSTEM - OPERATION (8) Metering unit
The graphs below illustrate the valve operation
Metering needle
Graph of fuel flow (Q) as a function of metering needle position (S) : each position corresponds to a fuel flow and each displacement ∆S corresponds to a proportional flow variation ∆Q.
The metering needle is a profiled needle which moves in a calibrated orifice. The fuel under pump pressure flows through the passage determined by the metering needle sliding in the orifice. Constant ∆P valve
Graph of fuel flow (Q) in relation to the pressure difference (∆P) : in transient conditions, the ∆P varies, but the valve operates to return it to its initial value with a slight static droop.
To obtain a fuel flow solely depending upon the metering needle position, this valve keeps a constant pressure difference across the metering needle. It consists of a diaphragm subjected metering needle pressure variation. Any variation of pressure difference (∆P) is sensed by this valve which returns more or less fuel to the inlet of the pump. In fact, the pump always supplies a flow higher than the engine requirements and the excess fuel is returned to the inlet. The ∆P transient variations are due to the pump pressure variations, to the downstream pressure variations and of course to the displacement of the metering valve. For example : when the metering needle opens, the pressure difference decreases, the valve diaphragm senses this and moves to close the return. More fuel is admitted to the engine, the upstream pressure increases and the nominal ∆P is regained.
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7.20 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual
FUEL RETURN
FUEL INLET
CONSTANT ∆P VALVE
Q
Q
Max
Min
∆Q
∆P Q AS A FUNCTION OF ∆P
METERING NEEDLE
∆S
S
Q AS A FUNCTION OF NEEDLE POSITIONS (S)
FUEL OUTLET
METERING UNIT
CONTROL SYSTEM - OPERATION (8) For training purposes only © Copyright - TURBOMECA - 2000
7.21 Edition : December 2000
CONTROL SYSTEM
Training Manual
ARRIEL 1
CONTROL SYSTEM - OPERATION (9) Limits of gas generator speeds
Min governed speed
The gas generator rotation speed varies (to adapt the engine to changing conditions) between two extreme limits represented by adjustable mechanical stops.
It is limited by a fixed adjustable mechanical stop to avoid low speeds corresponding to critical ratings. In operation, this limit is practically never reached because, even at zero torque, the power to drive the compressor requires a higher speed. Therefore, the stop is only a safety measure and it is only adjusted on the FCU test rig.
Max speed It is automatically limited by a fixed adjustable stop which represents the max operating rating.
Limits of fuel flow
TAKE-OFF - Max take-off power in the case of a single engine (in fact, this rating is given at a value slightly lower than the mechanical stop and the engine must be operated not to overcome it).
Fuel flow variation in transient conditions is limited by the acceleration control unit to obtain an optimum acceleration without compressor surge. The acceleration rate determines the response time. The slope of acceleration is only adjustable on the test rig.
MAX CONTINGENCY - Max power in the case of engine failure during takeoff or landing of a twin engine helicopter. In some versions an extreme rating called super contingency power is used.
The min fuel flow (limit to prevent flame-out) is limited by a mechanical stop on the metering needle. In some versions, this stop is variable with P2 pressure ; it is also called the deceleration control unit.
The effect of fuel temperature on the speed (variation of fuel viscosity changing the balance point of the hydromechanical governor) is compensated by the capsule in order to obtain speed invariability (especially max N1). A slight max N1 variation is however introduced but within given limits.
For training purposes only © Copyright - TURBOMECA - 2000
The max fuel flow is determined by the full opening of the metering needle for a given pressure difference ∆P. It is a factory adjustment which represents a sort of power limitation. In manual control (emergency control), the max fuel flow is limited at a lower value to avoid exceeding of the limits.
7.22 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual
N1 Max. 100%
90
80
70
Min. Q 100%
N1
N1 thermal limit
N2
Metering unit max Q
Manual control max Q (emergency)
N1 max as a function of fuel temperature
Metering unit min Q (with deceleration control unit)
N1limit to ensure power
Metering unit min Q (without deceleration control unit) t°
P2
N1 LIMITS
FUEL FLOW LIMITS (Q)
LIMITS
CONTROL SYSTEM - OPERATION (9) For training purposes only © Copyright - TURBOMECA - 2000
7.23 Edition : December 2000
CONTROL SYSTEM
Training Manual
ARRIEL 1
CONTROL SYSTEM - OPERATION (10) Limit of torque
Power turbine overspeed safety system
A max torque limit is required by the mechanical transmission. The control system does not ensure a torque limit and the operating instructions should be observed to prevent any overtorque. The flight manual indicates the torque limits : also see chapter "indication" of this manual for details of the torque measuring system.
This safety system is not included in the control unit but is often mentioned among the functions of the engine control system. The overspeed safety system is designed mainly to take into account the case of shaft failure resulting in a very sudden acceleration which cannot be contained by the speed governor. The system includes a speed detector, an electronic unit and the overspeed and drain valve of the fuel system. It is installed on some versions : twin engine configurations mainly (see details of the system in electric system chapter).
For training purposes only © Copyright - TURBOMECA - 2000
7.24 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual
OVERSPEED AND DRAIN VALVE
TACHOMETER BOX
N2 DETECTOR
Q
C TEST
TORQUE INDICATOR
LIMIT OF TORQUE - POWER TURBINE OVERSPEED SAFETY SYSTEM
CONTROL SYSTEM - OPERATION (10) For training purposes only © Copyright - TURBOMECA - 2000
7.25 Edition : December 2000
CONTROL SYSTEM
Training Manual
ARRIEL 1
CONTROL SYSTEM - OPERATION (11) Control system performance
Dynamic variation of power turbine speed
As regards the operation, the control system performance determines some flight characteristics.
It is the transient speed variation occurring during a load variation. The amplitude of this variation can be observed on the rotor speed indicator ; it is related to the other characteristics.
The following can be distinguished : - The response time
Static variation of power turbine speed
- The static and dynamic power turbine speed variations - The max speed of the gas generator.
Response time It can be defined as the time required to regain power turbine nominal speed in transient conditions. The response time is closely associated to the rate of acceleration of the gas generator. A check of the response time can be made by recording parameters during a load application. It is approx. 4 seconds between N1 min and max in standard conditions.
For training purposes only © Copyright - TURBOMECA - 2000
It can be defined as the speed variation at different ratings. This static variation (a static droop which is slightly overcompensated) can be checked by noting NR speed at different operating points (eg : ground fine pitch and cruise pitch). With the increase of power, the NR increases slightly within given limits.
Max available speed of the gas generator It is the max speed that can be obtained from the gas generator (take-off on single engine and max contingency on twin engine). This rating can be checked on a load application, noting the max speed obtained when the rotor speed starts decreasing.
7.26 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual
N2
N1
Max
100% ≈ 4 sec 90
80 Time
≈ 4 sec
70
Min
100% RESPONSE TIME AND DYNAMIC VARIATION OF THE POWER TURBINE SPEED N2
N2
STATIC VARIATION OF N2 POWER TURBINE SPEED
CONTROL SYSTEM PERFORMANCE
CONTROL SYSTEM - OPERATION (11) For training purposes only © Copyright - TURBOMECA - 2000
7.27 Edition : December 2000
CONTROL SYSTEM
Training Manual
ARRIEL 1
CONTROL SYSTEM - OPERATION (12) Twin-engine configuration Principle of load sharing In normal conditions, the helicopter rotor is driven by the two power turbines and therefore : NR = k N2 eng 1 = k N2 eng 2 The speed signals received by the two power turbine governors being identical (as well as the signals from the collective pitch), they determine identical datum signals sent to the two gas generator governors which meter fuel flow to keep them constant. As the power is closely related to the N1 speed and as the efficiency does not vary much from one power turbine to another, a fairly good load sharing is obtained. Operation on one engine In this case, the engine remaining in operation supplies the power while the other one is disconnected by the free wheel. The limit of the operative engine is represented by the max contingency rating automatically limited by the fuel control unit. This rating, determined for engine failure during take-off or landing, has a limited duration : 2 mn 30 s.
For training purposes only © Copyright - TURBOMECA - 2000
7.28 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual
MAIN GEARBOX
NR=k.N2 eng1=k.N2 eng2
COLLECTIVE PITCH
NR N2 (1&2)
N
Tq1&Tq2
FREE WHEEL REDUCTION GEARBOX
C
POWER TURBINE GAS GENERATOR N2
t4 t4
Q
POWER TURBINE GOVERNOR
N1 Max N1
N1 TRIM N2*
N1* GAS GENERATOR GOVERNOR
TWIN-ENGINE CONFIGURATION
CONTROL SYSTEM - OPERATION (12) For training purposes only © Copyright - TURBOMECA - 2000
7.29 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual
CONTROL SYSTEM - OPERATION (13) Control system loop (1)
Evolution of parameters
"Image" of load increase
θ
t = 0 - "Start" Collective pitch movement θ
-
The pitch increases
W1 > W
-
The resisting torque becomes higher than the drive torque
N2
-
The power turbine rotation speed decreases
G
-
The N2 governor detects the 2 signals, and sends a datum increase to the N1 governor : the N1 governor increases the fuel flow Q
Q
-
Instantaneous flow step
P2
-
The compressor discharge pressure increases
AC
-
The acceleration control unit enables the acceleration to continue
- Collective pitch Sudden increase from min. to max. almost instantly
N2 - Power turbine speed Transient decrease and rapid return to nominal speed after a slight overshoot, and a slight overcompensation of the static droop N1 - Gas generator speed Speed increase and stabilisation after a slight overshoot t
- Time in seconds
Combustion - The flow Q increases in the combustion chamber N1 - increases, the output power W increases, the N2 speed stops decreasing and returns to its nominal value when the equilibrium between torques W1 = W is achieved. t = 4 seconds End of transient
For training purposes only © Copyright - TURBOMECA - 2000
7.30 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual
NR
t=0 t t=4 N2
1 W >W
N2
3
1 W=W
1
N2
2 t
N2
G
N1 2
W
Q
N1
P2
3
1 t 1
3
AC
2
3
2
Combustion Q 1 "Image" of a load increase
N1
N2
Evolution of parameters during a load increase
CONTROL SYSTEM LOOP (1)
CONTROL SYSTEM - OPERATION (13) For training purposes only © Copyright - TURBOMECA - 2000
7.31 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual
CONTROL SYSTEM - OPERATION (14) Control system loop (2)
Evolution of parameters
"Image" of a load decrease
θ
t = 0 - "Start" Collective pitch movement
- Collective pitch Rapid decrease of pitch
N2 - Power turbine speed Transient increase and return to nominal speed (within the static droop)
θ
-
The pitch decreases
W1 < W
-
The resisting torque becomes lower than the drive torque
N2
-
The power turbine rotation speed increases
N1 - Gas generator speed Speed decrease and stabilisation
G
-
The governor detects the N2 increase and decreases the fuel flow Q
t
DC
-
The deceleration controller limits the min fuel flow (if needs be)
- Time in seconds
Combustion - The flow Q decreases in the combustion chamber N1 - decreases, the output power W decreases, the N2 speed returns to its nominal value. t = 4 seconds End of transient
For training purposes only © Copyright - TURBOMECA - 2000
7.32 Edition : December 2000
CONTROL SYSTEM
ARRIEL 1
Training Manual
NR
t=0 t t=4
N2
1 W 25 %
REARMING VERSION
25 %
N1 OK 0
Light off
N1
83 %
Light flashing 1E, 1S VERSION MONITORING
EVENTUAL INHIBITION OF THIS SYSTEM
TACHOMETER BOX - OPERATION (3) For training purposes only © Copyright - TURBOMECA - 2000
10.23 Edition : December 2000
ELECTRICAL SYSTEM
Training Manual
ARRIEL 1
SUPER CONTINGENCY POWER SYSTEM GENERAL Function
Main components
The purpose of this system is to provide on extreme power rating : super contingency power rating. This system is only available on some versions.
- Control box - Super contingency power electro-valve.
The control box, delivered with the engine ensures: - the recording and display of the engine operating hours in hundreths of an hour.
Note : The S.C.P. control box is associated with the module M03.
- the recording and indication by a red flag of the use of S.C.P. - the ouput of a duplicate signal to a flashing light in the cockpit to indicate use of S.C.P.
Position The electro-valve is on the FCU, the control box in the helicopter.
Main characteristics - Selection by button on the collective pitch lever.
For training purposes only © Copyright - TURBOMECA - 2000
10.24 Edition : December 2000
ELECTRICAL SYSTEM
ARRIEL 1
Training Manual
S.C.P. ELECTRO-VALVE
S.C.P. CONTROL BOX (associated with module M03)
RED FLAG
ENGINE HOUR COUNTER
ELECTRICAL CONNECTORS
SUPER CONTINGENCY POWER SYSTEM - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
10.25 Edition : December 2000
ELECTRICAL SYSTEM
Training Manual
ARRIEL 1
SUPER CONTINGENCY POWER SYSTEM DESCRIPTION - OPERATION Description The electro-valve on the fuel control unit opens when electrically supplied to permit an increase of modulated pressure and therefore an increase of the max available rating. The control box belongs to module n° 03, it indicates the engine hours and the operation of S.C.P. The system includes : • a selector on the collective pitch-lever • an automatic armament switch in the torque indicating system. • a flasher relay • an indicating device (light and flag)
Operation
The detection logic in the torque indicating system closes its contact thus supplying, through the pilot's selector, the S.C.P. electro-valves of both engines and the S.C.P. light in the cockpit. Super Contingency Power will now be available on the operative engine. Rating detection From 50 to 102.5 % N1 the S.C.P. box counts the engine hours. From 102.5 to 103.8 % N1, that is in S.C.P. mode, the engine hours counting is increased by a multiplication factor of 4.4. The S.C.P. light is on. If the N1 remains above 103.8 % for more than 5 seconds the bi-stable relay is supplied and relay (C) is supplied causing the flashing of the S.C.P. light. Simultaneously the red flag is activated and appears in the window.
S.C.P. Arming Two conditions are necessary for the arming of the S.C.P. system: - the pilot must select S.C.P. - there must be a torque difference between the engines ≥ 22 %.
For training purposes only © Copyright - TURBOMECA - 2000
Note 1 : Normal max N1 is 102.4 % for the Arriel 1M1 / 1MN1 without S.C.P. In S.C.P. mode the max N1 is 105 %. Note 2 : The maximum authorised accumulated operating time in S.C.P. is 1 minute. The use of this rating requires replacement of the engine and the S.C.P. box.
10.26 Edition : December 2000
ELECTRICAL SYSTEM
ARRIEL 1
Training Manual
TORQUE INDICATOR
+ 28 V
TO OTHER ENGINE (SCP electro-valve)
D ≥ 22%
COLLECTIF PITCH S.C.P. SELECTOR
RELAY TO ELECTRO-VALVES
S.C.P. + 28 V FLASHER UNIT C RELAY
S.C.P. CONTROL BOX
BI-STABLE RELAY + 28 V
FLAG N1 ≥ 103.8 %
T:5 secs
N1 ≥ 102.5 % (T x4.4) SIGNAL FROM N1 TACHO. GEN.
N1 ≥ 50 %
(T x1)
ENG. HOURS COUNTER
S.C.P. ELECTRO-VALVE
WINDOW
TO N1 INDICATOR
SUPER CONTINGENCY POWER SYSTEM DESCRIPTION - OPERATION For training purposes only © Copyright - TURBOMECA - 2000
10.27 Edition : December 2000
ELECTRICAL SYSTEM
Training Manual
ARRIEL 1
ELECTRICAL HARNESSES Function Harnesses link the engine accessories to the aircraft.
Description and operation All engine versions have a multi-pin plug for the engine/ aircraft interface and a second electrical plug for the pyrometric system (except on ARRIEL 1S1 : only one electrical plug for the two harnesses). On the twin-engine version : a harness for the speed detection to stop the engine in case of overspeed.
Note : The starter-generator cables must also be mentioned.
For training purposes only © Copyright - TURBOMECA - 2000
10.28 Edition : December 2000
ELECTRICAL SYSTEM
ARRIEL 1
Training Manual
SPEED DETECTION HARNESS FOR THE OVERSPEED SYSTEM (twin-engine version)
PYROMETRIC HARNESS
ACCESSORY HARNESS
ARRIEL 1S1 : only one connector
ELECTRICAL HARNESSES For training purposes only © Copyright - TURBOMECA - 2000
10.29 Edition : December 2000
ELECTRICAL SYSTEM
Training Manual
ARRIEL 1
11 - ENGINE INSTALLATION - Engine compartment ..................................................... - Engine mounting............................................................ - Power drive .................................................................... - Air intake........................................................................ - Exhaust system .............................................................. - Engine system interfaces .............................................. • Oil system .................................................................................... • Aircraft LP fuel system .............................................................. • Manual controls .......................................................................... • Air system.................................................................................... - Drain system .................................................................. - Fire protection ............................................................... For training purposes only © Copyright - TURBOMECA - 2000
11.2 11.4 11.8 11.10 11.12 11.14 11.14 11.16 11.18 11.20 11.22 11.24 to 11.25 11.1
Edition : December 2000
ENGINE INSTALLATION
Training Manual
ARRIEL 1
ENGINE COMPARTMENT Function
Description
The engine compartment accommodates the engines and ensures their ventilation.
A typical twin-engine installation includes the following components :
Position
- Two areas separated by a central firewall : • Right engine area • Left engine area
- At the rear of the helicopter main gearbox.
Main characteristics - Insulated compartments - Compartment ventilation by air circulation.
Main components - Firewalls - Cowlings - Support platform.
- Three main firewalls : • Front firewall • Rear firewall • Central firewall. - The main engine mountings - Two main cowlings : • The air inlet cowling which permits access to the air intake • The engine cowling which permits access to the engine and to the exhaust system. The compartment ventilation is ensured by air circulation in order to maintain an acceptable temperature in the various areas. The ventilation can be increased by the compressor bleed valve air discharging into the engine compartment.
For training purposes only © Copyright - TURBOMECA - 2000
11.2 Edition : December 2000
ENGINE INSTALLATION
ARRIEL 1
Training Manual
ENGINE
SUPPORT PLATFORM
FRONT FIREWALL
ENGINE MOUNTING
AIR INLET COWLING
MAIN GEARBOX
EXAMPLE OF SINGLE ENGINE INSTALLATION
CENTRAL FIREWALL
REAR FIREWALL
ENGINE COWLING
EXAMPLE OF TWIN-ENGINE INSTALLATION
ENGINE COMPARTMENT For training purposes only © Copyright - TURBOMECA - 2000
11.3 Edition : December 2000
ENGINE INSTALLATION
Training Manual
ARRIEL 1
ENGINE MOUNTING - GENERAL Function The engine mountings attach the engine to the airframe. The lifting brackets permit the removal and installation of the engine.
Position - Front mounting : at the front lower part of the accessory gearbox casing - Rear mounting : at the front lower part of the reduction gearbox casing, or on the protection tube (according to version) - Lifting brackets : 2 at the front part and one at the rear.
Main components - Front mounting : flange or yoke (according to version) - Rear mounting : clamps and cradle (according to version) - Engine lifting points : • two brackets on the centrifugal (compressor casing flange) • one bracket on the power turbine casing flange.
For training purposes only © Copyright - TURBOMECA - 2000
11.4 Edition : December 2000
ENGINE INSTALLATION
ARRIEL 1
Training Manual
FRONT LIFTING BRACKETS
FRONT FLANGE
REAR LIFTING BRACKET
CRADLE
CLAMPS
ENGINE MOUNTING - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
11.5 Edition : December 2000
ENGINE INSTALLATION
Training Manual
ARRIEL 1
ENGINE MOUNTING - FUNCTIONAL DESCRIPTION There are two types of engine mounting depending on the engine variant. - Variants A, B, C, D and M : Front support - ring of bolts on the front flange. Rear support - a cradle under the protection tube, secured by two clamps. - Variants E, K and S : Front support - yoke bolted to the front face of the accessory gearbox, supported on two trunnion mounts. Rear support - a rod connects to the bracket on the bottom of module 5.
For training purposes only © Copyright - TURBOMECA - 2000
11.6 Edition : December 2000
ENGINE INSTALLATION
ARRIEL 1
Training Manual
MOUNTING BY THE FRONT SUPPORT CASING FLANGE
MOUNTING BY CLAMPS ON THE PROTECTION TUBE
TYPE A - B - C - D - M
TYPE A - B - C - D - M
MOUNTING BY TWO ATTACHMENT POINTS ON THE AIRFRAME
REAR MOUNTING TYPE E - K - S
TYPE E - K - S
ENGINE MOUNTING - FUNCTIONAL DESCRIPTION For training purposes only © Copyright - TURBOMECA - 2000
11.7 Edition : December 2000
ENGINE INSTALLATION
Training Manual
ARRIEL 1
POWER DRIVE Function
Functional description
The power drive transmits the engine power to the helicopter transmission system.
The engine drive shaft consists of a steel tube, fitted with the following elements at each end :
The link is made by a transmission shaft designed to absorb the engine torque and slight misalignements (supply by aircraft manufacturer or TURBOMECA according to version)
- A triangular flange connected to the MGB input flange with a flexible coupling
Position - Between the engine and the helicopter main gearbox.
Main characteristics - Shaft designed to absorb the engine torque and slight misalignments
- A splined flange, connected to an adaptor flange which is connected to the engine drive shaft flange with a flector. The flexible couplings are installed between the flanges. They transmit torque, absorb shock and vibration and allow slight misalignment.
Note : In single engine versions, the free wheel unit drives the main gearbox and the tail rotor shaft drive.
- Rotation speed : 6000 RPM at 100 %.
Main components The main components are : • The engine drive shaft flange • The flector (engine end) • The adapting flange • The drive shaft • The flexible coupling (MGB end) • The main gearbox input flange.
For training purposes only © Copyright - TURBOMECA - 2000
11.8 Edition : December 2000
ENGINE INSTALLATION
ARRIEL 1
Training Manual
FLECTOR
ENGINE DRIVE-FLANGE
DRIVE SHAFT
1S VERSION
SPLINES
ADAPTOR FLANGE (splined) FLEXIBLE COUPLING MAIN GEARBOX INPUT FLANGE 1E VERSION
POWER DRIVE For training purposes only © Copyright - TURBOMECA - 2000
11.9 Edition : December 2000
ENGINE INSTALLATION
Training Manual
ARRIEL 1
AIR INTAKE Function
Functional description
The air intake system directs the ambient air into the engine.
A circular flange on the compressor casing permits connection of the aircraft air intake duct. The admission of air can be made through a static or a dynamic intake which can be provided with protection devices (filters, antiicing...). A pressurized seal can also be fitted to improve the connection sealing. Some versions are provided with a device for compressor washing.
Position - In front of the engine.
Main characteristics - Type : Static or dynamic, annular - Air flow : 2.5 kg/s (5.5 lb/sec.).
Main components - Helicopter air intake - Intake duct - Anti-icing system.
For training purposes only © Copyright - TURBOMECA - 2000
11.10 Edition : December 2000
ENGINE INSTALLATION
Training Manual
AIR DUCT
ANTI-ICING
ARRIEL 1
SEAL
FILTER
UNION FOR COMPRESSOR WASHING
AIR INTAKE For training purposes only © Copyright - TURBOMECA - 2000
11.11 Edition : December 2000
ENGINE INSTALLATION
Training Manual
ARRIEL 1
EXHAUST SYSTEM Function
Functional description
The exhaust system discharges the exhaust gas overboard.
The exhaust expels the gases directly but it can be adapted to the aircraft by means of an extension. The engine compartment ventilation can be accelerated by venturi effect between the engine exhaust pipe and the aircraft duct.
Position - At the rear of the engine.
Main characteristics - Type : divergent - Gas temperature : 600 °C (1080 °F).
Main components - Engine exhaust pipe - Exhaust extension.
For training purposes only © Copyright - TURBOMECA - 2000
11.12 Edition : December 2000
ENGINE INSTALLATION
ARRIEL 1
Training Manual
EXHAUST PIPE
EXTENSION
VENTURI TO ACCELERATE THE COMPARTMENT VENTILATION
EXHAUST SYSTEM For training purposes only © Copyright - TURBOMECA - 2000
11.13 Edition : December 2000
ENGINE INSTALLATION
Training Manual
ARRIEL 1
ENGINE SYSTEM INTERFACES (1) Oil system interfaces For each engine, the oil system has three interfaces as follows : - Oil return line to the aircraft oil cooler - Oil supply line to the oil pump pack - The vent line : from the oil tank to the accessory gearbox and to the exhaust.
For training purposes only © Copyright - TURBOMECA - 2000
11.14 Edition : December 2000
ENGINE INSTALLATION
Training Manual
OIL SUPPLY
AIRCRAFT
ARRIEL 1
BREATHING
ENGINE OIL RETURN TO THE COOLER
OIL SYSTEM INTERFACES
ENGINE SYSTEM INTERFACES (1) For training purposes only © Copyright - TURBOMECA - 2000
11.15 Edition : December 2000
ENGINE INSTALLATION
Training Manual
ARRIEL 1
ENGINE SYSTEM INTERFACES (2) Aircraft LP fuel system
Functional description
Function
The interface comprises the union on the FCU and return to tank union. The aircraft system may include various devices : vent, level indication, filler neck, booster pump, pressure indicator, flowmeter. The booster pump will prime the engine system and prevent cavitation of the pump.
The system supplies the engine with fuel under determined conditions of pressure, flow, temperature and filtering. Main characteristics - Filtering 10 micron. Main components
The filtering unit, normally fitted with a pre-blockage indicator and a by-pass valve is in the line before the shutoff valve which is used to isolate the engine compartment from the aircraft system.
- Fuel tank - Booster pump - Filter assembly
Note : In the 1S, 1E versions, the fuel inlet union is located on the LP fuel system, located under the engine.
- Fuel shut-off valve - Fuel inlet union - Return to tank union.
For training purposes only © Copyright - TURBOMECA - 2000
11.16 Edition : December 2000
ENGINE INSTALLATION
Training Manual
ARRIEL 1 HP PUMP PRESSURE (FCU)
FUEL INLET UNION FUEL SHUT-OFF VALVE
RETURN TO TANK UNION FUEL SUCTION FROM TANK FILTER UNIT (filtering 10 microns)
FUEL TANK
1S, 1E VERSIONS
BOOSTER PUMP (except 1S)
AIRCRAFT LP FUEL SYSTEM
ENGINE SYSTEM INTERFACES (2) For training purposes only © Copyright - TURBOMECA - 2000
11.17 Edition : December 2000
ENGINE INSTALLATION
Training Manual
ARRIEL 1
ENGINE SYSTEM INTERFACES (3) Manual controls Function To allow the control of the fuel valves and of the anticipator. Position The engine control lever and the collective pitch lever are in the cockpit and are mechanically connected to the F.C.U. Main components - Control lever - Collective pitch lever - Fuel control unit. Functional description - Engine control lever (Lever actuating 2 valves and a cam in the fuel control unit : see chapter "fuel system" and aircraft manuals for the mechanical linkage). - Anticipator control (Linkage with the helicopter collective pitch : see operation of the anticipator in the chapter "engine control" and details of the mechanical connection in the aircraft manuals).
For training purposes only © Copyright - TURBOMECA - 2000
11.18 Edition : December 2000
ENGINE INSTALLATION
ARRIEL 1
Training Manual
FUEL VALVE CONTROL
CONTROL LEVER
ANTICIPATOR CONTROL
COLLECTIVE PITCH LEVER
MANUAL CONTROLS
ENGINE SYSTEM INTERFACES (3) For training purposes only © Copyright - TURBOMECA - 2000
11.19 Edition : December 2000
ENGINE INSTALLATION
Training Manual
ARRIEL 1
ENGINE SYSTEM INTERFACES (4) Air system
Possible uses of the air
Function
- Cabin heating
The system provides warm compressed air to the aircraft for the aircraft services.
- Pressurized seal
Position
- Air intake anti-icing - Particle separator...
One tapping boss on each side of the centrifugal compressor casing. Main components
Note : Refer to aircraft manuals for detailed description of these systems.
Air tapping points (x 2). Functional description Aircraft pipes can be connected to the two tapping points to supply a given flow of P2 air. The flow is limited by restrictors but any air bleed affects engine performance.
For training purposes only © Copyright - TURBOMECA - 2000
11.20 Edition : December 2000
ENGINE INSTALLATION
ARRIEL 1
Training Manual
P2 P2 TAPPING
AIR SYSTEM
ENGINE SYSTEM INTERFACES (4) For training purposes only © Copyright - TURBOMECA - 2000
11.21 Edition : December 2000
ENGINE INSTALLATION
Training Manual
ARRIEL 1
DRAIN SYSTEM Function
Description
To drain fluids from certain engine components.
A drain collector is fitted on a bracket at the bottom of the accessory gearbox casing and is connected by a flexible pipe to an aircraft drain.
Position - Various pipelines on the engine connected to the aircraft drain system.
Four drain tubes are connected to the drain collector, the output casing drain, the pump drive drain, the combustion chamber drain and the overspeed and drain valve.
Main characteristics
The gas generator rear bearing vent pipe vents into the engine compartment.
- Stainless steel tubes.
The engine breather comprises a T union on the upper right side of the accessory gearbox. Connected to the front of this union is the oil tank breather and to the rear, the pipe which discharges into the exhaust.
Main components -
Combustion chamber drain valve General vent F.C.U. drive drain Overspeed and drain valve Exhaust pipe drain Output shaft casing drain Air vent of the Gas generator rear bearing Rear bearing collector drain.
For training purposes only © Copyright - TURBOMECA - 2000
The rear bearing supply collector has a drain into the engine compartment. The exhaust pipe drain connects into a pipe which is connected to an aircraft overboard drain.
11.22 Edition : December 2000
ENGINE INSTALLATION
ARRIEL 1
Training Manual
COMBUSTION CHAMBER DRAIN VALVE
AIR VENT OF THE GAS GENERATOR REAR BEARING
GENERAL VENT
OVERSPEED AND DRAIN VALVE
FCU DRIVE DRAIN
OUTPUT SHAFT CASING DRAIN EXHAUST PIPE DRAIN
TO AIRCRAFT
REAR BEARING COLLECTOR DRAIN
DRAIN SYSTEM For training purposes only © Copyright - TURBOMECA - 2000
11.23 Edition : December 2000
ENGINE INSTALLATION
ARRIEL 1
Training Manual
FIRE PROTECTION Function
Functional description
The fire protection system comprises overtemperature detection in the various engine areas, the indication in the cockpit, the extinguishing function.
The detection is ensured by non sealed detectors with normally closed contact (1A, B, C, D, K, M) or one sealed detector with normally open contact (1E) or by means of an aircraft mounted optical device (1S).
Main characteristics
Some detectors have a built-in resistor which permits the discrimination of circuit conditions (1C, D, K, M) : normal, overtemp, harness failed.
- Engine manufacturer supply (except 1S) • Bi-metallic detectors.
In the case of detectors with normally closed contact, the detectors are installed in series and have a setting which corresponds to the engine area of location ("cold" area or "hot" area) and thus they are not interchangeable.
- Aircraft manufacturer supply • Optical detectors (1S only) • Indicating system • Extinguishing system.
Main components - Engine • Six detectors (except : 1E : one detector, 1S : no detector) • Harness (fire proof cables).
Note : "cold" area or area 1 : area located forward of the junction of the compressor and the combustion chamber mounting flanges. "hot" area or area 2 : area located rear of the same junction.
- Aircraft • Two detectors (1S only) • Extinguishing system • Test system.
For training purposes only © Copyright - TURBOMECA - 2000
11.24 Edition : December 2000
ENGINE INSTALLATION
Training Manual
ARRIEL 1
1A,B,C,D,K,M (6 detectors)
1E (1 detector)
NON SEALED DETECTOR (1A, B, C, D, K, M )
SEALED DETECTOR AT REST (1E )
1S (2 detectors on aircraft) POSITION OF DETECTORS
Area 1 (cold)
Area 2 (hot)
+ Alarm
Detection logic
+ Aircraft
Engine
Test button EXTINGUISHING SYSTEM (bottle, manifold... )
+
Extinguishing button
EXAMPLE OF FIRE DETECTION / EXTINGUISHING SYSTEM
FIRE PROTECTION For training purposes only © Copyright - TURBOMECA - 2000
11.25 Edition : December 2000
ENGINE INSTALLATION
Training Manual
ARRIEL 1
12 - OPERATING LIMITATIONS AND PROCEDURES - Operating limitations ................................................... 12.2 - Operating procedures .................................................. 12.6 to 12.9
For training purposes only © Copyright - TURBOMECA - 2000
12.1 Edition : December 2000
OPERATING LIMITATIONS AND PROCEDURES
ARRIEL 1
Training Manual
OPERATING LIMITATIONS (1) The engine operating limitations are defined in the official manuals, however the following figures provide information for training purposes.
Power turbine rotation speed
Operating envelope
- Overspeed : 120 % N2 (twin-engine).
The engine is designed to operate within a clearly defined climatic range of temperature and pressure altitude e.g. : -50 °C to +50 °C (-58 °F to 122 °F) and -500 m to +6000 m (-1640 ft to 19680 ft).
The main limitation is :
t4 gas temperature These figures vary according to version : - Max during start : 750 °C
The starting envelope also has given limits e.g. : -500 m to 4500 m (-1640 ft to 14760 ft) and -50 °C to +50 °C (-58 °F to 122 °F) depending on the fuel and oil used.
- Max (t < 10 sec.) : 865 °C
Gas generator rotation speed
- Max take-off : 912 °C (< 5 min).
The main limitations are :
- Max OEI (2 min 30 sec) : 941 °C
- AEO max T/O 5 min max continuous : 98 % N1 - OEI max contingency - (2 min 30 sec) inter contingency - unlimited super contingency - according to version.
For training purposes only © Copyright - TURBOMECA - 2000
12.2 Edition : December 2000
OPERATING LIMITATIONS AND PROCEDURES
ARRIEL 1
Training Manual
FLIGHT ENVELOPE
POWER TURBINE ROTATION SPEED
Zp
Twin-engine : - Power turbine overspeed 120 % N2
- Flight - Starting
t0
GAS GENERATOR ROTATION SPEED - AEO max take-off (< 5 min) - AEO max continuous (98 % N1) - OEI (< 2 min 30 sec) - OEI inter contingency (unlimited) - OEI super contingency (according to version)
GAS TEMPERATURE - Max during start - Max (t < 10 sec.) - Max OEI (2 min 30) - Max take-off
OPERATING LIMITATIONS (1) For training purposes only © Copyright - TURBOMECA - 2000
12.3 Edition : December 2000
OPERATING LIMITATIONS AND PROCEDURES
Training Manual
ARRIEL 1
OPERATING LIMITATIONS (2) Torque The torque limit is imposed by the aircraft transmission. The max torque limits are given for steady power settings and for transitory overtorque in AEO and OEI modes.
Oil There are various limits associated with the oil system, e.g. consumption = 0.3 l/h ; max pressure 800 kPa (116 PSI) ; min pressure 130 kPa or 90 kPa according to version (18.85 PSI), max temperature 115 °C (239 °F).
Starting - shut-down There are many limits associated with engine starting : -
Min voltage before start (e.g. 25 V) Min voltage during start (e.g. 15 V) Start duration : between 25 and 30 sec Ventilation duration : < 15 sec Number of consecutive starts - according to version Waiting time after 3 start attempts (e.g. 20 min) Stabilisation time before shutdown : 60 sec Run-down time : > 30 sec from 30 % to 0 % N1.
Other limitations Max air tapping rate , electrical consumption, load factors, vibration, etc.
For training purposes only © Copyright - TURBOMECA - 2000
12.4 Edition : December 2000
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TORQUE
STARTING - SHUT-DOWN
- Stabilised max torque - Transient max torque
- Electrical voltage - Number of consecutive starts - Stabilisation, run-down and ventilation times
MISCELLANEOUS
OIL
- Air bleed - Electrical consumption - Loads factors - Vibration
- Max consumption - Max pressure - Min pressure - Max temperature
OPERATING LIMITATIONS (2) For training purposes only © Copyright - TURBOMECA - 2000
12.5 Edition : December 2000
OPERATING LIMITATIONS AND PROCEDURES
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OPERATING PROCEDURES (1) The operating procedures are considered for training purposes only. Refer to the aircraft manual.
Ventilation - Control lever to "stop"
Pre-start checks - Inspections, checks…
- Cranking button "on" (and maintained). The engine accelerates without ignition and fuel : ventilation should not exceed 15 seconds.
Starting
Relight in flight
- Power "on"
- Procedure identical to start on ground.
- Control lever to "start position" - Start button pressed and held. The engine starts and accelerates. During start, check : N1, N2, t4, oil Pr and t°. At 45 % N1, release the "start button"
Note : Confirm shut-down before start attempt. Wait until N1 has decelerated.
- Control lever moved to "Flight". The engine accelerates up to nominal rotor speed.
Shut-down - Stabilisation - Control lever to "stop". The engine shuts down : check the rundown time.
For training purposes only © Copyright - TURBOMECA - 2000
12.6 Edition : December 2000
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STARTING
SHUT-DOWN
90° 52° 5°
45°
RELIGHT IN FLIGHT
VENTILATION
START - SHUT-DOWN - VENTILATION - RELIGHT
OPERATING PROCEDURES (1) For training purposes only © Copyright - TURBOMECA - 2000
12.7 Edition : December 2000
OPERATING LIMITATIONS AND PROCEDURES
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OPERATING PROCEDURES (2) Flight
Training to engine failure
- Control lever in "flight" position. Automatic control : monitor engine parameters, especially the N1 indication.
This procedure must be carried out with a reduced helicopter mass, (refer to flight manual).
Engine failure (twin-engine) The engine remaining in operation supplies the power required, within its limitations (MCP : 2 min 30 sec).
Control system total failure The manual control procedure can be applied ("plus" and "minus" range) : close monitoring of parameters.
For training purposes only © Copyright - TURBOMECA - 2000
12.8 Edition : December 2000
OPERATING LIMITATIONS AND PROCEDURES
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ENGINE FAILURE (twin-engine)
FLIGHT
90° 52°
5°
45°
TRAINING TO ENGINE FAILURE
CONTROL SYSTEM TOTAL FAILURE
OPERATING PROCEDURES (2) For training purposes only © Copyright - TURBOMECA - 2000
12.9 Edition : December 2000
OPERATING LIMITATIONS AND PROCEDURES
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13 - VARIOUS ASPECTS OF MAINTENANCE - Maintenance concept .................................................... - TBOs and life limits....................................................... - Preventive maintenance ................................................ - "On-condition" monitoring .......................................... - Corrective maintenance ................................................ - Lubricants - Fuels - Materials ..................................... - Tooling ............................................................................ - Technical publications .................................................. - Product support ............................................................
For training purposes only © Copyright - TURBOMECA - 2000
13.2 13.4 13.6 13.8 13.10 13.12 13.14 13.16 13.22 to 13.23
13.1 Edition : December 2000
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MAINTENANCE CONCEPT Introduction
Second line maintenance (level "I") : engine maintenance in a workshop.
The engine is designed to have a high availability rate with reduced maintenance. The main aspects of the maintenance concept are the following : - Effective modularity
- Corrective maintenance : SRU and module removal and installation. Third line maintenance (level "H") : deep maintenance which involves module repairs. - Corrective maintenance : component replacement.
- Good accessibility
Fourth line maintenance (level "D") : overhaul and repair in specific workshop.
- Reduced removal and installation times - On-condition facility - Quick repair.
- Maintenance scheduled when the TBO is completed or when the life limits of some components are reached
Maintenance levels
- Corrective maintenance.
Four maintenance levels can be considered :
Other aspects of maintenance
First line maintenance (level "O") : engine installed in the aircraft.
Refer to the following pages.
- Scheduled and preventive maintenance • Checks and inspections • Life limit or time-ex removal.
Note : LRU - Line Replaceable Unit SRU - Shop Replaceable Unit.
- Corrective maintenance • Fault detection • Component replacement (LRU) • Check. For training purposes only © Copyright - TURBOMECA - 2000
13.2 Edition : December 2000
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MAINTENANCE LEVELS
1st LINE MAINTENANCE (level "O") (engine installed on aircraft) - Scheduled or preventive maintenance - Corrective maintenance
2nd LINE MAINTENANCE (level "I") (engine removed) - Corrective maintenance (modules, SRU)
3rd LINE MAINTENANCE (level "H") (engine removed) - Deep maintenance
4th LINE MAINTENANCE (level "D") (engine removed in specific workshop) - Scheduled maintenance (overhaul, repair) - Corrective maintenance
MAINTENANCE CONCEPT For training purposes only © Copyright - TURBOMECA - 2000
13.3 Edition : December 2000
VARIOUS ASPECTS OF MAINTENANCE
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TBOs AND LIFE LIMITS Engine, module and accessory TBOs
TBO components
TBOs (operating Time Between Overhauls) are defined for the engine, the modules and the accessories. These TBOs, determined by tests and experience, are subject to an extension programme.
- Engine
Component life limits
- Modules - Certain accessories.
Life limited components
Certain components (mainly rotating parts such as compressor, turbines, injection wheel, flectors…) have a life limit which requires the part to be scrapped when the limit is reached.
- Axial and centrifugal compressors - Injection wheel - Turbines.
The life is measured in operating cycles.
Counting of hours and cycles A cycle is a clearly defined operating sequence. Cycle counting is effected either manually or automatically. The method of counting cycles and the various limits are described in Chapter 5 of the maintenance manual. A counting check (comparison between automatic counting and manual counting) is a procedure planned in the periodic maintenance. A simple check can be carried out by comparing the two engine readings for a given period of operation.
For training purposes only © Copyright - TURBOMECA - 2000
13.4 Edition : December 2000
VARIOUS ASPECTS OF MAINTENANCE
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TBO
COUNTING
- Engine - Modules - Accessories
- Manual counting - Automatic counting - Counting check
CYCLE COUNTER
LIFE LIMITS Cycles for : - Compressors - Turbines - Injection wheel AUTOMATIC COUNTING
TBOs AND LIFE LIMITS For training purposes only © Copyright - TURBOMECA - 2000
13.5 Edition : December 2000
VARIOUS ASPECTS OF MAINTENANCE
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PREVENTIVE MAINTENANCE Preventive maintenance includes the procedures which must be systematically carried out.
Main inspection points of preventive maintenance - Visual inspections
Servicing inspections
- Magnetic plug and filter inspection
- Inspection before the first flight of the day
- Oil sampling for analysis
- Inspection after the last flight of the day.
- Level checks
(Refer to maintenance manual).
- Compressor cleaning (according to operating conditions)
Periodic inspections
- Operating checks and ground run test
- These procedures can be "blocked" (at fixed intervals for all the procedures) or staggered (each procedure is distributed over a period of time to reduce the turnaround time while still respecting the intervals)
- Cycle counting check - Static droop check - Run down check.
- 100 hour, 500 hour, 1500 hour or calendar inspections (18 months) - Special inspections : • Particular inspections • Inspections according to airworthiness.
For training purposes only © Copyright - TURBOMECA - 2000
13.6 Edition : December 2000
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Training Manual SERVICING INSPECTIONS
PERIODIC INSPECTIONS - Procedure "blocked" or "staggered" - 100 hour inspection - 500 hour, 1500 hour or calendar inspections (18 months) - Special inspections
- Inspection "after the last flight of the day" - Inspection "before the first flight of the day"
MAIN INSPECTION POINTS - Visual checks : air intake, compressor, exhaust, turbine, casings, attachments, pipes, wiring, controls - Inspection of filters : oil filter, fuel filter, air tapping unions and jets - Inspection of magnetic plugs - Oil sampling (for analysis) - Oil level (and replenishment if required) - Compressor cleaning (depending on operating conditions) - Ground run test - Static droop test - Run down check - Cycle counting check
PREVENTIVE MAINTENANCE For training purposes only © Copyright - TURBOMECA - 2000
13.7 Edition : December 2000
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Training Manual
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ON-CONDITION MONITORING When applying on-condition maintenance, the maintenance procedures are carried out according to the condition of engine components. It requires a monitoring which includes appropriate procedures studied during the engine design.
Objectives of on-condition monitoring The objective is to increase safety and to reduce maintenance costs. This is achieved because the monitoring ensures an early diagnosis of defects which could have seri ous consequences ; on the other hand, monitoring avoids unnecessary maintenance tasks.
On-condition monitoring resources On-condition monitoring implies an appropriate design of the engine which allows the use of monitoring tools.
- Lubricating oil check : various methods are used to check for the contamination of the oil (magnetic plugs, strainers, sampling). Samples of oil are taken at regular intervals and the samples are analysed to measure the contamination and anticipate incipient failures (analysis by magnetoscopy, ferrography, spectrometric oil analysis) - Vibration level check : the vibration level of the rotating assemblies gives an indication of the engine condition. Sensors installed at given points are used to measure the vibration level. This type of check is carried out during periodic inspections or according to engine condition - Visual inspection : conventional visual inspections are also considered for on-condition monitoring (air intake inspection , exhaust pipe inspection , exhaust and engine external inspections…).
The following procedures are considered : - Borescopic inspection : this permits inspection of internal parts which are not accessible without disassembly : compressor, combustion chamber and turbine. A special tool is used to allow direct visual inspection of the parts
For training purposes only © Copyright - TURBOMECA - 2000
13.8 Edition : December 2000
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OBJECTIVES OF ON-CONDITION MONITORING - To increase safety - To reduce maintenance costs
BORESCOPIC INSPECTION
VIBRATION CHECK
STRAINERS
MAGNETIC PLUGS
VISUAL INSPECTION
OIL SAMPLING
ON-CONDITION MONITORING For training purposes only © Copyright - TURBOMECA - 2000
13.9 Edition : December 2000
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Training Manual
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CORRECTIVE MAINTENANCE The objective of corrective maintenance is to put the engine back into normal service as soon as possible. Corrective maintenance includes all procedures which must be carried out when required (failure, defect…). It implies general and particular activities.
Corrective maintenance main tasks - Removal and installation : removal and installation of the complete power plant, of the accessories and of the modules and of some engine components as required. Note : Assembly and disassembly of the engine is dealt with in general overhaul and repair - Functional checks : functional check of systems, and accessories… - Condition checks - Adjustments - Miscellaneous procedures : cleaning, storage… - Repairing (components may be repairable or consumable) - Fault finding (refer to chapter 15 "FAULT ANALYSIS AND TROUBLE SHOOTING") - Particular instructions : for example, procedures in the event of oil contamination, surge, heavy landing, handling accident, lightning strike.
For training purposes only © Copyright - TURBOMECA - 2000
13.10 Edition : December 2000
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OBJECTIVES OF CORRECTIVE MAINTENANCE - To put the engine back into normal service as soon as possible
CORRECTIVE MAINTENANCE MAIN TASKS - Removal and installation - Functional and condition checks - Adjustments - Miscellaneous procedures (cleaning, storage ...) - Repairing (consumable or repairable components) - Fault finding - Particular instructions
CORRECTIVE MAINTENANCE For training purposes only © Copyright - TURBOMECA - 2000
13.11 Edition : December 2000
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LUBRICANTS - FUELS - MATERIALS This part deals with information on materials used : fuels, lubricants, greases, fluids.
Lubricants
The maintenance manual (chapter 71.00.02) contains tables indicating the fuel types with the corresponding US, UK, NATO and French specifications. Two types of fuel can be considered :
The engine manufacturer recommends the use of synthetic oils which keep their lubricating properties over a wide temperature range and have a longer operating life. Medium viscosity oils (5 cSt) are more particularly recommended but other types (3 to 3.9 cSt) may be used as an alternative. The maintenance manual (chapter 71.00.02) contains specification tables and precautions.
- The "normal fuels" which can be used without restriction in all the operating envelope - The "emergency fuels" (or replacement fuels) which may be used, but with particular restrictions and for a limited time in order not to affect the engine TBO.
Materials Various products are used for engine parts maintenance.
We shall remind you here that the mixture of oils of different types is not recommended. Therefore the system should be flushed when the oil specification is changed.
For example graphite grease, molybdenum disulphide for the installation of parts, cleaning and inhibiting products.
Fuels
The various products must be used carefully, for instance use of trichlorethylene on titanium alloy parts is forbidden.
The quality of the fuel is essential for the correct operation of the engine. It is particularly important to ensure a proper fuel supply : specification, water content, purity…
For training purposes only © Copyright - TURBOMECA - 2000
13.12 Edition : December 2000
VARIOUS ASPECTS OF MAINTENANCE
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LUBRICANTS (maintenance manual, chapter 71.00.02) - Normal lubricants : medium viscosity synthetic oils - "Emergency" lubricants : medium and low viscosity oils - No mixture of oils of different specifications - Flushing of the system when the oil specification is changed
FUELS (maintenance manual, chapter 71.00.02)
MATERIALS - Part installation : graphite grease, molybdenum disulphide…
- Normal fuels : (without restriction) - "Emergency" fuels (with particular restrictions : operating times, additives…)
- Cleaning : water, fuel, alcohol, detergent… - Storage : waterproof product
LUBRICANTS - FUELS - MATERIALS For training purposes only © Copyright - TURBOMECA - 2000
13.13 Edition : December 2000
VARIOUS ASPECTS OF MAINTENANCE
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TOOLING This part deals with information on maintenance tools.
- Packing equipment (e.g. : wooden or metal container)
Tools
- Tools used for removal and installation (e.g. : extractors, wrenches, supports for module removal and installation)
Maintenance requires certain tools, but in addition to the normal standard tools, a certain number of special tools and test equipment can be used. During a training course, these tools are used to carry out practical work : current maintenance and modular maintenance tools. The tools are described in an illustrated catalogue and also in the maintenance manual. In the catalogue, tools can be identified either by the function, or by the aspect or the reference.
Tool classification
- Tools for miscellaneous procedures and checking equipment : • Oil drain • Compressor washing • Vibration check • Borescopic inspection • Pressure transmitter inspection (torquemeter, fuel, oil) • Ignition system inspection • Harness inspection • Electrical measurement • Fuel injection system permeability.
We can distinguish : - Tools used for standard practices (e.g. : thread insert replacement)
Note : The tools are to ISO standard.
- Blanking devices - Handling equipment (e.g. : lifting device, engine support, transport trolley)
For training purposes only © Copyright - TURBOMECA - 2000
13.14 Edition : December 2000
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TOOLS
TOOL CLASSIFICATION
- Normal - Specific
- Standard practices - Blanking devices - Handling equipment - Packing equipment - Removal and installation - Checking procedures: • Oil drain • Compressor washing • Vibration check • Borescopic inspection • Pressure transmitter inspection • Ignition system inspection • Harness inspection • Electrical measurement • Fuel injection system permeability
CATALOGUE Identification by : - Function - Picture - Reference
TOOLING For training purposes only © Copyright - TURBOMECA - 2000
13.15 Edition : December 2000
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TECHNICAL PUBLICATIONS - GENERAL This part deals with the engine technical documentation.
Operation documents The operation documents are :
- The general overhaul and repair documents : • Overhaul manual • Standard practices manual • Work specification.
- The control documents (e.g. : flight manual)
- The deep maintenance documents (specific manual).
- The management documents : • Flight log book • Engine log book (records and provides information on the engine status).
Identification documents
Maintenance documents - The current maintenance documents are the following : • Maintenance manual (describes the engine and its systems and all the maintenance procedures) • Service bulletins (approved by the authorities, and issued to inform the operators of a modification or an instruction which affects the operational aspects) • Service letters (letter sent to inform the operator of certain instructions related to the operation of the engine) • Modification index
For training purposes only © Copyright - TURBOMECA - 2000
The identification documents are : - The current maintenance documents : • Spare parts catalogue (list and reference of all the spare parts) • Special tool catalogue (tool designations and references). - Overhaul and repair documents : • Illustrated parts catalogue (illustrates in detail all the engine and accessory parts ; only used for general overhaul) • Descriptive list and drawings.
Note : Before all maintenance procedures : - Refer to official documentation - Use the documentation "in a rational way" - Make sure that documentation is up-to-date.
13.16 Edition : December 2000
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DOCUMENTS
OPERATION
MAINTENANCE
Current maintenance
Control
Management
Example : Flight manual
Example : - Engine log book
CURRENT MAINTENANCE
- Maintenance manual - Service bulletins and letters - Modification index
IDENTIFICATION
Overhaul repair
- Spare parts catalogue - Special tool catalogue
GENERAL OVERHAUL REPAIR
- Overhaul manual - Standard practices manual - Work specification
- Illustrated parts catalogue - Descriptive list and drawings
DEEP MAINTENANCE
- Specific manual
TECHNICAL PUBLICATIONS For training purposes only © Copyright - TURBOMECA - 2000
13.17 Edition : December 2000
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TECHNICAL PUBLICATIONS MAINTENANCE MANUAL It describes the engine and its systems and all the maintenance procedures.
Layout This document has been compiled according to the requirements in the American standard "A.T.A. 100" as follows :
Installation .............................................from 401 to 499 Cleaning .................................................from 601 to 699 Replacement ..........................................from 701 to 799 Check, inspection...................................from 801 to 899 Servicing ............................................from 1101 to 1199 Storage ...............................................from 1201 to 1299 Tests ...................................................from 1301 to 1399
Layout of a chapter
CHAP
DESIGNATION
00 05 26 70 71 72 73 74 75 77 78 79 80 83
Introduction Time Between Overhauls and life limits Fire protection system Standard practices Power plant Turboshaft engine Fuel system Ignition system Air system Engine indicating Exhaust system Oil system Starting Accessory gear-box
0. 1. 2. 3. 4.
5. 6. 7.
Page numbering (ATA 100) Description and operation ............................from 1 to 99 Fault analysis .........................................from 101 to 199 Special procedures .................................from 201 to 299 Removal .................................................from 301 to 399
For training purposes only © Copyright - TURBOMECA - 2000
8.
Introduction General Purpose Complementary documentation Breakdown A. Chapters B. Page numbering C. Item numbering D. Illustration Effectivity Revisions A. Normal revisions B. Temporary revisions Use of this manual A. Systematic maintenance operation B. Optional maintenance operations C. Replacement of modules List of abbreviations
13.18 Edition : December 2000
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OBJECTIVE
LAYOUT
- Description / operation of the engine and its systems - Maintenance procedures
- Chapters - Sub-chapters - Paragraphs
CONSULTATION
NUMBERING
- Consultation method - Up-dating
- Gives the subject treated by the page
TECHNICAL PUBLICATIONS - MAINTENANCE MANUAL For training purposes only © Copyright - TURBOMECA - 2000
13.19 Edition : December 2000
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TECHNICAL PUBLICATIONS - TURBOMECA ENGINE LOG BOOK Function
- Section C : accessory replacement : when an accessory is replaced, the details should be entered on the right hand page.
This log book is used for : - Recording all information about the engine, the modules and the accessories, including the hours and cycles used and work carried out
- Section D : TBO : the TBO of a replacement module should be recorded here
- Recording the basic modification standard of the engine.
- Section E : • "Daily" column : record the daily hours and cycles
Contents
• "Total since new" column : record the accumulated hours and cycles
- Test bed results sheet - Section A : test certificate and record of modifications embodied on non modular parts
• "Total since start of life" column : record the accumulated hours and cycles since the last modular rebuild.
- Section B : record of modules Note : After changing a module the "total since start of life" column should be returned to zero.
- Section C : record of equipment - Section D : availability state - Section E : operation, maintenance and servicing - Maintenance and accessory log cards.
Use of the log-book - Test bed results sheet and section A : completed in the factory, may not be modified by the operator - Section B : when a module is replaced, record the reference number, the serial number and the date on the right hand page
For training purposes only © Copyright - TURBOMECA - 2000
• "Observations" column : Record : - The type of work carried out - The reference, serial N°, hours/cycles and reason for change of module or accessory replaced - The embodiment of a modification. • Module/Component log card : record fitting/removal details.
13.20 Edition : December 2000
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Training Manual SECTION B R
Désignation / Identity
Fabricant - Référence Manufacturer - Reference
N° Série Serial No
Date Signature
R
Désignation / Identity
Fabricant - Référence Manufacturer - Reference
N° Série Serial No
Date Signature
SECTION C R
Désignation / Identity
Fabricant Manufacturer
Référence / Reference Fabric. / Manuf. Motorist. / Eng. M.
N° Série Serial No
Tot. h. moteur / Total eng. hrs Prévi. dépose Pose / Fitting Forecast rmv.
h équipt pose Accy hrs when fitted
Date Signature
SECTION D
1 - POTENTIEL / T.B.O. Moteur non modulaire ou modules / Nonmodular engine or modules
Total h
Effectué Consumed h
2 - VIE LIMITE / LIVE LIMIT Disponible Available h
Pièces / Parts
Total Cycles
Effectué Consumed Cycles
Disponible To be run Cycles
Boîte accessoires Accessory gearbox Compresseur axial Axial compressor
Roue compresseur axial Axial compressor wheel
SECTION E FONCTIONNEMENT / TIME RUN Total depuis neuf Total depuis état de disp. Total since new Total since stat. of life Cycles Cycles Cycles H H Gas T.L. Gas T.L. Gas T.L. Gen P.T. Gen P.T. Gen P.T.
Journalier Daily Date H
Observations - Travaux effectués - Signature Observations - Works carried out - Signature
TECHNICAL PUBLICATIONS - TURBOMECA ENGINE LOG BOOK For training purposes only © Copyright - TURBOMECA - 2000
13.21 Edition : December 2000
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Training Manual
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PRODUCT SUPPORT General TURBOMECA provides the operator with the training and the assistance required to maintain the product in good operating condition.
Main aspects of the support The support covers the following fields : - Training - Technical documentation - Spare part provision - Technical assistance - Engine overhaul and repair - Contracts.
Subsidiaries and support centres Subsidiaries and support centres have been set up to provide a world wide support network.
For training purposes only © Copyright - TURBOMECA - 2000
13.22 Edition : December 2000
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TRAINING
TECHNICAL DOCUMENTATION
SUBSIDIARIES AND SUPPORT CENTRES
CONTRACTS
SPARE PART PROVISION
TECHNICAL ASSISTANCE
PRODUCT SUPPORT For training purposes only © Copyright - TURBOMECA - 2000
13.23 Edition : December 2000
VARIOUS ASPECTS OF MAINTENANCE
Training Manual
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14 - MAINTENANCE PROCEDURES - General .......................................................................... 14.2 - Inspection and check procedures ................................ 14.4 - Removal and installation procedures ......................... 14.52 - Deep maintenance.......................................................... 14.62 - Repair and overhaul ..................................................... 14.64 to 14.65
For training purposes only © Copyright - TURBOMECA - 2000
14.1 Edition : December 2000
MAINTENANCE PROCEDURES
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MAINTENANCE PROCEDURES - GENERAL This part is an introduction to the different maintenance procedures, which are described in the following pages for training purposes only.
- Permeability check
These procedures are dealt with in discussion and practical work during a training course.
- Removal and installation of the accessories
Procedures described
- Repair, general overhaul.
- Engine removal and installation
- Module removal and installation
- Standard practices - Cautions (Cautions, Warning) - Storage
Note : Refer to the maintenance manual and ensure that it is up to date before carrying out any maintenance procedure.
- Compressor washing - Oil checks - Miscellaneous checks - Borescopic inspection - Axial compressor inspection - Operating checks - Vibration check - Electrical harness check.
For training purposes only © Copyright - TURBOMECA - 2000
14.2 Edition : December 2000
MAINTENANCE PROCEDURES
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PROCEDURES
LISTS OF PROCEDURES
- Definition - Instructions and operating modes
- Standard practices - Cautions - Storage - Washing - Miscellaneous checks - Miscellaneous procedures - Removal, installation - Repair - Adjustments
Note : Refer to the maintenance manual before carrying out any maintenance procedure.
MAINTENANCE PROCEDURES - GENERAL For training purposes only © Copyright - TURBOMECA - 2000
14.3 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
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STANDARD PRACTICES General "Standard practices" are all the common procedures and practices, required for the maintenance and repair of engines. These "standard practices" are dealt with in one chapter of the maintenance manual (chapter 70). They are also dealt with in a specific document, called The Standard Practices Manual, mainly used by repairers.
Main practices Standard practices mainly deal with : - Torque loading - O'ring seal installation - Locking of assemblies - Pipe and union assembly - Thread insert replacement - Magnetic seal replacement - Application of miscellaneous products (loctite, graphite grease…) - Repair techniques (exhaust pipe welding, crack stop drilling…) - Installation of electrical connectors - Check and inspection (ex. : fuel/oil dilution check). For training purposes only © Copyright - TURBOMECA - 2000
14.4 Edition : December 2000
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Training Manual
O'RING SEAL INSTALLATION
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TORQUE LOADING (torque wrench) STANDARD PRACTICES - Manual - Chapter 70 of the maintenance manual
LOCKING OF ASSEMBLIES
THREAD INSERT REPLACEMENT
PIPE AND UNION ASSEMBLY
STANDARD PRACTICES For training purposes only © Copyright - TURBOMECA - 2000
14.5 Edition : December 2000
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ADVISORY NOTICES Three types of advisory notice are used in the technical publication :
NOTE : take the oil sample before carrying out any replenishment.
- WARNING
List of the main notices
- CAUTION
WARNING :
- NOTE.
- Toxicity of engine oil, cleaning products and extinguishing products
Interpretation
- Eye protection
WARNING : warns the reader of the possibility of physical harm (e.g. : wounding, intoxication, electrocution).
- Fire risk
CAUTION : warns the reader of the possibility of damaging the engine or tooling.
CAUTION :
NOTE : gives the reader advice on how best to carry out a task.
- Electrical discharge from HE ignition unit.
- Use of the correct tool - Use of certain products - Weak points of the engine or tools
Examples WARNING : do not breath the oil fumes. Do not leave oil in contact with the skin. CAUTION : if the flush is being carried out because of metal particles in the oil system, change the filter and thoroughly clean the tank.
- Tightening torques. NOTE : - Oil analysis - Cycle counting - Engine storage - Parameter measuring.
For training purposes only © Copyright - TURBOMECA - 2000
14.6 Edition : December 2000
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WARNING (physical harm)
- Toxicity of engine oil and vapours - Toxicity of cleaning products - Toxicity of extinguishing products - Eye protection - Fire risk - Electrical discharge from HE ignition unit : - electrocution - risks with use in an inflammable atmosphere
CAUTION (possibility of damage)
- Titanium part cleaning - Scrapping of O'ring seals - Use of the correct cleaning products - Engine cooling - Engine cleaning after use of extinguishing product - Orifice protection during removal - Borescope fragility - Tightening torque
NOTE (advice)
- Oil analysis - Cycle counting - Installation of O'ring seals - Engine storage - Insulation measurements - Procedural change with modification
ADVISORY NOTICES For training purposes only © Copyright - TURBOMECA - 2000
14.7 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
STORAGE General When an engine is not used for a long time, it must be protected against corrosive agents. The most efficient protection consists of : - Washing and protecting the air path by spraying a specific product - Housing the engine in a waterproof metal container with dessicant bags. If there is no container, the engine can be housed in a water and vapour proof cover with desiccant bags.
- "Short term" storage : procedure which protects the engine for a duration of less than 3 months if the engine is not installed in the helicopter. If the engine is installed in the helicopter : • When the engine is not used for less than 7 days, install the air intake and exhaust blanking devices and close the cowlings • When the engine is not used between 7 days and 6 months, drain and replace the oil, do a 5' ground run check every 7 days • When the engine is not used for more than 6 months, remove the engine and do the "long term" storage procedure.
Type of storage - "Long term" storage : procedure which protects the engine for a duration of more than 3 months if the engine is not installed in the helicopter. The engine is then inhibited in the package (in non sealed case or in metal container)
For training purposes only © Copyright - TURBOMECA - 2000
Note : Refer to maintenance manual for storage limits (eg. : 10 years in metal container).
14.8 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
GENERAL
ARRIEL 1 TYPE OF STORAGE
- Protection against corrosive agents - Cleaning, internal and external protection
- "Long term" : duration more than 3 months (storage in a container) - "Short term" : duration less than 3 months (protection cover)
PROCEDURES - For engine installed in aircraft (less than 7 days or between 7 days and 6 months) - For uninstalled engines (3 months and more than 3 months) - Internal and external protection - System protection - Inhibiting products - Blanking devices
PACKAGE - In non sealed case - In metal container : procedure, storage and periodic inspections Note : Package of engine, modules and accessories
STORAGE For training purposes only © Copyright - TURBOMECA - 2000
14.9 Edition : December 2000
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Training Manual
ARRIEL 1
CLEANING AND PROTECTION General Given procedures are applied to clean and protect the engine.
Main procedures - Internal cleaning and protection (rinsing, washing, cleaning, protection : refer to compressor washing) - External cleaning and protection - Procedure after usage of extinguisher - Procedure to protect the equipment (ex. : water in fuel…).
Note : Follow the instructions for the use of the cleaning products. Refer to maintenance manual, chapter 71.
For training purposes only © Copyright - TURBOMECA - 2000
14.10 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
GENERAL - Cleaning - Protection
PROCEDURES - For internal parts (refer to compressor washing) - For external parts - For equipment
NOTES - Precautions - Ref : Maintenance manual chap. 71
CLEANING AND PROTECTION For training purposes only © Copyright - TURBOMECA - 2000
14.11 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
COMPRESSOR WASH General
Procedures
Compressor washing avoids dirt accumulation and corrosion in the air path, particularly the compressor.
Compressor washing mainly consists of spraying a suitable product in the air intake during one or several ventilation sequences (water, Ardrox…).
Types of treatment - Washing and/or rinsing : removal of corrosive deposits (particularly salt deposits)
Note : Many aircraft are fitted with a compressor washing system. Washing and cleaning during a ventilation is considered the most efficient.
- Cleaning : removal of deposits likely to accumulate on the internal parts - Protection : protection of surfaces against corrosion. Frequencies - Washing : frequently in salt laden atmosphere - Cleaning : periodic inspection before storage, if necessary - Protection : before storage or in case of long grounding.
Note : Frequencies depend on operating conditions.
For training purposes only © Copyright - TURBOMECA - 2000
14.12 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
GENERAL
TYPES OF TREATEMENT
- To avoid dirt accumulation and corrosion in the air path, particularly the compressor - Preventive operation
- Washing and / or rinsing : removal of corrosive deposits (particularly salt deposits) - Cleaning : removal of deposits likely to harm the internal parts - Protection : protection of surfaces against corrosion
FREQUENCIES PROCEDURES
- Washing : frequently in salt laden atmosphere - Cleaning : at periodic inspection before storage, if necessary - Protection : before storage or in case of long grounding
- Spraying a suitable product in the air intake during one or several sequences - Spraying device - Products (water, ardrox)
COMPRESSOR WASH For training purposes only © Copyright - TURBOMECA - 2000
14.13 Edition : December 2000
MAINTENANCE PROCEDURES
ARRIEL 1
Training Manual
OIL SYSTEM SERVICING This part summarizes the maintenance procedures for the oil system.
- Sampling procedure - Word definition (ppm, concentration, contamination speed, thresholds…)
Particular instructions Maintenance manual instructions must be followed in the following cases :
- Result interpretation (warning threshold and immediate stop table).
- Oil specification change
Oil change
- Mixing with a product which is not in conformity with oil specification
- Drain conditions (blockage, particles, before removal) - Drain procedure (engine through magnetic plugs, cooling unit and tank according to aircraft manufacturer's procedure).
- Oil life limitation - Oil filter blockage
Oil filling
- Dilution.
- Aircraft manufacturer's procedure.
Particle sampling
Oil system flushing - Particle sampling procedure with magnetic plugs - Particle interpretation - Particle analysis.
Spectrometric oil analysis
- Conditions (oil specification change, contamination, life limitation…) - Procedure (draining, filling, ground run, draining, filter inspection, final filling).
- Purpose of the spectrometric analysis - Sampling frequency
For training purposes only © Copyright - TURBOMECA - 2000
14.14 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1 SPECTROMETRIC OIL ANALYSIS
PARTICULAR INSTRUCTIONS - Oil specification change - Mixing - Life limitation - Filter blockage - Oil dilution
- Purpose - Frequency - Procedure - Definition - Interpretation
OIL CHANGE - Conditions - Procedure
PARTICLE SAMPLING - Procedure - Interpretation - Analysis
OIL SYSTEM FLUSHING - Conditions - Procedure
OIL FILLING - Tank (aircraft manufacturer's procedure)
OIL SYSTEM SERVICING For training purposes only © Copyright - TURBOMECA - 2000
14.15 Edition : December 2000
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ARRIEL 1
Training Manual
MISCELLANEOUS PROCEDURES This part only mentions procedures which are part of the maintenance activity.
Introduction into service
- Exceeding of limits : particular instructions in case of temperature, torque and speed exceedance, and in case of engine flame out, compressor surge - Heavy landing
The introduction into service includes :
- Damage during transport.
- The preparation of an engine delivered in a wooden case
Treatment after use of extinguishers - The preparation of an engine delivered in a metal container - Installation in the aircraft - A ground run check.
The treatment required after use of a fire extinguisher or an accidental operation of the extinguishing system, minimises corrosion by extinguishing products. The treatment is different according to the conditions of the extinguisher use and to the extinguishing products (CO2, foam, powder, halon…).
Adjustments The engine is designed to require no current maintenance adjustments. Refer to corresponding pages and to maintenance manual for more details.
Particular instructions - Fuel : follow particular instructions in case of use of an alternative fuel and additives and in case of filter blockage - Foreign Object Damage (FOD) : procedure according to the nature of the body ingested (direct visual inspection, borescopic inspection, vibration check) For training purposes only © Copyright - TURBOMECA - 2000
14.16 Edition : December 2000
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ARRIEL 1
Training Manual
INTRODUCTION INTO SERVICE
ADJUSTMENTS
- Preparation of an engine delivered in a wooden case - Preparation of an engine delivered in a metal container - Ground run check
- The engine is designed not to require current maintenance adjustments. (refer to maintenance manual)
TREATMENT AFTER USE OF EXTINGUISHERS PARTICULAR INSTRUCTIONS
- Normal or accidental use - Treatment to reduce corrosion by extinguishing products - Treatment according to use conditions (fire or accidental use) and to the extinguishing product (CO2, foam, powder, halon...)
- Fuel - Foreign Object Damage - Exceeding of limits - Heavy landing - Damage during transport
MISCELLANEOUS PROCEDURES For training purposes only © Copyright - TURBOMECA - 2000
14.17 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
BORESCOPIC INSPECTION General Borescopic inspection allows the inspection of the internal parts which are not accessible without disassembly. This type of inspection uses a special tool which allows a direct visual inspection of the parts. Borescopic inspection can be carried out with the engine in or out of the helicopter, and on removed modules.
Combustion chamber borescopic inspection To do this inspection, it is necessary to remove an igniter plug. The combustion chamber inspection is done by entering the borescope through the igniter plug orifices
Borescopic inspection of the gas generator turbine It allows the visual inspection of the nozzle guide vane and the wheel (blades, blade roots...). The inspection is carried out using a flexible borescope and a guide in one of the igniter plug orifices.
For training purposes only © Copyright - TURBOMECA - 2000
14.18 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
Combustion chamber and turbine - Inspection of the internal parts which are not accessible without disassembly - Use of special tools - Borescopic inspection with the engine in or out of the helicopter
- Rotation of the N1 rotating assembly through one of the accessory drives or the compressor - Rotation of the N2 rotating assembly either through the rotor (engine on aircraft) or through the main power drive (engine removed)
BORESCOPIC INSPECTION For training purposes only © Copyright - TURBOMECA - 2000
14.19 Edition : December 2000
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Training Manual
ARRIEL 1
AXIAL COMPRESSOR INSPECTION Function
Criteria
This check permits the detection of dents, cracks and erosion.
The maintenance manual details the procedure to be followed, the number of dents permitted, their max depth and the max permitted erosion value. No cracks permitted.
Conditions This check can be carried out with the engine installed or uninstalled, and on a removed module.
Refer also to the maintenance manual for the rework procedure of the axial compressor 1st stage blades.
Procedures - Visual inspection of the blades - Erosion inspection using a gauge.
Visual inspection The blades must be inspected for cracks, folding, pitting, dents and nicks.
Erosion inspection This is carried out by placing the template on the inlet cone, with the indicator plate butted up against the blade root. The calibrated gauge is then introduced between blade and template to measure the erosion.
For training purposes only © Copyright - TURBOMECA - 2000
14.20 Edition : December 2000
MAINTENANCE PROCEDURES
ARRIEL 1
Training Manual
GAUGE
L Max limit sector D = 3 mm
D
Max limit sector A = 1 mm
2 mm (0.0787 inch) A B C D
TEMPLATE
3 mm (0.1181 inch)
EROSION INSPECTION
VISUAL INSPECTION
AXIAL COMPRESSOR INSPECTION For training purposes only © Copyright - TURBOMECA - 2000
14.21 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
FREEWHEEL CHECK On single engine version :
Function To check the oil level (single engine).
Conditions This check can be carried out engine installed or removed from the helicopter.
Procedure The free wheel is equipped with two plugs, for oil level check and oil draining. The filling port must be correctly positioned. On some versions, the oil supply is assured by means of a lubricating jet located inside the accessory gearbox.
For training purposes only © Copyright - TURBOMECA - 2000
14.22 Edition : December 2000
MAINTENANCE PROCEDURES
ARRIEL 1
Training Manual
OIL LEVEL CHECK POSITION :2 O'CLOCK OIL FILLING PORT
FREEWHEEL CHECK For training purposes only © Copyright - TURBOMECA - 2000
14.23 Edition : December 2000
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Training Manual
ARRIEL 1
CHECK OF INJECTION FUEL INLET UNION Purpose To check for leaks of fuel or P2 air.
Conditions This check is carried out in the aircraft during a ground run.
Procedure With the blanking screw removed and the engine running there must be no leaks from the orifice. In the event of leaks the seals must be replaced and a further check carried out.
For training purposes only © Copyright - TURBOMECA - 2000
14.24 Edition : December 2000
MAINTENANCE PROCEDURES
ARRIEL 1
Training Manual
"O" RING
COPPER SEAL
LEAK CHECK POINT (normally blanked)
CHECK OF INJECTION FUEL INLET UNION For training purposes only © Copyright - TURBOMECA - 2000
14.25 Edition : December 2000
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Training Manual
ARRIEL 1
VIBRATION CHECK Conditions The vibration check is systematically made at regular intervals and in the following cases : - After any failure due to an excessive vibration level - In case of doubt about the engine vibration level - After a modular maintenance operation.
Procedure This check is carried out with a vibration sensor fixed on the engine (on the HE unit support or on the rear flange of the turbine casing). The accelerometer measures the vibration generated by the gas generator and the power turbine. There are many vibration checking sets (refer to the maintenance manual).
For training purposes only © Copyright - TURBOMECA - 2000
14.26 Edition : December 2000
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Training Manual
ARRIEL 1 VIBRATION SENSOR
REAR SENSOR BRACKET (on the HE unit support or on the rear flange of the turbine casing)
Examples of a vibration measurement system. (Other systems can be used)
VIBRATION TEST SET
VIBRATION CHECK For training purposes only © Copyright - TURBOMECA - 2000
14.27 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
ENGINE POWER CHECK Conditions An engine power check can be carried out in flight by recording certain parameters and plotting them on a graph. For further details see the flight manual.
For training purposes only © Copyright - TURBOMECA - 2000
14.28 Edition : December 2000
MAINTENANCE PROCEDURES
ARRIEL 1
Training Manual
GOOD
Tq %
BAD
N1
NR
Zp
t0
Example of a diagram with an operating point shown with dotted lines
ENGINE POWER CHECK For training purposes only © Copyright - TURBOMECA - 2000
14.29 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
TORQUE TRANSMITTER AND LOW OIL PRESSURE SWITCH CHECK Purpose To check the operation of the torque transmitter and the low oil pressure switch.
Conditions The component to be checked must be removed from the engine.
Procedure The check can be carried out either using the Turbomeca test set or a Barfield pump. Torque transmitter : the pressure corresponding to 100 % torque is written on the module 5 log card. With the transmitter fitted on the test set the pressure is raised to the log card figure and the indication can then be checked and adjusted. Low oil pressure switch : with the unit fitted on the test set the pressure can be increased & decreased to check at what pressure the switch makes & breaks.
For training purposes only © Copyright - TURBOMECA - 2000
14.30 Edition : December 2000
MAINTENANCE PROCEDURES
ARRIEL 1
Training Manual
DIGITAL INDICATOR
REFERENCE CAPSULE
COCK
TORQUE TRANSMITTER
CONTROL
BARFIELD PUMP TEST SET LOW OIL PRESSURE SWITCH
TORQUE TRANSMITTER AND LOW OIL PRESSURE SWITCH CHECK For training purposes only © Copyright - TURBOMECA - 2000
14.31 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
IGNITION SYSTEM CHECK Purpose To check the operation of the engine ignition system.
Conditions This check can be carried out with the engine installed or uninstalled. The test set requires a 28 volt supply.
Procedure The test set is connected to the HE unit input connector. Selection of "ignition" on the test set supplies the HE unit, a light indicates a complete circuit and the igniters operate.
Note : The same test set can be used for testing the start injector electro-valve.
For training purposes only © Copyright - TURBOMECA - 2000
14.32 Edition : December 2000
MAINTENANCE PROCEDURES
ARRIEL 1
Training Manual
TO H.E. IGNITION UNIT
28 VDC SUPPLY
TEST SET
IGNITION SYSTEM CHECK For training purposes only © Copyright - TURBOMECA - 2000
14.33 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
OVERSPEED SYSTEM CHECK Purpose To confirm the integrity of the overspeed system.
Conditions The check can be carried out engine installed or uninstalled, tacho box installed or uninstalled.
Procedure With the test set supplied with 28 V and connected to the tachometer box signals of overspeed frequency can be supplied to the box to check its operation.
Note : The same test set can be used to check insulation and resistance of the overspeed pick-up probe.
For training purposes only © Copyright - TURBOMECA - 2000
14.34 Edition : December 2000
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ARRIEL 1
Training Manual
TACHOMETER BOX
TEST
TEST SET
OVERSPEED SYSTEM CHECK For training purposes only © Copyright - TURBOMECA - 2000
14.35 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
COMPRESSOR BLEED VALVE OPERATION CHECK Purpose To check that the bleed valve operates at the correct RPM.
Conditions This check can only be carried out with the engine running at high RPM, perhaps necessitating a take-off.
Procedure For the electro pneumatic valve check that the N1 threshold (opening and closing) is correct. For pneumatic valves, the threshold is function of altitude and atmospheric temperature. It is necessary to refer to a graph in the maintenance manual.
For training purposes only © Copyright - TURBOMECA - 2000
14.36 Edition : December 2000
MAINTENANCE PROCEDURES
ARRIEL 1
Training Manual
N1
Z = 2000 m Z=0
t0
Example of curve showing the N1 threshold as a function of t0 and Z. (pneumatic bleed valve)
COMPRESSOR BLEED VALVE OPERATION CHECK For training purposes only © Copyright - TURBOMECA - 2000
14.37 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
OIL PRESSURE CHECK Purpose To accurately check the engine oil pressure in case of doubt, after a module change or after assembling a repaired or overhauled engine.
Conditions Engine installed & running, the pressure is checked at 2 points using a calibrated pressure measuring tool.
Procedure Connect the measuring tool to the test point, start the engine and allow it to warm up to the normal operating temperature. Set the RPM at 85 % then read the temperature & pressure. Plot the temperature & pressure on the graph in the maintenance manual to see if the pressure is within tolerance.
Note : There are several graphs to allow for different oil viscosities.
For training purposes only © Copyright - TURBOMECA - 2000
14.38 Edition : December 2000
MAINTENANCE PROCEDURES
ARRIEL 1
Training Manual
P
t°
Example of graph to check oil pressure for a given oil specification on a given tapping point.
OIL PRESSURE CHECK For training purposes only © Copyright - TURBOMECA - 2000
14.39 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
START INJECTOR AND IGNITER PLUG PENETRATION CHECK Conditions In the event of starting problems on replacement of a plug or injector the penetration of the plug and injector must be calculated and adjusted using spacers and seals.
Procedure It is necessary to measure the length under the head of the injector and igniter and then measure the distance from the turbine casing face to the mixer unit, using a special gauge supplied by Turbomeca. Using the figures thus obtained, and the calculation table in the maintenance manual, the thickness and quantity of spacers and seals can be calculated.
Note : There must always be a seal against the face of the injector/igniter and against the face of the turbine casing.
For training purposes only © Copyright - TURBOMECA - 2000
14.40 Edition : December 2000
MAINTENANCE PROCEDURES
ARRIEL 1
Training Manual
L C
X
e
START INJECTOR
COMBUSTION CHAMBER
e' X'
IGNITER PLUG
C'
GAUGE
L'
MEASUREMENTS OF THE INJECTORS AND IGNITER PLUGS PENETRATION IN THE COMBUSTION CHAMBER
START INJECTOR AND IGNITER PLUG PENETRATION CHECK For training purposes only © Copyright - TURBOMECA - 2000
14.41 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
PERMEABILITY CHECK Conditions A permeability check of the fuel injection wheel must be carried out during periodic servicing. It may also be carried out in case of suspected problems.
Procedure The permeability test tool is connected to the injection wheel inlet union ; it is then filled to the top with water. After opening the cock at the inlet to the engine the time taken for the water level to pass between the two marks A and B on the tube is measured. A table in the maintenance manual shows the action to be taken according to the time recorded, e.g. t < 8 sec. - next check in 450 hours. t > 11 sec. - carry out wheel cleaning procedure.
For training purposes only © Copyright - TURBOMECA - 2000
14.42 Edition : December 2000
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ARRIEL 1
Training Manual
FUNNEL A MEASUREMENT OF FLOWING TIME BETWEEN A AND B B
COCK
INLET UNION
PERMEABILITY CHECK For training purposes only © Copyright - TURBOMECA - 2000
14.43 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
STATIC DROOP CHECK AND ADJUSTMENT This is mandatory check in the event of an anomaly such as :
It is particularly important to use high precision digital indicators for the readings during the check.
- drift of max N1 Note : Any adjustment of the temperature bulb must be recorded in the engine log book to ensure that the maximum adjustment limit is not exceeded.
- drift of NR - N1 difference between 2 engines.
Procedure The procedure is carried out with the engine running on ground and is defined in the Maintenance Manual. This check verifies the relationship between N1, the anticipator angle at min. pitch end the NR. The procedure then determines the necessary action. This may require adjustment of the temperature compensating bulb or its replacement if the adjustment limit is reached.
For training purposes only © Copyright - TURBOMECA - 2000
14.44 Edition : December 2000
MAINTENANCE PROCEDURES
ARRIEL 1
Training Manual
N1 % 89
87
85
83 82.3
22°
82 81.1
81
79
77 B = 0°
B = 10°
B = 20°
B = 30°
75 322
325
330
335
340
BEFORE TEMPERATURE COMPENSATOR ADJUSTMENT
345
350 346.2 347.7
355
358
NR min rpm
AFTER TEMPERATURE COMPENSATOR ADJUSTMENT
STATIC DROOP CHECK & ADJUSTMENT For training purposes only © Copyright - TURBOMECA - 2000
14.45 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
CHECK OF NR AND OF N1 MATCHING This check verifies the instrumentation and the adjustment of the components of the fuel flow control system. The check procedure is defined in the Flight Manual.
Note : It is particularly important to use high precision digital indicators.
For training purposes only © Copyright - TURBOMECA - 2000
Any anomaly will be either an indication anomaly (indication of NR, N1 or torque) or incorrectly rigged controls e.g. anticipator or an anomaly in the F.C.U. (temperature compensation bulb). Normally the first action to take is to carry out a static droop check.
14.46 Edition : December 2000
MAINTENANCE PROCEDURES
ARRIEL 1
Training Manual
TEMPERATURE COMPENSATING CAPSULE
N1
NR
N1
CHECK OF NR AND OF N1 MATCHING For training purposes only © Copyright - TURBOMECA - 2000
14.47 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
CHECK OF MAX. N1 The max. N1 check ensures that the maximum engine power is available.
Note : This check must be carried out using very accurate instruments such as digital RPM indicators.
The check procedure is described in the Flight Manual. Generally the check will show, according to the engine type : - Either that the engine reaches the max N1 stop - Or that the stop is beyond the normal max N1. This check may identify an anomaly such as fuel system blockage, leak in the fuel system, drift at the fuel control caused by the temperature compensator.
For training purposes only © Copyright - TURBOMECA - 2000
14.48 Edition : December 2000
MAINTENANCE PROCEDURES
ARRIEL 1
Training Manual
TEMPERATURE COMPENSATING CAPSULE (PRE-MOD TU183)
MARK
BIMETALLIC CORRECTOR (POST-MOD TU183) TEMPERATURE CAPSULE ADJUSTING SCREW (ADJUSTMENT, IF NECESSARY)
N1 max % Correct adjustment range
104,8
103,8
Fuel temperature °C -50
-40
-30
-20
-10
0
10
20
30
40
50
FCU SEEN FROM THE FRONT
CHECK OF MAX N1 For training purposes only © Copyright - TURBOMECA - 2000
14.49 Edition : December 2000
MAINTENANCE PROCEDURES
Training Manual
ARRIEL 1
CYCLE COUNTING Cycle counting enables the calculation of usage of life limited parts such as compressors, injection wheel and turbine wheels.
Power turbine cycle
Two types of cycles must be counted : gas generator cycles and power turbine cycles.
Refer to the maintenance manual, chapter 5 for full details of the cycle counting including the exclusions and obligations.
For the power turbine one flight equals one cycle.
Gas generator cycles There are two formulas which can be used, the recommended method and the lump method. The recommended method takes into account the max N1 (K1) and min N1 (K2) reached, as well as the number of partial cycles (n) during the flight. The lump method takes into account only the partial cycles during the flight. A partial cycle corresponds to a significant deceleration followed by a significant acceleration without stopping the engine.
For training purposes only © Copyright - TURBOMECA - 2000
14.50 Edition : December 2000
MAINTENANCE PROCEDURES
ARRIEL 1
Training Manual
Lump method
Recommended method CALCULATE N = K1 + nK2
CALCULATE N = 1 + n x 0.15 Highest N1 %
K1
100 99 98 97 96 95 94 93
1 0.9 0.8 0.7 0.65 0.6 0.55 0.5
N1%
Where : N = Number of cycles K = Number from chart for highest N1 n = Number of accelerations K2 = Number from chart for each accel.
Thus : N = 1 + 1 x 0.15 = 1.15
Lowest N1 %
Thus : N = 0.8 + 1 x 0.1 = 0.9 Gas Gen cycles
85 84 83 82 81
0.05
80 79 78 77 76
0.1
75 74 73 72 71 70
