Systems of Commercial Turbofan Engines

Size: px

Start display at page:

Download "Systems of Commercial Turbofan Engines"

Irene Berry
6 years ago
Views:

1 Systems of Commercial Turbofan Engines

2 Andreas Linke-Diesinger Systems of Commercial Turbofan Engines An Introduction to Systems Functions 123

3 Andreas Linke-Diesinger Lufthansa Technik AG Propulsion Systems Engineering Weg beim Jäger Hamburg Germany ISBN e-isbn DOI / Library of Congress Control Number: Springer-Verlag Berlin Heidelberg This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks. Duplication of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current version, and permission for use must always be obtained from Springer. Violations are liable for prosecution under the German Copyright Law. The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Typesetting and production: LE-TEX Jelonek, Schmidt & Vöckler GbR, Leipzig, Germany Cover design: Frido Steinen-Broo, estudio Calamar, Spain Printed on acid-free paper springer.com

4 Preface Many textbooks describing the function of a turbine engine are available on the market. These books describe the operation of the main components of an engine, its thermodynamic principles and the principle of thrust generation. They are available at any required level. For persons that first get in touch with the subject matter of turbine engines it is also important to understand the operation of the systems necessary for the operation of a turbine engine. With my long-term experience as a technical training instructor the idea developed to write a description of the engine systems to provide this as an add-on to the many text books available describing the operation of the basic turbine engine. For a complete understanding of functions of the engine systems it is important not to describe the systems isolated from the aircraft. Systems of modern turbine engines are highly integrated into the aircraft system architecture. Thus the functional interface with the aircraft is shown were necessary. It took some time to find a concept for this book that provides the information in a sequence that facilitates the understanding of the described functions. During the writing of this book I got some help from experts in their field for the optimization of the result. I wish to thank Johannes Lange and Dr. Hans Hansen for their expertise concerning the concept of this book; Sybille Schmidt and Wolfgang Lehmann for their useful linguistic suggestions. I also mustn t forget to thank my family for their patience while I worked on this book for some months. Hamburg, August 2007

5 Table of Contents 1 Introduction Engine Systems in General Grouping of Engine Systems Demands on Engine Systems Digital Aircraft Systems General Federated Avionics Architecture Integrated Modular Avionics Aircraft-Engine Interface Structural Interface System Interfaces Thermal Management Thermal Management for Engine Parts Thermal Management for Fuel and Oil Sample Engines Definitions and Terms Gas Path Stations Pressure Ratios Shaft Speed Designations Corrected Parameters Location Designations on Cases Engine Air Systems Internal Air Systems Component Cooling and Sealing Pressure Balancing Bearing Compartment Pressurization External Air Systems Cooling and Ventilation Systems Active Clearance Control Systems Compressor Control Systems Engine Lubrication System General... 49

6 VIII Table of Contents Properties of Engine Oil System Design and Components Lubricated Areas System Components Oil Tanks Pumps and Filters Oil Cooling Vent System Components System Indications and Monitoring Indication of Operating Data Indication System Sensors Data Processing, System Monitoring Debris Monitoring Engine Fuel Distribution System General Properties of Fuel Fuel Supply of the Engine Engine-Mounted Fuel Distribution System System Design and Components Operation Thermal Management for Fuel and Oil Oil Coolers and Fuel Temperature The Oil Cooling System of the CFM56-7B The Oil Cooling System of the CFM56-5A, -5B and -5C The Oil Cooling System of the PW The Oil Cooling System of the V2500-A Engine and Fuel Control System Main Tasks of the System Speed and Thrust Control Shaft Speed Control Thrust Control Engine Thrust Ratings Hydromechanical Control Systems Engine Control System of the CFM Control System of the CF6-80C2 (PMC Version) FADEC System System Design The EEC The Sensors Aircraft / Engine Interface

7 IX FADEC Systems of Selected Engines Future Trends in FADEC System Designs The Aircrew/Engine Interface Engine Indications Indicated Engine Parameters Engine Indications on an Electronic Instrument System Engine Indications on a Classical Instrument System Engine Controls HP Fuel Shut-Off Control System Mechanical Thrust Lever Systems Electrical Thrust Lever Systems Control Switches Thrust Control during Automatic Flight Starting and Ignition The Starting System General Starting System Components The Ignition System General Ignition System Components Cockpit Controls and Indications Starting System and Ignition System of the CFM Start System and Ignition System of the CFM56-7B Start System and Ignition System of the V2500-A Thrust Reverser Systems Operation of Thrust Reversers Basic Principle Reverser Operation Types of Thrust Reversers Airflow Deflection Systems Actuation Systems Reverser Control Systems Reverser Structure Fixed Structure Movable Structure and Actuation System Components Reverser Control System Control System of the B Control System of the A

8 X Table of Contents 9 Engine Anti-Ice System Ice Build-Up on Engine Parts Air Inlet Anti-Ice System General System Components of a Pneumatic Anti-Ice System Spinner Anti-Ice Power Plant Nacelle Bare Engine Power Plant Build-Up Engine Mounts Inlet Anti Ice System Electrical Power Generation Pneumatic System Hydraulic System Fuel Supply System Fire Detection and Extinguishing System Mechanical Engine Controls Sensors and Harnesses Engine Fluid Drains Appendix A Data Transfer in Digital Aircraft Systems A.1 Serial Interfaces A.2 Data Buses A.2.1 ARINC A.2.2 ARINC A.2.3 AFDX Appendix B Servo Valve Control for Actuator Positioning B.1 General B.2 Servo Valves with Spill Valves B.3 Servo Valves with Fuel Jet Nozzle B.4 Servo Valves with Pilot Valves B.5 Fail-Safe Actuator Positioning Appendix C Unsuccessful Engine Starts C.1 Types of unsuccessful Engine Starts C.1.2 The Hot Start C.1.3 The Wet Start C.1.4 The Hung Start C.1.5 The Start Stall

9 XI C.2 Further Abnormal Start Conditions detectable by FADEC Systems Glossary Bibliography Index

10 Abbreviations AC ACC ACOC ADC AFDX AIMS ALF ARINC ASC ASTM ATA A/THR AVM CBP CCS CDP CIT CONT COTS CS DAC DC DEU DMC EASA ECAM ECM ECU EEC EFIS EHSV EIA Alternating Current Active Clearance Control Air-Cooled Oil Cooler Air Data Computer Avionics Full Duplex Switched Ethernet Aircraft Information Management System Aft Looking Forward Aeronautical Radio Inc. Aircraft System Computer American Society for Testing and Materials Air Transport Association of America Autothrust Airborne Vibration Monitoring Customer Bleed Pressure Common Core System Compressor Discharge Pressure Compressor Inlet Temperature Continuous Commercial Off The Shelf Certification Standard Dual Annular Combustor Direct Current Display Electronic Unit Display Management Computer European Aviation Safety Agency Electronic Centralized Aircraft Monitor Engine Condition Monitoring Electronic Control Unit Electronic Engine Control Elecronic Flight Instrument System Electrohydraulic Servo Valve Electronic Industries Alliance

11 XIV Abbreviations EICAS EIU EIVMU EPR EUROCAE E/WD FADEC FCU FDRV FF FIFO FLA FMC FMU FMV FOB FRT ft FWC FWD GRD HMU HPC HPT IDG IEEE IGN IMA IPC IPT ISA LLP LPC LPT LRM LRU LVDT MCDU MEC Electronic Indication and Crew Alerting System Engine Interface Unit Engine Interface and Vibration Monitoring Unit Engine Pressure Ratio European Organisation for Civil Aviation Equipment Engine/Warning Display Full Authority Digital Engine Control Fuel Control Unit Fuel Diverter and Return Valve Fuel Flow First In First Out Forward Looking Aft Flight Management Computer Fuel Metering Unit Fuel Metering Valves Fuel On Board Flat Rate Temperature Feet Flight Warning Computer Forward Ground Hydromechanical Unit High Pressure Compressor High Pressure Turbine Integrated Drive Generator Institute of Electrical and Electronics Engineers Ignition Integrated Modular Avionics Intermediate Pressure Compressor Intermediate Pressure Turbine International Standard Atmosphere Life Limited Part Low Pressure Compressor Low Pressure Turbine Line Replaceable Modules Line Replaceable Unit Linear Variable Differential Transformer Multipurpose Control and Display Unit Main Engine Control

12 Abbreviations XV MEMS Microelectromechanical Systems Mn Mach Number N1, N2, N3 Engine Rotor Speeds OAT Outside Air Temperature ODM Oil Debris Monitor PMC Power Management Control PPBU Power Plant Build-Up QEC Qick Engine Change REV Reverse RTD Resistive Thermal Device RTDCA Radio Technical Commission for Aeronautics RTOS Real Time Operating Systems RVDT Rotary Variable Differential Transformer SAL System Address Label SDAC System Data Aquisition Computer SOAP Spectrographic Oil Analysis Program TAPS Twin Annular Premixing Swirler TAT Total Air Temperature TBV Transient Bleed Valve TIA Telecommunication Industry Association TLA Thrust Lever Angle TOGA Take-Off/Go Around TRA Thrust Lever Resolver Angle TSFC Thrust Specific Fuel Consumption UART Universal Asynchronous Receiver-Transmitter VBV Variable Bleed Valve VSV Variable Stator Vane Company Names Airbus Airbus S.A.S., Blagnac Cedex, France Boeing Boeing Commercial Airplanes, Renton, Wash., USA CFM CFM International S.A., Melun, France GEAE or GE GE Aviation, Cincinnati, Ohio, USA IAE International Aero Engines, East Hartford, Ct., USA LTT Lufthansa Technical Training, Hamburg, Germany Pratt & Whitney Pratt & Whitney, East Hartford, Ct., USA RR Rolls-Royce International Ltd., London, UK

Systems of Commercial Turbofan Engines

Systems of Commercial Turbofan Engines Andreas Linke-Diesinger Systems of Commercial Turbofan Engines An Introduction to Systems Functions 123 Andreas Linke-Diesinger Lufthansa Technik AG Propulsion Systems