AERO ENGINE MAINTENANCE AND
REPAIR
HINDUSTAN INSTITUTE
OF TECHNOLOGY AND
SCIENCE
OVERHAUL OF JET ENGINE
Engine Overhaul procedures :
Inspections and cleaning of components
Repairs schedules for overhaul
Balancing of Gas turbine components.
Condition monitoring of the engine on ground and at
altitude
Trouble Shooting - Procedures for rectification
Engine health monitoring and corrective methods.
Overhaul procedures
TBO-time between overhaul
On condition monitoring
Disassembly
vertical and horizontal disassembly
Vertical –front end downward, ground fixture
Horizontal-special turnover stand
Cleaning
Organic solvent to acid
Organic solvent kerosene, choloro ethane for paint stripping
Electrolytic solution for cleaning the turbine blades all rotating parts.
INSPECTION
Visual inspection
Structural inspection
Dimensional inspection
REPAIR
To restore the properties of the material
If stresses – due to distortion (welding) heat treatment done
to reduce the restore the properties of the material
Electroplating- chromium plating to restore the properties
of the material
BALANCING
• Due to high rotational speed unbalancing may happen in
main rotating assembly
• vibration and stress increases
• Rotational speed affects the vibration and stress.
• Single plane – unbalancing goes through the 90 of the disk
( individual turbine disk, compressor plate)
• Double plane balancing available- entire turbine blade
balancing
ASSEMBLY
the entire component is then assembled
Testing
• bell mouth air intake duct is used to eliminate
the loss of pressure at the inlet
• straight inlet have pressure drop
1. Ambient air temperature (Tamb)
2. Ambient air pressure (Pamb)
3. Exhaust total pressure (Pt7)
4. Low-pressure compressor rpm (N1)
5. High-pressure compressor rpm (N2)
6. Exhaust-gas temperature (EGT)
7. Fuel flow in pounds per hour (pph) (Wj)
8. Thrust (Fn)
9. Low-pressure compressor outlet pressure (Ps3)
10. High-pressure compressor outlet pressure (Ps4)
CONDITIONING MONITORING
Trend analysis involves the recording and analysis of gas turbine engine
performance and certain mechanical parameters over a period of time.
The primary aim of trend analysis is to provide a means of detecting significant changes in
the performance parameters resulting from changes in mechanical condition of the engine
A gas turbine engine operates with various performance parameters at steady state
condition.
Once the initial relationships have been established for the various parameters, a specific
change will not vary significantly from this calibration unless some external force
affects it.
Thus, abnormal performance of an engine will be indicated by parameter relationships
deviating from the norm.
CONDITIONING MONITORING
Data collection methods will vary depending on whether the data are collected manually
or by an onboard computer.
Data should be collected at regular intervals. Variable loads extracted from the engine,
such as generator, hydraulic, air conditioning, and bleed air, will have an effect on trend
accuracy.
To minimize these effects, each time a set of reading is taken, with regard to altitude and
power.
To reduce fluctuations in the data, ensure that the engine parameters are stabilized before
taking the data readings.
Condition monitoring devices are designed to give an indication of any engine
deterioration at the earliest possible stage.
This facilitates quick diagnosis which can be followed by either further monitoring
or immediate action on the problem.
Condition monitoring devices and equipment can be categorized into the areas of flight
recorders and ground indicators.
Trouble shooting and rectification procedures
Troubleshooting may be defined as the detection of fault indications and the
isolation of the fault or faults causing the indications.
When the fault is isolated or identified, the correction of the fault is simply a
matter of applying the correct procedures.
Fault indicators
Fault indicators include any instruments or devices on an aircraft which can
give a member of the crew information about a problem developing in the
operation of the engine.
These indicators may be divided into two groups:
i. The standard engine instruments used to monitor the operation of the
engines, and
ii. Special devices designed to detect indications of trouble which may not be
revealed by the engine instruments.
Trouble shooting and rectification procedures
Typical engine instruments for a gas turbine engine are
EGT (Exhaust Gas Temperature) gauges,
percent rpm gauges (N1 and N2),
EPR (Engine Pressure Ratio) gauges,
oil temperature gauges,
oil pressure gauges, and
fuel gauges.
When turboshaft or turboprop engines are installed, torque-indicating gauges
are often included. These instruments are all effective in detecting faults.
For long-term troubleshooting, these parameters are monitored over a period
of time so that a trend can be noticed. This will allow corrective action to be
taken as promptly as possible.
TROUBLE SHOOTING AND PROCEDURES
Engine health monitoring and corrective methods
Engine health monitoring (EHM) is a system that tracks and monitors the
performance of an engine to help ensure its availability.
EHM systems can provide data to support condition-based maintenance and
help prevent unplanned events.
Engine Health Monitoring is a proactive and continuous process that identifies
potential problems before they evolve into flight safety issues.
Well trained and experienced analysts pinpoint potential problems at the
earliest possible occurrence, enhancing both safety and cost of operation.
EHM systems can transfer data from an aircraft's engine to a ground-based
operational center. This data can be used to record and monitor the engine's
performance, and to help ensure the engine's availability.
EHM systems can also help pilots and maintenance crews identify issues such
as out-of-balance rotors.
Engine health monitoring and corrective methods
Some common methods for monitoring engine health include:
Graphic displays
These displays can show key engine parameters to help identify trends in
engine performance or instrumentation malfunctions.
Computer programs
Programs like Pratt & Whitney Aircraft's Engine Condition Monitoring
Computer Program can provide graphical parameter trends to help improve
visibility of engine health.
Engine health monitoring and corrective methods
➢ Rolls-Royce uses engine health management (EHM) to track the health of
thousands of engines operating worldwide, using onboard sensors and live
satellite feeds.
➢ EHM is a proactive technique for predicting when something might go
wrong and averting a potential threat before it has a chance to develop into a
real problem.
➢ EHM covers the assessment of an engine’s state of health in real time or post-
flight and how the data is used reflects the nature of the relevant service
contracts.
➢ Essentially, EHM is about making more informed decisions regarding
operating an engine.
➢ The EHM method has proven effective by preventing or delaying
maintenance, as well as an awareness of potentially costly technical problems.
Sensor locations on the turbofan engine
