Phase 7

Wael El-Maghrabi PW4000 94-INCH FAN ENGINE ATA 70
th

ATA 7u
9:00 to 15:00 Eng. Batem Bossain Abuul Kauei
1
st
Bay 0bjectives
Training course lesson plan and Study plan
Introduction to PW4000 engine series
PW4158 engine specifications
PW 4 0 00
Pratt and Whitney Family 0 Boieng,1 Airbus 4 MD Max output thrust
Case Study FTDM
2
st
Bay 0bjectives
Yesterday review
5800 T/O Sea level
Flat rated up to 30
o
C
Bypass Ratio 5:1
94 Fan Diameter
CPR 30:1Gas path Configuration
1/4/11/2/4
Nacelle Configuration Short Duct
GB Core engine mounted HPC case
Engine Weight 4200 kg
Power Plant Weight 5200 Kg = Engine + Nacelle + QAC Quick Accessory
Components
N1
redline
= 111.4%
N2
redline
= 105.5%
EGT
redline
= 650
o
C, 625
o
C, 535
o
C
Non SCU Supplemental Control Unit in all our Aircraft which provides:
o Backup power for EEC
o AUTO start

Wael El-Maghrabi A300-600 ATA 70
th

Spring 2013 Page 2 of 15

Gas path Configuration
How many groups Major assemblies make the complete engine?
a. 14 groups
What subsystem must be rigged on the Engine?
a. VSVs
LP N
1 rotor
Bearings 1 B,1.5 B,4 R
a. LPC 1+4 boosters stages:
i. 1
st
, 1.6
th
, 2
ed
, 3
ed
, 4
th
Booster Discharge will be stage 4
b. LPT Stages 4

stages
i. 3
th
,4
th
,5
th
,6
th

HP N
2 rotor
Bearings 2 B,3 R
a. HPC 11

stages
i. 5
th
to 15
th

ii. VSVs are IGV + 5
th
, 6
th
, 7
th

1

b. HPT Stages
i. 1
st
,2
ed

Accessory
CC: is an Annular not segmented

1
How many VSVs stages in HPC? Answer will be 4, assuming good intuition because IGV is not a stage
th


Air uses:
Fan Air 4
th
Stage 8
th
Stage 9
th
Stage 12
th
Stage 15
th
Stage = P
s3
1. Pre-cooler
2. Engine
accessory
Cooling
3. No.3 Bearing
Buffer Cooler
4. Thrust.
5. IDG Air/Oil high
power
6. LPTCCV HPTCCV
7. Nacelle Zone
Cooling
8. Thrust Reverser
1. Cooling and
Pressurization
No. 1,2 Bearing
2. No. 4 bearing
3. Anti-Ice for inlet
cone
4. N1 Shaft
Cooling
5. LPT Disk Cooling
6. 2.5 BV stability
Bleed Air 1. Cooling and
Pressurization of FWD
Bearing Compartment
(1.5,2)
2. 2.9 bleed = Stability
Bleed
3. LPT discs cooling
1. No 3
Bearing
buffer
cooler
2. TVBCA
1. Bleed Air in Low power
setting
2. 1
st
stage of HPT cooling
3. Nose cowl Anti Ice
4. P
s3
: As a muscle for all 4
ways solenoids
5. Monitor HPC exist
pressure
6. CC cooling
7. Nose cowl Anti-Icing
8. Thrust reverser
operation
9. 2ed HPT blades
10. 1
st
HPT
continuous
11. P
3
/T
3
sensor
12. Thrust balance
Vent vent tube

th


Engine Flanges
CLS Cowl Load Sharing one of nacelle configuration functions: at D and D1 flanges
make V grooves with cowl which makes Fuel/Thrust saving, like which called cowl
load sharing latches in B777.
Engine Flanges Function:
a. ENGINE True flanges Disassembly
b. Surface False=Welded Flange Stiffener and External Hard ware
support
c. Balance Flange Here it is a Fan disk flange
Engine Flanges locations:
a. Intermediate Case is engine FWD Mount
i. Is Engine Forward Main Support.
ii. Ride on Bearings 1 B,1.5 R,2 R FWD Sump
b. Diffuser Case:
i. Ride on bearings3 R, under CC
c. Turbine exhaust case is engine AFT Mount:
i. Rides on Bearings 1.5 R, 2 B.
Engine Stations Identifying Gas path locations /Sensors
Core Stages
2: Engine Inlet:
a. EPR f
(T2, P2)

2.5: LPC Exit Function in SCU:
a. P
2.5
Bleed Valve monitor System Ring
b. T
2.5
Performance Monitor
2.9: 9
th
Stage Exit = 2.9 Bleed Annulus System Surge bleed valves
a. 2 Valves RHS Start BV, LHS Stability
b. If stuck open causes High EGT
3
ed
: HPC Exit
a. P
3
surge monitor
b. T
3
: Starting Fuel Flow
3.5
th
: Surrounding CC Cooling Air may be caused by Damaged Seal
4
th
: Combustor Exit, P2.5/T2.5 sensor
a. TIT Turbine Inlet Temperature
4.5
th
: LPT Inlet
4.95
th
: LPT Exit (at turbine exhaust case rear flange)
a. EGT = T
4.95

b. EPR =
P4.95
P2.5

Fan Stages: 13, 14
Wae
Spri

VIB
N2:
N1 s
Cas
Not

el El-Maghr
ing 2013
Accelerom
from Alter
sensor
se Study
SCU
Engine
tes:
cws.cfm
72-0644
PW400
rabi
meter: only o
rnator
Data multip
m56 envirm
4
0 94 Fan bl
one sensor
plexer P
2.5
,
n.pdf, Env
ade Hand S
A300-600
on 12 Oclo
,T
2.5

ironment D
Scrape
ock on Fan c
Distress cons
case
sideration
ATA
Page 5 o

CFM56-5b
70
th

of 15
SB
th


S
eu
Bay 0bjectives
Main Engine Bearings & seal types
1. FBC Forward Bearing Compartment Ball = Thrust
a. Bearing No: 1, 1.5 and No. 2 Oil Damping Bearing
b. Bearing Type: B, R, B
c. Bearing Location: LPC, Coupling HPC, Front Shaft
d. Load transfer: Intermediate case 9 Struts
e. Seal Type: Carbon Seal Face type + 1.5-2 Carbon Seal
f. Pressurizing Air: 4
th
, 9
th
, 4
th
Internally
g. Issues:
i. 4
th
stage may cause foam and oil smell in cabin if CS damaged.
2. MBC Middle Bearing Compartment
a. Bearing No: 3
b. Bearing Type: R
c. Bearing Location: HPC Rear Shaft
d. Load transfer: Diffuser Case 24 Struts
e. Seal Type: CS Face type
th
Externally
g. Issues:
i. Weep line,
ii. Cooling air after pressurizing this compartment, it goes as a
buffer air for 2
ed
HPT and inspected by Borescope.
iii. DOT 3: Differential Oil Temperature, if increases indicates that
12
th
stage HOT air entering the compartment
3. ABC Aft Bearing Compartment
a. Bearing No: No. 4 Oil Damping Bearing
b. Bearing Type: R
c. Bearing Location: LPT rear End Shaft
d. Load transfer: TEC Turbine Exhaust Case
e. Seal Type: CS in front Ring type+ Packing Oil Seal in rear
th
Internally
g. Issues: LPT Shear
Note: FAN Keep out Zone: Range of N1 that not recognized to keep with in which
may cause Mechanically Damaged.
Wae
Spri

Stru
Int
RCC
The
the
Surg
stag

el El-Maghr
ing 2013
uts: FBC 9, M
ermediat
D1-E Int
o
o
o
o
o
o
o
o
o
o
C: Ring Case
e reason for
Case defor
ge due to b
ges.
rabi
MBC 24, AB
te case com
termediate
Struts rides
1 Oclock
HPC
IDG
2 Oclock:
4
th
stage fir
4 Oclock H
5 Oclock
2.9
N1 t
6 Oclock: A
7 Oclock: 2
8 Oclock: E
10:5 Ocloc
HPC
TVB
12 Oclock:
e Configurat
r new RCC:
med as T3
ack flow fro
C 15
mponents
case:
s on FBC 1,
4 Way Sole
C flow contr
(ACOC, HE
No.3 Bearin
rst by ACAC
Heat Exchan
4 way two S
Bleed valve
transmitter
AGB
2.5 Bleed Va
Engine air/o
ck 4 Way S
C flow contr
BCA solenoid
1
st
HPT
control
2
ed
HPT
TVBA a
: Forward m
tion which i
in Old Quad
reaches > E
om rear high
A300-600
s
1.5, 2
noid :
rol Valve(RH
) Override s
ng buffer Ai
C
nger: Fan in
Solenoids:
es 9
th
stage
r
alve Actuat
oil Heat exc
Solenoid:
rol Valve (LH
d:
blades from
led.
T blades fro
nd 50% and
mount
s a new con
drant Segm
EGT in High
h pressure
HS V) Cance
solenoid.
ir cooler fro
high power

e air
tor
hanger
HS Valve) C
m 15
th
whic
m 12
th
whic
d the rest 50
nfiguration.
mented Conf
h Power an
stages to th
elled after R
om 12
th
stag
r or 4
th
in Lo
ancelled aft
h is continu
ch 50% is co
0% is contin

figuration a
d causes Hi
he frontal lo
ATA
Page 7 o
RCC
ges cooled b
ow power
ter RCC
uous and no
ontrolled by
nous.
at High pow
igh Power
ow pressure
70
th

of 15

by
ot
y
wer,
e
Wae
Spri

AG
Core
N2
el El-Maghr
ing 2013
GB modul
e mounted
IGBTow
rabi
le
wer ShaftAGBMGB
A300-600
B

ATA
Page 8 o

70
th

of 15
th


MGB
Example of Famous Components locating:
o FMU: Located at FF RHS
o Manual Crank pad: to rotate N2 manually
2
Crank pad located
at Front face RHS
o Rear Hydraulic Pad: RF RHS
o Lubrication Unit 1 Pressure pump and 5 Scavenge pumps at
RF at 6 Oclock
o EEC Alternator:
o Starter:
PW4158 engine borescoping
AP1
14 Slots, upper 8 have a screen
The best at 8
th
Oclock
AP2
AP3
AP4
AP5- AP7
Inner Plug needs Special Tool
AP6
AP8, AP9, AP11, AP10
Hot Section
AP11
Between HPT Vanes
AP10
LPT vanes

2
In engines which have a brush seal, it is found that it is hardly to rotate the engine against its neutral
rotation direction rather than the damage possibility.
th


4
th
Bay 0bjectives
Fan blades Removal
1. Wear Strip:
We have 6 Rows, we measure at 3ed Row
Use Special Tool on 8 points around the 60 bolts of A flange , at each
position: 0.260 - reading wear
Then Calculating Top half average and Lower half average, any half out of
limit we have to replace the engine
EEC:
Closed Loop Concept
Guarantee:
o Steady state
o Transient
o Surge
VSVs
Its a Control System
Fully open until N
2c
= 5% then starts to close until N
2c
= 15% reaches Fully
closed then starts open again with N
2c
increased EEC
EECTM VSV torque motorfeedback by LVDT
Adjustable ROD move Unison Ring which have 4 actuators
Fully Extend Down direction to Open
Fail safe:
Electrically Fail: Fully Open as a worst Case
Loss of Dual Feedback: Full Open as a worst Case
Muscle lost: No more than the last position, Rigging is required
Rigging
Links are between Unison ring and Bell crank.
Is required on a fully Open position
When Engine is OFF: VSV must be fully open
During Start: VSV fully close
Fault Causes
1. Torque motor or solenoid wrap around check.
2. Feedback LVDT or sensor wrap around check.
3. Command Feedback Track Check.
4. Control System Status.
5. Cross Check.
6. Rat change Check.
th


S
th
Bay 0bjectives
2.5 bleeds subsystem
Affects LPC Stability by Controls 4
th
Stage Air
Critical valve
N
2c
= N2 corrected which is a function of T
2.5
and T
2.5
=f (N
1
, N
2
, T
2
)
Control System
N
2c
+ 2.5 Bleed Valve Position Fully open until N
2c
= 70% then starts to close
until N
2c
= 84% reaches Fully closed EEC
Override signal to fully OPEN in cases of:
o Transient
o Surge
o T/R
EECTM torque motorDual Command2.5 bleed valve actuator, RVDT
De-energized= Actuator Retracted = Valve open
When opens it vents 4
th
stage air to join Bypass flow
When closes 4
th
stage air continue in core flow, which cooling IDG oil in high
power Configuration
2.5 Valve is Not LRU
o Rigging is required to restore EGT margin 1 mm 24
o
C, each 1
o
C
allow more 100 FC
o Rigging Carried out by adjusting the Shoulder Bolt Left Hand Thread
2.5 Bleed Valve Actuator is a LRU:
o We may need about 33 rotations to remove.
Electrically Controlled and Hydraulically Operated with RVDT feedback.
Fail safe:
Electrically Fail: Fully Open as a worst Case is a surge
Loss of dual Feedback: Full Open as a worst Case, No mathematical model
for feedback like that in CFM
Muscle lost: No more than the last position, Rigging is required

th


2.9 bleeds subsystem
Electrically Controlled and Pneumatically Open
Critical valve
HPC Stability by 9
th
stage air
Service bleed
Stability Bleed Valve
Intermediate case 5 Oclock 4 way two Solenoids of 2.9 Bleed valves 9
th
stage
air
The 2 solenoids are one for LHV and other for RHV
N
2c
= N2 corrected which is a function of T
2.5
and T
2.5
=f (N
1
, N
2
, T
2
)
Performance Valve
P
3

NO FEED BACK
EEC2.9 Bleed Valve two Solenoid Dual command to LV + Dual command
to RV
Faults
Solenoid Wrap around Check
Fail safe
1. Left valve:
o Electrically lost: fail safe Open
2. Right valve:
o Electrically lost: fail safe Closes
When Engine is not running
Both are Open, because no P
3
Signal
Left valve:
N
2c
Fully open while N
2c
< 2% below Idle, then Fully closed
De-energized Open, P
3
vented and spring load it to open
Pneumatic relay valve: Quick response to Open LV as it vent P
3
directly
through relay valve instead of long travel to neutral vent passage
LV: Left Stability Bleed Valve, De-energized Opens in Transient Condition
Right valve:
N
2c
Fully Open while N
2c
< 2% below Idle, then Fully closed
Energized Open
RV: Right Start Bleed Valve, for starting Only

Wae
Spri

Com
TCC

el El-Maghr
ing 2013
mpresso
C
Performanc
FAN Stage a
ON = Maxim
Cruse
EECDual
Actuator
LVDT feedb
Modulated
Spring load
Rigging:
o It is
o On t
o Part
o The
Electrically
LPT Case on
Fail Safe is
When Engi
rabi
r Airflow
ce
air, LPTCCV
mum Coolin
Command
One contro
back

ded Closed
Required, b
the Fully O
tial Rigging
e Cable has a
Controlled,
nly is ON =
Closed T/O
ne is OFF, t
w cooling
V, HPTCCV
ng during
Torque M
ol CableD
by 3 Rigging
pen Positio
LPT case
a shear loca
, Hydraulica
Life time d
O = High po
he valve is f
A300-600
g Subsyste
Motor
Dual
g Pins
n
or Fully Rig
ations Be c
ally Operate
during T/O
wer configu
fully closed
ems
gging HPT c
careful durin
ed by Fuel
uration as a
case
ng Rigging t
worst case
ATA
Page 13 o
the Actuato
e
70
th

of 15
or
th


6
th
Bay 0bjectives
Engine Borescoping/Rigging (Video Show)
OK
TVBCA subsystems
TVBCA
2
ed
HPT controlled
Electrically Controlled, Pneumatically operated, Feedback switch on RHS valve
only
Have a visual Position Indicator, when the PIN extended EXTENDED PIN OPEN
POSITION
12
th
Stage Air for 2
ed
HPT
OFF during Cruse
Failsafe Fully Open Worst case T/O
When Engine OFF Spring Loaded Opens
2
ed
HPT NG Vanes from 12
th
which 50% is controlled by TVBA The 50% non-
controlled comes from outside the valve. Through external tubes (2,5)
2
ed
Blades HPT 50% from 12
th
stage after making a supplementary cooling first to
No. 3 bearing + reduced 15
th
stage + Buffer phases is continuous. Through
external tubes (3,6)
Cruse Condition + N
2cr
+AltitudeEECSingle Input from Chanel A non-Critical
to TVBCA valve SolenoidP
3
as a controller muscle
When EnergizedP
3
applyClosed
Another Cooling
15
TH
Stage for 1
st
HPT
1
st
HPT non controlled
2
ed
HPT NG Vans from 12
th
continuous none controlled Not through the TVBA
valves. Through external tubes (1, 4).

th


SFC Secondary Flow Control subsystems
During Cruse, allow HPC to Expand, energized valve to be fully Close.
Fail Safe, De-energized fully open T/O.
Valve Position Indication
N
2c
+ALTEECSFC solenoid + CH. A to RFCS + /CH. B to LFCSControlled
by P
S3
.
From 9
th
stage: When SFC valve open to cool HPC Inner Cavity,
1 Oclock 4 Way Solenoid :
o HPC flow control Valve(RHS V) Cancelled after RCC
10:5 Oclock 4 Way Solenoid:
o HPC flow control Valve (LHS Valve) Cancelled after RCC
Engine air Uses
3 For Control
3 For Stability
Note: The only Sensor has an Ecam Indication is Nacelle Zone Temperature Sensor
on Right ECAM only

Phase 7

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Wael El-Maghrabi PW4000 94-INCH FAN ENGINE ATA 70

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