Boeing 737 Oxygen System

Air Conditioning & Pressurization System

LECTURER NAME MR. ADBUL AZIZ BIN AHMAD STUDENT NAME Mohammad Hudzairi Bin Mohd Kamal 3 BMe 1 53259211245 Ahmad Kamil Izzudin Bin Idris 3 BMe 1 53259211176 Adam Sharez Azahari 3 BMe 1 53259211159

Contents
INTRODUCTION .................................................................................................................................. 2 INSTALLATION .................................................................................................................................... 3 A. B. C. Flight Crew ........................................................................................................................... 3 Passenger & Therapeutic................................................................................................. 4 Portable................................................................................................................................. 6

OPERATION ......................................................................................................................................... 7 A. B. C. D. Flight Crew ........................................................................................................................... 7 Passenger ............................................................................................................................ 7 Therapeutic .......................................................................................................................... 8 Portable................................................................................................................................. 9

MAINTENANCE PRACTICES.......................................................................................................... 11 A. B. Flight Crew ......................................................................................................................... 11 Passenger & Therapeutic............................................................................................... 12

SAFETY PRECAUTION .................................................................................................................... 13 CONCLUSION .................................................................................................................................... 15 REFERENCES ................................................................................................................................... 16

INTRODUCTION
The oxygen systems supply low pressure oxygen in gaseous form to the crew and passengers. Two separate oxygen systems are included: the flight crew oxygen system and the passenger oxygen system. In addition, emergency oxygen is supplied by portable oxygen cylinder assemblies.

The flight crew oxygen system has a supply of high pressure gaseous oxygen and distributes and delivers it at low pressure to the crew. High pressure oxygen is kept in an oxygen cylinder assembly. The oxygen cylinder assembly includes a safety discharge device to protect against too much pressure. Oxygen cylinder pressure is reduced through a pressure regulator. Low pressure oxygen is distributed through individual mask/regulator and mask stowage boxes.

The passenger oxygen system automatically releases oxygen masks to the passengers and attendants whenever the cabin pressure falls to a value equivalent to an altitude of 14,000 feet. Oxygen is kept in chemical oxygen generators and oxygen flow is started by the action of the passenger or attendant pulling the oxygen mask down to the face. Mask deployment also can be operated by a switch on the P5 aft overhead panel.

The portable oxygen equipment includes portable oxygen cylinder assemblies and protective breathing equipment (when installed). The portable cylinders supply oxygen for emergency, first aid or sustaining oxygen for the passengers and/or crew. The smoke hood (PBE), emergency escape breathing device (EEBD) and the crew protective breathing equipment (CPBE) supply portable emergency respiratory and eye protection for the crew in an oxygendeficient, smoke filled or other toxic atmosphere.

INSTALLATION
A. Flight Crew

1) 2) 3)

Make sure the oxygen mask harness and oxygen supply hose are not twisted. Make sure the foam padding on the oxygen mask is soft. Make sure the foam padding on the oxygen mask quickly moves back to the initial position when you push on the foam padding.

4) 5)

Remove any loose pieces of foam that you find in the face mask. Make sure the clips hold the oxygen hose to the bottom of the mask stowage box.

6)

Hold the mask and put the oxygen supply hose into coils. Push the hose down to get symmetrical coils.

7)

When most of the supply hose is put into coils, put two large spacers at the back of the oxygen mask harness.

8) 9) 10) 11) 12)

Put the spacers carefully on the supply hose. Install the mask harness into the stowage box. Move the oxygen mask forward to help position the mask harness. Make sure the oxygen harness is on top of the supply hose. Make sure the tab on the front of the mask is on the horizontal plastic surface inside the stowage box.

13) 14)

Make sure the first two spacers of the harness are on top of the mask face piece. Make sure the oxygen mask harness does not catch on the ON-OFF valve of the flow blinker when you close the mask stowage box.

15) 16)

Put the supply hose at the centre of the bottom of the mask stowage box. Make sure the disconnects on the oxygen supply hose do not touch the mask face seal.

17)

Make sure the dilution control is on 100% and the safety pressure button is on normal.

18) 19) 20) 21)

Close the left lid of the mask stowage box. Move the RESET lever on the left lid and make sure the flag goes out of view. Engage the pin on the left lid in the hole on the left side of the mask regulator. Close the right lid of the stowage box.

Figure 1 B. Passenger & Therapeutic

1) 2) 3)

Lower the service unit To remove the mask box cover, carefully lift the cover away from the mask box. If the oxygen masks hang through the bottom of the mask box door, do the steps that follow: a) Carefully pull each mask up through the top of the mask box. b) Let the masks hang from the side of the passenger service unit.

4) 5)

Push the test stop button up until one of the two conditions that follow occur. NOTE: If the actuator fires, the sound of a click will show that the actuator is set. If the actuator does not fire, you will feel the pressure increase while you push the test stop button up.

6) 7) 8) 9)

You hear the sound of a click. You feel the pressure increase. Release the test stop button. Close and latch the mask box door. 4

10) 11) 12)

If the masks are in the mask box, do the steps that follow: Carefully remove each mask with its lanyard and tubing from the mask box. Isolate each mask and permit the masks to hang from the top side of the passenger service unit.

13)

If the release cable is not put through all the mask lanyard rings, do the step that follows: Put the release cable out of the mask box.

Figure 2 14) Do the steps that follow for therapeutic oxygen masks. If the release cable without a pull ring is not put through the mask lanyard ring, do the step that follows: a) Put the release cable out of the mask box. b) If the cable with the pull ring is not put through the slot in the mask box, put the release cable out of the mask box.

15)

Examine the masks to make sure the masks are serviceable before you install the masks.

16)

To see if the oxygen generator fired, do the steps that follow: a) If the heat sensitive band on the generator has a black colour the oxygen generator fired. b) If the firing pin is in the fired position, the oxygen generator fired or the firing mechanism is bad.

C. Portable

1)

Go into the flight compartment to get access to the storage area for the portable protective breathing equipment, located below the second observer's seat.

2) 3)

Put the portable protective breathing equipment on the support bracket. Tighten the straps to hold the portable protective breathing equipment in place.

Figure 3

OPERATION
A. Flight Crew The crew oxygen system keeps gaseous oxygen under high pressure and supplies oxygen to each crew member at low pressure. High pressure oxygen flows from the crew oxygen cylinder into the cylinder coupling assembly, then into the attached pressure regulator. The pressure regulator takes an input pressure range of 60 to 1850 psi and reduces it to an output pressure range of 60 to 85 psi. Also connected to the cylinder coupling assembly is a pressure transducer which transmits an electrical signal to control the high pressure indicator on the aft overhead panel and (if installed) on the external fill panel.

A system shutoff valve that is manually operated is installed in the line to control flow to the crew oxygen outlets. The shutoff valve is a slow opening type and is normally open. Operation of the oxygen system is automatic when the cylinder shutoff and system shutoff valves are open and the mask/regulator is removed from the mask storage box. Each individual crew member uses a mask/regulator to control the operation of the system. B. Passenger Chemical oxygen generators are used to supply oxygen to each passenger and attendant. Oxygen flow to the masks is started when the mask is pulled downward. This causes the chemical oxygen generator to start a chemical reaction one product of which is oxygen.

Mask deployment for all mask boxes, except therapeutic mask boxes (when installed), occurs automatically when cabin pressure decreases to that equal to an altitude of 14,000 feet. At this pressure the altitude pressure switch energizes the door latch actuator. This causes the mask box door to open and the masks to fall free. Mask deployment can also occur manually by moving the passenger oxygen switch on the aft overhead panel to ON.

Mask deployment (automatic or manual) energizes the R324 oxygen indicator relay. This relay supplies a ground for the PASS OXY ON light on the aft overhead panel and the OVERHEAD annunciator light on the P7 lightshield. The ground causes these two lights to come ON.

Figure 4

C. Therapeutic

a) Mask Deployment Deployment occurs when the mask box door is manually opened. Insert a thin flat tool (such as a table knife) into the gap between the mask box door and the PSU faceplate. The hidden latch actuation tab is installed in the centre of the inboard edge of the mask box door. Push the flat tool up to operate the door latch. The mask box door will swing open. This releases the oxygen mask.

b) Oxygen Flow To cause oxygen to be generated and flow to the mask, pull down on the mask. This starts the oxygen generator. Put the mask on the passenger's face. After the first generator has been used, pull the ring in the module for fifteen more minutes of oxygen.

Figure 5

D. Portable

Oxygen for First Aid and sustaining purposes is kept in portable oxygen cylinders. These cylinders are installed at easily reached locations throughout the airplane.

There are two types of portable oxygen cylinders, those with a demand regulator and those without a demand regulator. The basic cylinder assembly contains these parts: high pressure oxygen cylinder, constant flow pressure regulator, ON-OFF valve, relief valve, safety plug, charging valve, outlet assemblies, and pressure gage. A demand-type mask can be attached to cylinders with a demand regulator.

The pressure gage shows oxygen pressure in the cylinder and thereby the quantity of oxygen available. Cylinder pressure should be 1850 psig at 70F. The safety plug contains a fusible alloy which melts in case of too much heat. This permits the cylinder to vent into the atmosphere. The ON-OFF valve controls the flow of high pressure oxygen into the pressure regulator. 9

The pressure regulator contains a pressure reducing mechanism which reduces the oxygen pressure before it is supplied to the outlet assembly or the demand regulator. The oxygen pressure is reduced because low pressure oxygen is required for the masks. The pressure regulator also has a recharging valve assembly which permits the cylinder to be refilled.

Outlet assemblies are connected directly to the constant flow pressure regulator. There are two outlet assemblies on each cylinder without a demand regulator and one on each cylinder with a demand regulator. Each outlet assembly contains an internal check valve, a flow metering device and an oxygen hose plug-in adapter. When a plugin is inserted, it opens the check valve and permits oxygen to flow into a mask when the cylinder ON-OFF valve is open. The two outlet assemblies on cylinders without a demand regulator have flow rates of 2 litres per minute (LPM) and 4 LPM. The outlet assembly on cylinders with a demand regulator has a flow rate of 3 LPM.

An oxygen mask and hose is attached to each portable oxygen cylinder assembly. For use, the hose must be connected to the oxygen outlet on the cylinder.

Figure 6

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MAINTENANCE PRACTICES
A. Flight Crew

a) Leak Test Slowly and carefully open the shutoff valve on the crew oxygen cylinder. Close the cylinder shutoff valve immediately if you hear air leaks or other indications of air leakage. Apply the leak detection compound to all parts of the fittings. Make sure there is no leakage. Remove the leak detection compound immediately after you examine the connections.

b) Mask/Regulator Test Supply electrical power. Make sure these circuit breakers are closed. P18 Oxygen System Panel and Oxygen System Ind Make sure the shutoff valve of the crew oxygen cylinder is open. Make sure the shutoff valve of the crew oxygen system (found in the crew compartment) is open. Make sure that the pressure indicator of the crew oxygen system on the aft overhead panel shows a cylinder pressure of 150 - 1900 psi.

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B. Passenger & Therapeutic

Inspection of Firing Mechanism and Heat Sensitive Band Open the service unit as applicable to get access to the oxygen generator: a) For the Passenger Service Unit (PSU), do these steps to lower the PSU: i. ii. iii. b) Put a rod into the latch access hole (2 locations). Push up on the rod to unlatch the cam latches. Lower the PSU.

For the Attendant Service Unit (ASU) or Lavatory Service Unit (LSU), do these steps: i. Put a rod or flat tool into the latch access hole or door gap, as applicable.

Push up on the tool to unlatch the door latch. Open the oxygen box door. Let the oxygen masks fall out. Visually inspect the firing mechanism to make sure the release pin is correctly installed in the larger of the two holes in the firing pin. Do these checks to find if the generator fired: a) b) If the heat sensitive band on the generator is black, the generator fired. If the firing pin is in the fired position (you cannot install the release pin), the generator has fired.

If the generator has fired, do these tasks: a) b) c) Remove the generator. Install a new generator. Repack oxygen masks, if applicable.

If no other maintenance is necessary, close the service unit as applicable: a) For the Passenger Service Unit (PSU), push the PSU panel upward to engage the cam latches. The latches will generally make a "click" sound when they fully engage. a) For the Attendant Service Unit (ASU) or Lavatory Service Unit (LSU), do these steps: i. ii. Repack the oxygen masks. Close the oxygen box door and push on it to engage the door latch.

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Figure 7

SAFETY PRECAUTION
1) Do not work on the pressurized oxygen system when there is oil, grease, flammable solvents, dust, lint, metal particles or other flammable materials. These materials can cause a fire or explosion when they touch pressurized oxygen. 2) Do not work on the pressurized oxygen near oil, grease, flammable solvents, dust, lint, metal fittings, or other flammable materials. 3) 4) Make sure the airplane is electrically grounded. Keep the oxygen away from all sources of ignition (hot exhaust, sparks, flame, smoking). 5) Keep the oxygen away from flammable material (fuel, paint, thinners, and cleaning solvents). 6) Make sure your hands, clothing, equipment, and tools are clean and free of petroleum materials. 7) 8) 9) Put on clean, nylon gloves that are lint-free during oxygen system maintenance. Use the approved leak detection compounds to do the test. Immediately after the test, rub off the leak detection compound with a clean cotton cloth. 10) Make sure there is a sufficient flow of air through the area when you do maintenance on the oxygen system. 13

11)

Use only clean components that come from a sealed bag. Make sure that the label on the bag identifies the components as sufficiently clean for the oxygen system. Contamination on components can cause a fire or an explosion. This can cause injuries to personnel and damage to equipment.

12)

Do not lubricant or gaskets, unless specifically identified in these procedures, when you connect the fittings in the crew oxygen system, the lubricant or gasket can cause a fire or explosion when they are near pressurized oxygen.

13)

When you install a component in the oxygen system, make sure you remove all protective caps.

14)

Make sure the fittings are clean and free of contamination, thread particles and unwanted particles. NOTE: Oxygen clean fittings come from a sealed package labelled for oxygen system installation. Make sure that you use only oxygen clean fittings. Some fittings used in the oxygen system are the same as fittings in other systems and are not oxygen clean. If it is necessary to clean parts, use the applicable oxygen procedures to clean the parts. This also applies to tube caps or plugs which must be as clean as the installation connections.

15)

Do not align the components with the B-nut. NOTE: If the components are aligned with the B-nut, a leak can occur and cause a fire and an explosion.

16) 17)

Do not tighten the fittings with the oxygen system pressurized. Open the shutoff valve on the oxygen cylinders slowly. If you do not open the shutoff valve slowly, high temperature can occur. High temperatures can occur. High temperature can cause a fire or explosion of the oxygen.

18)

To open all the oxygen valves slowly, do these steps: NOTE: This will prevent a sudden increase in pressure. This will decrease the possibility of a fire because of an increase in temperature. Make sure that the valves are also opened fully.

19)

Slowly open the oxygen cylinder valve to the fully open position with your hand. NOTE: Do not use more than 25 pound-inches of torque (finger-tight).

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CONCLUSION
In the Boeing 737 aircraft these PSUs' contain four continuous flow masks that are connected to each generator. A generator with two masks is located above each flight attendant seat and in each lavatory. The passenger system is activated two ways. It is activated automatically when the cabin altitude goes above 14,000 feet. It can also be activated by the pilots in the cockpit when they flip a switch. In either case, masks will drop down from the PSU. The oxygen generators are activated when any mask in the Unit is pulled down. Pulling one mask down causes all of the masks to come down and 100% oxygen flows to all of the masks. A green flow indicator within your oxygen hose is visible whenever oxygen is flowing to the mask. Your oxygen will last approximately 12 minutes and can't be shut off.

The flight crew system is supplied by a separate cylinder usually located in the forward cargo compartment. There is a thermal discharge relief valve that is connected to this cylinder to prevent an overheat condition. If these valve release pressures due to possible overheat, a disc will blow out and vent the excess pressure. On the Boeing 737, this disc is green in colour and is located on the outside of the forward, right fuselage. This is one of the items the pilots will check on their "walk-around". It uses quick-donning masks at each pilots' position. There is also one at the observer's station. When pulled out of their respective boxes at each pilot position, the masks can be fitted and formed around your face by air that enters a harness comprised of small diameter and flexible tubes. A microphone is installed so that the pilots can talk to each other and on the radio while wearing the oxygen mask.

The portable system is comprised of the passenger portable system and the flight crew portable system. The passenger system has several bottles and connected masks located throughout the cabin, mainly used for first aid. The flight crew system usually has a full face mask and bottle in the cockpit.

All oxygen systems need to be checked carefully to make sure they are working properly and have the sufficient amount of pressure and quantity. This is one of the items that maintenance crew will verify on their before flight checks.

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REFERENCES
Company, Boeing. (2007). Aircraft Maintenance Manual B737. Washington, USA: Boeing Commercial Airplanes Group.

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