BY C.

JAGANATHAN DEPARTMENT OF AERONAUTICAL ENGINEERING EXCEL ENGINEERING COLLEGE

Certification is a process by which the power plant is recognized as Fit To Fly . Certification process addresses following issues:

Flight within the acceptable mach no & altitude combinations Flights within the prescribed sorties None of the flight duration exceeded prescribed time limits None of the flights exceeded any of the laid down acceptable parameters of the engine or aircraft Permissible failures of the non critical components of the engine .

Driver documents for certification are

AIR STAFF REQUIREMENTS (ASR) Aircraft designer documents, dictate the following Single / double engine configuration Typical type of sorties Thrust requirements at various legs of sorties Minimum SFC operation in DRY & WET Unlimited throttle operation (no Embargo) Life of the engine in TBO, CL, TTL, CYCLIC LIFE etc Weight of the engine not exceeded in ____ Kgs . PRELIMINARY DESIGN DOCUMENTS OF THE ENGINE COVERING THE ABOVE ASPECTS

 PRELIMINARY

DESIGN REVIEW (PDR) of the

engine Following documentary evidences to be realized

Technical specification of the engine Performance documents of the engine Performance deck to aircraft designer Pedigree of all components subsystems used along with failure rates & boundary conditions Design recognition vis vis accepted specification for conformance

 Allied

documents are the following

Failure mode effect & criticality analysis (FMECA) Fault tree analysis (FTA) Reliability analysis Risk assessments of critical components & mitigation methodology proposed List of class A, B, c components of engine

A B C

Life & Safety Critical Life Critical Non Critical

Necessary to prove by test life & safety critical components Zero max Zero cycles of 7000 for cold end Zero max Zero cycles of 3500 for cold end Boundary conditions while taking testing should match engine environment For safety critical components cyclic loads may have to be 1.5 times than the max cyclic load Analysis of the component life has to be carried out using the material property having (-) 3 values All stress values (LCF & HCF) and creep properties have to be arrived (-) 3 values Castings, Forging properties have to be evolved from specimens extracted out of castings & forgings

 Temp

plates are evolved for various proposed sorties to classify under benign, medium & critical categories Critically factors not to exceed 1.35, 1.8 & 2.0 for benign, medium & critical categories respectively This is arrived by using conventional proposals namely A+ B/4 + C/40 Before start off the tests, it is necessary to finalize test procedure, test item, measurements & failure criteria etc

 Tests

have to be identified as safety level & life tests based on single of multiple engine configured aircraft Similarly, class A components under single engine configuration may be downgraded to class B components for a double engine configured aircraft Wrong identification can lead to unexpected failure of component during operation

 Over

speed test of compressor & turbine disc spun to 115% and dwelt for 30 seconds at max rpm During the test, boundary conditions are to be as that of engine environment Over temperature test of turbine (+ 40o C) from max operations temperature and maintained for 30 seconds Lane failure test during transient of engine all watch dogs are to be made reactive and unresponsive alternatively

 Disk

burst speed test at 122 % and dwelt for 10 seconds at this max rpm Necessary to maintain boundary conditions as that of the engine Blade off test (Both TURBINE & COMPRESSOR) at max rpm and engine allowed to settle at a lower rpm without much distress Engine over speed test, wherein the shaft is made to fail & turbine rotor spool should lodge into its respective NGV

 ACCELERATED

MISSION TEST (AMT) with a severity factor of not less than 2.0. Ten hours dedicated for hot air test Failure definition is mandatory for the engine, subsystems, modules etc. Single engine aircraft, fuel system test for switch over from automatics to manual mode & vice versa Single engine aircraft, oil interruption test Casing, pipelines for pressure burst test

 ACCELERATED

SIMULATED MISSION ENDURANCE TEST (ASMET) Engine endurance test Altitude test with simulated altitude conditions Flying test bed Subsonic platform Supersonic platform Performance of engine & its subsystems Identification of critical speeds

 Ice

inspection test Sand ingestion test Armament gas ingestion test Corrosion susceptibility test Vibration test & its response Gyroscopic load test Water ingestion test Customer air bleed contamination test Blade & disc deflection test

 PRE

FLIGHT RATING TEST (PFRT) Partial endurance test Development endurance test (10000 Hrs) Model specification of engine Engine health monitoring proven system

 No

major issues during & after first flight clearance, FINAL FLIGHT CLEARANCE (FFC) is given.

Thank you