Turbine Engine Design Construction

7/28/2019 Turbine Engine Design Construction

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01/07/2013 BY: ANDA S. MAHMUD 1

TURBINE AIRCRAFT ENGINEDESIGN & CONSTRUCTION


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CASR PART 33 : A. GENERAL

B. DESIGN AND CONSTRUCTION ; GENERAL

C. DESIGN AND CONSTRUCTION ;

RECIPROCATING AIRCRAFT ENGINES

D. BLOCK TESTS; RECIPROCATING AIRCRAFT ENGINES

E. DESIGN AND CONSTRUCTION ;

TURBINE AIRCRAFT ENGINES

F. BLOCK TESTS ;



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DESIGN AND CONSTRUCTION ;

GENERAL


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33.11 APPLICABILITY

General design and construction

requirements for reciprocating and

turbine aircraft engines.


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33.14 START / STOP CYCLIC

STRESS ( LOW CYCLE FATIGUE)

Operating limitations must be established

which specify the maximum allowable

number of start/stop stress cycles foreach rotor structural part : discs, spacers,

hubs, and shafts of compressor and

turbines.


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33.15 MATERIALS

The suitability and durability of

materials must :

- Be established on the basis of experience or tests; and

- Conform to approved specification


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33.17 FIRE PREVENTION

The design and construction of the

engine and the materials used must

minimize the probability of theoccurrence and spread of fire.

Each external line, fitting, and other

component which containsflammable fluid must be fire resistant


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33.17 FIRE PREVENTION (cont)

Components must be shielded or

located to safeguard against the

ignition of leaking flammable fluid.Flammable fluid tanks and supports

must be fireproof or be enclosed by a

fireproof shield.


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33.17 FIRE PREVENTION (cont)

For turbine engine in supersonic

aircraft, each external component

which contains flammable fluid mustbe fireproof .

Unwanted accumulation of

flammable fluid and vapour must beprevented by draining and venting.


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WHAT IS A DIFFERENCE

BETWEEN FIRE RESISTANTAND FIREPROOF MATERIAL ?


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33.19 DURABILITY Engine design and construction must

minimize the development of an unsafe

condition of the egine between overhaulperiod.

The design of compressor and turbine

rotor cases must provide for thecontainment of damage from rotor bladefailure.


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33.19 DURABILITY (cont.)

Energy levels and trajectories of

fragments from rotor blade failure must

be defined.

Each component of the propeller blade

pitch control system must meet CASR

35.42.


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33.21 ENGINE COOLING Engine design and construction must

provide the necessary cooling under

conditions in which the airplane is

expected to operate


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33.23 ENGINE MOUNTING

ATTACHMENTS AND STRUCTURE

The maximum allowable limit and ultimate

loads for engine mounting attachments

and related engine structure must be

specified.

The engine mounting attachments and

related structure must be able to

withstand -


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33.23 ENGINE MOUNTING

ATTACHMENTS AND STRUCTURE(cont.)

The specified limit loads withoutpermanent deformation.

The specified ultimate loads without

failure, but may exhibit permanentdeformation.


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33.25 ACCESSORY ATTACHMENTS

The engine must operate properly with

accessory drive and mounting

attachments loaded. Each engine accessory drive and

mounting attachment must include

provisions for sealing to prevent leakagefrom interior.


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33.25 ACCESSORY ATTACHMENTS

(cont.) A drive and mounting attachment

requiring lubrication for external drive

splines , or coupling by engine oil, mustinclude provision for sealing.

The design of the engine must allow for

the examination , adjustment, or removalof each accessory.


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33.27 TURBINE, COMPRESSOR,

FAN, AND TURBOSUPERCHARGER

ROTORS

Turbine, compressor, fan, and turbosuper -

charger rotors must have sufficient strength.

The design and functioning of engine control

devices, systems, and instruments must give

reasonable assurance that those engine

operating limitations that affect rotor structuralintegrity will be exceeded in service.


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ROTORS (cont.)

The most critically stress rotorcomponent (except blades) of eachturbine, compressor, and fan, includingintegral drum rotors and centrifugalcompressors in an engine or turbosuper-

charger , as determined by analysis orother acceptable means must be testedfor a period of 5 minutes -


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ROTORS (cont.) At its maximum operating temperature

At the highest speed of the following, as applicable:

- 120 percent of its max. permissible rpm if tested on a rig

- 115 percent of its max. permissible rpm if

tested on an engine

- 115 percent of its max. permissible rpm if tested on turbosupercharger driven by hot gas


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ROTORS (cont.) - 120 percent of the rpm at which, while cold

spinning, it is subject to operating stress that

are equivalent to those induced at the max.

operating temperature and max. permissible

rpm.

- 105 percent of the highest speed that would result from failure of the most critical

component or system


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ROTORS (cont.) - The highest speed that would result from the

failure of any component or system , in

combination with any failure of component or

system that would not normally detected

during operation.

- Following the test, each rotor must be within approved dimensional limits for an over speed

condition and may not be cracked .


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33.27 INSTRUMENT CONNECTION

- Each instrument connection must be

marked to identify it with corresponding

instrument.

- A connection must be provided on each

turbojet engines for an indicator system

to indicate rotor system unbalance.


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DESIGN & CONSTRUCTION



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33.61 APPLICABILITY

This subpart prescribesadditional design and

construction requirements forturbine aircraft engines


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33.62 STRESS ANALYSIS

A stress analysis must beperformed on each turbine engine

showing the design safety marginof each turbine engine rotor,spacer, and rotor shaft.


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33.63 VIBRATION

Each engine must be designed andconstructed to function throughout itsoperating range of rotational speedsand engine power without inducingexcessive stress in any engine partbecause of vibration and withoutimparting excessive vibration forces

to the aircraft structure.


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33.67 FUEL SYSTEM

With fuel supplied to the engineat the flow and pressure specifiedby the applicant, the engine must

function properly under eachoperating condition.

Each fuel control adjusting

means must be secure by alocking device and sealed.


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33.67 FUEL SYSTEM (cont.)

The following provisions apply to eachstrainer or filter :

It must be accessible for draining andcleaning and must incorporate a screen orelement that is easily removable.

It must have a sediment trap and drain.

It must be mounted so that its weight is not

supported by connecting lines or by inletor outlet connection of the strainer or filter.


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It must have the type and degree offuel filtering. The applicant must show:

That foreign particles passing

through the specified filtering meansdo not impair the engine fuel systemfunctioning.


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The fuel system must capable ofsustained operation throughout its

flow and pressure range with the fuel

initially saturated with water at 80F(27C) and having 0.025 fluid ounces

per gallon (0.20 milliliters per liter) of

free water added and cooled for icinglikely to be encountered in operation.


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The applicant must demonstrate thatthe filtering means has the capacity to

ensure that the engine will continue to

operate within approved limits, withfuel contaminated to the maximum

degree of particle size and density

likely to be encountered in service.


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Any strainer or filter bypass mustbe designed and constructed sothat the release of collected

contaminants is minimized byappropriate location of thebypass to ensure that collected

contaminants are not in thebypass flow path.


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If provided as part of the engine,the applicant must show or each

fluid injection (other than fuel)

system and its controls that theflow of the injected fluid is

adequately controlled.


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33.68 INDUCTION SYSTEM ICING

Each engine, with all icing protectionsystem operating , must

Operate throughout its flight power

range (including idling) without theaccumulation of ice on the engine

components that adversely affects

engine operation.


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33.68 INDUCTION SYSTEM ICING

(cont.)

Idle for 30 minutes on ground , withthe available air bleed icing for eachengine, with all icing protectionsystem operating , must

Operate throughout its flight powerrange (including idling) without theaccumulation of ice on the engine

components that adversely affectsengine operation.


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33.69 IGNITION SYSTEM

Each engine must be equipped withan ignition system for starting the

engine on the ground and in flight.

An electric ignition system must haveat least two igniters and two separate

secondary electric circuits, except

that only one igniter is required forfuel burning augmentation systems.


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33.71 LUBRICATION SYSTEM

GENERAL:

Each lubrication system must

function properly in all operating

conditions. OIL STRAINER OR FILTER:

There must be an oil strainer or filter

through which all of the engine oilflows.


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33.71 LUBRICATION SYSTEM(cont.)

Each strainer or filter that has abypass must be constructed and

installed so that oil will flow at the

normal rate through the rest of thesystem with the strainer or filter

element completely blocked.


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The type and degree of filteringsystem must be specified.

The applicant must demonstrate that

foreign particles passing through thespecified filtering means do not

impair engine oil system functioning.


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Each strainer or filter must have thecapacity to ensure that the engine oil

system functioning is not impaired

with the oil contaminated to a degreethat is greater than above.

Each strainer or filter must have a

means to indicate contamination.


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Any filter bypass must be designedand constructed to ensure that the

collected contaminants are not in the

bypass flow path. Each strainer or filter that has no

bypass must have provisions for

connection with a warning means towarn the pilot.


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Each strainer or filter must be accessiblefor draining and cleaning.

OIL TANKS : Each oil tank must have an expansion

space of not less than 10 percent of the

tank capacity.

It must be impossible to inadvertently fill

the oil tank expansion space


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Each recessed oil tank filler connection

that can retain any appreciable quantity of

oil must have provision for fitting a drain. Each oil tank cap must provide an oil tight

seal.

Each oil tank filler must be marked with the

word oil.


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Each oil tank must be vented from the top

part of the expansion space.

There must be means to prevent entranceinto the oil tank or into any oil tank outlet ,

of any object that might obstruct the flow

of oil through the system.

There must be a shutoff valve at theoutlet of each oil tank

33 71 LUBRICATION SYSTEM( )


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.

Each unpressurized oil tank may not leakwhen subjected to a maximum operating

temperature and an internal pressure of 5

psi.

Each pressurized oil tank may not leak

when subjected to a maximum operating

temperature and an internal pressure that

is not less than 5 psi plus the maximumoperating pressure of the tank.


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Leak or spilled oil may notaccumulate between the tank and

the remainder of the engine.

Each oil tank must have an oilquantity indicator or provisions

for one.


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OIL DRAINS: A drain must be provided to allow safe

drainage of the oil system.

Each drain must :

- Be accessible

- Have manual or automatic means for

positive locking in the closed position


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OIL RADIATORS :Each oil radiator must withstand,

without failure , any vibration,

inertia, and oil pressure load towhich it is subjected during the

block tests.


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33.72 HYDRAULIC ACTUATING

SYSTEMS Each hydraulic actuating system must

function properly under all conditions in

which the engine is expected to operate. Each filter or screen must be accessible for

servicing.

Each tank must meet the design criteria of

CASR 33.71.


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33.75 SAFETY ANALYSIS

Analysis should be shown for any probablemalfunction or any probable single or

multiple failure, or any probable improperoperation the engine will not cause theengine to -.

- Catch fire

- Burst ( release hazardous fragment through the engine case)


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33.75 SAFETY ANALYSIS (cont.)

- Generate loads greater than those

ultimate loads specified in CASR

33.23 (a)

- Lose the capability of being shutdown


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33.77 FOREIGN OBJECT INGESTION

Ingestion of 4 pound birds may not cause

the engine to

- Catch fire

- Burst (release hazardous fragments

through the engine case)

- Generate loads greater than those

ultimate loads specified in CASR 33.23(a)


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(cont.) Ingestion of 3 ounce birds or 1.5 pound birds

may not

- Cause more than a sustained 25 percent

power or thrust loss.

- Require the engine to be shut down within

5 minutes from the time of ingestion.

- Result in a potentially hazardous condition.


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(cont.) Ingestion of water , ice, or hail may not

cause a sustained power or thrust loss

or require the engine to be shut down. It must be demonstrated that the engine

can accelerate and decelerate safely

while inducing a mixture of at least 4

percent water by weight at engine

airflow.


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(cont.) For an engine that incorporates a protection

device need not be demonstrated with respect

to foreign ingestion if it is shown that-

- Such foreign objects are of a size that will

not pass through the protective device.

- The protective device will withstand the

impact of the foreign objects.


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(cont.) - The foreign object, or objects,

stopped by the protective device will

not obstruct the flow of induction air

into the engine with a resultant

sustained reduction in power or

thrust .


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33.79 FUEL BURNING THRUST

AUGMENTOR Each fuel burning thrust augmentor,

including the nozzle, must -

- Provide cutoff of the fuel burning thrust augmentor.

- Permit on/off cycling.

- Be controllable within the intended

range of operation.


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33.79 FUEL BURNING THRUST

AUGMENTOR (cont.) Upon a failure or malfunction of augmentor

combustion, not cause the engine to losethrust other than that provided by the

augmentor. Have a controls that function compatibility

with the other engine controls andautomatically shutt off augmentor fuel flow if

the engine rotor speed drops below theminimum rotational speed at which theaugmentor is intended to function.

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