TURBINE HANGER UNIVERSITY KUALA LUMPUR.docx

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    UNIVERSITY KUALA LUMPUR

    MALAYSIAN INSTITUTE OF AVIATION TECHNOLOGY

    Subject Code:

    Subject:

    Report: Jet Star Engine Removal, Inspection & Installation.

    Prepared For: Sir Roslan B. Basit

    Prepared By:

    1.2.3.4.5.6.7.8.9.

    Date: 16 November 2011

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    Introduction:

    Cerita Jet Star Gas Turbine Engine

    Objective:

    i. To Remove an Engine From Its Pylon Using a Hoisting For General & VisualInspection .

    ii. To Familiarize with Different Type of Gas Turbine Engine Assembly.Tools & Equipment:

    i. Dial Torque Wrench F igure 1ii. Flashlight

    iii. RatchetF iqure 1iv. Socket ExtensionF igure 1v. Socket SetF igure 1

    vi. Spanner Open End Head Set F igure 1vii. Engine StandF igure 2

    F igure 1

    F igure 2

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    Removal:

    General: The Engine Removal is done when the engine experiences an internal damage

    Or When Engine Performance Doesnt Achieve It Desirable Values whereby

    Engine Trimming is required.

    Procedures Pictures

    The Nacelle can be divided into two

    areas with the box beam being the

    dividing point. The Top forward side

    of each nacelle has a door for

    providing access to the upper part of

    the engine.

    The Access Panel is Open to allow

    for the hoist to be hooked on

    specified location only stated by

    Manufacturer Manual .

    Once the both side have been

    properly and securely hoist .

    Remove the following connection:

    i. Fluid Linesii. Electrical Connection

    iii. Control Cable

    Make Sure Before Any Connection

    or Mechanical Linkages Is being

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    removed , Switch Off the Master

    Switch and Wait For a Few Minutes.

    Once both C-Clamp Fasteners have

    been removed , the engine will be

    lowered straight and level to prevent

    collision with the pylon and any

    accessory mounted with the pylon.

    2 Personnel were required in this

    process to monitored it from the

    Front and Rear of the Engine.

    Both C Clamp Fasteners will

    be removed prior lowering

    down the engine .

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    The Engine Stand need to placed

    parallel to the engine .

    The Engine has two support strut on

    both side . These support strut is

    used to hold the engine when it is on

    the engine stand .

    Upon Reaching the Engine Stand ,

    the Support Strut need to be exactly

    matched with the Engine Stand

    Support Strut.

    Engine Support Strut Need to be

    Firm and Secured to hold the engine

    prevent it from swinging back and

    forth .

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    Once the engine has been totally

    lowered , the hoist will be removed

    from engine before sending it for

    inspection.

    Additional Locking Method is

    used to prevent Engine Rear

    and Front Bottoming .

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    Inspection

    General: Inspection Done in Shop Maintenance involves checking engine component ,

    list down any missing component , State the defects and look out for

    any components that require replacement or in need for repair .

    Observation:

    Component Figure

    Combustion Chamber:

    1) Combustor Type : Can AnnularDefects:

    1) Heavily dent on all side ofsurfaces.

    2) Combustor Lining is badlydamage.

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    CClamp

    Defects:

    1) Sealant or Packing need to bereplace as fluid is seen leaking or

    proper lubrication method need

    to be followed.

    2) Each Bushing and Nuts RequireReplacement as the bushing is

    damage and the nut thread has

    already worn.

    Missing:

    1) Upon Removal found that OneBushing is missing from C-

    Clamp .

    3) Ignition Exchanger insulation

    & connection required to be

    replace .

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    Exhaust Assembly

    Defects:

    1) Tearing of Insulation Material

    2) Realignment and RewiringLocking of thermal probe

    3) Dent on Edge of Exhaust Cone.

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    Result:

    Parts Defects Action Taken

    Combustion Chamber

    i. Ignition Exchanger Dent Rust Corrodes

    Replaced

    CClamp

    i. Fastenersii. Packing / Seals

    Bushing Missing Leaking Thread Wear

    Replaced

    Repair

    Replace

    Exhaust Assembly

    i. Thermal Probeii. Insulation

    iii. Exhaust Cone

    Tearing Rust Corrodes Dent

    Replaced

    Replaced

    Replaced

    Repair

    Reassembly:

    Procedures Pictures

    Similar Procedures but with a few

    Differences .

    The Engine , again hook it into

    designated places .

    Before hoisting the engine up , the hoist

    cables need to be straighten and stress .

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    This time , the C-Clamp Nuts are

    required to be torque as stated in the

    manual which is 50 inch pound .

    The engine need to be aligned with

    the C- Clamp with straight and level

    hoisting for both cables.

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    Conclusion:

    The removal of the engine requires a lot of workforce and consumed a lot of

    downtime for the aircraft which eventually deal with the aircraft operators budget . So ,

    necessary removal engine will only be done on certain cases such as internal damage of

    the engine whereby further inspection for internal component , major overhauling &

    engine trimming.

    Diagram of How Jet Star Engine is being Removed / Reinstall

    Reference:

    Jet Star Engine Installation & Removal Vol. 1.

    Jeppesen Airframe Textbook .

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