Key NeW OWNeR WISDOm YOUR Y OUR PT6A TURbOPROP
Know your pt6A turboprop
Congratulations on your acquisition o an aircrat powered by the Pratt & Whitney Canada Corp. (P&WC) dependable PT6A Turboprop Engine! Just like you, operators around the globe have made the PT6A engines their choice in the business and general aviation market – engines known to provide exceptional power, perormance and peace o mind. By making this wise choice, you are beneting rom 45 years and 300 million hours o in-service experience resulting in unmatched reliability. This handbook has been designed to give you a brie overview o the PT6A engine as well as some maintenance and power management recommendations. Always reer to the Pilots Operating Handbook (POH), Aircrat Flight Manual (AFM), Engine Maintenance Manual (EMM), Service Bulletin’s (SB) or other service inormation documentation or a complete text o the approved / recommended procedures and latest inormation.
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Know your pt6A turboprop
Congratulations on your acquisition o an aircrat powered by the Pratt & Whitney Canada Corp. (P&WC) dependable PT6A Turboprop Engine! Just like you, operators around the globe have made the PT6A engines their choice in the business and general aviation market – engines known to provide exceptional power, perormance and peace o mind. By making this wise choice, you are beneting rom 45 years and 300 million hours o in-service experience resulting in unmatched reliability. This handbook has been designed to give you a brie overview o the PT6A engine as well as some maintenance and power management recommendations. Always reer to the Pilots Operating Handbook (POH), Aircrat Flight Manual (AFM), Engine Maintenance Manual (EMM), Service Bulletin’s (SB) or other service inormation documentation or a complete text o the approved / recommended procedures and latest inormation.
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Know your pt6A turboprop
Should you require additional information related to: AOG / critical emergency services Technical / maintenance consultation Warranty Publications Field Service Representative (FSR) contact ino Rental Engines Engine status in any P&WC Service Centre Eagle Service Plan® (ESP®) AOG Parts Ater Hours, our Customer FIRST Centre is available 24 hours a day, 7 days a week to assist you. In Canada and the United States: Tel: 1-800-268-8000 International: Tel: International Access Code + 8000-268-8000 Other Numbers: Tel: (450) 647-8000
Fax: (450) 647-2888
Email: c
[email protected] Visit our website at: www.pwc.ca
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Know your pt6A turboprop
Take note o your PT6A engine model and serial number. This will help us to coordinate our support in a timely manner. Engine Model: Engine Serial Number: Engine Logbook: Each engine is supplied with a logbook(s) to record all maintenance actions as well as engine running times and cycles. The logbook(s) must accompany the engine or module each time they are sent to an approved service or overhaul acility.
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DisclAimer
Disclaimer The inormation contained herein has been set out in summary orm and is provided or general reerence purposes only and may be changed without prior notice. It should not be construed as creating any obligation on the part o Pratt & Whitney Canada Corp. While every care has been taken to avoid errors, Pratt & Whitney Canada Corp. makes no representations about the accuracy o these guidelines and accepts no responsibility or any error herein. In no event shall P&WC be liable or any damages whatsoever resulting rom the misuse, misinterpretation, analysis, interpretation or application o any o the guidelines contained herein. The inormation contained herein does not replace or supersede the inormation contained in the appropriate airrame or engine maintenance manuals or other ocial publications. Always reer to the Pilot’s Operating Handbooks (POH), Aircrat Flight Manuals (AFM), Engine Maintenance Manuals (EMM), Service Bulletins (SB) or other Service Inormation documentation or a complete text o the approved / recommended procedures and latest inormation. PT6 and PT6A are trademarks o Pratt & Whitney Canada Corp.
© Copyright Pratt & Whitney Canada Corp. May not be reproduced, in whole or in part, without prior written consent 5
nomenclAture
ADAS
Aircrat Data Acquisition System
AFM
Aircrat Flight Manual
AGB
Accessory Gearbox
AOG
Aircrat On Ground
CT
Compressor Turbine
ECTM®
Engine Condition Trend Monitoring®
EESP
Extended Engine Service Policy
EPL
Emergency Power Lever
ESP®
Eagle Service Plan®
FOD
Foreign Object Damage
FSR
Field Service Representative
HSI
Hot Section Inspection
ITT
Interturbine Temperature
LCF
Low Cycle Fatigue
MOR
Manual Override
Ng
Gas Generator Speed
6
nomenclAture
Np
Propeller Speed
PPSP
Primary Parts Service Policy
PLA
Power Lever Assembly
POH
Pilot’s Operating Handbook
PT
Power Turbine
RPM
Rotations Per Minute
SB
Service Bulletin
SHP
Shat Horsepower
SIL
Service Inormation Letter
STOL
Short Takeo and Landing
TBO
Time Between Overhaul
TSO
Time Since Overhaul
TTSN
Total Time Since New
TCSN
Total Cycles Since New
UAC
United Aircrat Corporation
Wf
Fuel Flow Rate
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Know your pt6A turboprop
Initial Customer Support Presentation P&WC oers a three-part introduction to the company, engine maintenance and our atermarket support logistics. You have the option o scheduling a meeting at your convenience or we will be happy to send you an inormation kit with brochures and a copy o the presentation that you may review at your leisure. When the time comes, your local FSR can provide guidance on such things as uel nozzle exchange, boroscope inspection o the hot section or other maintenance areas.
Publications P&WC oers a package o high-quality technical publications or new aircrat operators. Moreover, a ree two-year revision service is provided or each new publications subscription. Additional publications may also be purchased. The price list or commercial publications is available upon request by contacting Publications Customer Services. For additional details on our Technical Publications, including contact ino, please visit us at our website, www.pwc.ca
Warranty P&WC prides itsel in oering transerable warranty coverage that is amongst the best in the aerospace business. The new engine warranty is comprised o the Basic Coverage Period and may be supplemented by one or both o the ollowing available service policies:
· The Primary Parts Service Policy (PPSP) is a renewable pro-rata warranty coverage or the repair or replacement o specic engine parts damaged due to a deect in material or manuacturing workmanship during their P&WC commercially-supported class lie. · The Extended Engine Service Policy (EESP) applies or a premature, engine-chargeable event when an overhaul is required.
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Know your pt6A turboprop
Once we have been inormed o a new PT6A engine delivery to an aircrat operator, a copy o the applicable new engine warranty will be sent to the new owner by the P&WC Warranty Administration department. Notication o new aircrat sales is normally received directly rom aircrat manuacturers, their licensed dealers or directly rom the owner. Note that warranty coverage is attached to the engine serial number, not to the owner. For any warranty questions, please eel ree to email us at
[email protected]. I your aircrat is involved in an incident which aects the engine (e.g. prop strike, hard landing), you must inorm P&WC Warranty by lling out the orm included in SIL GEN-039. This will ensure that your warranty policy is reinstated ollowing the corrective maintenance actions.
Customer Portal Pratt & Whitney Canada is committed to providing global support services that delights our customers. The P&WC Customer portal is just one o the many ways in which we collaborate with our customers. The portal will give access to an increasing list o on-line services and inormation. Register today on our website, www.pwc.ca, ree o charge, to receive the P&WC Extranet Application URL, username and password once the registration request has been approved and processed.
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pt6A engine generAl
PT6A Engine Overview Unmatched versatility, dependability and perormance have made the PT6A engine the most thoroughly proven and popular turboprop engine amily in the 500- to 1,700-shp class, covering a diverse range o applications across all aircrat markets. We continually invest in technology to make our engines the most environmentally riendly and to oer even greater value in the orm o higher perormance and digital engine control. The PT6 engine, a lightweight ree turbine engine incorporating a reverse fow combustion path, is designed or aircrat propulsion use. It utilizes two counter-rotating turbines; one driving the compressor and the other driving the propeller through a reduction gearbox. The latter turbine is “ree” or independent o the compressor turbine. More recent, higher powered models incorporate a two-stage power turbine. Over the years, the PT6 engine has evolved and adapted to a multitude o uses. The PT6A engine is the turboprop designation, powering commuter, corporate and utility aircrat, aerobatic trainers, agricultural aircrat, short takeo and landing (STOL) aircrat and water bombers. This handbook is dedicated to the PT6A variant. The PT6B, C & T (Twin-Pac®) engines are turboshat variants, providing reliable power to many o the worlds helicopters and more recently to tiltrotors. The ST6 engine is an industrial variant o the PT6 engine, originally developed or the United Aircrat Corporation (UAC) TurboTrain and intended or stationary application.
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moDulArity
The design o the PT6A engine allows it to be split into two major parts called the power section assembly and the gas generator assembly. Only certain engine models are dened as being modular, which allows the interchange and tracking o each module. Three criteria must be met or the engine to be modular. 1. Each major assembly is equipped with a data plate and a third data plate is located on the inlet case or the complete engine assembly. 2. There is a logbook or each module. 3. In the appropriate SB on service lives, there will be an overhaul interval quoted or each module and the engine assembly. On non-modular PT6A engines, the power section assembly can be removed and sent or service, but must be returned and installed on the same gas generator assembly.
Small PT6A Engine
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ADvAntAges of the pt6A engine Design
A number o advantages are derived rom the design o the PT6A engine which have proven valuable in routine eld operation. During an engine start, only the compressor section o the PT6A engine needs be rotated by the starter-generator. By comparison, a xed-shat engine must spin all rotating components including the reduction gearbox and propeller during an engine start, resulting in a requirement or heavier starting systems. The PT6A engine ree turbine design allows the propeller RPM to be reduced and the propeller eathered during ground operation without shutting down the engine. This acilitates ast passenger loading and permits very quiet ground operation. Propeller RPM can also be varied in fight (on most applications) permitting propeller RPM to be set or quieter cruise and optimum eciency.
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principles of operAtion
The PT6A engine consists o two main sections, the gas generator section and the power section. The gas generator section compresses and delivers air to the combustion chamber where it is mixed with uel and ignited. The resulting hot gases turn the compressor turbine which provides the power to run the compressor and the accessory gearbox located at the rear o the engine. The hot gases continue on to the power turbine where the remaining energy is extracted to turn the propeller.
Np
Tq
Nf
T5 (ITT)
Ng
FCU
Wf
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Airflow
Air is directed to a compressor consisting o three axial stages (Four axial stages on large PT6A engine models) and one centriugal stage. Compressed air leaving the compressor passes through diuser pipes which turn the fow 90 degrees, reduce its speed and direct the air into the combustion chamber. In the annular combustion chamber the air is mixed with uel and burned. Two igniter plugs are used to light the uel/air mixture when the engine is started. They are not required to maintain the combustion process and can be shut o once the engine has reached idle speed. The expanding hot gases are directed rst through the compressor turbine and then through the power turbine. Ater passing through the power turbine, the gases are exhausted through ports on each side o the engine. (Some engines are tted with a single-port exhaust.) The exhaust stubs tted to the engine are normally directed to utilize the remaining energy o the gases in the orm o thrust or additional aircrat propulsion. Two bleed air systems are incorporated in the PT6A engine. Automatic bleed air rom the compressor prevents compressor stall during acceleration rom low engine speeds or deceleration rom high engine speeds. For aircrat use, air may be bled or heating or pressurizing aircrat cabins.
Medium PT6A Engine 14
power trAin
A shat connects the power turbine to the two-stage planetary reduction gearbox. The rst stage reduction ring gear foats axially against a hydraulic torquemeter cylinder. The oil pressure in this cylinder is proportional to output torque which is displayed on the torque indicator in the cockpit. Bevel gears located orward o the second stage planetary gears drive the ollowing accessories mounted on the orward reduction gearbox case:
· propeller governor or constant speed unit · propeller overspeed governor · tachometer-generator COMPRESSOR TURBINE 2 ND STAGE REDUCTION GEAR
1 ST STAGE REDUCTION GEAR
POWER TURBINES
COMPRESSOR
ACCESSORY GEARBOX
PROPELLER SHAFT
Large PT6A Engine The accessory gearbox, mounted on the rear o the engine, is used to drive the ollowing engine accessories:
· High-pressure uel pump · Fuel control unit · Oil scavenge and oil pressure pumps. Space is also provided or aircrat manuacturer provided accessories such as the starter-generator, gas generator tachometer-generator, uel boost pumps or hydraulic pumps. 15
beArings
Support o the main shats in the PT6A engine is accomplished by a combination o ball and roller bearings. Ball bearings support axial and radial loading, while the roller bearings support only radial loads, allowing or thermal expansion.
Propeller Shaft
Power Turbine
Compressor
No. 5: Roller
No. 3: Roller
No. 1: Ball
No. 6: Ball
No. 4: Ball
No. 2: Roller
No. 7: Roller** ** Smaller reduction gearboxes do not utilize a No. 7 bearing.
7
6
5
A-60 A-65 A-67
A-52 A-61 A-64 A-66
6
5
4
3
2
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1
foD protection
Inertial Separator The nacelle inlet o many aircrat models includes an inertial separator provided by the aircrat manuacturer to prevent heavy particles rom entering the engine inlet. Most installations incorporate two moveable vanes, one upstream o the engine inlet and the other blocking the bypass duct. For bypass operation, the inlet vane is lowered and the bypass duct vane is opened permitting maximum separating eciency. In some installations, the vanes are xed in the bypass mode. As shown in the sketch, air entering the engine inlet must turn sharply past the inlet vane (shown in the lowered position). Particles heavier than air are carried straight through, by their own inertia, into the bypass duct and dumped overboard. The at radial inlet design provides many advantages such as superior anti-icing utilizing the principle o inertial separation, low noise levels and unequalled protection rom FOD.
BYPASS (ICING) POSITION
NORMAL POSITION
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fuel system
The uel system is designed to deliver clean uel to the engine at the pressure and fow that are necessary or all engine operating conditions. The airrame uel system contains the necessary boost pumps, transer pumps, selector/shuto valves, strainers and lters required to supply uel to the engine(s) and to manage the uel load distribution in the airplane. The engine is equipped with a uel system which consists o a uel heater, high-pressure uel pump, uel lter, uel control unit, start control or fow divider unit and a maniold with uel injection nozzles. The uel control unit is either a hydro-pneumatic or a hydro-mechanical system which meters the correct amount o uel to the engine to maintain the gas generator speed selected by the pilot via the power control lever. It also controls uel fow scheduling during engine starting, acceleration and deceleration. The PT6A engine is approved or operation with all commercial jet uels, JP-4, JP-5 and or a maximum o 150 hours during any overhaul period with all grades o aviation gasoline. Specic grades o diesel uel are approved as alternate uels or restricted use. No engine adjustments are required in changing rom one uel to another, nor is it necessary to purge the uel system when changing uels, except when using alternate uels. For listings o approved uels and uel additives reer to the appropriate Service Bulletins or each PT6A engine model.
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oil system
The PT6A engine has a sel-contained oil system with the exception o the oil cooler, air duct and associated plumbing. The oil level should be veried ater engine shutdown and while the oil is still hot, using either a dipstick or a sightglass.
For more information related to the oil system, please refer to page 29.
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typicAl pt6A engine instrumentAtion
Incorporated into the design o the PT6A engine are accurate and reliable torque and ITT measuring systems that give the pilot an accurate indication o the primary engine operating parameters. Torque Pressure is sensed by a torque pressure transducer mounted on the reduction gearbox, to indicate the torque being developed by the engine. Torque is the primary parameter used to set power or takeo and cruise operation or specied propeller speeds. ITT is monitored to ensure that combustion gas temperature limits o the engine are not exceeded. Two tachometer-generators are installed on the engine: one on the reduction gearbox monitors propeller speed (Np), and the other on the accessory gearbox monitors gas generator speed, (Ng). Pressure and temperature gauges monitor the oil system.
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controls
Cockpit Powerplant Controls PT6A engine applications use the engine power management system and propeller beta control capability to obtain optimum airplane fight and ground handling capability. The powerplant unctions are typically commanded rom the cockpit by means o three control levers and pushpull cables. In some applications where certain powerplant unctions are not required, simplied systems using two or even one cockpit control lever may be used.
MIN. POWER REVERSE
TAXI RANGE
POWER RANGE
BETA
MAX. POWER MIN. RPM MAX. RPM
FEATHER
POWER LEVER
PROPELLER LEVER
CAM ASSY
PROPELLER GOVERNOR
LOW IDLE SHUT-OFF
HIGH IDLE
FUEL LEVER
Control
Location
Control Function
Condition
Fuel control unit (or start control)
Fuel cut-o and idle speed(s)
Power
Fuel control unit
Gas Generator speed
Propeller
Propeller governor
Prop speed and eathering
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controls
Secondary control inputs located on the propeller governor include the beta valve and the uel governor reset. These controls are used in conjunction with the propeller low blade angle eedback system and the engine propeller reversing control system or propeller beta control and reverse thrust control. A cambox unit is part o the engine control system and its purpose is to schedule gas generator speed and propeller angle by means o linkages to the uel control power lever and to the propeller governor beta valve and uel governor reset controls.
Propeller Low Blade Angle Reset Systems During the development program o an airplane, the most desirable propeller low pitch limits (primary blade angle) and engine fight idle settings required or optimum fight handling are determined. In some cases, certain ground operating requirements such as propeller restricted speed ranges may dictate a dierent propeller low pitch limit or ground operation. Some installations utilize an airrame-supplied propeller low pitch reset system actuated by means o a switch which senses the weight o the airplane on the main landing gear. This unctionality is integrated with the engine-supplied propeller beta control system. The system automatically sets the propeller low pitch limit to either the ground or light positions.
Automatic Feathering Takeo perormance or multi-engine aircrat is based upon having one engine inoperative. Most multi-engine aircrat are equipped with aircrat manuacturer provided automatic eathering systems to reduce drag on the aircrat. However these systems are normally not armed during most other phases o fight. Automatic eathering is not used in single-engine PT6A engine applications. Please reer to the applicable AFM or specic operating instructions. Because the ree turbine conguration o the PT6A engine has less rotating inertia than a xed turbine engine, an uneathered propeller creates less in-fight drag. Thereore, negative torque sensing systems are not required.
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controls
Propeller Overspeed Governor All PT6A turboprop installations are equipped with an airrame-supplied propeller overspeed governor. This unit has its own dedicated drive rom the engine reduction gearbox and is intended to limit the propeller speed to a predetermined maximum value in the event o a malunction o the primary propeller governor. In most installations which eature an automatic eathering system, the automatic propeller eathering unction is perormed by an electricallyactivated propeller servo oil dump valve on the overspeed governor.
Overtorque Limiter On some PT6A engine installations an overtorque limiter is installed to limit maximum engine output torque to a preset value. This unction has been utilized on applications where the normal power setting and monitoring procedures cannot be used, such as military trainer aircrat which are intended to maintain the maximum operational similarity to high-perormance jet aircrat. Other applications with substantially fat rated PT6A engines utilize an overtorque limiter to prevent inadvertent excessive power settings by the pilot. An electronic limiter system is also installed on some engine models intended or military trainer aircrat. This system oers both torque and ITT limiting capability.
Manual Override All PT6A engines intended or single-engine aircrat are equipped with a manual override unction installed on the uel control unit. The manual override can be connected to an Emergency Power Lever (EPL) in the cockpit by an airrame-supplied linkage, i required by the aircrat manuacturer.
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emergency power lever
Introduction The manual override unction, when connected to the EPL, is intended or use during emergencies or closely monitored training only and must never be used during normal engine operation. This lever should only be used to modulate engine power to allow the pilot to continue fight to the nearest airport in the event o malunction in the uel control pneumatic system resulting in one o the ollowing conditions: 1. Uncommanded power roll back and inability to recover with the Power Lever Assembly (PLA). 2. No response to PLA movement, when starting rom or around idle. 3. PLA becomes stuck at or around idle. The EPL does not duplicate the unction o the PLA and is not to be used as an optional means o controlling the engine. The EPL overrides all automatic uel control eatures and acts directly on the uel valve to directly modulate the uel fow to the engine. Rapid movements o this lever should not be made or any reason whatsoever. EPL sensitivity increases with altitude and above 5000 t., extreme care should be exercised. Please reer to the applicable AFM or POH or correct operation o the EPL.
CAUTION: WHEN USING THE MANUAL OVERRIDE SYSTEM, THE ENGINE RESPONSE MAY BE MORE RAPID THAN WHEN USING THE POWER LEVER. A RAPID INCREASE IN EMERGENCY POWER LEVER POSITION TOWARDS MAXIMUM IS TO BE AVOIDED, AS THIS CAN CAUSE ENGINE SURGE, ENGINE OVERTEMPERATURE, Ng OVER-SPEED OR OVER-TORQUE. Inappropriate use o the EPL will increase maintenance costs and can be a contributory actor to CT blade ractures.
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scheDuleD mAintenAnce
The ollowing inormation is intended as an overview o maintenance practices. For a complete description please reer to the Engine Maintenance Manual (EMM). Chapter 70-00-00 describes standard practices including servicing the engine oil system. Chapter 71-00-00 contains inormation on maintenance practices, including adjustment, test and cleaning. Chapter 72-00-00 outlines inspection criteria or various sections o the engine. The inspection procedures are considered a normal unction o the operating organization and are intended as a guide or minimum inspection and maintenance requirements. The aircrat manuacturer may have additional requirements or suggest dierent service intervals. See the airrame maintenance manual or details.
25
engine inspections
Chapter 72-00-00, Table 601, o the EMM contains the minimum recommendations or regular inspections o the engine. There are two primary intervals, ROUTINE and MINOR. More precise intervals are used or specic components when required.
· ROUTINE inspections coincide with the daily or prefight airrame inspection.
· MINOR inspections coincide with a typical airrame zone inspection. The intervals at which these inspections are perormed may be altered by the aircrat manuacturer’s maintenance program and approved by the operator’s local airworthiness authority. Engines operating in sandy or dusty environments or in smog or salt-laden atmospheres should be subjected to additional inspections or corrosion and compressor erosion. The engine maintenance manual quotes recommended intervals, which the operator can adjust, based upon operating experience. Typical maintenance actions include:
· Engine washing - Compressor Desalination Wash - Compressor Turbine Desalination Wash - Compressor Perormance Recovery Wash
· Foreign Object Damage (FOD) inspection o the compressor - Inspection o Compressor Inlet Case or corrosion - Inspect the uel system based upon environment and uel quality - In-situ uel nozzle cleaning - Fuel nozzle inspection, cleaning and tip replacement - Ignition system - Oil system fush - Borescope inspection o combustion chamber, compressor turbine vane and blades Two areas o the PT6A engine have no scheduled maintenance intervals:
· Reduction gearbox · Propeller control system 26
oil system inspection AnD servicing
Oil Level Sightglass Some PT6A engine models are equipped with a sightglass to simpliy the inspection o the engine oil level. The sightglass has a centre green zone with red on each end. Engine operation is permitted with the oil level at any point in the green zone. The oil level dipstick must be checked when the oil level is in either the red zone or is not visible in the sightglass.
Oil Level Check Oil level should be checked regularly and replenished as necessary. Although consistency is the most important actor when establishing a schedule or checking the oil level, P&WC recommends this check be done 15 minutes ater every shutdown.
Oil Replenishment P&WC recommends that the engine not be lled over the “MAX COLD” level on the oil level dipstick. This corresponds with the centre o the green band on the oil level sightglass. A high oil level may result in an increase in either the oil consumption rate or the amount o oil mist passing through the engine oil breather. Each engine will seek its own normal operating oil level. Space is required in the oil tank or expansion as the oil reaches ull operating temperature. I the oil level is over the “MAX HOT” level, drain some o the oil. Reer to the EMM or complete instructions. A listing o approved oils is provided in the appropriate Service Bulletins or each PT6A model. When switching to another approved oil brand or should oil o dierent brands or viscosities become mixed it is necessary to drain and fush the complete oil system.
27
oil system inspection AnD servicing
Oil Temperature and Colour High oil temperature will accelerate the accumulation o carbon particles in the oil and the deterioration o oil additives. Oil colour will darken with usage and exposure to light. The rate o colour change is dependent upon the oil manuacturer’s ormula. A darkening o the oil does not indicate deterioration in the lubricity o the base stock. Additives are replenished with the addition o oil during level servicing.
Chip Detectors All PT6A engines are tted with an RGB chip detector, while some models also have a chip detector in the AGB housing. AGB chip detectors are not equipped with a sel-closing valve. When the chip detector is removed, the oil in the accessory gearbox will drain rom the engine. During normal operation, there will be approximately ½ litre (17 oz.) o residual oil. Chip detectors should be checked regularly or continuity and any oreign material. I the aircrat is equipped with a cockpit indication o the chip detector, the whole system should also be checked regularly. Reer to the applicable maintenance manuals or inspection intervals.
Oil Filter Debris Analysis The oil lter must be changed or cleaned at scheduled intervals. At the same time a visual inspection o the oil lter and chip detectors should be done. This is a simple and reliable method o assessing the wear o oil-wetted parts. As an extra step, a solvent may be used to fush trapped particles rom the engine oil lter. The solvent is poured through lter paper to collect the debris. This is reerred to as a lter “patch” check. The lter paper is sent to a laboratory or analysis. Laboratory techniques can be used to determine the alloy o the particles which helps determine their source. With successive samples, a wear trend or oil-wetted parts can be established.
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performAnce checK
Over the lie o the PT6A engine, the perormance charts have evolved in name, style and unction. Today, a variety o charts can be ound. They may be titled Power Assurance Check, Perormance Check or Ground Power Check charts. The charts allow operators o PT6A engines to monitor the condition o their engines and the results o maintenance actions. The chart may be used over a wide range o ambient temperature and altitude. The chart is intended to indicate when maintenance action might be required and the results o the repair when data is recorded beore and ater the maintenance action. With regular use, the chart can become a useul tool or scheduling maintenance. Check charts do not appear in all engine maintenance manuals. Some o them are published in the airrame maintenance manual. The perormance check is infuenced by the powerplant as a whole, not just the engine. The eects o poor nacelle seals, bleed air leaks, accessory drive power and instrumentation errors are all refected in the recorded data. Do not use the chart to reject engines rom service. Engines may remain in service provided that no operating limits are exceeded at the certied powers. P&WC recommends that troubleshooting and a fight test be done at the typical fight altitude to determine engine serviceability and that any step changes in parameters be investigated. The perormance check charts are based upon estimated “average” engine perormance. Every engine has its own unique characteristics. On certain types o perormance check charts, this will aect the slope o the lines. By recording data at a ew dierent ambient temperatures, within a short time o each other, the slope or a particular engine can be determined. P&WC recommends that this be done soon ater aircrat delivery to establish a baseline or investigating uture, perormance-related issues.
29
engine wAshing
Atmospheric pollutants may contaminate the engine gas path, leading to a build up o deposits on airoils, the initiation o corrosion, sulphidation or perormance deterioration. These eects can be alleviated with engine washing. Internal engine washes are done while motoring the engine at 10-25% Ng speed or a thorough cleaning.
Compressor Desalination Wash Used to remove salt deposits which can cause corrosion, however light dirt deposits may also be removed. Wash fuid is drinking quality water, provided minimum standards are met. Water is injected into the engine intake using either an installed compressor wash ring or a hand held wash wand.
Compressor Turbine Desalination Wash Used to remove salt deposits rom the compressor turbine blades and stator which can cause sulphidation, a reaction between the salt and sulphur rom the uel. This wash must be done immediately ollowing a compressor desalination or perormance recovery wash as contaminants will be transerred rom the compressor to the hot section during a compressor desalination or perormance recovery wash. Wash fuid is drinking quality water, provided minimum standards are met. Water is injected through a wash tube inserted through one o the ignitor ports.
Compressor Performance Recovery Wash Used to remove more stubborn deposits which cannot be removed during normal desalination washes. Wash fuid includes an approved detergent. This wash should only be done when engine perormance loss is noticeable or trend monitoring dictates. Wash fuid is injected into the engine intake using either an installed compressor wash ring or a hand held wash wand. A water rinse o both the compressor and compressor turbine is required ollowing the detergent wash.
30
engine wAshing
External Engine Wash Used as an eective method o tracing oil leaks, as well as removing salt and other environmental contaminants rom the engine external suraces. Wash fuid is drinking quality water, provided minimum standards are met.
Wash Schedule When operating continuously in a salt laden environment (typically within 10 nautical miles rom the sea and under 10,000 t), it is recommended to perorm compressor and compressor turbine desalination washes and external washes daily, ater the last fight o the day to prevent corrosion rom initiating overnight. For occasionally salt laden operation, weekly desalination washes and external washes are recommended. Perormance recovery washes are only recommended when a noticeable perormance shit is recorded. In all cases, engine washing requency should be based on operator experience and regular inspections o engine components to check or initiation o corrosion. Reer to P&WC SIL PT6A-144 or additional inormation and FAA Advisory Circular 43-4A or a comprehensive overview o corrosion. On the next page you will nd a map o North America showing areas where environmental conditions will require particular attention to corrosion. Maps o the rest o the world can be ound in the above mentioned Advisory Circular.
31
engine wAshing
Fairbanks Anchorage
Seattle Montreal Denver New York
Los Angeles Dallas
Atlanta
Houston Miami Havana Mexico
Haiti Puerto Rico
Jamaica St. Domingo
Corrosion Severity Zone Mild Moderate Severe
Figure 1 North American Corrosion Severity Map, extracted rom FAA Advisory Circular 43-4A,
32
hot section inspection
A Hot Section Inspection (HSI) is usually done halway through the basic TBO interval or when perormance loss dictates. This involves splitting the engine between the compressor and power turbines at “C” Flange. Since it is generally not necessary to remove the engine rom the aircrat during an HSI, the inspection procedure is both simple and ast.
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overhAul
The basic Time Between Overhaul (TBO) and Hot Section Inspection (HSI) interval is published in the appropriate Service Bulletin or each PT6A engine model. Under extreme conditions, maintenance action prior to the recommended overhaul lie may be necessary. The TBO interval depends on the specied operation o the engine. The interval can be escalated incrementally with the approval o your airworthiness authority, using an “on-condition” or a sampling program. The current TBO escalation is limited at 8,000 hours or single-engine aircrat and 10,000 hr to 12,500 hr, or twin-engine aircrat, depending on the application. TBO escalation recommendations take into account the average eect o fight duration, time at a given power level, climate, environment, maintenance practices, utilization and engine hardware standard.
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cycle counting
Certain rotating components o the engine have a limited lie based upon the number o operating cycles they experience. These lives are quoted in the Rotating Component Lives Service Bulletin or each PT6A engine model. It is important to continuously record the number o operating cycles and partial cycles to track rotor lives. Rotor components not supported by proper documentation are to be removed rom service. Prior to engine servicing, the total cycles and all fights and starts must be recorded in the appropriate engine logbook. At engine overhaul, a calculation will be made o the remaining service lie or each rotating component. This calculation is based upon the rate o cycle accumulation recorded in the engine logbook.
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engine conDition trenD monitoring®
ECTM® is a computer sotware program sold by P&WC that assists in early detection o potential problems through continuous monitoring o engine operation. The advantage o using ECTM® is a savings in troubleshooting time, reduced maintenance costs, the ability to schedule corrective action and an increased dispatch rate. The pilot or an on-board monitoring system must record the readings o the aircrat and engine gauges ater the aircrat has been fying at a stable cruise condition or several minutes. Gauge readings are to be recorded daily or once per fight. Alternatively, you may send your recorded trend data to a designated analysis centre or processing and recommendations. Accurate and consistent readings are crucial to eective trend monitoring; the quality o the engine condition evaluation is only as good as the quality o the data provided.
On-board data recording Altair Avionics markets a PT6A engine-mounted data recording system called TrendCheck Plus+, and the Aircrat Data Acquisition System (ADAS), an airrame-mounted engine monitor, or a wide variety o PT6A engine applications. These monitors enhance saety and reduce direct operating costs through sophisticated aircrat exceedance monitoring and automated trend sample collection. Operated in conjunction with Altair’s internetbased TurbineTracker™ system, these monitors are a powerul diagnostic tool and engine health monitor. While both systems monitor the engine parameters o turbine temperature, gas generator speed, power turbine speed, torque pressure and uel fow as well as pressure altitude, aircrat airspeed and ambient temperature each system has their own unique recording capabilities as well. TrendCheck Plus+ system records time history into a storage buer. The ADAS system provides the ability to monitor the airrame parameters o approach faps, landing faps, gear extended and weight on wheels.
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engine conDition trenD monitoring®
Automatic trends can be dened or pilot-initiated samples can be captured by the push o a button. Data stored in the Altair Internet based TurbineTracker™ system can be used directly with the ECTM® program. Additional inormation on these products can be ound at www.altair.aero.
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recommenDeD pt6A engine power mAnAgement
The PT6A engine power management system has been designed to give the pilot control o the powerplant thrust over the entire airplane fight and ground-operating envelope. It is a simple and reliable system, which ully compliments the inherent operating fexibility o a ree turbine engine.
Mission In conjunction with the Aircrat Manuacturer, a mission prole is established or every PT6A engine application. This mission is used to analyze and establish engine component lives and durability actors such as Low Cycle Fatigue (LCF), Creep, Oxidation and Vibration. Using this data and taking into consideration airrame infuences such as bleed extraction, accessory loading and inlet eciency, the power setting inormation is established and then published in the POH / AFM.
Take-off Climb Cruise SHP
Descent Taxi
Taxi
TIME
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recommenDeD pt6A engine power mAnAgement
Rating Philosophy P&WC’s power rating philosophy is to ensure the maximum likelihood that your PT6A engine will deliver the power specied in the POH / AFM throughout its overhaul lie. To achieve this, all PT6A engine installations use torque as the primary power setting parameter. All other engine parameters are only monitored to veriy they are within acceptable limits. The POH / AFM contains power setting inormation which must be used to determine the torque setting or all ratings which vary according to altitude, ambient temperature and aircrat weight. This is important because the P&WC rating philosophy is based on the engine being operated per the POH / AFM and maintained in accordance with the EMM / AMM including all applicable periodic inspection recommendations by P&WC. Operating the engine in accordance with the POH / AFM will achieve optimum reliability and durability while minimizing operating costs.
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recommenDeD pt6A engine power mAnAgement
Performance Margins “New Engine” production acceptance limits are designed to allow a sucient margin to carry the engine through a desired overhaul period. Any engine overhauled and put back into service must meet similar standards. However, with use, the engine perormance margins will gradually reduce characterized by an increase in ITT, Ng and/or uel fow (W) while maintaining POH / AFM specied power
Maximum certified operating limit
Deterioration margin SPEED AND TEMP
n g i t a i o r r e t d e e n i E n g
TIME IN SERVICE - HRS
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recommenDeD pt6A engine power mAnAgement
Power Ratings The take-o rating is the maximum power certied or takeo and is time limited to ve minutes. The maximum continuous rating is a certied power setting or in-fight emergency use only, typically or twin engine applications where one engine is inoperative. Maximum climb and maximum cruise ratings are the maximum powers approved by P&WC or climb and cruise operation.
TAKE-OFF MAX. CONTINUOUS MAX CLIMB MAX CRUISE
POWER
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recommenDeD pt6A engine power mAnAgement
Flat Rating At constant ITT, PT6A engine power reduces with both increasing ambient temperature and altitude. This represents the thermal capacity o the engine or “thermal rating” and is how the engine would perorm without the mechanical limitations o the reduction gearbox.
TAKE-OFF MAX. CONTINUOUS MAX CLIMB MAX CRUISE
POWER
AMBIENT TEMPERATURE AND ALTITUDE
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recommenDeD pt6A engine power mAnAgement
It is a general characteristic o aircrat that or a particular gross weight, the power required or take-o varies comparatively little with ambient conditions. PT6A engines are typically “fat rated” to allow or the maximum possible take-o power required by the aircrat over a wide range o ambient temperatures without having to work the engine harder than is necessary at any time.
Take-off Max. Continuous Max Climb Max Cruise Gearbox Limit
POWER Ambient Temperature and Altitude
The fat-rated power is available up to the thermal capability o the engine, specied as an ambient temperature and altitude.
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recommenDeD pt6A engine power mAnAgement
Power Settings All PT6A engine applications use engine output torque as the primary power setting parameter. The POH / AFM contains power setting inormation which must be used to determine the correct torque settings to achieve take o and cruise in accordance with altitude, ambient temperature and aircrat weight.
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recommenDeD pt6A engine power mAnAgement
The power lever should be set to the position which produces the required torque. Other engine parameters such as ITT and Ng are monitored only to veriy that they are within acceptable limits. Operating the engine in accordance with the POH / AFM by using torque as the primary power setting parameter will achieve optimum reliability and durability while minimizing operating costs.
Maximum fully deteriorated limit
ITT or NG
MARGIN REDUCING
POWER
Torque set as per POH
0
LIFE
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100%
recommenDeD pt6A engine power mAnAgement
Operating the engine beyond the recommended power settings specied in the POH / AFM or a prolonged period will result in accelerated margin deterioration due to hot section component distress and will aect engine reliability and durability. This eect is cumulative and will lead to the engine prematurely reaching an operating limit (usually ITT) beore the recommended power is produced. Reer to P&WC SIL PT6A-125 or additional inormation.
Maximum fully deteriorated limit
ITT or NG
POWER SET AT MAX ITT LIMIT
Ac tu a l t o rq u e POWER Normal torque as per POH
0
LIFE
PREMATURE OVERHAUL
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100%
