TRANING PRESENTATION ON JET SHOP INJET ENGINE OVERHAULCOMPLEX (J.E.O.C) AT

NEW DELHI

Submitted By –Gaurav (13/597)Aero. Engg.(IV Yr.)

SCHEDULE OF JET SHOPSECTIONS DEPARTMENT HEAD

Final assembly JT8D engine Mr. Ashutosh

Final assembly V2500 engine Mr. Ashutosh

View Room Mr. Bandhopadhya

Cleaning Room Mr. Mukhrjee

NDT Mr. Mukhrjee

Standard Room Mr. Bandhopadhya

Machine Shop

Test Cell

Mr. Mukhrjee

Mr. Trilochan

SCHEDULE OF HYDRAULIC SHOP

1.BRAKE ASSEMBLY

2.WHEEL ASSEMBLY 3.ESCAPE SLIDE

4.HALL

History Founded by J. R. D. Tata in 1932 i.e. on 15 October 1932 as Tata Airlines

Tata Airlines became a public limited company on 29 July 1946 under the name Air India.

On 8 June 1962, the airline's name was officially truncated to Air India.

In 1971, the airline took delivery of its first Boeing 747-200B named Emperor Ashoka.

In 1994 the airline was registered as Air India Ltd.

In 2007, the Government of India announced that Air India would be merged with Indian Airlines.

Your Palace in the Sky

IATA ICAO CALLSIGN

AI AIC AIRINDIA

Parent Company AIR INDIA LIMITED

Headquarters Indian Airlines House, New Delhi

Key People Ashwin Lohawani Chairman & MDAlliance Star AllianceSubsidiaries • AIR INDIA EXPRESS

• AIR INDIA REGIONALFleet Size 109Destinations 84Frequent flyer program

Flying returns

INTRODUCTION

Primary Hubs – Indira Gandhi International Airport (Delhi)Secondary Hubs – Chhatrapati Shivaji International Airport (Mumbai)

Revenue ₹197.81 billion

Operating income ₹2.171 billion

Net income ₹5.81 billion

Employees 25,285 (August 2016)

Website www.airindia.in

Air India Limited

Air India

Air India Express

Air India Regional

Air India Engineering Services Ltd.

Air India Transport Services Ltd.

Airline Allied Services Ltd.

Airport Services Ltd.

Hotel Corporation of India Ltd.

Air India Charters Ltd.

Structure

Air India Fleet

Aircraft In Service Total Passengers

Airbus A319-100 22 144Airbus A320-200 26 168Airbus A320neo - 162Airbus A321-200 20 182Boeing 747-400 5 423Boeing 777-200LR 3 238Boeing 777-300ER 12 342Boeing 787-8 21 256

Awards and recognitions Preferred International Airline for travel and hospitality from Awaz Consumer Awards (2006) Best Corporate Social Responsibility Initiative by Galileo Express Travel World Best Short-Haul International Airline by Galileo Express Travel World Amity Corporate Excellence Award by Amity University  Reader's Digest Trusted Brand Dun and Bradstreet Award (D&B), first in terms of revenue out of the top airline companies out of India Best South Asian Airline, Mice and business travel publications Cargo Airline of the Year, 26th Cargo Airline of the Year Awards The Montreal Protocol Public Awareness Award by the United Nations for environmental protection[

Air India was named India's most trusted airline by The Brand Trust Report 2015. Air India was chosen as India's Most Reputed Airline in a consumer and media research in July 2016 by Bluebytes News and TRA Research  Air India's ground services became the first ground service provider to acquire ISO 9002 certification on 31 January 2001.

ON DEPENDING ON AIRCRAFT PARTS, AIR INDIA LIMITED IS DIVIDED IN FOLLOWING 2 SECTIONS1. ACCESSORIES/HYDRAULICS SHOP: 1) Wheel Shop 2) Brake shop 3) Escape Slide 4) Miscellaneous Topics(Hall) 5) Test Rig

2. JET ENGINE OVERHAUL COMPLEX: 1) Fitting/Welding 2) Mechanical Cleaning/Painting 3) View Room/Blade/NDT 4) Sub Assembly/Gear Box 5) Final Assembly 6) Test Cell

MAINTENANCE IN JEOC Maintenance of commercial aircraft engine.(i.e.

V2500-A1 , JT8D , CFM-56B )

Maintenance is done in levels.

QUALITY CONTROL unit decide type of maintenance.

Maintenance begins from final assembly ,that dissembles engine.

MAINTENANCE LEVELS IN JEOCL1 :

Initial stage of maintenance. Visual inspection ,vacuum check done Minor level of maintenance.

L2 : If any defect observed in L1. It includes minor repairs , replacement and seals etc. Maintenance of only a particular module.

L3 : Highest level of maintenance. Include 90% of complete overhaul In this every part separated and send to sub- assembly.

Centers in JEOC

Engine Repair Centre

Receiving Section

Final Assembly

View Room

Gear Box Section

Cleaning Section NDT Standar

d Room

Engine Test centre

Centers in J.E.O.C

Description regarding the method of operation of the engine shop are :

Receiving Section : This section is provided with 2*7.5 tons hoist for loading /off loading the engine/ equipment.

Final Assembly : Any engine visiting the JEOC for servicing is taken in this section. The section has been divided into two sub sections, one for each type of engine.

Sub Assembly : This section is responsible for activity on V2500, CFM56-5B engines. There are distinct work bays to handle V2500-A1, CFM56-5B

The modules are sent for further processing like cleaning, NDT, and after inspection. The part and modules are assembled in this area

NDT(Non Destructive Testing) : This section carries out NDT inspections of the components using following technique.

(a) Eddy Current (b) Ultrasonic Inspection (c) FPI/FMPI

View Room : Here the components of the respective engines are inspected for their serviceability status & sent to NDT section / repair section / Sub assembly / Final assembly / Stores, as per inspection results & shop requirements.

Gear Box, Bearing and Seals : Gear box of engines are sent here for disassembly, inspection, assembly process.

All bearings and seals are sent for cleaning , inspection & preservation in this section

Cleaning Section : Chemical & Mechanical cleaning of disassembled parts is undertaken here in accordance with manufacturer recommended processes & procedures1) Mechanical Cleaning2)Chemical Cleaning

Standard Room : All the master calibration equipment is placed in this section. The gauges equipment & tooling used in various sections are calibrated.

Test Facility Cell : It is fully computerized data acquisition facility & is capable of testing V2500-A1, JT8D engines.

V2500-A1 Engine Axial flow High by pass ratio Twin spool Turbo fan Engine Designed primarily for 150 seats short to medium range aircraftSpecification :-Propulsion Unit Weight 7300lbs (3311 kg)Fan Tip Diameter 160 cmPropulsion Unit Overall Length 4940.3 cmEngine Overall Length 3200 cmTake Off Thrust 25000 lbs.Total Airflow 355 kg/secBy-pass Ratio 5.42 : 1Overall Pressure Ratio 29.4 :1

SCHEMATIC DIAGRAM FOR JET ENGINE

V2500-A1 ENGINE MODULES

1. Fan Module2. Intercase Module3. High Pressure Compressor4. Diffuser / Combustor Module5. High Pressure Turbine6. Low Pressure Turbine

LOW PRESSURE SYSTEM Four stage low pressure compressor Three primarily stages, driven by a 5 stage axial flow low pressure turbine An annular bleed valve is located at the outlet from the booster stage

HIGH PRESSURE SYSTEM 10 stage axial flow compressor driven by a 2 stage axial flow high power turbine 4 stages of variable stator vanes Variable angle inlet guide vanes

GEARBOX Radial drive via a tower shaft from high pressure system to fan case mounted angle & main gearboxes Gearbox provides mountings & drive for all engine driven accessories & the pneumatic stator motor.

COMBUSTION SYSTEM Annular, two piece with 20 fuel nozzles

Electronic Engine Control (E.E.C)E.E.C provides a full range of control of : Engine fuel flow Automatic Engine starting Compressor airflow control system Heat management system Fuel diverter & fuel return to tank valve Thrust Reverser

JT8D ENGINE Axial Flow Dual Spool The JT8T has a full length annular fan duct. Turbofan engine having a 13 stage split compressor, 9 can annular combustion chamber and a split 4-stage reaction impulse turbine. Low by-pass ratio Used in Boeing 737 The engine operates similarly to all turbojet versions of a gas turbine engine in that it derives its propulsive force through the application of Newton’s third law for every action there is an equal and opposite reaction.

DIAGRAM OF JT8D ENGINE

ENGINE SECTION OF JT8D The engine has six general sections: The front compressor (also called the LPC): - Has six stages (two fan stages, four primary stages) - Is driven by the front compressor drive turbine and is connected to it by a drive shaft (inner).  The rear compressor (also called the HPC):

- Has seven stages - - Is driven by the rear compressor drive turbine and is connected to it by a drive shaft (outer).

  The combustor has :

- Nine fuel nozzles - Nine can annular combustion chambers.

The rear compressor drive turbine (also called the HPT): - Has three stages

- Drives the HPC, to which it is connected by a drive shaft (outer)

 The front compressor drive turbine (also called the LPT): - Has three stage - Drives the LPC, to which it is connected by a drive shaft(inner). The exhaust section:

Receives LPT discharge airReceives secondary air from outer duct.

DIFFERENCE BETWEEN V2500 & JT8D ENGINES

V2500 JT8D

1.

High by-pass ratio with the ratio 5.24:1

Low by-pass ratio with the ratio of 1:1

2.

75% of thrust is attained by Fan 50% of thrust is attained by Fan

3.

10 HPC stages 7 HPC stages

4.

2 stages HPT& 5 Stages LPT Single stage HPT & 3 stages LPT

5.

Fuel system is Electronic hydraulic Fuel system is Hydro mechanical

6.

5 types of bearings are used 7 types of bearings are used

7

8.

20 fuel nozzles are required

Thrust produced is 25000 lbs.

9 fuel nozzles are required

Thrust produced is 16000 lbs.

REFERENCES

Training manual issued by AIR INDIA LTD. Air India Ltd. Data (FY 2014-15) https://en.wikipedia.org/wiki/Air_India_Limited Google images https://en.wikipedia.org/wiki/Pratt_%26_Whitney_JT8D https://en.wikipedia.org/wiki/IAE_V2500 International Aero Engines - Wikipedia, the free encyclopediahttps://en.wikipedia.org/wiki/International_Aero_Engines

THANK YOU