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Fundamentals

eJAMF
Module 15.10
Gas Turbine Engine/Lubrication
ATA 79

EASA Part-66

A
EJAMF_M15.10_A_E

Issue:
21.10.2008
Author:
SwD
For Training Purposes Only
E LTT 2006

Training Manual

For training purposes and internal use only.


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EJAMF
Gas Turbine Engine

MODULE 15

M15.10 LUBRICATION SYSTEMS

FOR TRAINING PURPOSES ONLY!

Lufthansa Technical Training

M15 GAS TURBINE ENGINE

HAM US/F

SwD

01.04.2008

ATA DOC

Page 1

EJAMF
Gas Turbine Engine

MODULE 15

BASIC LUBRICATION SYSTEM


INTRODUCTION
The lubrication system distributes oil to the engine bearing compartments and
the gearboxes.
Most gas turbine engines use a selfcontained dry sump lubrication system.
The oil is re-circulated through this system by pumps. The system keeps the oil
in a fit condition to perform its tasks.
The basic lubrication system has four subsystems:
S an oil reservoir and supply system
S a scavenge system
S a vent system
S and a monitoring system.

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M15.10 LUBRICATION SYSTEMS


BASIC LUBRICATION SYSTEM

HAM US/F

SwD

01.04.2008

01|Intro/A/B1

Page 2

EJAMF
Gas Turbine Engine

MODULE 15

FOR TRAINING PURPOSES ONLY!

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M15.10 LUBRICATION SYSTEMS


BASIC LUBRICATION SYSTEM

Figure 1
HAM US/F

SwD

01.04.2008

Basic Lubrication System


01|Intro/A/B1

Page 3

EJAMF
Gas Turbine Engine

MODULE 15
OIL RESERVOIR AND SUPPLY SYSTEM
The oil reservoir and supply system is also called the pressure oil system.
The main components of this system are:
S the oil tank
S the supply lines
S the supply pump
S and the supply filter.
The oil is stored in the oil tank and pumped by the supply pump through the
supply lines to the oil nozzles in the engine bearing compartments and the
gearboxes.
The oil is filtered before it reaches the oil nozzles.
The supply filter is located downstream of the supply pump. The filter removes
any foreign particles from the oil before it reaches the oil nozzles. This prevents
blockage of the nozzles.

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LUBRICATION SYSTEMS
BASIC LUBRICATION SYSTEM

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01.04.2008

02|Oil Supply Syst/A/B1

Page 4

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Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEMS
BASIC LUBRICATION SYSTEM

Figure 2
HAM US/F

SwD

01.04.2008

Pressure Oil System Schematic


02|Oil Supply Syst/A/B1

Page 5

EJAMF
Gas Turbine Engine

MODULE 15
SCAVENGE SYSTEM
The scavenge system is part of every dry sump lubrication system. It returns
the oil from the bearing compartments and the gearboxes to the oil tank.
This prevents the accumulation of lubrication oil in the bearing compartments
and the gearboxes.

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BASIC LUBRICATION SYSTEM

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06|Scavenge System/A/B1

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Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEMS
BASIC LUBRICATION SYSTEM

Figure 3
HAM US/F

SwD

01.04.2008

Oil Scavenge System

06|Scavenge System/A/B1

Page 7

EJAMF
Gas Turbine Engine

MODULE 15
VENT SYSTEM
The vent system releases air from the lubrication system to the atmosphere.
Bearing compartments have a vent line to release the sealing air and maintain
the airflow across the seals.

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LUBRICATION SYSTEMS
BASIC LUBRICATION SYSTEM

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08|Vent System/A/B1

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Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEMS
BASIC LUBRICATION SYSTEM

Figure 4
HAM US/F

SwD

01.04.2008

Vent System

08|Vent System/A/B1

Page 9

EJAMF
Gas Turbine Engine

MODULE 15
OIL SYSTEM MONITORING
The oil monitoring system measures and indicates oil quantity, oil pressure,
and oil temperature.
The oil monitoring system provides a flight crew warning if the oil pressure
drops below the minimum level or if the scavenge filter becomes clogged.
The monitoring system needs several sensors to detect this information.
The sensors are:
S the oil quantity sensor
S the oil pressure sensor
S the oil temperature sensor
S the low oil pressure switch
S and the filter clogging switch.
Mechanical clogging indicators are used to indicate a clogged filter when the
engine is stopped. They are also called popout indicators.
The contamination in the oil can indicate the condition of the lubricated engine
parts. The contamination can be checked by inspecting the filters and by using
magnetic chip detectors.
Magnetic chip detectors are small magnets which are in contact with the
scavenge oil. They collect particles of magnetic metal which are passing
through the oil.
They are usually installed in the individual scavenge lines of each sump. This
makes it easy to isolate the source of the contamination.
The detectors are easily removed for inspection.

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LUBRICATION SYSTEMS
BASIC LUBRICATION SYSTEM

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SwD

01.04.2008

11|Oil Monitoring System/A/B1

Page 10

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Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEMS
BASIC LUBRICATION SYSTEM

Figure 5
HAM US/F

SwD

01.04.2008

Oil Indicating System

11|Oil Monitoring System/A/B1

Page 11

EJAMF
Gas Turbine Engine

MODULE 15

ENGINE OIL MONITORING SYSTEM


OIL QUANTITY INDICATION
The oil quantity transmitter in the tank sends the information via a computer,
which performs the measurement, in this example called the engine interface
unit (EIU), to the display units in the cockpit.

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

HAM US/F

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01.04.2008

01|Oil Qty Indic/A/B1

Page 12

EJAMF
Gas Turbine Engine

MODULE 15

FOR TRAINING PURPOSES ONLY!

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

Figure 6
HAM US/F

SwD

01.04.2008

Oil Quantity Indicating Schematic


01|Oil Qty Indic/A/B1

Page 13

EJAMF
Gas Turbine Engine

MODULE 15
Oil Quantity Indication cont.
The oil quantity transmitter is normally installed at the top of the oil tank.
This allows the transmitter to be changed without draining the tank.
Two types of transmitter are used
S the capacitance type transmitter and
S the reed switch type transmitter.

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

HAM US/F

SwD

01.04.2008

02|Oil Qty Indic/A/B1

Page 14

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Gas Turbine Engine

MODULE 15

FOR TRAINING PURPOSES ONLY!

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

Figure 7
HAM US/F

SwD

01.04.2008

Different Types of Quantity Transmitter


02|Oil Qty Indic/A/B1

Page 15

EJAMF
Gas Turbine Engine

MODULE 15
OIL PRESSURE INDICATION
The oil pressure transmitter is connected to the oil supply line and to the oil
tank vent line.
The transmitter senses the pressure difference between the total oil pressure in
the oil supply line and the vent pressure in the oil tank.
Oil pressure information is sent from the oil pressure transmitter to the engine
interface unit, which performs the measurement and then to the display unit in
the cockpit.

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

HAM US/F

SwD

01.04.2008

05|Oil Press Indic/A/B1

Page 16

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Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

Figure 8
HAM US/F

SwD

01.04.2008

Oil Pressure Indication System Schematic


05|Oil Press Indic/A/B1

Page 17

EJAMF
Gas Turbine Engine

MODULE 15
LOW OIL PRESSURE SWITCH
An additional pressure switch is used in the engine oil system to initiate a low
oil pressure warning.
The pressure switch is also connected to the oil supply line and the oil tank
vent line.
If the oil pressure decreases below the limit, the low oil pressure switch closes,
a signal is sent to the flight warning computer, and a warning message appears
on the display unit in the cockpit.
Note also, that the engine low oil pressure warning is always accompanied by
an acoustic warning in the cockpit.

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

HAM US/F

SwD

01.04.2008

07|Low Oil Press Switch/A/B1

Page 18

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Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

Figure 9
HAM US/F

SwD

01.04.2008

Low Oil Pressure Switch

07|Low Oil Press Switch/A/B1

Page 19

EJAMF
Gas Turbine Engine

MODULE 15
Low Oil Pressure Switch cont.
Here you can see the location of the oil pressure transmitter and the low oil
pressure switch on an engine.
In this example they are installed on the fan case in the ten oclock position.
You can see where each is connected to the oil supply line and the oil tank vent
pressure line.

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

HAM US/F

SwD

01.04.2008

08|Low Oil Press Switch/A/B1

Page 20

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Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

Figure 10
HAM US/F

SwD

01.04.2008

Pressure Transmitter & Low Pressure Switch Location


08|Low Oil Press Switch/A/B1

Page 21

EJAMF
Gas Turbine Engine

MODULE 15
OIL TEMPERATURE INDICATION
The location of the oil temperature sensor in the lubrication system depends on
the engine type.
The sensor can be found in the scavenge system, where it senses the hot oil
temperature upstream of the oil cooler, or it can be found in the pressure
system, where it senses the temperature of the cooled oil.
Oil temperature information is sent from the oil temperature sensor to a
computer, which performs the measurement and then to the display unit in the
cockpit.

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

HAM US/F

SwD

01.04.2008

09|Oil Temp Indic/A/B1

Page 22

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Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

Figure 11
HAM US/F

SwD

01.04.2008

Oil Temperature Indication


09|Oil Temp Indic/A/B1

Page 23

EJAMF
Gas Turbine Engine

MODULE 15
Oil Temperature Indication cont.
There are two main types of oil temperature sensors:
S the thermocouple and
S the thermistor.

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

HAM US/F

SwD

01.04.2008

10|Oil Temp Sensor/A/B1

Page 24

EJAMF
Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

Figure 12
HAM US/F

SwD

01.04.2008

Oil Temperature Sensor Location


10|Oil Temp Sensor/A/B1

Page 25

EJAMF
Gas Turbine Engine

MODULE 15
OIL CONTAMINATION MONITORING
As you already know, the engine oil carries particles from the bearings and the
gears to the filters in the lubrication system.
You can monitor the quantity, the size, and the type of material of these
particles to get some indication of the internal wear of lubricated engine parts.
A process called Spectrometric Oil Analysis Program, or SOAP for short, is
used to find out about internal wear of lubricated engine components.
This SOAP analysis can find particles in the oil, which are so small that they
can not be caught by the oil filters. These particles range in size from 0.001
mm to 0.02 mm.
It is important to monitor the concentration of these particles in the oil to
identify increased wear at an early stage.
Many particles indicate increased wear and knowledge of the material helps to
identify the engine part with increased wear.
Oil samples for SOAP are taken from the oil tank at regular intervals and sent
to the laboratory for analysis.

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

HAM US/F

SwD

01.04.2008

11|Oil Contam Monitorg/A/B1

Page 26

EJAMF
Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

Figure 13
HAM US/F

SwD

01.04.2008

Spectrometric Oil Analysis Program


11|Oil Contam Monitorg/A/B1

Page 27

EJAMF
Gas Turbine Engine

MODULE 15
Oil Contamination Monitoring cont.
The scavenge oil filter element catches larger particles which are of a size of
more than 0.015 mm. These particles can be removed and sent for analysis.
The problem with this is that the filter element is not changed very often and
each filter inspection takes time.
Magnetic chip detectors are an easier and less time consuming method to get
information about the condition of the oil.
Magnetic chip detectors catch metal particles which are attracted to the
magnet. They can be easily removed and the condition can be checked.
The magnetic chip detectors can be manually checked at fixed intervals or on
some modern aircraft they can be electronically monitored and removed when
necessary.

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

HAM US/F

SwD

01.04.2008

12|Oil Contam Monitorg/A/B1

Page 28

EJAMF
Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

Figure 14
HAM US/F

SwD

01.04.2008

Magnetic Chip Detectors

12|Oil Contam Monitorg/A/B1

Page 29

EJAMF
Gas Turbine Engine

MODULE 15
Oil Contamination Monitoring cont.
Here you see an electronically monitored chip detector, installed in the
scavenge oil line.
This chip detector has two magnets at its tip.
The resistance between the two chip detector magnets is monitored by the
electronic control unit.
The resistance decreases when particles connect with the magnets.
When the resistance between the magnets gets below the limit, the electronic
control unit sends a maintenance message for the post flight report.

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

HAM US/F

SwD

01.04.2008

13|Oil Contam Monitorg/A/B1

Page 30

EJAMF
Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEM
ENGINE OIL MONITORING SYSTEM

Figure 15
HAM US/F

SwD

01.04.2008

Electronic Magnetic Chip Detectors


13|Oil Contam Monitorg/A/B1

Page 31

EJAMF
Gas Turbine Engine

MODULE 15

MAINTENANCE PRACTICES
SYSTEM SERVICING
On aircraft the oil quantity in the engines is checked at intervals specified in the
maintenance schedule for the aircraft.
The oil quantity can be checked at the sight gages on the oil tanks of the
engines, or on the ECAM or EICAS displays in the cockpit.
On most engines the oil tank is located above the level of the gearbox.
There is a slow oil flow from the tank to the gearbox due to the siphon effect.
To prevent this, an anti-siphon device is installed.
On engines without anti-siphon it is important to check the oil quantity between
5 and 20 minutes after engine shut-down when all of the oil is in the tank.
The oil can be refilled via the oil tank filler port.
Note, that you must wait at least 5 minutes after engine shut-down before you
open the oil tank filler cap.
If you dont wait at least 5 minutes after engine shutdown, hot oil can spray
out of the filler port when you open it.
You should also observe the smell of the oil when you open the filler cap.
If you smell fuel, this indicates a leakage in the fuel cooled oil cooler. Further
troubleshooting is required.

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LUBRICATION SYSTEMS
MAINTENANCE PRACTICES

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01.04.2008

01|System Servicing/A/B1

Page 32

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Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEMS
MAINTENANCE PRACTICES

Figure 16
HAM US/F

SwD

01.04.2008

Oil Quantity Check

01|System Servicing/A/B1

Page 33

EJAMF
Gas Turbine Engine

MODULE 15
System Servicing cont.
You can refill the oil out of oil cans, or you can use an oil servicing system.
If you use oil cans the process is called gravity filling, and if you use an oil
servicing system the process is called pressure filling.
Remember, that you should always make sure that you are using the correct
type and same manufacturer of oil before you refill the tank.
You can find details of the required oil type on a label close to the oil tank filler
cap.
The use of oil cans should be minimized for environmental reasons. If you must
use oil cans, always use new, closed cans and open them immediately before
the filling process.
You should put all empty oil cans in a special disposal container.

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MAINTENANCE PRACTICES

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02|System Servicing/A/B1

Page 34

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Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEMS
MAINTENANCE PRACTICES

Figure 17
HAM US/F

SwD

01.04.2008

Oil Servicing Methods

02|System Servicing/A/B1

Page 35

EJAMF
Gas Turbine Engine

MODULE 15
System Servicing cont.
If the oil servicing system is used, the hoses are connected to the pressure fill
port and to the overflow port of the oil tank.
Its an advantage to use a transparent hose for the overflow port so that you
can see directly when the tank is full.
On tanks with a sight gage, however, you fill the tank until the oil level reaches
the full mark.
You should always check the oil level on the sight gage to prevent an overfill.
An overfill is dangerous, because a large amount of oil can be pumped through
the oil tank vent line into the forward bearing compartment or the deoiler.
It is important to monitor the oil consumption of the engine.
For this reason you must enter the quantity of oil added to the tank in the
technical log book.

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MAINTENANCE PRACTICES

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03|System Servicing/A/B1

Page 36

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Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEMS
MAINTENANCE PRACTICES

Figure 18
HAM US/F

SwD

01.04.2008

Oil Servicing

03|System Servicing/A/B1

Page 37

EJAMF
Gas Turbine Engine

MODULE 15
SOAP SAMPLING
Oil samples are taken from the engine oil tank for the spectrometric oil analysis
program. A plastic bottle with a hose is used to take the oil sample. The hose is
inserted through the sampling tube of the filler assembly into the oil tank.
A number of safety precautions must be observed for SOAP sampling.
S You should always use a new plastic bottle and a new hose to prevent
contamination of the oil.
S Remember to wait at least 5 minutes after engine shut-down before you
open the oil tank filler cap.
S You should wear gloves to protect your hands, because the oil can be hot.
S You must close the bottle and label it immediately after the sample is taken.
The label is necessary to prevent samples getting mixed up.
You can see that the label must have details of:
S the aircraft registration,
S the engine position,
S the engine serial number,
S the station where the sample is taken,
S the date, and
S the time of the sample.
When the label is completed, the sample can be sent for analysis.

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MAINTENANCE PRACTICES

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04|SOAP Sampling/A/B1

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Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEMS
MAINTENANCE PRACTICES

Figure 19
HAM US/F

SwD

01.04.2008

Soap Sampling

04|SOAP Sampling/A/B1

Page 39

EJAMF
Gas Turbine Engine

MODULE 15
MAGNETIC CHIP DETECTOR INSPECTION
Magnetic chip detectors are inspected at fixed intervals.
For safety reasons maintenance staff should only check the detectors on one
engine and a crosscheck by a second mechanic is required. This is to
minimize the effect of working errors.
A wrong detector installation can lead to a leak in the oil system and an
in-flight shut-down of the engine.
Typically the magnetic chip detectors are designed so that they can be
removed without tools.
Note, that the detectors may be hot from the oil so you should wear gloves to
protect your hands.
You remove the magnetic chip detector by pressing it in and then by turning it
counter clockwise.
When a detector is removed, a check valve closes in the housing to prevent an
oil leakage.
You must handle the magnetic chip detectors with care. Any chips must be
removed with a sheet of paper and secured for analysis and the detector must
be cleaned before you install it again.

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LUBRICATION SYSTEMS
MAINTENANCE PRACTICES

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01.04.2008

05|MCD Inspection/A/B1

Page 40

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Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEMS
MAINTENANCE PRACTICES

Figure 20
HAM US/F

SwD

01.04.2008

Magnetic Chip Detector Inspection


05|MCD Inspection/A/B1

Page 41

EJAMF
Gas Turbine Engine

MODULE 15
Magnetic Chip Detector Inspection cont.
Some chip detectors have two seals:
S a re-usable seal and
S an Oring.
Other chip detectors just have two Orings.
The old Orings in the magnetic chip detectors must be replaced with new
ones to help prevent leakage.
Keep in mind that the most common work error is to forget to install the
Orings.
You must check, that the detector has engaged correctly.

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MAINTENANCE PRACTICES

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06|MCD Inspection/A/B1

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Gas Turbine Engine

MODULE 15

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LUBRICATION SYSTEMS
MAINTENANCE PRACTICES

Figure 21
HAM US/F

SwD

01.04.2008

Magnetic Chip Detector Installation


06|MCD Inspection/A/B1

Page 43

EJAMF M15.10 A E

TABLE OF CONTENTS
M15.10 LUBRICATION SYSTEMS . . . . . . . . . . . .

BASIC LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL RESERVOIR AND SUPPLY SYSTEM . . . . . . . . . . .
SCAVENGE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL SYSTEM MONITORING . . . . . . . . . . . . . . . . . . . . . . .

2
2
4
6
8
10

ENGINE OIL MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .


OIL QUANTITY INDICATION . . . . . . . . . . . . . . . . . . . . . . .
OIL PRESSURE INDICATION . . . . . . . . . . . . . . . . . . . . . .
LOW OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . .
OIL TEMPERATURE INDICATION . . . . . . . . . . . . . . . . . .
OIL CONTAMINATION MONITORING . . . . . . . . . . . . . . .

12
12
16
18
22
26

MAINTENANCE PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SOAP SAMPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAGNETIC CHIP DETECTOR INSPECTION . . . . . . . . .

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EJAMF M15.10 A E

TABLE OF FIGURES
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Basic Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Pressure Oil System Schematic . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Scavenge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Indicating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Quantity Indicating Schematic . . . . . . . . . . . . . . . . . . . . . . . .
Different Types of Quantity Transmitter . . . . . . . . . . . . . . . . . . .
Oil Pressure Indication System Schematic . . . . . . . . . . . . . . . .
Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transmitter & Low Pressure Switch Location . . . . .
Oil Temperature Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Temperature Sensor Location . . . . . . . . . . . . . . . . . . . . . . .
Spectrometric Oil Analysis Program . . . . . . . . . . . . . . . . . . . . .
Magnetic Chip Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Magnetic Chip Detectors . . . . . . . . . . . . . . . . . . . . .
Oil Quantity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Servicing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Soap Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Chip Detector Inspection . . . . . . . . . . . . . . . . . . . . . .
Magnetic Chip Detector Installation . . . . . . . . . . . . . . . . . . . . .

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TABLE OF FIGURES

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TABLE OF FIGURES

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TABLE OF FIGURES

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