ALF 502 STUDENT WORKBOOK CHAPTER 1 DESIGN PHILOSOPHY AND OUTPUT CAPABILITIES Chapter 1 will introduce you to the ALF 502 Turbofan Engine by providing gen- eral Information concerning the design concept of the engine end also what its output capabilities are. The information will include a general description along with leading particu- lars, terms and abbreviations pecurliar to the engine. In addition, an explan= ation of modular concent and interface with a description of major module sub- assemblies. You will learn what components make up the high pressure (Nw) and low pressure (N,) rotating systems along with directional references, direction of rotation and main bearings supporting the two systems. Perfor- mance information will show examples of the design output of the engine under sea level static, standard day conditions ‘TRAINING PURPOSES ONLYALF 502 STUDENT WORKBOOK GENERAL DESCRIPTION OF THE ALF S02 ENGINE The ALF S02 is a two-spool nigh bypass turbofan gas turbine engine which makes use of a gear reduction unit to drive a single stage fan off of the two stage low pressure turbine. The engine basically consists of four major modules; the fan module, the gas producer module, the combustor turbine module and the ac- cessory gearbox module. These modules have their own data plates and are inde~ pendently replaceable of one another. The core engine consisting of the gas producer module and combustor turbine module are derivatives of the Ayco Lycoming TSS series gas turbine engine LEADING PARTICULARS Height aaretes /336 Lbs Dimensions yo.ecin Far i Diameter ain SHSin Dib wWide rey length a OB Fine of spmnert Mecar ghia Thrust FN T® 6970 Noss RS &-4—GPO ToS RES Mex ConT Ess Lbs Fan Bypass Ratio 8.721 Gear Reduction Ratio 2.3019:1 Lpturbine to S2n Fon 260% rym Fuels LET 1F499 rym Kerosene Jet A & Jet Al JP-5& JP-8 Wide-Cut Jet 8 & JP-4 Lubricating Oil Type I MIL-L-7808 Type II MIL-L-23699 Oil Tank Capacity 3.6 U.S. Gals Operating Ambient Temperature -65°F to 122°F we ale may IL % BI) anes, Ing ge tems 1-2ALF 502 STUDENT WORKBOOK TERMS AND ABBREVIATIONS The following terms and abbreviations are common to the ALF 502 To NC GI P TSFC Wa ue T6r wot NLM Ala Na RPM. Fu Takeoff - Maximum guaranteed power, 5 minute time limit Maximum Continuous - Maximum guaranteed power for continuous engine operation Ground Idle - The lowest engine self sustaining power setting Pressure - Read in pounds per square inch (psi). Can be given as gage pressure (psig), absolute pressure (psia) or differential pressure (psid) Temperature - Read in degrees centigrade (°C) or degrees fahrenheit Cr) Thrust Specific Fuel Consumption - A numerical value that telts how much fuel the engine burns per hour to produce a pound of thrust. Airflow Rate - Measured in Ibs/sec Fuel Flow Rate - Measured in Ibs/hr. Measured Gas Temperature - Temperature of the hot cases before they enter the low pressure turbine area. Speed of the Low Pressure compressor system, usually read in percent- age Speed of the High Pressure compressor system, usually read in per- centage Revolutions per minute. Net Thrust - Propulsive force generated by the engine, read in pounds.ALF $02 STUDENT WORKBOOK 1 FANMODULE 3 COMBUSTOR TURBINE MODULE FRAME SUPPORT ASSY COMBUSTOR HOUSING AND LINER, SINGLE STAGE FAN LP. TURBINES AND NOZZLES REDUCTION GEAR Assy. ‘TURBINE SUPPORT BEARINGS COWL SUPPORT ASSY FUEL MANIFOLOS AND M.G.T. ASSY 2. Gas PRODUCER MODULE [ACCESSORY DRIVE GEAR ASSY. HP. COMPRESSOR ASSY. STATOR AND HOUSING ASSY [AIR DIFFUSER ASSY. 12. TURBINES AND NOZZLES . % A ‘ pte anaes at Ut \e TRAINING PURPOSES ONLY eee qeecaeaanee 4) ACCESSORY GEARBOX MODULE ~ BACK TO BACK MOUNTING PAD DRIVES FOR: FUEL CONTROL AND BOOST PUMP INTEGRATED ORIVE GENERATOR AND STARTER IL PUMP ANO HYDRAULIC PUMP xa-1190196 Figure 1-1. Engine Modules 1-47 ALF 802 STUDENT WORKBOOK MODULAR CONCEPT (Figure 1-4), For maintenance ease and flexibility, the engine is composed of four basic modules that can be handled and serviced separately. The fan (1), gas producer (2), combustor turbine (3) and accessory gearbox (4) modules. These modules shown in Figure 1-1, are individually replaceable and have been specifically designed for ease of maintenance. MODULE INTERFACE (Figure 1-1). Gas Producer Module to Fan Module: Attachment of these modules is accomplished by 40 machine bolts extending through the stub frame flange of the Gas Pro- ducer Module and threading into self-locking devices on the inner diameter of the fan support frame of the Fan module. Combustor Turbine Module to Gas Producer Module: The interface attachment of these two modules is accomplished between the Gas Producer Module Air Diffuser flange and Combustor Turbine Module Combustor Housing ame ier Fifty-two (52) machine bolts extend through holes in the air diffuser flange and screw into threads located in the combustor housing. Each bolt is then saftied with locking tabs. Additionally, the sungear is secured to the forward end of the low pressure shaft. A bolt housed in the low pressure shaft is threaded into a self-locking ut housed in the sun gear. Once the sun gear bolt is tightened the NL power train is complete. The low pressure turbine assembly is attached to the combustor housing assembly by means of a mounting ring and thirty-eight (38) machine bolts. Removal of either assembly allows certain maintenance tasks to be performed Accessory Gearbox Module to Fan Module: The Accessory Gearbox Module ts at- tached to the Fan Module with four (4) bolts. This attachment is accomplished by placing four (4) bolts through holes in the accessory gearbox housing and threading these bolts into self-locking inserts secured into the fan Module frame support. The accessory drive gear train is then completed by installing a drive shaft that couples the rotating force of the high pressure compressor with the accessory gearbox module 1-5ALF 802 STUDENT WORKBOOK[ALE S02 STUDENT WORKBOOK NL and NH ROTATING SYSTEMS (Figure 1-20 NL (low pressure) system consists of a single stage fan (1) and single stage low pressure compressor (2), these items are bolted together and mounted on the fan shaft (3). The mechanical energy necessary to drive the fan and L.P compressor 1s provided by a two stage (4) and (5) L.P. turbine section and transmitted to the front of the engine via the third turbine rotor assembly shaft (6). The reduced R.P.M. required by the fan is accomplished through a single stage sun/planetary gear arrangement made up of a ring gear (7), plane- tary gear carrier (contains seven helical gears) and a sun gear (8) WysGlE srrb€© Far SewGlE Sfa6E Low PsQng AA PeeOe fou sary third fusgive forer orscembly shop Sinple stage sem /plavictor cor NH eho! Yrs 2.182 ~ Fras? Steval 5 @ |s%. ALF 602 STUDENT WORKBOOK a 7 CAFO BN | of. an amvuren) -a Veg _ osu WORKSHEET -92 - DESCRIPTION OF ENGINE PERFORMANCE RATING. % The engine is rated at a take-off thrust of R-d & 5, 6970 Tbs. sand R-3, 6700 lbs. and @ maximum continuous thrust of R-d & 5, 6550 Ibs and &-3 6300 lbs under static, standard sea level conditions (Figure 1-5) (Table ifi). The flat rating limits described above are pilot monitored. Take-off thrust is pilot monitored by means of fan speed. Maximum continuous rating is monitored by means of fan speed and the low pressure turbine inlet temperature gauge. The fan speed is the criteria to establish that the engine is producing model spe~ cification thrust. The engine's characteristic temperature at this thrust is then used to maintain the rating by keeping the temperature constant irrespec- tive of bleed air, power extraction and Flight congitions — 93.28 — 9356 Table 1-1. Performance at Sea Level Static Standard Atmospheric Conditions No loading of accessory drives, zero customer bleed and 100% ram recovery. NH Nt Ppreeust specepp tome Are] (Maximum) | Maximum Host amor see Lasfee. RS. (rpm) (rpm) vf <>) FN 100% = joo = | T.S.F.c wa ating cMinimum) | 20,000 rpm | 7,600 rpm | (Maximum | + 2% Fe5. Take-off 6970 oFTt diz aia 209.8 19420 RPM | 7160 RPM 5 F, Max imum 6550 ek Bex 4a 242.5 Continuous 1s36e-RPM | 7007-RPM 7 NK NH NL, _ — (Maximum) | (Maximum) e RS (rpm) (rpm) 2 100% = 100% =| T.S.F.C. Wa 7,600 rom | (Maximum) +m Rating (Minimum) 7090_epm—~ £ . = a Take-of F 6700 7 96.5% oS a 245.1 ee 19300 RPM | 7076 RPM Maximum _--[~ 6300 95% 90.9% 408 ~~] 238.2 [continuous 19000 RPM | 6908 RPMRET THRUST = NET THRUST ALF 502 STUDENT WORKBOOK SI TaKe-ort 2 = MAXIMUM CONTINUOUS. 20 RE we o Pe: CONTINUOUS: ALF SOPRA, 4,5 ESTIMATED PERFORMANCE SEA LEVEL, STATIC CONDITIONS. [NO INSTALLATION LOSSES. ALF S02RS ESTIMATED PERFORMANCE SEA LEVEL, STATIC CONDITIONS [NO INSTALLATION LOSSES Figure 1-5. Engine Performance Rating