Basic Engines - MODULE 6

 Piston Engine Theory and construction

 Thermodynamic laws related to internal combustion engines. Heat engines

 The Otto cycle and the relationship between volume, temperature and pressure.

 Terms used in the theory of piston engines and calculations of parameters from the given data.

 Various efficiencies involved in internal combustion engines.

 Differences between two stroke and four stroke engines.

 The function, construction, classification and material of the various parts and accessories of the engine including the induction, exhaust, cooling systems and engine mounting.

 A general understanding of the propeller terms.

 Purpose and functioning of all parts of a constant speed, variable pitch and feathering propeller and their associated control system components.

 Various factors affecting the engine performance.

 Engine fire detection and protection systems.

 Engine Fuel and oil System

 The principle of operation and constructional features of carburetors.

 The constructional features and function of components of engine fuel system.

 Types, characteristics of aviation fuel, common sources of contamination and methods to prevent such contamination. Method of checking for contamination.

 Types, characteristics of lubricants used in piston engine oil system.

Contamination of oil and its identification.

 Various components of oil system.

 Ignition and starting System.

 Principle of operation, constructional features and function of magnetos and ignition system components, Magneto timing procedure.

TRAINING

 Principle of operation, constructional features and function of various types of engine starters.

 Engine Instruments

 Principle of operation of the engine instruments, the replacement and in-situ operational tests thereof.

 Supercharged System

 Principle of operation, constructional features and function of various types of supercharged and its related components/parts.

Engine Maintenance

 Trouble shooting of minor defects and methods of their rectification; riggining of engine controls; periodical inspections necessary to check the serviceability of the engine; inspection after propeller strike.

 Engine starting; ground run-up; adjustment and checking of the performance of the engine and its components including systems; Top overhaul procedure and engine on-condition maintenance.

 NDT techniques as applicable to engine parts.

 Engine preservation and de-preservation procedures.

Turbine Engines and Variable Pitch Propellers

 Gas Turbine Engine Theory and construction

 Thermodynamics laws related to gas turbine engines.

 Otto Cycle and Brayton’s Cycle and the relationship between volume, temperature and pressure.

 Terms used in the theory of gas turbine engines and calculations of parameters from the given data.

 Advantages and disadvantages of various types of gas turbine engines.

 Function, construction, classification and material of the various parts and accessories of the engine including the induction, exhaust, cooling systems, thrust augmentation and engine mounting, anti-icing of engine.

 Various factors affecting the engine performance.

 Condition monitoring and performance monitoring of gas turbine engines.

 The engine fire detection and protection systems.

 Engine Fuel and Oil system

TRAINING

 Principle of operation and constructional features of fuel control units.

 Constructional features, function of the components of engine fuel control system/metering system.

 Types,. Characteristics of aviation fuel, common sources of contamination and methods to prevent such contamination. Method to check contamination with precautions.

 Types characteristics of lubricants used in gas turbine engine lubrication system. Identification of contaminants with interference drawn.

 Function of various components of lubrication system.

 Ignition and starting system

 Principle of operation, constructional features and function of ignition system components. Types of ignition; flame propagation.

 Constructional features and function of various types of engine starters.

 Engine Instruments

 Principle of operation of the engine instruments, and replacement and in-situ operational tests thereof.

 Power Augmentation System

 Principle of operation and function of various types of power augmentation devices.

Propeller

 A general understanding of the propeller terms.

 Function of all parts of a constant speed, variable pitch and feathering propeller and their associated control system components.

Thrust Reversers

 Constructional features and function of various types of thrust reversers and their related components.

Auxiliary power unit.

 Purpose, constructional features of compressors, combustion chambers and turbine arrangement; speed and load control; limiting factors; fire protection and indication; its operational features.

 Bleed Control System

TRAINING

 Terms related to bleeding of air from the engine; compressor surge;

compressor line; compressor stall; Bleed loads and condition under which bleed is tapped.

Air Oil system

 The air oil system used on a typical gas turbine engine.

 Engine Maintenance

 Trouble shooting of minor defects and methods of their rectification; rigging of engine controls and field adjustments of fuel control unit; periodical inspections necessary to check the serviceability of the engine; special inspection schedules; duplicate inspection of engine controls.

 Engine starting; ground run-up; trimming; and checking of the performance of the engine and its components including systems.

 Engine preservation and de-preservation procedures.

Piston Engines

 General Requirements

 The layout of the overhaul workshop including Engine test-bed.

 Use of workshop inspection aids, including NDT equipments; factors and limitations effecting the choice of equipment and methods of inspection used.

 Care, use and checking for accuracy of special tools used in overhaul of the engine.

 Metallurgy

 Effect of various alloying elements in steel; Properties and use of Alloyed Steel.

 Heat treatment of steel and Aluminum.

 Surface hardening processes used on engine parts.

 Workshop processes, welding and protective treatments.

 Materials used in engine construction; Procedures for testing the soundness of these materials.

 Methods of assessment and removal of corrosion including treatment and reprotection.

 Inspection and Repair

 Preparation of inspection reports prior to repair/overhaul.

TRAINING

 Preparing the engine for complete overhaul/inspection; procedure of dismantling the engine.

 Repair, reconditioning, adjustment and assembly of major components;

inspection before during and after the repair / reconditioning of the components.

 Repair, inspection and testing of oil heat exchanger units, fuel and oil systems and engine control systems.

 Procedure for final inspection of the engine after overhaul / major repair.

 Various methods of engine testing (dynamometer etc.); the procedure of testing the engine after complete overhaul and monitoring its performance with the help of graphs / curves.