Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE

ATA 72 ENGINE
0 TABLE OF CONTENTS
1 1.1 1.2 1.3 1.4 1.5 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 3.4 4 4.1 4.2 4.3 4.4 5 5.1 5.2 5.3 5.4 6 6.1 6.2 6.3 6.4 6.5 7 7.1 7.2 7.3 Low pressure compressor Low pressure compressor (JT15D-1/1A/2B) Low pressure compressor (JT15D-4/4B/4D) Low pressure compressor (JT15D-5A) Low pressure compressor (JT15D-5D) Low pressure rotor trim balancing Intermediate case Purpose Construction Impellor inlet stator (JT15D-4 series only) Maintenance N1 and N2 speed sensors Purpose Construction Operation Maintenance Tower shaft Purpose Construction Operation Maintenance Accessory gearbox Purpose Construction Breather impellor Maintenance High pressure compressor High pressure compressor (JT15D-1 and 4 series) High pressure compressor (JT15D-5 series) Bleed valve (JT15D-5 series) Bleed valve operation (JT15D-5 series) Bleed valve logic (JT15D-5 series) Gas generator case Purpose Construction Maintenance 5 5 7 9 11 13 15 15 15 16 16 17 17 17 18 18 19 19 19 20 20 21 21 21 22 22 23 23 25 27 28 30 31 31 31 32

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE

8 8.1 8.2 8.3 9 9.1 9.2 9.3 9.4 10 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 11 11.1 11.2 11.3 11.4 11.5 11.6 12 12.1 12.2 12.3 13 13.1 13.2 13.3 13.4 13.5 13.6

Combustion chamber liner Purpose Construction Maintenance Small and large exit ducts Purpose Construction Operation Maintenance High pressure turbine (and associated parts) High turbine stator Small exit duct Shroud segments High turbine air seal High turbine baffle Sealing rings (2) Operation Maintenance High pressure turbine Purpose Construction Operation Reference Maintenance Tip clearance effect on engine parameters High pressure rotor trim balancing Purpose Construction Operation Low pressure turbines and stators (and associated parts) Low pressure turbine stators Low pressure turbines Inter-shaft transfer tube Low pressure turbine stator support nd Effect of 2 stage vane on T4 and N2 at a constant power Maintenance

33 33 33 34 35 35 35 35 36 37 37 37 37 38 38 38 38 39 40 40 40 41 41 41 42 43 43 43 45 46 46 46 47 47 47 47

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE

14 14.1 14.2 14.3 14.4 14.5 14.6

Exhaust duct and No.4 bearing housing Exhaust duct No.4 bearing housing No.4 bearing cover No.4 bearing housing retention No.4 bearing heat shield (all except post SB 7134) Maintenance

48 48 48 48 48 49 49

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE 1
1.1

LOW PRESSURE COMPRESSOR

Low Pressure Compressor (JT15D-1/1A/1B)

1.1.1 Purpose Provide the airflow to the core and bypass sections of the engine. 1.1.2 Inlet Cone Double wall, continuously anti-iced with P3 air Made of steel Airflow to the inlet cone also supplies pressure to no. 1 bearing labyrinth seal 1.1.3 Low pressure compressor (fan) 19 titanium blades, titanium hub, dovetail retention 1.1.4 Inlet case Stainless steel Incorporate bypass stator, two staggered row of 66 vanes Core stators single row, 33 vanes

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
1.1.5 References Rotation: Max speed (JT15D-1): Max speed (JT15D-1A/1B): Bypass ratio: Maximum airflow: Bypass flow: Core flow: Fan blades tip clearances: 1.1.6 Maintenance Visually inspect fan blades for FOD If FOD is within Fly back limits, engine can be operated for 10 hours before fan replacement Visually inspect stator vanes for FOD Inspect inlet case for rub If fan tip clearance needs adjustment, use class shims (3 different classes) to obtain proper clearance. Reducing shims thickness by 0.005 inches increases the tip clearance by 0.001 inches. Maximum shims thickness must not exceed 0.080 inches clockwise 15540 rpm or 99% N1 16540 rpm or 103.3% N1 3.3:1 73.6 Ibs/sec 56.6 Ibs/sec 17.0 Ibs/sec 0.035 to 0.055 inches

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
1.2 Low Pressure Compressor (JT15D-4/4B/4D)

1.2.1 Purpose Provide the airflow to the core and bypass sections of the engine. 1.2.2 Inlet cone Double wall, continuously anti-iced with P3 air Made of steel Airflow to the inlet cone also supplies pressure to no. 1 bearing labyrinth seal 1.2.3 Low pressure compressor (fan) 19 titanium blades, titanium hub, dovetail retention 1.2.4 Inlet case Stainless steel Incorporate bypass stator, two staggered row of 66 vanes Core stators single row, 38 vanes 1.2.5 Booster Stage 43 titanium blades, titanium hub, dovetail retention Increase the core inlet pressure Rear stage stator behind booster, 37 vanes

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
1.2.6 References Rotation: Max speed (JT15D-4/4D): Max speed (JT15D-4B): Bypass ratio: Maximum airflow: Bypass flow: Core flow: Fan blades tip clearances: 1.2.7 Maintenance Visually inspect and blend repair fan blades for FOD If FOD is within Fly back limits, engine can be operated for 10 hours before fan replacement Visually inspect booster blades for FOD Inspect inlet case for fan rub Inspect and blend repair stator vanes for FOD If fan tip clearance needs adjustment, grind fan positioning spacer to obtain proper clearance. Reducing the spacer thickness by 0.005 inches decreases the tip clearance by 0.001 inches. Grind the inlet cone positioning spacer to the same clockwise 16540 rpm or 104% N1 16860 rpm or 106% N1 2.08:1 77.8 Ibs/sec 56.6 Ibs/sec 21.2 Ibs/sec 0.035 to 0.055

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
1.3 Low Pressure Compressor (JT15D-5A)

1.3.1 Purpose Provide the airflow to the core and bypass sections of the engine. 1.3.2 Inlet Cone Double wall, continuously anti-iced with impeller back face air pressure Made of steel Airflow to the inlet cone also supplies pressure to no. 1 bearing labyrinth seal 1.3.3 Low pressure compressor (Fan) 19 titanium blades, titanium hub, dovetail retention 1.3.4 Inlet case Stainless steel Incorporate bypass stator, single row of 60 vanes Core stators single row, 52 vanes 1.3.5 Booster Stage 50 titanium blades, titanium hub, dovetail retention Increase the core inlet pressure Rear stage stator behind booster, 47 vanes

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
1.3.6 References Rotation: Max speed: Bypass ratio: Maximum airflow: Bypass flow: Core flow: Fan blades tip clearances: Fan blades tip clearances; 1.3.7 Maintenance Visually inspect and blend repair fan blades for FOD If FOD is within Fly back limits, engine can be operated for 10 hours before fan replacement Visually inspect booster blades for FOD Inspect inlet case for fan rub Inspect and blend repair stator vanes for FOD If fan tip clearance needs adjustment, grind fan positioning spacer to obtain proper clearance. Reducing the spacer thickness by 0.0065 inches decreases the tip clearance by 0.001 inches. Grind the inlet cone positioning spacer to the same thickness as the fan positioning spacer. clockwise 16540 rpm or 104% N1 2.08:1 80.1 Ibs/sec 54.1 Ibs/sec 26.0 Ibs/sec 0.050 to 0.060 inches (if pre SB 7368) 0.060 to 0.070 inches (if post SB 7368)

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
1.4 Low Pressure Compressor (JT15D-5D)

1.4.1 Purpose Provide the airflow to the core and bypass sections of the engine. 1.4.2 Inlet cone Single wall, continuously anti-iced with impeller back face air pressure Made of aluminium alloy Airflow to the inlet cone also supplies pressure to no. 1 bearing labyrinth seal 1.4.3 Low pressure compressor (fan) Integral bladed rotor (IBR), made of titanium, 17 blades incorporated 1.4.4 Inlet case Aluminium Kevlar containment on the outside Honey comb and abradable liner on the inside Incorporate bypass stator, single row of 60 vanes Core stators single row, 52 vanes 1.4.5 Booster Stage Integral bladed rotor (IBR), made of titanium, 50 blades incorporated Increase the core inlet pressure Rear stage stator behind booster, 47 vanes

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
1.4.6 References: Rotation: Max speed: Bypass ratio: Maximum airflow: Bypass flow: Core flow: Fan blades tip clearances: 1.4.7 Maintenance: Visually inspect and blend repair fan blades for FOD If FOD is within Fly back limits, engine can be operated for 10 hours before fan replacement Visually inspect booster blades for FOD Inspect inlet case for fan rub Inspect and blend repair stator vanes for FOD If fan tip clearance needs adjustment, grind fan positioning spacer to obtain proper clearance. Reducing the spacer thickness by 0.0065 inches decreases the tip clearance by 0.001 inches. Grind the inlet cone positioning spacer to the same thickness as the fan positioning spacer. clockwise 16860 rpm or 100% N1 2.1:1 82.8 Ibs/sec 56.8 Ibs/sec 27.0 Ibs/sec 0.012 to 0.025 inches

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
1.5 Low Pressure Rotor Trim Balancing

1.5.1 Purpose The purpose of trim balancing is to correct for misalignment of rotor centrelines and to eliminate residual unbalance. 1.5.2 Operation Prior to the engine assembly, the fan, the booster and the nose cone are individually balanced. Then at engine test, the low pressure rotor residual unbalance is corrected by the addition of trim weights to the front rim of the fan hub. The location of the trim weights is indicated on the engine trim data plate.

Operators may perform low rotor trim balancing as necessary to reduce vibration. This procedure requires the use of a vibration analyser, an optical tachometer, vibration sensor and reflecting tape.

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE

NOTE: The fan can be replaced without having to rebalance the entire assembly as long as trim weights identical to those on the defective fan are installed onto the new fan in the positions indicated on the trim data plate. Refer to the engine maintenance manual for complete procedure.

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE 2
2.1

INTERMEDIATE CASE
Purpose Support engine mounts Main support for engine and AGB Airflow plenum Integral oil tank Support no. 1 and no. 2 bearings

2.2

Construction Machined magnesium casting Coated for corrosion protection Rear cavity forms oil tank, sealed off by oil tank cover Oil tank filler neck can be installed at 4 or 7 o'clock to suit engine/aircraft installation Oil pressure and scavenge tubes pass through case to deliver oil to no. 1, 2 and 3 bearings No. 1 bearing housing supports no. 1 bearing Rear inner bore supports no. 2 bearing and air seal Bypass air transfer tube (JT15D-1 series only) vent the cavity form by the oil tank cover and the gas generator case

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
2.3 Impeller inlet stator (JT15D-4 series only) Direct airflow to impeller Fit in rear inner section of intermediate case 2.4 Maintenance Inspect studs and engine mount inserts for damage Inspect coating condition

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Pratt & Whitney JT15D Series (CAT C)

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3.1

N1 AND N2 SPEED SENSORS

Purpose Provide N1 and N2 speed signals to the cockpit gauges and to the BVC.

3.2

Construction N1 Speed sensor One single coil sensor Signal goes to the cockpit gauge Treads are used to set the sensor gap N2 Speed sensors Two single coil sensors One sensor for the BVC and the other for the cockpit gauge Shims are used to set the sensors gap

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
3.3 Operation Induction type speed sensors (pulse pickups) are installed adjacent to a toothed wheel or gear. Frequency output from sensor is proportional to rotational speed of gear. 3.4 Maintenance: Remove and inspect sensors for evidence of rubbing, replace if rub is evident Use Tech-Rep test set to measure internal resistance of coils Adjust probe gap N1 = 0.0167" to 0.0194" (JT15D-5A) or 0.0417" to 0.0444" (JT15D-5D) N2 = 0.006" to 0.010"

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE 4
4.1

TOWER SHAFT
Purpose Link the high pressure rotor to the accessory gearbox. Link the low pressure rotor to the N1 tachometer (JT15D-1 and 4 series).

4.2

Construction High pressure rotor tower shaft Steel shaft with two bevel gears Duplex ball bearings support each bevel gear Low pressure rotor tower shaft (JT15D-1 and 4 series) Steel shaft with one bevel gear and one gear shaft Plain bushings support each gear and the shaft

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
4.3 Operation The high pressure rotor tower shaft provides the power to drive all accessories mounted on the accessory gearbox (JT15D all models). The low pressure rotor tower shaft drive the N1 tachometer located on the top of the intermediate case (JT15D-1 and 4 series). 4.4 Maintenance Replace rubber lip seal on the low pressure rotor tower shaft (JT15D-1 and 4 series) None at field level (JT15D-5 series)

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE 5
5.1

ACCESSORY GEARBOX
Purpose Provide mounting pads and drive for: Fuel pump Starter generator Oil pumps Hydraulic pump N2 tacho generator (JT15D-1 and 4 series) N2 speed sensors (JT15D-5 series)

5.2

Construction Magnesium cast housing and rear cover Coated for corrosion protection Wet spline drive shafts Hardened steel gears Anti-foaming tray at bottom of AGB

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
5.3 Breather impeller Integral part of the starter gear shaft, separates air from oil, expelling oil radially and air overboard through the breather. 5.4 Maintenance Carbon seal replacement Rubber lip seals replacement Oil pump assembly replacement Studs replacement

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE 6
6.1

HIGH PRESSURE COMPRESSOR

High pressure compressor (JT15D-1 and 4 series)

6.1.1 Purpose Provide the engine with the correct pressure and airflow to sustain combustion, cool hot section components and produce thrust. 6.1.2 Construction Impeller Housing Impeller shroud housing contains air flow through the impeller Impeller Centrifugal compressor made of forged titanium 16 full blades, 16 splitter blades Shafts Front, high pressure compressor shaft assembled to the front of impeller and supported by no. 2 bearing. Also incorporates inter-shaft carbon seal and bevel gear Rear, high turbine shaft assembled to the rear of the impeller and supported by no. 3 bearing

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
6.1.3 References JT15D-1/1A/1B Compression Ratio: Core flow: Maximum N2: JT15D-4/4B/4D Compression Ratio: Core flow: Maximum N2 (D-4): Maximum N2 (D-4B/4D): 6.1.4 Maintenance Boroscope inspect the high pressure compressor for FOD Perform compressor desalination washes NOTE: Perform a boroscope inspection of high pressure compressor before hot section inspection (HSI). 10.2:1 21.2 Ibs/sec 96% - 31450 RPM 97% - 31800 RPM 8.0:1 17.0 Ibs/sec 95% - 31120 RPM

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
6.2 High pressure compressor (JT15D-5 series)

6.2.1 Purpose Provide the engine with the correct pressure and airflow to sustain combustion and cool hot section. 6.2.2 Construction Impeller Housing Impeller shroud housing contains air flow through the impeller Incorporates bleed valve mechanism Impeller Centrifugal compressor made of forged titanium 18 full blades, 18 splitter blades Shafts Front, high pressure compressor shaft assembled to the front of impeller and supported by no. 2 bearing. Also incorporates inter-shaft carbon seal and bevel gear Rear, high turbine shaft assembled to the rear of the impeller and supported by no. 3 1 bearing, also support no. 3 /2 bearing

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Pratt & Whitney JT15D Series (CAT C)

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6.2.3 References JT15D-5A Compression Ratio: Core flow: Maximum N2: JT15D-5D Compression Ratio: Core flow: Maximum N2: 6.2.4 Maintenance Boroscope inspect the high pressure compressor for FOD Perform compressor desalination washes NOTE: Perform a boroscope inspection of high pressure compressor before hot section inspection (HSI). 5.3:1 27.0 Ibs/sec 97% - 31777 RPM 5.3:1 26.0 Ibs/sec 96% - 31450 RPM

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
6.3 Bleed Valve (JT15D-5 series)

6.3.1 Purpose Prevent the booster stage from stalling during adverse operating conditions. 6.3.2 Construction The system consists of an annular bleed valve, linkages, interconnecting rod, hydraulic actuator and a solenoid valve. 6.3.3 Operation The forward section of the high pressure compressor impeller housing can be moved axially with the bleed valve linkages. As the impeller housing moves forward, P2.5 air pressure bleeds off and discharges into the bypass airflow via slots in the gas generator case. This air bleed helps to stabilise the airflow through the high pressure compressor therefore preventing the booster stage from stalling.

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
6.4 Bleed Valve Operation (JT15D-5 series)

6.4.1 Bleed valve actuator Consist of a piston, a solenoid valve and a pressure relief valve Control the bleed valve opening as a function of the BVC command 6.4.2 Operation The bleed valve actuator uses high pressure fuel to close or to open the bleed valve. With the solenoid valve in a normally closed position, the high pressure fuel flows only to the top portion of the piston. This causes the piston to stay down, therefore keeping the bleed valve in a closed position. A pressure relief valve (400 psid) limits the hydraulic force being applied to the piston by bleeding off excessive fuel pressure into the bypass fuel circuit. (See Fig 72-16a) When commanded by the BVC, the solenoid valve opens, allowing high pressure fuel to flow to both sides of the piston. Due to different working areas, the actuator piston moves up and causes the interconnecting rod and linkages to open the bleed valve.

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
6.4.3 Maintenance Perform rigging on bleed valve linkage as follows: Opened position Remove bolt from rod end bearing Push interconnecting rod up Pull actuator yoke up Align bolt holes using rod end bearing Closed position Push actuator yoke down Pull interconnecting rod Align bolt holes using adjustment screw, then back off half a turn NOTE: Every time a fuel pump, FCU or bleed valve actuator is removed or replaced, the bleed valve should be rigged again.

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
6.5 Bleed Valve Logic (JT15D-5 series)

6.5.1 Operation The bleed valve is closed at a pressure altitude less than 25,500 feet. Above this pressure altitude, the bleed valve: Closes when: N2 speed is higher than 86% N2 speed is between 76% and 86% and the rate of acceleration or deceleration is less than established limits (schedule "B", slow accel/decel) Opens when: N2 is lower than 76% N2 speed is between 76% and 86% and the rate of acceleration or deceleration is greater than established limits (schedule "A", fast accel/decel) NOTE: If pressure altitude drops below 25,500 feet and the bleed is in an open mode, it stays open for 5 more seconds before closing.

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE 7
7.1

GAS GENERATOR CASE

Purpose Houses and supports various engine components The diffuser pipes change the air velocity into static pressure and cause the compressor air to turn 90

7.2

Construction Welded assembly of steel alloy machined parts and sheet metal with a corrosion resistant coating 20 diffuser pipes (JT15D-1 and 4 series) 24 welded diffuser pipes (JT15D-5 series) The case provides: Support for the impeller housing Support for the no. 3 bearing 2 bosses for igniter plugs 2 bosses for drain valves 2 bosses for P3 air (airframe bleed) 2 bosses for P3 air (anti-ice stators, T1 probe and FCU) Support for the large exit duct and high pressure stator assembly. Locate deflector segments, strips and support ring (JT15D-1 and 4 series)

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
7.3 Maintenance Visually inspect case, diffuser pipes, deflector segments, strips and support ring for wear, cracks and general condition whenever engine disassembly is sufficient to permit inspection. At hot section inspection, visually inspect case and diffuser pipes for wear and cracks.

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE 8
8.1

COMBUSTION CHAMBER LINER

Purpose Provide an area for combustion of the fuel/air mixture.

8.2

Construction Annular, reverse flow type combustion chamber Made of nickel alloy sheet metal 12 fuel nozzle adapter bosses 2 spark igniter bosses at 5 and 7 o'clock position Cooling rings maintain a layer of cooling air to protect the combustion chamber walls from the flame Liner is supported by 6 support pin through low turbine support case

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
8.3 Maintenance At HSI, visually inspect for evidence of burning, cracking, buckling, etc. Some damage is acceptable (refer to the maintenance manual) Re-gap cooling rings if they are distorted

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ATA 72 ENGINE 9
9.1

SMALL AND LARGE EXIT DUCTS

Purpose Direct the gasses from the combustion chamber to the high turbine stator by changing the direction of airflow 180 (reverse flow).

9.2

Construction The small and large exit ducts consist of two layers of heat resistant steel in the JT15D-1 and 4 series. The small and large exit ducts consist of two layers of nickel alloy sheet metal in the JT15D-5 series. P3 air flows through and cools the two ducts. P3 air flows to the high turbine stator via the small exit duct for internal cooling of each vane.

9.3

Operation P3 air enters the combustion chamber through holes in the inner and outer liner walls. The shape, size and location of these holes provide the correct fuel/air ratio for all operating conditions. The combustion chamber combined with the large and small exit ducts form an envelope that turns the gas 180 (reverse flow). This configuration permits location of the turbines closer to the compressor and within the combustion chamber area, thus making the engine shorter and lighter. Cooling rings direct P3 air into the combustion chamber, close to the walls, to form a flame barrier.

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9.4 Maintenance During a Hot Section Inspection, inspect the small and large exit ducts for evidence of burning, cracking or coating loss.

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Pratt & Whitney JT15D Series (CAT C)

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10.1

HIGH PRESSURE TURBINE STATOR (AND ASSOCIATED PARTS)

High turbine stator Direct the gases toward the high turbine at optimum angle and speed Convergent vanes change the static pressure into velocity Nickel or cobalt alloy casting coated using a diffused aluminide process (JT15D-1 and 4 series) Nickel alloy casting coated using a diffused aluminide process (JT15D-5 series) Air cooled core passages allow P3 air to flow through each vane (15 on JT15D-1 series, 14 on JT15D-4 series) Air cooled vanes (JT15D-5 series) Locate small exit duct

10.2

Small exit duct Locate sealing ring Support shroud segments Slots in the duct match with corresponding lugs on the high turbine stator to prevent side play

10.3

Shroud segments 15 on JT15D-1 series 14 on JT15D-4 series 14 on JT15D-5 series Manufactured from nickel alloy steel, provide adequate turbine blade tip clearance and minimise gas leakage Classed for different high turbine wheel diameters

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Pratt & Whitney JT15D Series (CAT C)

ATA 72 ENGINE
10.4 High turbine air seal Directs airflow over high turbine disk for cooling and to no. 3 bearing labyrinth seal Locates and supports high turbine stator 10.5 High turbine baffle Control cooling of high turbine disk JT15D-1 and 4 series; two configuration, pre SB7399 (sheet metal type) or post SB7399 (machined) JT15D-5 series; two configuration (D-5A only), pre SB7399 (sheet metal type) or post SB7399 (machined) 10.6 Sealing rings (2) One prevents P3 air leakage between high turbine stator and the small exit duct. The second one prevents P3 air leakage between small exit duct and the low turbine support case 10.7 Operation The high turbine stator receives hot gases from the combustion chamber. The stator directs the gases at optimum angle to drive the turbine while the convergent shape of the vane airfoils changes the gas pressure into velocity. The high turbine stator is subject to the highest temperatures within the engine and cooling of the stator determines its life expectancy. P3 air flows inside each vane airfoils to keep them at a temperature lower than the gases flowing on the outside. After cooling, air is ejected in the gas path (JT15D-1 and 4 series). After cooling, air is ejected from each vane trailing edge into the gas path (JT15D-5 series).

Segments come in different classes to fit different high turbine diameters and maintain the necessary clearance between the high turbine blades and the segments.

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10.8 Maintenance During a Hot Section Inspection, inspect components for evidence of burning, cracking and coating loss Insure proper sliding fit (lugs to slots) with mating parts Check small exit duct sealing face Check sealing ring diameter in small exit duct

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11.1

HIGH PRESSURE TURBINE

Purpose Extract energy from the hot gases to drive the high pressure compressor.

11.2

Construction The high turbine is a two-plane balanced disk assembly, the disk is made of nickel alloy steel with fir tree serrations that provide a firm attachment as well as allowing for thermal expansion between the blades and the disk. Rivets are used to axially retain the 71 blades on the disk. A master spline ensures reinstallation of the high turbine in its initial position on the high turbine shaft during maintenance. High turbine blades PRE SB7293 are made from a nickel based alloy. Features include triple taper design, fir tree retention, growth check pad and diffused corrosion resistant protective coating. (JT15D-1 and 4 series). High turbine blades POST SB7293 are made from a nickel based alloy using a directionally solidified casting process known as "D.S. blades". Features include triple taper design, fir tree retention, growth check pad and a diffused corrosion resistant protective coating. (JT15D-1 and 4 series). High turbine blades are made from a nickel based alloy using a directionally solidified casting process known as "D.S. blades". Features include triple taper design, fir tree retention, growth check pad and a diffused corrosion resistant protective coating. (JT15D-5 series).

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11.3 Operation Expanding gases accelerate through the stator and hit the turbine blades. The energy available in the gases converts into rotational movement to drive the high pressure compressor and the engine accessories. Two thirds of the energy available is used to drive the high pressure compressor and the remaining energy drives the low turbines and generates thrust. 11.4 Reference N2 at 95% N2 at 96% N2 at 97% N2 at 96% N2 at 97% 31,129 RPM (JT15D-1 series) 31,450 RPM (JT15D-4) 31,800 RPM (JT15D-4B/4D) 31,450 RPM (JT15D-5A) 31,777 RPM (JT15D-5D)

The turbine is individually balanced on two planes with detail weights. This feature allows for turbine replacement in the field. 11.5 Maintenance During a Hot Section Inspection, inspect turbine blades for: tip rub, cracks, sulphidation, erosion, burning and coating loss Tip clearance (JT15D-1 and 4 series): new segment 0.023" - 0.029" old segment 0.015" - 0.029" Tip clearance (JT15D-5 series): new segment 0.028" - 0.033" old segment 0.020" - 0.033"

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11.6 Tip clearance effect on engine parameters When the turbine tip clearance is too large, more gases leak at the tip of the blades, preventing the turbine from extracting all the power it takes to drive the compressor. However to maintain a constant power, fuel flow and T5 must increase, but N2 remains below normal because of the inefficient turbine. NOTE: High turbine blades POST SB7293 are no longer time limited. (JT15D-1 and 4 series)

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12.1

HIGH PRESSURE ROTOR TRIM BALANCING

Purpose The purpose of trim balancing is to correct for misalignment of rotors centrelines and to eliminate residual unbalance.

12.2

Construction The high pressure rotor consists of the high pressure compressor, the high pressure compressor shaft, the high 1 turbine, the high turbine shaft, the no. 2, 3 and 3 /2 bearings and their associated air seals.

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12.3 Operation The high pressure compressor and high turbine are individually balanced. The high pressure rotor is then assembled and balanced again (trim balance). Trim weights are added to the front and rear faces of the high turbine and to the high pressure compressor rear face. To make the turbine field replaceable without having to rebalance the whole rotor, turbine trim weights (sizes and positions) are indicated on the data plate. Whenever a new high turbine is installed, trim weights must be added to the front and rear faces of the high turbine according to the data plate.

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13.1

LOW PRESSURE TURBINES AND STATORS (AND ASSOCIATED PARTS)

Low turbine stators Direct the gases toward the low turbine at optimum angle and speed to drive the low turbine Convergent vanes change the static pressure into velocity Cobalt alloy casting (2nd stage) and nickel alloy casting (3rd stage) Baffle with air seal to control cooling Only 2nd stage stator exit area is classed

13.2

Low turbines Extract energy from the gases to drive the fan and booster The low turbines are a two-plane balanced disks assembly The disks are made of nickel alloy steel Fir tree serrations provide a firm attachment and allow for thermal expansion between the blades and the disks Rivets axially retain the 61 blades (2nd stage) and 55 blades (3rd stage) The blades are shrouded at the tip to prevent hot gases leakage Both turbines are mounted on the low turbine shaft which is supported by no. 4 bearing

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13.3 Inter-shaft transfer tube Supply oil to the No. 3 /2 bearing Hollow tube made of steel Carbon seal at rear end minimizes leakage One support diameter prevent tube deflection at operating speed (JT15D-1 and 4 series) Two support diameters prevent tube deflection at operating speed (JT15D-5 series) 13.4 Low pressure turbine stator support Locate and support the 2nd and 3rd stage stators, fuel nozzles, fuel shut-off valve and combustion chamber liner Annular construction made of nickel alloy steel 6 pins support the combustion liner Slots in case match with corresponding lugs on 2nd and 3rd stage stators Sealing ring diameter for the interstage sealing ring 13.5 Effect of 2nd stage vane area on T5 and N2 at a constant power Increase area Decrease area 13.6 Maintenance During a Hot Section Inspection, inspect the low turbines for: cracks, burning, coating loss, corrosion, impact damage and blade shift Return the low turbines assembly with the inter-shaft transfer tube to an authorized overhaul facility if the low turbine assembly needs to be repaired. N2 up N2 down T5 down T5 up
1

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14.1

EXHAUST DUCT AND NO. 4 BEARING HOUSING

Exhaust duct Direct exhaust gases to the atmosphere Made of nickel alloy steel Support the no. 4 bearing housing, automatic fuel shut-off mechanism, T6 probes, oil supply and scavenge transfer tube A boroscope inspection port is located in the tail cone

14.2

No. 4 bearing housing Made of nickel alloy steel Provide support to no. 4 bearing The no. 4 bearing labyrinth seal stator is part of the housing

14.3

No. 4 bearing cover Made of nickel alloy steel Support the inter-shaft transfer tube carbon seal, actuator rod, and emergency shut-off mechanism 1 Provide oil supply for the no. 3 /2 and 4 bearings

14.4

No. 4 bearing housing retention Studs and slab nuts or t-head bolts and spacer sleeves (post SB7193) retain the no. 4 bearing housing in position in the exhaust duct (JT15D-1 and 4 series) T-head bolts and spacer sleeves retain the No. 4 bearing housing in position in the exhaust duct (JT15D-5 series)

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14.5 No. 4 bearing heat shield (all except post SB7134) Sheet metal construction, bolted over the no. 4 bearing housing to protect it from the hot gases 14.6 Maintenance At hot section inspection inspect: Exhaust duct for cracks No. 4 bearing housing for security of shut off mechanism Oil leaks and rub mark on labyrinth seal runner Carbon seal condition

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