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CHAPTER 10
POWER PLANT INSPECTION, REPAIR, AND TESTING
The purpose of this chapter is to familiarize you with the types and authorized repair limits for
Intermediate Maintenance Activities (IMAs). Intermediate maintenance applies to those maintenance
functions normally performed in centrally located facilities for support of the operating units. The
facilities are designated as Aircraft Intermediate Maintenance Departments (AIMDs) at sea or Fleet
Readiness Center (FRCs) on shore.
The primary purpose of the IMA or FRC is to support and supplement the work of organizational
maintenance activities. Squadron personnel assigned to the IMA, ashore or afloat, are assigned to
perform the total work (within their skills) of the intermediate activity and not just the work related to
support of the squadron from which they were assigned.
The Gas Turbine Maintenance Program defines the repair functions of AIMD power plants. Repair
capabilities are different for each particular engine and AIMDs. It is important that you become
familiar with the repair capabilities and functions of your IMA.
This chapter covers some of the procedures and equipment used in an intermediate maintenance
department. Because of the number of different engines used in naval aviation, the maintenance
procedures in this chapter are general in nature. Components and repair limits discussed are
representative. Do not refer to them when working on a specific engine or its components; always
refer to the applicable MIMs of the specific aircraft type.

LEARNING OBJECTIVES
When you have completed this chapter, you will be able to do the following:
1. Recognize the types of repairs accomplished at the intermediate maintenance level.
2. Identify the repair limits for the intermediate level of maintenance.
3. Identify the different methods of cleaning and marking engine parts.
4. Identify the different types of test cells and their components.
5. Recognize the purpose and entries on the engine test log sheets.

THREE-DEGREE GAS TURBINE ENGINE MAINTENANCE PROGRAM

The Gas Turbine Engine Maintenance Program was formed under the three-degree concept as
specified in Commander Naval Air Forces Instruction (COMNAVAIRFORINST) 4790.2(series). Under
this concept, each engines intermediate maintenance manual defines specific engine maintenance
actions as either first-, second-, or third-degree functions. These functions are largely determined by
the degree of difficulty and frequency of repair (Figure 10-1 frames 1, 2, 3).

First-Degree Repair
First-degree repair is the repair of a damaged or non-operating gas turbine engine and its
accessories or components. When the compressor rotor is replaceable, the repair includes
compressor rotor replacement and/or disassembly.

10-1
Second-Degree Repair
Second-degree repair is also the repair of a damaged or non-operating gas turbine engine and its
accessories or components. The difference is that second-degree repair will normally include the
repair/replacement of turbine rotors and combustion sections. Repairs include afterburners and the
replacement of externally damaged, deteriorated, or time-limited components, gearboxes, or
accessories. Minor repair to the compressor section is made in second-degree repair. The repair or
replacement of reduction gearboxes and torque shafts of turboshaft engines comes under second-
degree repair. The repair or replacement of compressor fans of turbofan engines also comes under
second-degree repair activities.

Third-Degree Repair
Third-degree repair encompasses major engine inspections and the same gas turbine engine repair
capability as second-degree maintenance. Certain functions that require high maintenance man-
hours and are of a low incidence rate are excluded. The functions described represent broad
generalities. Refer to the appropriate engine maintenance plan or intermediate maintenance manual
to determine the degree of assignment for specific repair functions.

Interaction Available

Figure 10-1 Three levels of maintenance, (Frames 1 first degree, 2 second

degree, 3 third degree).

10-2
AIRCRAFT INTERMEDIATE MAINTENANCE DEPARTMENT
Once an engine arrives at an AIMD/FRC activity, it is cleaned and evaluated for repair. If inducted for
repair, a major inspection and all repairs required to place the engine back in ready for issue (RFI)
status are accomplished. The first steps for inspecting aircraft engines include the cleaning and the
marking of parts. After cleaning, engines are inspected in accordance with applicable Maintenance
Instruction Manuals (MIMs) or disassembled for further repair.

Cleaning
Good mechanics clean all engine parts thoroughly before inspecting them. Cleaning and close
inspection make it possible to detect faults that endanger safe engine operation and maximum
performance. The primary purpose of engine parts cleaning is to accomplish the following:
Permit thorough inspection of components for flaws, damage, and dimension wear.
Prepare surfaces for repair (plating, welding, or painting).
Remove organic or inorganic coatings for inspection of underlying surfaces or remove coatings
adversely affecting engine performance.

WARNING
Many of the chemical solutions and their components used
in cleaning, inspecting, and repairing are toxic, flammable,
and extremely corrosive. Improper mixing or use of these
chemicals can produce violent reactions, rapid heat
generation, and explosive/toxic gases. Personnel
performing maintenance procedures should consult the
applicable MIMs and be familiar with the safety precautions
associated with the hazardous materials or equipment. The
warnings in these technical manuals identify the types of
hazards and precautions to take. The Material Safety Data
Sheets (MSDS) and your safety office have specific
information for hazardous material in your work center.

Selection of cleaning materials and processes for any engine part is determined by the nature of the
soil, the type of metal or coatings, and the degree of cleanliness necessary for a thorough inspection
and repair.
Generally, engine parts operating in relatively low temperature ranges (cold section parts) are
cleaned by solvent washing, degreasing tanks, and vapor degreasing. Cleaning engine parts that
operate in hot sections of the engine (combustion and turbine sections) require more comprehensive
cleaning.
Soft carbon deposits are removed by degreasing and steam cleaning. Degreasing removes dirt and
sludge by immersing or spraying the part with cleaning solvent. Hard carbon deposits are removed by
decarbonizing, brushing, scraping, or grit-blasting. The following text provides general cleaning
procedures to familiarize you with the methods and materials used for cleaning parts. Always refer to
the appropriate maintenance manual for the latest cleaning procedures. Constant changes are made
in cleaning and finishing (coatings) materials.

Degreasing (Solvent Cleaning)

Small accumulations of grease, oil, and dirt may be removed by hydrocarbon solvent cleaning. This
method is not effective in removing baked-on oil deposits or most surface coatings.
10-3
Dry-cleaning solvent (MIL-PRF-680B) is the recommended cleaner. Solvent cleaning uses a tank with
cleaning solvent to soak the part clean. Some tanks have pumps to provide mechanical agitation to
help clean parts. You can also use a soft bristle brush to remove stubborn stains. The cleaning tank
should have a hinged, counterweighted cover so it can be covered when not in use. Since some
plastic- and rubber-based materials are attacked by hydrocarbon solvents, steam clean these parts to
remove contaminants.

WARNING
Degreasing solvents are flammable, and their vapors are
toxic. Keep all solvents away from open flames, and use
only in well-ventilated areas. Avoid solvent contact with
skin, eyes, and clothing by wearing rubber gloves, a face
shield or goggles, and an apron or coveralls.

Steam Cleaning
Steam cleaning is a cleaning process used when you do not want to remove paint and surface
coatings. To properly clean with steam, it is necessary to add cleaning compounds. Do not steam
clean oil-impregnated parts.
Set steam valve to the proper strength and force required for the job. Hold the steam gun about 12
inches from the part at a 45-degree angle. When cleaning plastic parts, you should be careful to avoid
heat buildup. After cleaning thoroughly, dry the part and apply corrosion prevention compounds.

Vapor Degreasing
Vapor degreasing removes oil, grease, and preservative compound by solvent vapor. A flat bottom
tank with heating coils on the bottom and cooling coils midway around the tank is required. The part is
suspended in the vapor area below the cooling coils. Heated cleaning solvent vapor condenses on
the cool part. It dissolves oils, grease, and preservatives. Cleaning action stops when the part
reaches the vapor temperature. If further degreasing is necessary, the part must be cooled before
using vapor degreaser again. Vapor degreasing cannot be used on titanium parts because
recommended solvents cause stress corrosion at high temperatures.

Decarbonizing
Decarbonizing is the chemical removal of carbon deposits. Decarbonizing agents are detergents,
sodium silicates, chlorinated hydrocarbons, and various acid solutions. This cleaning method is
effective for paint stripping, rust removal, and general cleaning of ferrous and high temperature parts.
Parts are soaked in hot or cold tanks and rinsed with high-pressure water.

WARNING
Carbon removers require careful handling. Wear goggles,
rubber gloves, and aprons when using these solutions.

Some carbon removers attack aluminum and magnesium parts if they are left in the solution too long.
There is also the possibility of a chemical reaction when aluminum, magnesium, and steel parts are
immersed in the same tank. This practice often results in damage to magnesium parts, such as
dissimilar metal corrosion.
Upon removal from cleaning solutions, rinse the parts in a soap-and-water solution or with a
petroleum solvent. Change the rinse water frequently to prevent a buildup of acid or alkaline in the
10-4
water. Air-dry the engine parts, and then coat them with a corrosion preventive if they are not to be
processed further.
Decarbonizing loosens most hard carbon deposits remaining after degreasing. The complete removal
of all hard carbon deposits generally requires brushing, scraping, or grit-blasting. Use caution during
these procedures to avoid damaging parts. In particular, do not use wire brushes or metal scrapers
on machine surfaces or bearings.

Abrasive Blasting
Use abrasive blasting to remove hard carbon or lead deposits, rust, and heat scale. The type (wet or
dry) and size of abrasives vary for different engine parts. Mask all openings, identification markings,
and other areas as required before blasting. Grit materials such as ground corn, apricot or peach pits,
walnut shells, clover seed, and cracked wheat or rice are in general use.
Dry grit blasting is sometimes done in a sandblast cabinet. The part must first be degreased or put
through a decarbonizing solution, and then rinsed and dried thoroughly. After grit blasting, remove the
dust by air blasting, and clean with petroleum solvent or hot water. Some types of soft grit leave a
light grease film on the part. Remove this film by degreasing if the part is to be subjected to
fluorescent penetrant inspection.
Wet abrasive blasting is an effective method to remove heat scale, carbon deposits, and temporary
markings, and to produce a uniform satin finish on metals. This type of blasting removes metal, but so
slowly that dimensions change very little.

MARKINGS
Marking engine parts and assemblies aids in identification, reassembly, and tracking the service life
of parts. All marks are applied to produce maximum legibility and durability without affecting the
function or serviceability of the part. Markings are either permanent or temporary. Permanent
markings are those markings that remain during the entire service life of the part. They are applied
during manufacturing or after modification of parts. Temporary markings maintain identification of
parts or reference positions during ordinary handling, storage, and final assembly. Temporary
markings ensure parts may be returned to original assembly position. If a part is going to be cleaned,
inspected, and repaired, temporary markings will probably be removed by solvents during cleaning. If
part identification needs to be maintained, attach tags or place parts in separate containers.

Temporary Markings
Certain materials must be used for temporary marking during assembly and disassembly. Use only
approved pure dye markers to mark engine hardware. Using nonapproved markers can leave harmful
elements on engine parts. You may use layout dye (lightly applied) to mark parts that are directly
exposed to the engine gas path. Some exposed items are the turbine blades and disc, turbine vanes,
and combustion chamber liners.

CAUTION
Do not use any temporary marking method that leaves a
heavy carbon deposit. Do NOT use any marking that leaves
a deposit of copper, zinc, lead, or similar residue, such as
pencil or black grease pen. These deposits may cause
carbonization or intergranular attack when the part gets
very hot. Parts marked with unauthorized materials should
have all traces of markings removed before using them.

10-5
Permanent Markings
Permanent markings should be positioned in the area of lowest stress. Do not apply markings within
0.030 inch of corners, radii, fillet, or edges. Choose an area where markings will not be worn off or
obliterated by contact with another part. If possible, place new markings next to original markings.
Always refer to applicable engine manuals and power plant changes for recommended marking
methods and details. Some of the methods of permanent markings include using a metal stamp,
vibropeen, blasting, and acid-etching.

GENERAL ENGINE REPAIR AND INSPECTIONS

Before starting disassembly of an engine, check the applicable technical instructions to confirm the
scope of repair necessary. Use the step-by-step procedure and repair limits contained in the current
technical publications for the particular engine. In the process of engine disassembly, many
associated parts become accessible for inspection. Inspect these parts as closely as possible to
prevent later failure. During assembly and disassembly, make sure you use the proper equipment to
support the engine. This will prevent overstressing during maintenance. In addition to preventing
stress, it allows proper alignment of parts being removed or installed.
Immediately upon removing each subassembly or individual part from the engine, transfer it to a parts
rack. Arrange the part to protect it or the assembly from damage. Provide proper covering and
supports to protect shafts, gears, studs, or any projecting piece from being bent, scratched, or
otherwise damaged. Be careful to prevent the entrance of dirt and other foreign materials into the
engine. Whenever practicable, use temporary covers to seal all openings in dismantled engines.
Cover the ends of all removed tubing. Take extreme care not to lay carbon seals and plates on the
sealing surfaces. Provide appropriate containers to hold each part separately until the time for
reinstallation. During disassembly, examine all parts and assemblies for cracks, scoring, and burning.
Check the engine for indications of work incorrectly performed during any previous repair or overhaul.
You must pay particular attention to the material requirements for the nuts and bolts used in the
turbojet engine. Hot sections require common hardware (nuts, bolts, safety wire, and cotter pins) that
are resistant to high operating temperatures. Other engine parts may require special hardware, and it
is imperative that all properly coded parts (if serviceable) be placed in their original positions.
Welding is permissible on some parts of the turbojet engine. Refer to the applicable technical
instructions before attempting to repair an engine or component by welding.

Compressor Section Repairs

Most intermediate-level maintenance activities are responsible for the replacement of compressor
sections and the repair of those compressor blades in the later compressor stages that cannot be
serviced without the removal of the compressor halves. Compressor repair usually results from
foreign object damage (FOD), although other failures occur. A number of compressor failures may be
broadly classified under air leaks and compressor contamination. The AIMD or FRC may also be
required to modify the compressor rotor or stator blades as a result of a technical change or bulletin.
Modifications may include reworking the components, changing blades by stages, or replacing the
entire rotor assembly.

NOTE
Compressor cases are machined in matched sets. Damage
beyond repair to one case is cause for rejection of the
opposite case. A new compressor rotor is not required
when replacing the entire case assembly.

10-6
Compressor Contamination
Accumulation of dirt on the compressor blades reduces the aerodynamic efficiency of the blades. Dirt
hurts engine performance. The efficiency of the blades is impaired by dirt deposits similar to that of an
aircraft wing under icing conditions. High exhaust gas temperature (EGT) may result when foreign
deposits are on compressor components. On some turbojet engines, high EGT requires early engine
overhaul. Slow acceleration could also result from foreign material obstructing the compressor outlet
vanes. This obstruction could result in a needless engine overhaul.

Compressor Leaks
Air leaking from the compressor results in low engine performance. Air leakage may occur between
the high and low compressors, or at some intermediate stage. It may also occur because of bleed-air
valves stuck open or cracks in the compressor case itself. Air leaks in the compressor are found
through engine monitoring or low engine performance; for example, when the engine fails to meet
minimum power
requirements for takeoff.

Compressor Failures
Loose objects often enter
an engines compressor
either accidentally or
through carelessness.
Thousands of dollars
worth of damage to a
compressor rotor can
result from a tool left in the
air intake (Figure 10-2). A
nut and bolt holding pliers
together came loose and
went through the
compressor, causing the
Figure 10-2 Compressor damage.
damage shown in the
illustration. A simple solution to the problem is a tool checklist.
Internal mechanical failures, such as a compressor blade breaking off, result in compressor efficiency
loss. These failures are difficult to detect. Broken blades and vanes result in high exhaust gas
temperatures or an increase in compressor round per minute (rpm) due to loss of efficiency. Of
course, mechanical failures of compressor blades could result in severe damage to the compressor,
combustion chamber, and the turbine as FOD.

Compressor Blade Damage and Repair

Table 10-1 lists the blade damage inspection limits chart. Defining and showing examples of damage
may help you to recognize damage and make repair of damage easier. Figure 10-3 shows examples
of possible blade damage to an axial-flow engine. The damages are enlarged to show detail; if you
know by close examination what causes the damage, you may be able to reduce the cause.

10-7
Table 10-1 Blade damage inspection limits chart

10-8
 Figure 10-3 Blades showing various types of damage.
You may make minor repairs to compressor blades, provided the repairs are made without exceeding
allowable limits in the prescribed MIMs. Well-rounded damage to leading and trailing edges is
acceptable without rework. No rework is necessary provided the damage is in the outer half of the
blade. The indentation may not exceed values specified in the MIMs. A figure 10-4 frame 1, 2, and 3
illustrates representative repairable limits. Figure 10-5 shows examples of blade repairs.
When working on the inner half of the airfoil, you should treat damage with extreme caution. Make no
attempt to remove damage by straightening. Inspect repaired compressor blades by dye check,
magnetic particle inspection, or by fluorescent penetrant inspection methods. Remove all traces of
the damage. All surfaces must be smooth. All repairs must be well blended. No cracks of any extent
are tolerated in any area. Bowed or bent blades are not reused. If gauges are not available, the
repaired blades are aligned and compared with a new blade of the same stage.
Use a smooth file when removal of considerable amounts of material is necessary. File or blend at
right angles to the width of the blade. If you cannot reach the damaged area with a file, use coarse
emery cloth. A medium stone can be used on areas that have been reworked with a file or emery
cloth. Use a medium stone for areas containing small nicks and dents.
Use fine emery cloth and/or a fine abrasive stone to polish the reworked area. Polish until the finish
looks and feels like the original. If two blended areas overlap to form a sharp point or ridge, blend out
the point or ridge. Blend the contour surfaces with a medium stone and finish with emery cloth and/or
a fine abrasive stone. The finished repair should be as much like the original finish as possible.
Front compressor blades that require replacement are replaced by blades having the same moment
balance code. The moment balance codes are marked on the front face of the root of the blade. At
the original buildup of the compressor rotor discs and blades, a set of blades coded according to
individual moment were installed. The installation on the disc minimizes the static imbalance due to
variations in the blade moment. The blades are numbered in clockwise sequence, as viewed from the
front. Install blades in their correct numbered position. Make sure new blades are correctly numbered
for the blades they replace.
10-9
 NOTE
The blade part number follows a change designation
number. Never take this number as the moment weight
code of the blade. The code letter is stamped adjacent to,
but not following, the part number.

Interaction Available
Figure 10-4 Repairable limits and examples of maximum repair,
frames 1, 2, 3.

Figure 10-5 Compressor blade repair.

10-10
Compressor Stator Vanes
Pitting or corrosion, if within the allowed tolerance, is not serious on the compressor stator vanes of
axial-flow engines. Do not attempt to repair any vane by straightening, brazing, welding, or soldering.
Use crocus cloth, fine files, and stones to blend out damage. Remove a minimal amount of material,
and leave a surface finish comparable to that of a new part. The purpose of this blending is to
minimize stresses, which concentrate at dents, scratches, and cracks. Maximum blend out of limits
damage greater than 50 percent of the stator assembly vanes requires assembly replacement. When
vanes are damaged to the maximum blend out of limits in any 60-degree sector of one stage, replace
the assembly. Send parts damaged beyond maximum repair limits to overhaul for repair and
replacement of vanes. The use of pre-bored compressor vane and shroud assemblies permits the
replacement of one-half of any low compressor
stator. The inspection and repair of air inlet guide
vanes and swirl vanes on engines require the use of
a strong light. Attach this light to a rigid support to
enable positioning in hard-to-reach areas. Inspect
all sections of both screen assemblies for breaks,
rips, or holes. Screens may be tin-dipped to tighten
up the wire mesh, provided the wires are not worn
too thin. If the frame strip or lugs have separated
from the screen frames, rebrazing may be
necessary.
Inspect guide and swirl vanes for looseness.
Inspect the outer edges of the guide vanes. Pay
particular attention to the point of contact between
the guide and swirl vanes. Check for cracks and
dents due to the impingement striking of foreign
particles. Also, inspect the edges of the swirl vanes.
Inspect the downstream edge of the guide vanes
very closely, as cracks are more prevalent in this
area. All cracks which branch out in such a manner
that a piece of metal could fall into the compressor
is cause for rejection.
Blending of hollow vanes on the concave and
convex surfaces, including the leading edge, is
limited; some small, shallow dents are acceptable.
The damage may be rounded or gradual contour
type, but not a sharp or V-type. Do not allow any
cracked or torn vane material to exist in the
damaged area.
Blend the trailing edge if one-third of the weld seam
remains after repairs, as shown in Figure 10-6.
Concave surfaces of rubber-filled vanes may have
allowable cracks extending inward from the outer
airfoil. These cracks are allowable provided there is
no suggestion of pieces breaking away. Using a
light and mirror, inspect each guide vane trailing
edge and vane body for cracks and damage
caused by foreign objects. Cracks in the vane body
Figure 10-6 Guide vane trailing edge
are cause for rejecting the entire weld.
before/after blending.

10-11
Figure 10-7 Combustion chamber liner limits.
10-12
Combustion Section Repairs
The combustion section can be removed, repaired, or replaced in part or entirely depending on the
extent of damage encountered. The combustion section consists of liners, support duct, outer and
inner case, and the first stage turbine nozzle assembly. Most repairs to this section are accomplished
by welding or replacement of components.

Combustion Chamber Liners

Inspect combustion chamber liners for cracks by using dye penetrant or the fluorescent penetrant
method of inspection. Cracks converging so that metal could break loose or any loose, cracked, or
damaged swirl vanes are cause for rejecting a liner. Remove liners having buckled areas in a weld
seam. Areas that have more than a three-sixteenths-inch wave, which does not include the weld
seam, require removal from service (Figure 10-7).
Combustion chamber liners may be retained in service with some flaws. For example, liners with
cracks less than 0.125 inch long starting from combustion air holes (no more than three per section)
7may remain in service. Liners with radial or circumferential cracks less than 0.750 inch long
extending from or around the crossover tubes or igniter plug bosses may also remain in service. You
may reuse combustion liners that are burned. Rework cracked deflectors to remove the cracked area
by blending or cutting before reuse. Burning of the cooling louver must not exceed two tabs totally
burned or a total area of two tabs per liner.

Combustion Chamber Support

Cracks in the combustion chamber support can be repaired by inert-gas fusion welding. Repairs must
not result in distortion or misfit of parts at assembly. If a hole is distorted as a result of welding, use a
file to restore it to its original configuration. The weld bead must be blended by hand after the welding.
See Figure 10-8.

Combustion Chamber Inner and Outer Ducts

Operational cracks in the inner and outer outlet ducts are permissible. The cracks may not exceed 3
inches in length. Repair cracks more than 3 inches long and exceeding 75 percent of the entire
circumference of the duct by gas fusion welding. When repairing a duct, use a silicon carbide grinding
wheel. Grind a 90-degree V groove, 0.035-inch deep, for the entire length of the crack. It is
permissible to remove some of the parent material when grinding. Adequate depth is necessary to be
sure that the grinder removes all material from the crack. Repairs must not result in distortion or misfit
of the parts at assembly. File out any distorted hole, as a result of welding, to restore it to the original
configuration. Figure 10-9 gives an example of inner and outer ducts repair limits.

Turbine Section Repairs

Inspect turbine sections and components thoroughly because of the extreme heat encountered in this
section. Turbine sections can be replaced in whole or in part. The turbine rotor is usually repaired by
changing individual blades or an individual rotor. It is not feasible to describe all of the damage
conditions that may be found in the turbine. If the damage is within prescribed limits, but there is
doubt about the rework, you should replace the turbine rotor or part.
Some first-stage turbine blades are coated with a protective coating to prevent sulfidation. Alpak is
diffused coating of aluminum and chromium used for protection of the turbine blades. Without this
coating, these blades are very susceptible to sulfidation.

10-13
 Figure 10-8 Combustion chamber support limits.

Figure 10-9 Combustion chamber inner and outer duct.

10-14
Turbine Blade Sulfidation
Sulfidation is high-temperature
corrosion. Sulfidation starts with the
excessive levels of sodium and sulfur
in the air and fuel mixture entering the
engine. This type of environment

Interaction Available
attacks turbine blades and stator
vanes. Sulfidation first appears as a
rough or crusty surface on the leading
edge and concave surface of the
airfoil. It progresses to scaling, splitting
(delamination), and eventual metal
loss. The sulfidation process
accelerates with an increase in sulfur
intake and an increase in engine
operating temperature.
All blades should be inspected for
sulfidation. This form of corrosion is
permissible if evidenced only by a
rough or crusty appearance at the
leading edge, on the concave side of
the airfoil section, or on the platform at Figure 10-10 Examples of unacceptable sulfidation
the root of the airfoil. The rotor should of turbine blades and vanes, frames 1 and 2.
be replaced if there is evidence of
splitting, delamination, separating, flaking, or loss of
material in any area of the blade. Figure 10-10 frames 1
and 2 shows an example of unacceptable sulfidation of
turbine blades.

Turbine Blades
You may inspect turbine blades on axial-flow engines,
and clean them in the same manner as compressor
blades. However, because of the extreme heat under
which the turbine blades operate, they are more easily
damaged. Inspect the turbine blades for stress rupture
cracks and deformation of the leading edge (Figure 10-
11).
Stress rupture cracks usually appear as fine hairline
cracks. These cracks are found on or across the leading
or trailing edge at a right angle to the edge length. Visible
cracks may range in length from one-sixteenth inch
upward.
Deformation, due to over temperature, appears as
waviness along the leading edge. The leading edge must
be straight and of uniform thickness along its entire
length, except areas repaired by blending. Stress rupture
cracks or deformation of the leading edge are often
mistaken for foreign material impingement damage. When
any stress rupture cracks or deformation of the leading

10-15 Figure 10-11 Stress rupture cracks.

edge of the first-stage turbine blades is found,
suspect an over temperature condition. Check
the individual blades for stretch, and the turbine
disc for hardness and stretch.
Inspect the turbine blade outer shroud for air seal
wear. If you find evidence of shroud wear,
measure the thickness of the shroud at the worn
area. Use a micrometer (or another suitable
measuring device) to be sure of a good reading in
the bottom of the narrow wear groove.

Turbine Stator Vanes

The inspection of turbine vanes is accomplished
in the same manner as described in the previous
section for the compressor vanes. Damage may
be greater as turbine vanes experience extremely
high heat. Blend minor nicks and dents with fine
stones or emery cloth. Visually inspect the vanes
for signs of bowing. Replace bowed vanes that
are in excess of the allowable clearance with
vanes of the same classification. Use a
straightedge and feeler gauge stock to measure
bowing (Figure 10-12). Damage that does not
crack the metal or reduce the vane thickness by
more than allowed is acceptable without rework.
This is true if the damage is of a gradual contour
shape and not sharp or V-shaped. Round bottom
dents on the leading edge may be acceptable
Figure 10-12 Checking vane bowing.

without rework. Dents must not exceed allowable

limits in depth and must not crack or tear the vane.
Blend sharp indentations to remove stress
concentration.
Determine how many vanes you need to replace
on the particular engine before you measure the
nozzle guide vane area. If the replaced blades
exceed the allowed number and you must measure
the area, it is better to replace the assembly.
One of the final procedures in the maintenance of
the turbine section of a turbojet engine is to check
for clearances. The service instructions manual
gives the procedures and tolerances for checking
the turbine. Figures 10-13 and 10-14 show
clearances being measured at various locations.
Use special manufacturers tools to obtain accurate
readings. Also, use the tools described in the
Figure 10-13 Measuring the turbine blade
to shroud tip clearance. service instructions manual for specific engines.

10-16
Exhaust Section Inspection
The exhaust section of the turbojet engine is
very susceptible to heat cracking. Inspect this
section thoroughly, along with the combustion
section and turbine section of the engine. The
exhaust section of an afterburning engine is
subject to extreme heat and pressures. Inspect
the external area of the exhaust cone and tail
pipe for cracks, warping, buckling, and hot
spots. Hot spots on the tail cone are a good
indication that a fuel nozzle or combustion
chamber is not functioning properly. If there is
an afterburner, inspect the afterburner flap
segments for burning, warping, or
misalignment. Figure 10-15 shows an
afterburner duct and nozzle assembly with flap
segments closed. Inspect the afterburner
synchronizing gear segments for worn and
missing teeth and security of installation.
Inspect the nozzle actuation pistons for cracks
and/or bent, chafed, or scored piston rods. Figure 10-14 Measuring the turbine wheel to
Inspect the roller guides for warpage and the exhaust cone clearance.
turnbuckle for security of installation.
Inspect the internal area of the exhaust
pipe and afterburner for evidence of hot
streaks, buckling, and warping,
including the flame holder. Also, inspect
all external fuel and hydraulic lines for
evidence of distortion, buckling, or
leakage. Accomplish the repair and
replacement of parts of the exhaust
section using the latest technical
instructions for that particular engine.

Main Engine Bearings

Inspection
Because of the high rpm, main engine Figure 10-15 Afterburner duct and nozzle
bearings are critical sections of an assembly.
engine. The number of main engine
bearings may differ from one engine model to another. With the engine disassembled and in the
vertical position, all bearings and housings can be inspected and replaced as necessary.

Accessories Drive Section and Mating Gear Inspections

The accessories drive section contains the various gearboxes for driving the accessories. These
gearboxes should be inspected for cracks and worn areas, and the splines should be checked for
proper fit and clearances. When you remove or replace gearboxes, the splined drive shafts must be
carefully removed or installed to prevent spline damage.
Most mating gears require backlash as well as end clearance checks. You should carefully inspect
the gear and spline teeth for irregular or excessive wear, galling, and flaking. Usually, runout
10-17
measurements are not required if there is no evidence of gear teeth spalling. These checks may
require partial assembly of the parts, and will be accomplished during assembly of the components.

JET ENGINE TEST CELLS

For a jet aircraft engine to operate properly, it must be adjusted properly. The checks for proper
adjustment can best be made during controlled operation of the engine. The various types of test
facilities, or test cells, are designed for service testing of the jet engine according to procedures and
manuals published by the Naval Air Systems Command (NAVAIRSYSCOM). Most engine test cells
are used at the intermediate-or depot-level maintenance facilities.
Operators of these test facilities are required by COMNAVAIRFORINST 4790.2 (series) to be certified
by completion of the following basic methods of operator training:
1. Formal local (in-service) training and On the Job Training (OJT) can be provided under the
supervision of a Naval Air Technical Data and Engineering Service Command (NATEC) jet test
supervisor (JTS) representative or designated Gas Turbine Engine Test Systems (GTETS)
Qualifier for the test cell and type engine regardless of command assigned. Training shall be
obtained at the IMA/FRC or activities using the standardized training in conjunction with locally
prepared site-specific OJT. OJT syllabuses shall be developed and maintained by the program
manager/coordinator, GTETS Qualifiers, and Quality Assurance (QA) personnel and be
approved for use by the Maintenance Officer/Production Officer. Marine Corps personnel will
use the Maintenance Training Management and Evaluation Program (MATMEP) individual
qualification record for Aircraft Power Plant Test Cell Operator.
2. NATEC on-site training can be provided by a NATEC JTS representative and is normally
requested by the activity to be performed coincident with the initial installation and calibration
of the test facility. NATEC on-site training can also be requested to improve technical
knowledge and skill to improve operational readiness and allow for the maximum use of
propulsion testing facilities, equipment, and human resources across all IMA activities.
3. Upon completion of training, the nominee must satisfactorily complete a written exam
administered by the QA/Training Management Office and a practical exam (pass/fail)
administered by a GTETS Qualifier or NATEC JTS representative. Both written and practical
examinations shall be prepared by QA/Training Management Office, GTETS Qualifiers, or
NATEC JTS representatives and maintained by QA/Training Management Office. The
Maintenance Officer/Production Officer will issue a letter of certification indicating the engine
test system and type engine(s) and completion of OJT under the direct supervision of a senior
petty officer or civilian technician who is a certified test stand operator and who has been
designated by the activitys commanding officer to provide this training.
4. Navy and contracted GTETS Operators and Qualifiers are required to maintain proficiency for
each type engine for which they are certified. As a minimum, GTETS Operators and Qualifiers
will run any type/model aircraft engine each 90 days, and will run at least one engine for each
type certified every 12 months. Engine runs for proficiency may be run on any type test cell
with a certified operator for that test cell, and will be documented in the individuals
qualification/certification record. Every attempt should be made to maintain proficiency on all
type engines for safety and effectiveness. Failure to maintain proficiency on one type engine
within a one-year period will result in loss of certification for that specific type engine.
5. Navy and contracted GTETS Operators will be recertified every 24 months. Recertification will
consist of a written examination administered by QA/Training Management Office and a
practical exam (pass/fail) administered by a GTETS Qualifier or NATEC JTS representative on
any one type engine for which they are certified. Afloat activities that are unable to operate
their test cell for extended periods of time (greater than 3 months) may perform their

10-18
 recertification practical exams at another activity with a NATEC JTS representative or GTETS
Qualifier designated in writing for that type test cell. Additionally, for planning purposes and
operational commitments, recertification exams can be completed up to 3 months prior to the
GTETS Operators certification expiration date. Recertification exams should place emphasis
on safety and emergency procedures. GTETS Operators exceeding 24 months will not be
considered certified until they have completed refresher training by a GTETS Qualifier or
NATEC JTS representative and successfully completed a written and practical examination.
GTETS Operators failing either the written or practical examinations will be required to
complete refresher training or complete the entire OJT syllabus, as determined by the program
manager/coordinator.
All certified test cell operators must hold a valid support equipment (SE) license and ensure that each
particular engine and engine test system is indicated on the license. Refer to COMNAVAIRFORINST
4790.2 (series) for training and licensing procedures.
Engine testing is accomplished primarily in a test cell or test house that is fully equipped to measure
the entire desired engine operating parameters. The building is usually of concrete construction and
contains both the control and engine rooms, although in some installations only the control or the
instrumentation room is enclosed. Most of these cells have noise silencers installed in the inlet stack
for noise suppression and a water spray in the exhaust section for cooling. Many of the test cells use
computers to automatically record all instrument readings and correct them to standard day
conditions. A typical enclosed test facility is described in the following paragraphs. Portable universal
engine run-up test systems and the engine test log sheets are also described.

Jet Engine Test Instrumentation (JETI) System

The JETI provides full performance engine test capability at the AIMD/FRC, ashore and afloat, for
manual and automatic testing of gas turbine engines. The system capabilities include instrumentation,
data acquisition, engine and facility control, and status display. These enhanced capabilities allow
interface and control of Full Authority Digital Electronic Control (FADEC) aircraft engines and are
required to properly test and evaluate the performance of the F414-GE-400 engines. The JETI
system also enhances full performance testing capabilities for legacy engines such as the F404-GE-
400/402, and the GTC36-200/GTCP36-201 Auxiliary Power Units (APU). The JETI is a Commercial
Off-The-Shelf (COTS) Personal Computer (PC)-based test system that interconnects two major
functional elements, the Engine under Test (EUT) and the test facility. The JETI provides an
enhanced computer-based measurement and automated data control system for the purpose of
intermediate level testing of aircraft gas turbine engines in either an indoor or outdoor environment
both afloat and ashore. It is designed to monitor and display all parameters of an engine being tested,
and allows out-of-airframe testing and troubleshooting. The system integrates six different functions:
Instrumentation
Data Acquisition
System Processor-Controller
Programmable Throttle System
Distributed Electrical Power
Operator-Maintenance Control and Display
The system also provides a printout of the calculated engine performance data during normal testing.
The test equipment is capable of handling 30,000 pounds of jet thrust during performance tests. The
test facility building configuration has an engine mass airflow capacity of 180 pounds per second, or
approximately 17,000 pounds of thrust, including afterburner operation.

10-19
All three versions of the JETI (shipboard, land-based (fixed), and land-based (transportable) are
planned to have the same number of cabinets with identical instrumentation. The difference in facility
configuration is the control room floor plan. There are no restrictions anticipated for site activation of
land-based (T-10B/T-36A) installations. Shipboard configuration will differ based on the existing floor
plan. A Ship Alteration (SHIPALT) may be required to accommodate the difference in size of
instrumentation cabinets required to facilitate installation of the JETI system. Funding for necessary
SHIPALTs will be provided on an as required basis. The installed dimensions of the system are eight
feet high by eight feet wide by two feet deep, with an installed weight of 1,800 pounds.
In the original installations, the JETI interfaces with the existing test systems utilizing common
hardware items such as Electrical Junction Boxes (EJBs), Mechanical Junction Boxes (MJBs),
Programming Harness Boxes (PHBs), power supplies, ancillary equipment, power interface buses
etc., but will have separate cabling, software, and stand-alone computer control systems. The JETI
power distribution systems, electrical and electronic test instrumentation, system indicators, facility
and test system interface components, and controls are contained in specifically configured cabinet
assemblies and control console assemblies contained in the environmentally controlled test facility
control cab. Ninety-five percent of the test system components are contained within the test facility
control room area.
The following paragraphs provide a general description of the System Control Cabinet/Test Console
Assemblies and major system subassemblies of the JETI system.

Test Control Console Assembly I

Figure 10-16, frames 1 and 2, shows this
console, which permits monitoring and
control of the EUT. Major assemblies and
subassemblies contained in this console
include the following:
Two Rack-Mounted Control
Computers (TPS Computer and Data
Acquisition [DAQ] Computer)

Interaction Available
Computer Drawer Assembly 1
Flat Panel Touchscreen Display
Keyboard Panel Assembly
Emergency Panel Assembly
Emergency Cable Assembly
Keyboard-Video-Monitor (KVM) Cable
Assembly
Keyboard Cable Assembly

Throttle Control Console Assembly II

This console permits monitoring and control
of the EUT and houses the mount for the
engine control dual throttle lever assemblies.
Major assemblies and subassemblies
housed in this console include:
Flat Panel Touchscreen Display
Figure 10-16 JETI work stations, frames 1 and 2.
Assembly
10-20
 Throttle Computer
Intercom Panel Assembly

Terminal Strip Cabinet Assembly

This cabinet assembly provides the electrical interface buses consisting of terminal blocks and
interface wiring required for intersystem connections.

Data Acquisition Instrument Cabinet Assembly

The DAQ Cabinet Assembly houses two rack-mounted 1261B Versa Module Europa Extension for
Instrumentation (VXI) bus chassis (upper and lower) that contain the system data collection
electronics. The upper chassis contains the bulk of the acquisition instruments as well as the
Interface Test Adapter (ITA). The Lower Chassis (1261 VXI) (Figure 10-16, frames 1 and 2) contains
the following:
Vibration Analyzer
2-Channel 1553 Controller
Counter-Timer
Second Harmonic Signal Conditioner Instruments
Subassemblies contained in the Lower Chassis include the following:
Mainframe Extender Module
Vibration Monitor Module
1553 Bus Interface Module
Second Harmonic Signal Conditioner Module
Receiver Assembly
ITA

Control Cabinet Assembly

Figure 10-16, frames 1 and 2 shows the Control Cabinet Assembly which contains the system
instrumentation required to monitor engine parameters specified by the manufacturer as being critical
and necessary for final test. Sub-assemblies contained in this cabinet assembly include:
Power Distribution Module Assembly
Uninterruptible Power Supply (UPS)
400 hertz (Hz) Alternating Current (AC) Power Supply
Panel Assembly Power Strip
Facility Equipment Control Cabinet (T-10B [land-based] Test Facility)

Variable Height Stand Assembly

The variable height stand assembly, or thrust bed, is used to support, restrain, and position the
engine in the desired testing altitude. This assembly is also used to transfer the engine from the trailer
to the thrust bed. The thrust bed positioning system and the thrust measuring system are part of the
variable height stand.

10-21
Thrust Bed Positioning System
The thrust bed positioning system is essentially a pneumatic-powered, hydraulic oil-driven device
capable of raising and lowering the test engine to any altitude within operating range. Operating
controls are mounted on the left front A-frame of the thrust bed.
In addition to supplying lifting force for height positioning of the thrust bed, oil pressure is used to
drive the calibration cell cylinder whenever controlled thrust pressure is required.

Thrust Measuring System

The thrust measuring system becomes operative when the thrust button is acted against by the load
cell as a result of slight forward motion of the engine under power. If desired, the load cell may be
preloaded by the preload unit. As thrust is developed by the engine, and the pressure between the
button and the cell produces an electric potential within the cell. The electric current thus established
is connected to the thrust-measuring circuit box, where it is amplified sufficiently to power the thrust
indicator. The thrust indicator is calibrated to read directly in pounds of engine thrust.

Exhaust Augmenter Assembly and Exhaust Gas Cooling System Assembly

The exhaust augmenter assembly (augmenter) and the exhaust gas cooling system assembly
(exhaust cooling system) are provided to ensure proper disposition of engine exhaust by controlling
exhaust gas, flow characteristics, and temperature. These factors can be monitored, both manually
and automatically, with the controls and instrumentation installed. For example, if exhaust stack
temperatures in excess of a preset temperature are experienced during afterburner operation, the
afterburner is automatically cut off by a latching relay. When this occurs, the afterburner cannot be
relit until safe temperature conditions prevail and the relay is reset. Provisions have been made for
manually overriding the exhaust stack temperature control system should it fail or otherwise prove
inadequate. Another helper of the exhaust augmenter is a noise attenuation device, comprising of a
carbon steel pipe which is aligned axially with direction of exhaust from the jet engine. The carbon
steel pipe is positioned within an augmenter within the test cell. Cold air enters the front end of the
carbon-steel pipe. Adding three times the mass of cold air to that of the hot jet exhaust allows the hot
jet exhaust to mix with the cold air forming an engine exhaust-cool air mixture. When the engine
exhaust-cool air mixture reaches the outlet end of the carbon steel pipe, its temperature is reduced
from 3800 degrees F. to less than 1200 degrees F., which substantially reduces noise generated by
the jet exhaust. Located in proximity to the rear end of the carbon steel pipe is an annular region
which is formed between perforated side plates within the carbon steel pipe and the inner wall of the
augmenter. The flow is diffused as the flow area expands in the annular region. The combination of
the carbon steel pipe and the annular region slow the velocity of the jet engine exhaust-cool air
mixture, further reducing noise production from the jet engine.

Fuel System Monitoring Assembly

The fuel system monitoring assembly (fuel system) consists of the devices required for fuel filtration,
flow and specific gravity measurement, and flow control.
The fuel system consists of two 10,000-gallon underground fuel tanks, two fuel pumps, two motor-
driven fuel line valves, the fuel system monitoring assembly, and various controls and pilot lights at
the control board. The fuel system is interlocked to the basic interlock system, to the CO2 fire-
extinguishing system, and to the exhaust gas cooling system.

Engine Oil Assembly

The engine oil reservoir and engine auxiliary lubricating oil-cooling system component assembly
(lubricating system) provide a 20-gallon engine oil reservoir and an auxiliary means of cooling engine
oil to a controlled temperature.
10-22
The engine oil reservoir system is made up of a 20-gallon tank equipped with suitable fittings, a sight
gauge, and breather vent. The engine lubricating oil is supplied from the storage tank, by way of the
oil outlet to the engine lubricating system and back to the tank, through the oil inlet. The amount of oil
in the tank can be readily determined by observing the oil level in the sight gauge. The storage tank is
located at an extension of the connector panel in the test cell.
The auxiliary lubricating oil-cooling system is provided for use as required by specific engines. Refer
to applicable engine test instructions. It consists of an oil temperature regulator valve, a heat
exchanger, and suitable plumbing. Water, by way of the oil temperature regulator valve, passes
through the cooling elements of the lubricating oil heat exchanger, which is used to cool the engine oil
circulating through the exchanger. The temperature of the oil returned to the engine is sensed by the
oil temperature regulator valve by a sensing bulb installed in the heat exchanger oil line. The oil
temperature regulator reacts to the bulb signal by positioning a poppet valve. This increases or
decreases water flow through the heat exchanger, thus maintaining the oil outlet temperature
between proper limits. The oil temperature regulator is provided with a hand wheel so that the
temperature range may be adjusted to maintain outlet oil temperature within the allowable range. The
water used for cooling the engine lubricating oil flows from the main water supply system to the load
bank water tank (containing heating elements), and then to the oil temperature regulator valve.

Compressed Air Component Assembly

The compressed air component assembly (compressed air system) provides pneumatic power, air
system hardware, and pneumatically operated controls and actuating cylinders necessary for remote
control of numerous devices throughout the test facility.
The air compressor (a two-stage, air-cooled, electric motor-driven system) is located in the pump
room, and is controlled by a switch located on the master control center in the control room. Two
plug-in outlets supply unregulated compressed air for test cell utility purposes as required. Air filtration
and partial dehydration are accomplished by two float-type air filters for two main branch supply lines.
The pressure to each branch line is controlled by two manually set air pressure regulators. Beyond
the pressure regulators, the air system branches off to the various control components for other major
systems, such as the fuel system and the exhaust gas cooling system.

Intercommunication System
The intercommunication system consists of an eight-station intercom master in the control room, a
suitable amplifying system, and two remote stations equipped with trumpets and microphones. The
six spare station switches at the master control are not used as installed. The master unit is equipped
with a volume control, a push-to-talk button, and push-to-talk lock button. Remote stations are
equipped with push-to-talk buttons only. Station No. 1 is located in the test cell; station No. 2 is
located at the test cell observation port.

Engine Starting and Ignition System

The starting of a jet engine or any other type of gas turbine engine requires that the engine be rotated
at a speed that will provide sufficient air for the required fuel-air ratio. Provisions are made for
energizing the ignition system to fire the spark (igniter) plugs at the proper time, and for the engine to
be accelerated until the power developed by the turbine is adequate for self-sustained rotation. Initial
rotation of the engine during starting may be accomplished by use of either an electrically operated
starter motor or a compressed, air-operated, air turbine starter motor. The electric starter motor
requires a source of direct current (DC) voltage. The air turbine motor requires a source of
compressed air.

10-23
Fire-Scope 2000 Fire Suppression System
This system is water mist technology providing the advantage of rapid fire extinguishment. The
system uses minimal amounts of water, distributed evenly around the engine casing, avoiding any
damage to the turbine by cooling it too rapidly. Thirteen spray nozzles are placed around critical
areas of the engine and six spray nozzles for the fuel supply area. The water system is pressurized
by eight compressed air cylinders, and driven by an electronic control box.

Aircraft Test and Evaluation Facility (ATEF)

A Hush House is a facility primarily designed for military fighter aircraft use. The Hush House
provides an enclosed work area for preparing the aircraft or un-installed engine, also equipment
rooms and an environmentally controlled, acoustical control room for test operators to work in during
engine operation. The Acoustic treatment provided by the facility reduces the environmental impact
on the surrounding area by reducing the sound created by running aircraft engines.
Hush houses are also capable of testing un-installed jet engines mounted on a movable test stand
with support equipment to supply fuel and air for engine running. Engine operation and testing in line
with the engine requirements is controlled and monitored using a computerized system. The test bay
is sized to allow the users aircraft to be safely installed and restrained while running the engine(s)
through their full performance tests as determined by the aircraft/engine to enable performance
issues to be identified and corrected. Various aircraft systems can also be checked while the aircraft
engine(s) are running as per the Aircraft requirements (Figure 10-17).

Figure 10-17 Aircraft test and evaluation facility.

10-24
PORTABLE UNIVERSAL ENGINE RUN-UP TEST SYSTEMS
Figure 10-18, frames 1 and 2, shows some of the more commonly used portable engine run-up test
stands. These stands provide the aircraft maintenance activities with a portable and universal system
for the operational and functional testing of jet aircraft engines. Figure 10-19, frames 1 and 2, shows
a T-56 Turbo Prop Engine Test System in use today. The T-56 Turbo Prop Engine Test System
consists of an instrumentation and control cab, a fuel system installation, an engine test bed, four
flood lights, interconnecting cables and hoses with various adapters used with specific engine
models.

Interaction Available
Figure 10-18 Portable universal engine run-up test system, frames 1 and 2

These systems perform the basic functions of checking all the engine performance characteristics
against the engine manufacturers operational parameters, as approved by NAVAIRSYSCOM. The
test cells display engine temperatures, vibrations, fuel metering, fuel flow pressures, thrust, lube oil
temperatures and pressure, compressor pressure, hydraulic oil pressure, anti-ice pressure, turbine
rpm, and position indications such as nozzle and stator vane and throttle.
Some engines require special testing consoles. The console provides the electrical circuits to
satisfactorily conduct functional and performance tests.
The console provides junction facilities to connect the cell power to the engine, a system for remote
control measurement of throttle position, a transmitter and receiver to indicate inlet guide vane
position, and a DC electronic indicating system for measuring nozzle position. A thermocouple type of

10-25
anti-icing temperature indicator, a starter circuit, and switches and cables necessary for operation of
the engine and console under test conditions are included in some consoles.
Just as starting procedures vary with the various types of engines, the controls and instrumentation
vary with different test cells. Checking the engine for proper operation consists primarily of reading
engine instruments and then comparing the deserved values with those given by the manufacturer for
specific engine conditions, atmospheric pressures, and temperatures.

NOTE
These test systems may be used at any site location that
has been provided with adequate tie-downs (either
concrete embedded or buried expansion anchors).

Interaction Available

Figure 10-19 Turboprop engine test system, frames 1 and 2.

10-26
ENGINE TEST LOG SHEETS
The engine test log records the data obtained during the engine test run. The log provides a record of
the engine tests for future reference and acts as documentary proof that the engine was subjected to
the prescribed test procedures. The data must be complete, accurate, neat, and legible. Upon receipt
of the engine for testing, the operator will enter the name of the testing activity, the engine model,
serial number of the engine, and the date of the engine test.
During the test, record all unusual occurrences in the remarks section of the test log, while recording
all starts, shutdowns, times for accelerations, times for adjustments and settings during all operational
cycles. During starts, record the time of day the engine was started, maximum turbine inlet
temperature encountered, and the duration of that temperature, as well as recording the time for
acceleration and stabilization.
At the end of the test, record the engine coast-down time. Coast-down time is defined as the time
elapsed from the moment fuel is cut off to the time the engine comes to a complete stop. Coast-down
time has no absolute value. A record maintained for engines will show what the expected average
coast-down time should be. Any engine with an abnormally short coast-down time should be viewed
with suspicion and investigated for compressor rub or other malfunctions. The operator is required to
sign all the test run logs, and is held responsible for the accuracy and completeness of all the test
data.
Test schedules will vary with each different model of engine and manufacturer. Always refer to the
appropriate engine manual when performing engine test runs.

10-27
 End of Chapter 10
Power Plant Inspection, Repair, and Testing
Review Questions
10-1. Who supports and supplements the work of organizational maintenance activities?

A. DCAA/FAA
B. DEA/UPS
C. FBI/CIA
D. IMA/FRC

10-2. How many degrees of maintenance are formed under the Gas Turbine Engine Maintenance
Program?

A. Two degrees
B. Three degrees
C. Four degrees
D. Five degrees

10-3. What action is required prior to inspecting engine parts/components?

A. Analyze
B. Clean
C. Disregard
D. Turn in

10-4. What is the recommended solvent for vapor degreasing?

A. MIL-PRF-680B
B. MIL-PRF-23699
C. MIL-PRF-83282
D. MIL-PRF-87257

10-5. What is the primary cause of reduced aerodynamic efficiency in compressor blades?

A. Dirt
B. Design
C. Fuel
D. Heat

10-6. What type of coating is used on turbine blades to protect them from sulfidation?

A. Alcohol
B. Alpak
C. Epoxy
D. Polymer

10-28
10-7. How often do you need to be recertified to operate an engine test cell?

A. Every 12 months
B. Every 16 months
C. Every 24 months
D. Every 30 months

10-8. How many different functions does the JETI system integrate within the engine test cell?

A. 2
B. 4
C. 6
D. 8

10-9. What is the purpose of the variable height stand assembly?

A. Support, restrain, and position the JETI equipment

B. Support and position the fire suppression system
C. Support and position the fuel tank system
D. Support, restrain, and position the engine

10-10. What is the other name given to the Aircraft Test and Evaluation Facility?

A. Big House
B. Care House
C. Hush House
D. Quiet House

10-11. What requirement is needed for portable test cell use?

A. Adequate tie downs

B. Level ground
C. Noise safety area
D. Open field

10-12. What are engine test logs used for?

A. Record test cell operators on the job training

B. Record engine performance data during a test run
C. Record engine life cycles
D. Record the periodic maintenance equipment inspections

10-29
RATE TRAINING MANUAL USER UPDATE
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COMM: (850) 452-9700 Ext. 3102 for the N7 Director.
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10-30