C-17FlowDivider_TestInstruction.pdf.pdf

T.O. 2G-GTCP331-3-3

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FUEL FLOW DIVIDER

P/N 3883156-2

(TRIUMPH AIR REPAIR, INC.)

1 GENERAL INFORMATION

The fuel flow divider is used in conjunction with the fuel control unit to regulate fuel flow to the GTCP331-250G auxiliary power unit. During start the fuel flow divider directs high pressure fuel from the fuel control unit to the primary fuel manifold for optimal light-off conditions. After light-off and during on-speed operation, the flow divider directs fuel to both the primary and secondary manifolds. After shut-down, the flow divider drains the fuel manifolds. A functional schematic is provided in Figure 1-1. See Table 1-1 for a list of flow divider specifications. See Figure 1-2 for a physical layout.

Table 1-1. Fuel Flow Divider Specifications

Parameter Specification

Operating Temperature Range -65 to 250F

Check Valve Crack Point 100 to 105 psig

Drain Valve Closing Pressure 7 to 8 psig

Figure 1-1. Functional Schematic

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Figure 1-2. Fuel Flow Divider Layout

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3 TESTING AND FAULT ISOLATION

3.1. Test steps shall be performed in the sequence provided. If adjustments are necessary, all previous test steps shall be repeated.

3.2. Refer to Table 3-1 for a list of test equipment and materials:

3.3. Refer to Table 3-2 for a troubleshooting guide.

Table 3-1. Test Equipment and Materials

Material/Equipment Manufacturer Information

NOTE: Equivalent substitution may be made.

281600-7 Fuel Accessories Test Stand Honeywell

Engine, Systems, and Services

Aerospace Support Equipment

717 North Bendix Drive

South Bend, IN 46628

TE0000242-1 Restrictor Triumph Air Repair

TE0000242-2 Restrictor 4010 S. 43 rd

Place

TE3310523-1 Hook-up Kit Phoenix, AZ 85040

TE3310525-1 Holder Phone: (602) 437-1144

URL: www.triumphairrepair.com

MIL-C-7024 Type II Calibration Fluid – Reference Number: 1

3.4. Prepare for test as follows:

3.4.1. Mount fuel flow divider on TE3310525-1 Holder.

3.4.2. Remove all caps and plugs.

3.4.3. Maintain a fuel inlet temperature of 80 + 20°F throughout the test procedure.

3.5. Test fuel flow divider as follows:

3.5.1. Perform primary leakage test as follows:

3.5.1.1. Construct test hook-up as shown in Figure 3-1.

WARNING

Calibration fluid may flow from open primary port, causing a hazardous condition.

Direct open primary port towards test stand sink.

3.5.1.2. Increase FUEL SUPPLY to obtain 2 to 4 psig.

3.5.1.3. Observe leakage from primary port. Leakage shall not exceed 2.0 cc/min.

3.5.1.4. If leakage is excessive, adjust thickness of shims (IPB Figure 11-2, item 70) as necessary.

3.5.1.5. Record results on test data sheet (Figure 3-8).

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3.5.2. Perform primary drain valve crack pressure test as follows:

3.5.2.1. Slowly increase FUEL SUPPLY until primary drain valve opens as indicated by flow from primary port.

3.5.2.2. When drain valve opens, FUEL SUPPLY shall be 4.0 to 9.5 psig.

3.5.2.3. If FUEL SUPPLY is not as specified, adjust thickness of shims (IPB Figure 11-2, item 70) as necessary.

3.5.2.3.1. Increasing the thickness of shims by 0.010 inch increases crack pressure by approximately 1 psig.

3.5.2.4. Record results on test data sheet (Figure 3-8).

3.5.3. Perform primary internal leakage test as follows:

3.5.3.1. Construct test hook-up as shown in Figure 3-2.

3.5.3.2. Increase FUEL SUPPLY until fuel flow is within 50 to 70 lb/hr.

3.5.3.3. Adjust backpressure to 3 to 4 psig on PRIMARY RETURN while maintaining flow as previously specified.

3.5.3.4. Observe leakage from drain port. Leakage shall not exceed 50 cc/min.

3.5.3.5. Record results on test data sheet (Figure 3-8).

3.5.3.6. Increase back pressure to 19 to 21 psig on PRIMARY RETURN while maintaining flow as previously specified.

3.5.3.7. Observe leakage from drain port. Leakage shall not exceed 1 drop/min.

3.5.3.8. Record results on test data sheet (Figure 3-8).

3.5.4. Perform primary drain mode test as follows:

3.5.4.1. Slowly decrease FUEL SUPPLY until drain valve opens as indicated by discharge (at least 5 cc/min) from the drain port.

3.5.4.2. Drain valve shall open at a FUEL SUPPLY pressure greater than 1.5 psig.

3.5.4.3. If FUEL SUPPLY is not as specified, adjust thickness of shims (IPB Figure 11-2, item 70) as necessary.

3.5.4.4. Record results on test data sheet (Figure 3-8).

3.5.5. Perform secondary start flow test as follows:

3.5.5.1. Construct test hook-up as shown in Figure 3-3. Note the following:

WARNING

Calibration fluid may flow from open secondary port, causing a hazardous condition.

Direct open secondary port towards test stand sink.

3.5.5.2. Slowly increase FUEL SUPPLY pressure until flow divider opens as indicated by a sudden increase in flow from the secondary port.

3.5.5.3. When the flow divider opens, the flow rate shall be 78 to 84 lb/hr.

3.5.5.4. If flow rate is out of range, adjust check valve (IPB Figure 11-3, item 80) as follows:

3.5.5.4.1. Loosen locknut (IPBFigure 11-4, item 60).

3.5.5.4.2. Adjust gland (IPB Figure 11-4, item 50) as necessary to achieve flow rate within range.

3.5.5.4.2.1. Clockwise rotation or the gland increases flow rate. Counter-clockwise rotation decreases flow rate.

3.5.5.4.3. Tighten locknut (IPB Figure 11-4, item 60) in accordance with Table 9-2, Ref. No. 4.

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3.5.5.4.4. If unable to achieve required flow rate by adjusting gland, shims (IPB Figure 11-4, item 70) may be added or removed to adjust flow rate.

3.5.5.5. Record results on test data sheet (Figure 3-8).

3.5.6. Perform secondary leakage test as follows:

3.5.6.1. Decrease FUEL SUPPLY pressure as necessary to obtain a flow rate of 72 to 74 lb/hr flow.

3.5.6.2. Observe leakage from secondary port. Leakage shall not exceed 2.0 cc/min.

3.5.6.3. Record results on test data sheet (Figure 3-8).

3.5.7. Perform secondary pressure drop test as follows:

3.5.7.1. Construct test hook-up as shown in Figure 3-4.

3.5.7.2. Adjust FUEL SUPPLY as necessary to obtain 295 to 305 lb/hr flow.

3.5.7.3. DIFFERENTIAL PRESSURE shall not exceed 140 psid.

3.5.7.4. Record results on test data sheet (Figure 3-8).

3.5.8. Perform total drain port leakage test as follows:

3.5.8.1. Adjust FUEL SUPPLY to obtain 130 + 5 psig.

3.5.8.2. Observe drain port for leakage. Leakage shall not exceed 1 drop/min.

3.5.8.3. Record leakage in the automated test software.

3.5.8.4. Adjust FUEL SUPPLY to obtain 550 + 5 psig.

3.5.8.5. Observe drain port for leakage. Leakage shall not exceed 1drop/min.

3.5.8.6. Record results on test data sheet (Figure 3-8).

3.5.9. Perform primary pressure drop test as follows:

3.5.9.1. Construct test hook-up as shown in Figure 3-5.

3.5.9.2. Adjust FUEL SUPPLY as necessary to obtain 190 to 200 lb/hr flow.

3.5.9.3. DIFFERENTIAL PRESSURE shall be 7 psig maximum.

3.5.9.4. Record results on test data sheet (Figure 3-8).

3.5.10. Perform secondary internal leakage test as follows:

3.5.10.1. Construct test hook-up as shown in Figure 3-6. Note the following:

3.5.10.1.1. Remove TE0000242-X Restrictor, Typical.

3.5.10.2. Adjust FUEL SUPPLY as necessary to obtain a flow rate of 150 to 170 lb/hr. Maintain this flow rate throughout this test step.

3.5.10.3. Apply 3 to 4 psig back pressure on PRIMARY RETURN. Verify flow as previously established.

3.5.10.4. Observe leakage from drain port. Leakage shall not exceed 50 cc/min.

3.5.10.5. Record results on test data sheet (Figure 3-8).

3.5.10.6. Apply 9 to 11 psig back pressure on PRIMARY RETURN. Verify flow as previously established.

3.5.10.7. Observe leakage from drain port. Leakage shall not exceed 1 drop/min.

3.5.10.8. Record results on test data sheet (Figure 3-8).

3.5.11. Perform secondary drain mode test as follows:

3.5.11.1. Slowly decrease FUEL SUPPLY until secondary drain valve opens as indicated by discharge (at least 5 cc/min) from the drain port.

3.5.11.2. When the drain valve opens. Backpressure shall be at least 1.5 psig.

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3.5.11.3. If backpressure is not as specified, adjust thickness of shims (IPB Figure 11-2, item 70) as necessary.

3.5.11.3.1. Increasing the thickness of shims by 0.010 inch increases backpressure by approximately 1 psig.

3.5.11.4. Record results on test data sheet (Figure 3-8).

3.5.12. Perform external leakage test as follows:

3.5.12.1. Construct test hook-up as shown in Figure 3-7. Note the following:

3.5.12.1.1. Open valve 549A inside test stand.

3.5.12.2. Adjust inlet pressure to obtain 40 to 60 psig on GP1.

3.5.12.3. Maintain this test condition for 60 seconds minimum.

3.5.12.4. Observe external surfaces of flow divider for leakage. No leakage permitted.

3.5.12.5. Record results on test data sheet (Figure 3-8).

3.5.13. Adjust inlet pressure to zero.

3.6. Post Test Procedure:

3.6.1. Disconnect all hoses and fittings.

3.6.2. Replace missing lockwire in accordance with section 8.

3.6.3. Remove flow divider from TE3310525-1 Holder.

3.6.4. Complete test data sheet as shown in Figure 3-8.

Figure 3-1. Test Hook-up #1

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Figure 3-2. Test Hook-up #2

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Figure 3-3. Test Hook-up #3

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Figure 3-4. Test Hook-up #4

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Figure 3-5. Test Hook-up #5

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Figure 3-6. Test Hook-up #6

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Figure 3-7. Test Hook-up #7

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Figure 3-8. Test Data Sheet

2G-GTCP331-3-3_changes.pdf