404. FACILITY OPERATIONS MANUAL. An FAA-approved facility performing in-service engine acceptance testing should have in place a facility operations manual, or other document(s) acceptable to the FAA, that defines a specific set of requirements for maintaining and operating the test cell and for maintaining a satisfactory correlation status. These requirements should include, but are not limited to, the following:
a. Recordkeeping. As a minimum, facility records must conform to the requirements of part 145.
The current edition of FAA AC 145-3, Guide for Developing and Evaluating Repair Station Inspection Procedures Manuals, prescribes recommended practices for recordkeeping.
b. Test Cell Operations. The engine make, model, and configuration for each operation in the test cell should be documented. Provisions should be made for recording the dress kit hardware and serial numbers, as applicable. This dress kit should be the same configuration as the one used for correlation, unless the dress kit has otherwise been checked out as described in paragraph 305j. Facility operating procedures should be developed. The procedures should include operations under normal and emergency conditions (such as fire, engine failure, compressor stalls, etc). In addition, procedures should be developed in the event of engine operational warnings, as indicated on the test cell console, including the disposition of these warnings.
c. Facility Maintenance Procedures. A procedure must be established to record all repairs and modifications to the facility, especially those that may affect test cell operation and correlation status.
This procedure should specify that the respective FSDO be notified of any facility modifications that may affect the correlation status. Also, a procedure should be developed to ensure that facility maintenance and instrument calibration is regularly scheduled and performed and that pertinent information is recorded.
d. Quality Control Procedures. The facility must have provisions in place to maintain a satisfactory correlation status. Various options for correlation monitoring and maintenance are discussed in paragraph 403. In addition, the facility should have a system to maintain, in a current status, the following:
(1) OEM’s documents, such as a facility planning manual, if published;
(2) Service engine acceptance test procedures taken from the OEM’s Instructions for Continued Airworthiness, and pertinent specifications and Technical Orders for each model being tested;
(3) Correlation reports; and
(4) Other pertinent documents.
NOTE: The provisions and systems discussed above should be defined in a facility operations manual or other documents(s) acceptable to the FAA.
Par 404 Page 33
Appendix 1
APPENDIX 1. RELATED TEST CELL PUBLICATIONS AND MATERIALS
1-1. FAA Advisory Circulars (AC), current edition.
a. The following free ACs may be obtained from the U.S. Department of Transportation Subsequent Distribution Center, Ardmore East Business Center, 3341 Q 75th Avenue, Landover, MD 20785.
(1) AC 20-77, Use of Manufacturers’ Maintenance Manuals.
(2) AC 20-88, Guidelines on the Marking of Aircraft Powerplant Instruments (Displays).
(3) AC 20-124, Water Ingestion Testing for Turbine Powered Airplanes.
(4) AC 20-125, Water in Aviation Fuels.
(5) AC 25.939-1, Evaluating Turbine Engine Operating Characteristics.
(6) AC 33-2, Aircraft Engine Type Certification Handbook.
(7) AC 33-5, Turbine Engine Rotor Blade Containment/Durability.
(8) AC 33.65-1, Surge and Stall Characteristics of Aircraft Turbine Engines.
(9) AC 39-6, Summary of Airworthiness Directives, Announcement of Availability.
(10) AC 43-9, Maintenance Records.
(11) AC 45-3, Installation, Removal, or Change of Identification Data and Identification Plates on Aircraft Engines.
(12) AC 145-3, Guide For Developing and Evaluating Repair Station Inspection Procedures Manuals. (Note: AC 145-3 may be superceded in the near future. Use the most current edition).
b. AC 43-4, Corrosion Control for Aircraft, is for sale and is obtainable from the Superintendent of Documents, U.S. Government Printing Office, 710 North Capitol Street, NW., Washington, D.C. 20402.
1-2. Industry Documents.
a. Society of Automotive Engineers (SAE) publications may be obtained from SAE Aerospace International, 400 Commonwealth Drive, Warrendale, PA 15096.
(1) SAE Aerospace Recommended Practice (ARP) 741B, Turbofan and Turbojet Gas Turbine Engine Test Cell Correlation, Revision B. Revised 2000-12-07 (or latest revision).
(2) SAE Aerospace Information Report (AIR) No. 4869, Design Considerations for Enclosed Turbofan/Turbojet Engine Test Cells. Issued October, 1995.
(3) SAE AIR Report No. 5026, Test Cell Instrumentation. Issued November, 1996.
Appendix 1
(4) SAE ARP Report No. 4990, Turbine Flowmeter Fuel Flow Calculations. Issued September, 1997.
b. American Society for Testing and Materials (ASTM) publications may be obtained from ASTM, 100 Barr Harbour Road, Conshohocken, PA 19428.
(1) ASTM D341-89, Volume 5.01. 1990.
(2) ASTM D287, Fuel Specification, Gravity API. Latest revision.
c. DM-009, NCR No. 30165, A Derivation of Gross Thrust for a Sea Level Jet Engine Test Cell.
MacLeod, James; National Research Council of Canada. May be obtained from: National Research Council of Canada, Montreal Road, Ottawa, Ontario, Canada K1A OR6.
d. Advisory Group for Aerospace Research & Development (AGARD) publications may be obtained from 7 Rule Ancelle, 92200 Nevilly Sur Seine, France.
(1) AGARD Lecture Series No. 169, Comparative Engine Performance Measurements.
(2) AGARD Advisory Report No. 248, Propulsion and Energetics Panel Working Group 15 on the Uniform Test Programme.
Appendix 2 *FSDO or Representative of the FAA
APPENDIX 2. ENGINE TEST CELL APPROVAL SCHEDULE FLOW CHART
Perform Testing at Baseline/Reference Facility. If Witnessed by FSDO*, FSDO* Acquires Copy of Raw Data Before Leaving Applicant Notifies FSDO of Test Schedule FSDO Performs Initial Checks
- Gets Verification of Baseline/Reference Facility FAA-Approval and Traceability Data, as Applicable
- Requests and Reviews Applicant’s Instrumentation Calibration Data FSDO/ACO Provide Relevant Information to Applicant on Cell Correlation Approval Procedures FSDO Requests Aircraft Certification Office Review of Correlation Plan and Follow-On Support for Correlation Applicant Submits Correlation Plan to FSDO Applicant Submits Letter To Local Flight Standards District Office (FSDO) Requesting Test Cell Approval
Perform Testing at Applicant’s Facility. If Witnessed by FSDO*, FSDO* Acquires Copy of Raw Data Before Leaving FSDO Approves Facility and Specifies any ACO or FSDO Recommendations/Requirements FSDO Reviews Facility Operations Manual (or Other Document(s)) ACO Reviews Report and Provides Findings to FSDO FSDO Forwards Correlation Report to ACO for Review Applicant Provides Correlation Report and Facilities Operations Manual (or Other Document(s)) to FSDO for Acceptance Page 1 (and 2)
Appendix 3
APPENDIX 3. SAMPLE CORRELATION PLOTS
CORRELATION 550 600 650 700 750 800 850 900 950 4000 6000 8000 10000 12000 14000 16000 18000 20000 CORRECTED FN (Lbf)
CORRECTED EGT (DEGREES FAHRENHEIT)
APPLICANTS CALIBRATION BASELINE CALIBRATION
CORRELATION
1.6
1.8 2
2.2
2.4
2.6
2.8 3
3.2
3.4
3.6 4000 4500 5000 5500 6000 6500 7000 CORRECTED N1 (RPM) COMPRESSION RATIO, PS3/PT2
APPLICANTS CALIBRATION BASELINE CALIBRATION
Page 1 (and 2)
Appendix 4 APPENDIX 4. GLOSSARY OF ACRONYMS AND ABBREVIATIONS
AC adv isory circular
ACO Aircraft Certification Office
ARP Aerospace Recommended Practice
ASTM American Society for Testing and Materials
DER Designated Engineering Representative
EGT Exhaust Gas Temperature
EPR Engine Pressure Ratio
/g176F Temperature in degrees Fahrenheit
FAA F ederal Aviation Administration
fps feet per second
FSDO Flig ht Standards District Office
in-HgA Inches of Mercury Absolute
ISO International Standards Organization
/g176K Temperature in degrees Kelvin
kPa k ilopascal absolute
LHV Lower Heating Value
NIST National Institute of Standards and Technology
OEM Original Engine Manufacturer
Pcd Cell Depression
psi Pounds Per Square Inch
psia Pounds Per Square Inch Absolute
QEC Quick Engine Change
/g176R Temperature in degrees Rankine
SAE Society of Automotive Engineers
Page 1 (and 2)