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MODULE 13
ENGINE STARTING SYSTEM
TABLE OF CONTENTS
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CHAPTER 1
STARTING SYSTEM OF GAS TURBINE ENGINE
1. INTRODUCTION
Gas turbine engine operates with low volatility1 fuel and in extremely adverse
environmental conditions as the aircraft needs to operate over a wide range of speed
from take-off, climb, and cruise to high-speed flight. The aircraft also needs to fly in
large altitude ranges from take-off at sea level to cruising altitude of 36,000 ft.
Hence, the engine starting system is paramount to the satisfactory operation of the
gas turbine engine.
For normal engine starting, two separate systems are required to ensure that
a gas turbine engine will start successfully, they are;
1. Provision must be made for the compressor and turbine to be rotated
to a speed at which adequate air passes into the combustion system to mix with the
fuel sprayed into the combustion chamber.
2. Provision must be made for ignition of the air/fuel mixture in the
combustion chamber.
During engine starting, these two systems must operate simultaneously, and it
must also be possible for individual system to operate independently so as to be able
to;
1. Motor the engine over without ignition during maintenance checks.
2. Operate only the ignition system for engine ‘re-light’ during flight.
The operation of both systems is co-ordinated during a starting cycle and their
operation is automatically controlled after the initiation of the throttle via an electrical
circuit.
Figure 1-1, shows a typical sequence of events during the start of a turbojet
engine. In general, the engine start is initiated by setting the throttle to ‘Ground idle’
position and switching on the starter. The starting cycle, which consists of a number
of events, would then continue automatically. The events during an engine starts is
as follows;
IGNITON
OFF
a. Starter Selected – The starter system would start to rotate the engine.
c. High Pressure Fuel ‘ON’ – The engine fuel pump would also be rotated
as it is also mounted on the engine accessories gearbox (AGB). As the
rotational speed increases, the fuel pump would provide sufficient fuel pressure
to allow the fuel to be sprayed into the combustion chamber.
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g. Ignition Off – The ignition will be cut off just before engine reaches idle
speed.
h. Idle RPM – The engine will continue to rotate by itself and increase in
speed (RPM) until it reaches the specified idle speed (RPM).
Figure 1-1 depicts parameters such as percent RPM, percent turbine gas
temperature (TGT) and duration of start (timing). We could read from the graph that;
a. Upon initialisation of ‘start select’, engine speed will reach at least 10%
N2 (Compressor speed) before ignition will turn-on when throttle is push up to
Ground Idle at about 15%.
b. Fuel will then be injected into the combustor and engine ‘lights-off’
should occur below 20% N2 within 15 seconds. It is indicated with a sharp rise
in TGT from 40°C to 200°C
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c. After the engine ‘lights-off’ the increase in RPM and TGT should be
continuous and smooth without any momentary hang-up. The engine would
reach self-sustaining speed at about 45%-50% N2 and the starter are cancelled
around 53% N2.
d. Engine will continue with the increase in RPM and TGT must be closely
monitored to ensure that the maximum allowable limit during engine start is not
exceeded.
e. Engine will reach ground idle RPM and the timing of the start are
terminated. Duration of start in this case is 30 seconds. The duration should be
within the specified duration from the engine manufacturer. Changes in ambient
environment or different types of fuel used would affect the starting timing. i.e.
Duration for engine start in cold ambient temperature will be longer.
It is also noted that upon reaching the ground idle RPM, the maximum TGT
would decrease and stabilised at the ground idle TGT limit as the engine has
stabilise and is more efficient in its internal cooling.
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CHAPTER 2
TYPES OF STARTER
1. INTRODUCTION
Gas turbine engines are generally started by starter power input to the main
accessory gearbox, which in turn rotates the compressor and engine accessories.
The purpose of the starter system is to;
a. Rotate the compressor so as to provide the engine with sufficient air for
combustion.
b. Assists in the acceleration of the gas turbine engine to the point where the
turbine is producing enough power to continue the engine’s acceleration. This point
is known as the self-accelerating or self-sustaining speed.
The type and power source for the starter varies in accordance with engine
and aircraft requirements. Some starters use electrical power, while others may use
gas, air or hydraulic pressure and each has its own merits. The choice of a starting
system depends on several factors, namely;
1. Length of starting cycle
2. Availability of starting power
3. Design features
2. LENGTH OF STARTING CYCLE
1 hot start as the name implies is a start where the turbine or exhaust gas temperature limits are
exceeded.
2 hung start is a situation where the engine accelerate to some intermediate RPM below the ground
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4. DESIGN FEATURES
5. TYPES OF STARTERS
idle and stays there. A hung start if not handled immediately could develop into a hot start.
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This electric starter has generally given way to the starter-generator in order
to save weight and simplify accessory gear arrangements. The starter-generator has
a dual function of providing the rotating torque for engine start and after the engine is
started, it also functions as an electrical generator to provide electrical power for the
aircraft system. Figure 2-1(a) and 2-1(b), show a typical electric starter and the
starter clutch assembly.
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An air starter motor transmits power through a reduction gears and clutch to
the starter output shaft that is connected to the engine. The air turbine starter
converts energy from the compressed air to shaft power. This is accomplish by the
reduction gears contained within the starter, which convert the high speed and low
torque of the turbine wheel into a relatively low speed and high torque at the output
shaft to rotate the engine. Engagement of the starter is usually accomplished
through a jaw or pawl-and-ratchet clutch. When a predetermined engine speed is
reached, the clutch will automatically disengage from the engine. Figure 2-2(b),
shows a diagram of an air turbine starter and the clutch assembly.
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The starter consists of a small compact gas turbine engine, usually featuring a
turbine-driven centrifugal compressor, a reverse flow combustion system and a
mechanically independent free-power turbine. The free-power turbine is connected
to the main engine via a two-stage epicyclic reduction gear, automatic clutch and
output shaft.
On initiation of the starting cycle, the gas turbine starter is rotated by its own
starter motor usually powered by electric or hydraulic, until it reaches self-sustaining
speed, after which, the starting and ignition systems are automatically switched off.
Acceleration then continues up to a controlled speed of approximately 60,000-RPM.
While the gas turbine starter engine is accelerating, exhaust gas is being directed,
via nozzle guide vanes, into the free-power turbine to provide the torque to rotate the
main engine. Once the main engine reaches self-sustaining speed, a cut-off switch
will operate and shuts-down the gas turbine starter. As the starter runs down, the
clutch automatically disengages from the output shaft and the main engine
accelerates up to idling RPM under its own power.
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Engine that utilised this starting system is the Fairchild J44, in which the air is
fed to the compressor, and some models of the General Electric J85 and J79
engines. In the latter two engines, air is directed into the rear of middle turbine
wheel stages. Obviously, the advantage of this system is manifested in its extreme
simplicity and lightweight but it is only best suited for smaller engines, as larger
engines would require very high volume of air supply. Figure 2-5, shows an air
impingement starting.
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d. Engaging mechanism
necessary.
2. Air Turbine a. High torque to weight ratio. a. High volume air supplies
Starter (5-10 times higher than required.
electrical motor)
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d. Relatively simple.
c. Extremely light.
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CHAPTER 3
IGNITION SYSTEM
1. INTRODUCTION
The function of the main ignition system in a gas turbine engine is primarily to ignite
the air/fuel mixture in the combustion chamber during an engine starting cycle. As
the aircraft is constantly operating in a wide spectrum of altitude and airspeed, hence
the secondary function of the ignition system is to be able to provide engine in-flight
‘re-light’ in the event of a flameout, which might occur during take-off, landing or bad
weather operation. Due to this requirement, the Federal Aviation Airworthiness
(FAA) requires that a single engine aircraft must be installed with two-ignition system
having its own electrical power supply source.
Gas turbine engine ignition system falls into two general classifications, the
induction type and the capacitor type. The induction type uses the basic principle of
high-voltage induction by a transformer to reach the necessary voltage capable of
causing an arc across the wide-gap igniter plug. This induction type ignition system
is now obsolete, as it is not efficient with modern engines, which operate at higher
altitude and greater loading.
The capacitor type produces not only high-voltage spark but also high heat
intensity (hot spark) sparks by condenser discharge covering a larger area. This
provides excellent chance of igniting the air/fuel mixture at reasonably high altitudes.
Hence, this capacitor type ignition system has been universally accepted for gas
turbine engines. The capacitor type ignition system can be divided into two basic
categories;
Both low-voltage and high-voltage ignition systems are in general use, and
they are designed to use either direct (DC) or alternating current (AC) as the input
power. Direct current (DC) operated systems receive their power from the battery
while alternating current (AC) system usually receive their power from a engine
mounted alternator.
3. JOULE RATINGS
Gas turbine engine ignition system is rated in joules. A joule (J) is also an
expression of electric energy, being equal to the amount of energy expended in one
second by an electric current of one ampere through a resistance of one ohm.
Mathematically, it can be expressed as,
J
W
T
Where,
W = Watts expended
J = Joule rating
T = Time for spark to jump gap
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The relationship between power (W) and time (T) is shown below for a 4-joule
(J) ignition unit.
W W
I E
E I
Where,
I = current in ampere
E = voltage in volts
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4. SPECIAL HANDLING
Because of this high voltage, extreme care must be taken when performing
maintenance work on the ignition system to prevent from receiving a lethal electrical
shock. At all times, reference must be made to the manufacturer’s manual. Typical
procedures are as follows:
a. Ensure that the ignition switch is turned off before performing any
maintenance on the system.
b. To remove the igniter plug, disconnect the transformer input lead, wait for
the time prescribe by the manufacturer (usually 1 to 5 minutes), then
disconnect the igniter lead and ground the centre electrode to the engine
to discharge the capacitor. The igniter is now safe to remove.
f. Do not energise the system for trouble-shooting if the igniter plugs are
removed as it may cause serious overheating of the transformer.
h. Always use a new gasket where the plug is re-installed. The gasket is
essential in providing a good conductive current path to ground.
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Power source for the ignition could come from a battery or engine driven
alternator. The battery will deliver direct current (DC) usually 28 volts while the
engine alternator delivers alternating current (AC) 115 volts, 400 Hz. The alternator
supply is usually for the main ignition system while the battery supply is for the back-
up ignition system.
The high-tension lead is the connecting harness from the transformer exciter
to the igniter plug. It is an electrical path for the high voltage direct current to the
igniter plug.
The function of the igniter plug is to provide a source for the high-energy
electrical pulses to be discharged and result in an arc across the electrode. The gap
at the igniter plug tip is wide and the electrode is designed to withstand a much
higher intensity spark.
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Igniter plug with annular-gap projects slightly into the combustion chamber
liner so as to provide an effective spark. Igniter plug with constrained-gap need not
project into the combustion chamber liner, as the spark produced tends to jump in an
arc that carries it beyond the face of the chamber liner. Hence, the constrained-gap
type will operate at a cooler temperature as compared to the annular-gap type.
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Activation of the ignition system is usually linked directly to the throttle system
and is automatic through the use of micro-switches and relays. In general, there are
four ways of wiring the circuit to fire the ignition system. They are:
a. Normal starting
b. In-flight auto re-light
c. Manual activation
d. Throttle activated ignition
This method of activation is used for normal engine starting. The activation of
the ignition system is linked directly through the throttle or known as Pilot Lever
Angle (PLA) linkage. When the throttle is set in the pre-designed position for
starting, usually at the ‘Ground idle’ position, the Main Fuel Control (MFC) micro-
switch is activated. This will remove the ignition circuit earth and the power supply
from the alternator would supply into the exciter and to the main igniter. Hence the
igniter would fire. Figure 3-3(a), shows a typical electrical circuitry for the ignition
during normal engine starting.
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This method of activating the ignition system is designed for use when the
engine flameout in flight. It is automatic and does not require the pilot’s intervention
to activate the ignition system. The engine electronic control system, which is an
engine onboard computer, is constantly receiving engine performance indications i.e.
Compressor speed (N2) and exhaust gas temperature (T5). Some engine may
sense the combustion chamber discharge pressure for the engine to identify a
possible engine flameout condition.
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This method of activating the ignition is the simplest method of firing the
igniter. This design is usually incorporated in the secondary or backup ignition
system. As the name implies, its operation is as simple as switching a toggle switch
to the ‘ON’ position just like switching on the light. This method of ignition is usually
a last resort for the pilot to achieve engine re-light in-flight as it is a direct circuit, the
ignition will be firing continuously throughout until the switch is positioned to the
‘OFF’ position.
When the toggle switch is selected to ‘ON’ position, the power will be supplied
to the secondary exciter by the battery bus and the igniter will continuously fire.
Hence, it is important that the switch is re-selected to the ‘OFF’ position when the
engine is started. Prolong firing of the igniter would cause localised over-heating of
the combustion liners as the igniter generates high heat intensity sparks. Figure 3-
3(d), shows the secondary ignition circuit path.
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This is another method of ignition designed to assist the pilot during an in-
flight engine flameout emergency. The continuous operation of the gas turbine
engine relies on the continuous burning of air/fuel mixture in the combustion
chamber. When a flameout occurs, the fuel is still spraying out continuously from the
fuel nozzle as the engine is coasting down, unless the throttle is shutoff immediately.
This fuel would wet the electrode of the igniter plug, which causes it to fail to fire
during the subsequent attempt to re-lighting the engine.
Hence, the pilot’s emergency action will require him to cut-off the throttle to
stop the fuel spraying into the combustion chamber. At the same time, he will
manoeuvre the aircraft into a slight nose-dive position for the incoming air to blow-
dry the combustion chamber and the igniter plug before another attempt to re-light
the engine is carry out. The nose-diving of the aircraft also assists in rotating the
compressor for subsequent start. (This is also the reason why starter need not be in
operation during flight).
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As the pilot position the throttle to the ‘OFF’ position to stop the fuel from
spraying into the combustion chamber, the throttle linkage would close micro-switch
A and allow the electrical power to flow through to energise relay A. When relay A is
energised, it will close the switch A1 and allow the circuit to be completed till micro-
switch B and B1. Figure 3-4(b), shows the circuitry of the event.
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When the pilot decides to commence the engine re-light, he only needs to
advance the throttle from ‘OFF’ position to any position above the ‘Ground Idle (GI)
position. This action would cause the throttle linkage to close the micro-switch B and
allows the relay B to be energised to close switch B1. The electrical power will flow
through the circuit and continue to energise relay C and closes switch C1.
With all the switches closed, the 28 volts DC battery bus will be directed to the
igniter through the static inverter and fired the ignition system. Figure 3-4(c), shows
the complete circuitry of the throttle-activated method of ignition.
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