1、 _ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising ther
2、efrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2017 SAE International All rights reserved. No part of this
3、publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-49
4、70 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/AIR6364 AEROSPACE INFORMATION REPORT AIR6364 Issued 2017-11 Test Facility Shakedown and Commis
5、sioning RATIONALE This SAE Aerospace Information Report (AIR) is intended to provide guidance and recommendations to future or existing users of turbofan, turbojet, and turboshaft/turboprop gas turbine engine test facilities regarding commissioning readiness of new, modified, or re-located facilitie
6、s. TABLE OF CONTENTS 1. SCOPE 3 2. REFERENCES 3 2.1 Applicable Documents 3 2.1.1 SAE Publications . 3 2.1.2 Other Publications . 4 2.2 Definitions/Acronyms 4 3. PHASE 1 OFF SITE (FACTORY) EQUIPMENT COMMISSIONING CHECKS 5 3.1 Introduction . 5 3.2 Mechanical 6 3.3 Electrical 6 3.4 Software 7 4. PHASE
7、2 ON SITE STATIC EQUIPMENT COMMISSIONING CHECKS (NO ENGINE RUNNING) . 8 4.1 Introduction . 8 4.2 Handling and Hoisting Systems 9 4.3 Thrust Stand 9 4.4 Engine Test Adapters 9 4.5 Fuel System, including the Inhibiting Oil System (if installed) 9 4.6 Hydraulic System (Loading System, Pressure Power Pa
8、ck ) . 9 4.7 Lubrication System (Engine and/or Drive Line Equipment) 10 4.8 Air Start System 10 4.9 Electrical Start System 10 4.10 Water System (TS/TP Applications) . 10 4.11 Drive Line (TS/TP Applications) 10 4.12 Instrumentation . 11 4.13 Control System 11 4.14 CCTV and Intercom 11 4.15 DAS . 11
9、SAE INTERNATIONAL AIR6364 Page 2 of 13 5. PHASE 3 ON SITE DYNAMIC EQUIPMENT CHECKS (INCLUDES ENGINE RUNNING) 11 5.1 General 11 5.2 Dynamic Commissioning. 12 5.3 Documentation and training 13 6. NOTES 13 6.1 Revision Indicator 13 SAE INTERNATIONAL AIR6364 Page 3 of 13 1. SCOPE The paper discusses in
10、general terms the activities required to be undertaken or demonstrated during the establishment of the facility such as: the assessment checks prior to forwarding to the end users site for embodiment into the facility system the establishment of the facility such as trial installations of hardware,
11、functionality checking of lifting transportation and access systems, centerline pull checks, pressure testing of fuel and air start systems, flushing of wet systems and electrical continuity checking. the commissioning of the facility such as instrumentation calibrations, engine starts, engine runni
12、ng, assessment of command and control system, assessment of DAS system, aerodynamic and acoustic surveys. The paper will concentrate on the main engineering engine related aspects of the facility and will not necessarily contain information on the construction validation activities such as HVAC, ele
13、ctrical, facility fire system, waste water etc. Risk analysis may be performed during the design phase whose results could lead to pay particular attention to some specific equipment / functionalities during the commissioning phase. If identified, these risks should be translated to specific tests a
14、nd integrated into the validation plan, either at the factory or on site or both. If the test cell is designed to test several engine types, the acceptance process should validate upon which engine the test cell will be commissioned these discussions should take place at the early stage of the desig
15、n process if not during the bidding phase. Moreover, an agreement between the Contractor and the Customer may have to be reached in order to clearly define how the scaling will be demonstrated in the case of the available engine types for commissioning are not representative of the full capacity upo
16、n which the facility is designed (e.g. the requirements are assessed based on future engine types). It is particularly relevant to air flow and acoustic levels and tones where effects arent only linear. Correlation activities are outside the scope of this document. Document is primary intended for t
17、ypical overhaul (MRO) test cells. Development/Production facilities may include additional and specific equipment that requires dedicated shakedown and commissioning processes and procedures issued directly from the OEMs. Outdoor test cell specifics are not covered by this document. 2. REFERENCES 2.
18、1 Applicable Documents The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between
19、 the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth D
20、rive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. AIR4827 Physical Modeling Techniques for Jet Engine Test Cell Aerodynamics AIR4869 Design Considerations for Enclosed Turbofan/Turbojet Engine Test Cells AIR4951 Test Cell Thrust
21、 Measurement AIR4989 Design Considerations for Enclosed Turboshaft Engine Test Cells AIR5026 Test Cell Instrumentation SAE INTERNATIONAL AIR6364 Page 4 of 13 AIR5295 Design Considerations for Enclosed Turboprop Engine Test Cells ARP741 Turbofan and Turbojet Gas Turbine Engine Test Cell Correlation A
22、RP4755 Turboshaft/Turboprop Gas Turbine Engine Test Cell Correlation ARP5435 APU Gas Turbine Engine Test Cell Correlation ARP5758 Trend Analysis for Maintaining Correlation of Gas Turbine Engine Test Cells ARP5759 Acoustical Considerations for Engine Test Cells ARP6028 Configuration Control for Main
23、taining Correlation of Gas Turbine Engine Test Cells ARP6068 Gas Turbine Engine Test Facility Vibration Measurement 2.1.2 Other Publications “Measurement Uncertainty: Methods and Applications“, 4th Edition, Dieck, Ronald H.; ISA The International Society of Automation, 2007, ISBN-13: 978-55617-915-0
24、. 2.2 Definitions/Acronyms The following list defines certain terms and phrases used in this document: ACOUSTIC TONE: Sound pressure at a constant frequency that can vary in amplitude. In the area of aero engine testing, the apparition of a tone in the exhaust section could be potentially problemati
25、c if it coincided with the natural frequency of any engine part and/or test cell equipment. AIR: Aerospace Information Report ARP: Aerospace Recommended Practice BY-PASS RATIO: Cell by-pass ratio, known as well as entrainment ratio ratio of the airflow that does not go through any part of the engine
26、 to the airflow that goes through the engine COC: Certificate of Conformity CORRELATION: The comparison of gas turbine engine performance parameters measured on a common engine tested in two test facilities, where one facility is the reference DAS: Data Acquisition System DYNAMIC TESTS: Tests perfor
27、med with an engine running, meaning it includes both steady and transient sequences and the collection and analysis of high speed test data FAT: Factory Acceptance Test FDR: Final Design Review, happens generally at the final stage of the design at approx. 90% of progress FOD: Foreign object damage
28、(to engine) GSE: Ground support equipment H and S: Health and Safety HVAC: Heating Ventilation and Air Conditioning SAE INTERNATIONAL AIR6364 Page 5 of 13 ISA: International Standard Atmospheres ISO: International Standards Organization IT: Information Technology MAX: Maximum MRO: Maintenance, Repai
29、r and Overhaul OEM: Original Equipment Manufacturer PDR: Preliminary Design Review, happens generally at the early stage of the design at approx. 10 to 20% of progress PLC: Programmable Logic Controller SAT: Site Acceptance Test SLS: Sea level static SME: Subject Matter Expert SQA: Software Quality
30、Assurance STATIC TESTS: Tests performed without an engine running TEST FACILITY: An area in which a gas turbine engine is operated TS: TurboShaft TP: TurboProp 3. PHASE 1 OFF SITE (FACTORY) EQUIPMENT COMMISSIONING CHECKS 3.1 Introduction During the establishment of a new or modified engine test faci
31、lity the Prime Contractor for the facility should interpret the specification from the End User and design the solution accordingly. The solution will generally be a mix of uniquely designed and off-the shelf components that are combined to provide the complete solution. It is general engineering be
32、st practice that all Prime Contractor supplied items (including items bought off the shelf) are subjected to checking prior to forwarding to the end users site for embodiment into the facility system. All of the bespoke designs and the off the shelf items need to be assessed for applicability at the
33、 design definition stage and quality at the receipt stage and upon delivery to the End Users site. The designs for the solutions generally fall into the categories of mechanical, electrical and software. For “complex” systems which involve multiple competences (e.g., skids), it is preferable to coor
34、dinate the different acceptance tests at the supplier site. For a specific project, it might be required to perform tests of the complete and integrated system (full or partially). These tests may be performed after each individual equipment test and will have the objective to represent as close as
35、possible the end-user environment and architecture. Main reasons to perform such “global” tests are to mitigate interface issues and where complex interactions are designed between the different sub-systems. Information may need to be retrieved in the Factory Acceptance Test (FAT) procedures and rep
36、orts to be collected during the off-site equipment commissioning checks as described here after per typology (mechanical, electrical and software). SAE INTERNATIONAL AIR6364 Page 6 of 13 3.2 Mechanical The engineering mechanical components of the new or modified engine test facility may include, (bu
37、t not be limited to) the facility main support frame, engine frames, engine rigging frames, engine access systems, engine transportation systems, engine lifting equipment, facility cranes, items of Ground Support Equipment (GSE), air, oil and fuel system components, drive line assembly for turboshaf
38、t/turboprop dyno type of test cell (including shafts, flywheel, dynamometer, gearbox, in-line torquemeter and all associated equipment such as lubrication systems) and thrust load cells. All of the main mechanical items should be subject to a formal design review process between the Prime Contractor
39、 and the customer to ensure that the equipment proposed meets the design intent of the specification. The design process commonly used is in the form of the PDR/FDR process. Where possible all of the engineering mechanical components should be subject to: Drawings control Welding inspections (includ
40、ing welders certificates) if required, the welding inspections could be witnessed which means that additional visit will be organized prior to the painting step Visual inspections (marking, edges, general aspect and dimensions, painting ) Non-conformances/deviations reports Interfaces control Torque
41、 control (screws, bolts ) Balancing control (for rotating parts) Dimensional inspection reports (including calibration certificates of the tools/devices) Functional checks (pumps, electrical motors, gearbox, rotating drivetrain ) Proof loading checks and reports by certified third party company ATEX
42、 (or equivalent) certificates if applicable Pressure and leak checks CoCs (Certificate of Conformity) Declaration of Conformity to legal requirements (e.g., CE marking). All of the above checks should be supported by documentation in the form of reports and certificates, Certificates of Conformity (
43、CoCs), dimensional inspection reports, stress reports, validation reports, Factory Acceptance Test (FAT) procedure reports and as agreed with the End User. All documentation for each of the mechanical components should be retained within the facility handover file that will be submitted to the end u
44、ser at facility handover. 3.3 Electrical The engineering electrical components of the new or modified engine test facility may include, (but not be limited to) the facility wiring looms, engine harnesses, facility throttle systems, control system equipment, vibration monitoring equipment, display sc
45、reens, IT equipment, Uninterruptible Power Supplies (UPS) equipment, electrical distribution equipment and engine instrumentation. SAE INTERNATIONAL AIR6364 Page 7 of 13 All of the main electrical items should be subject to a formal design review process between the Prime Contractor and the customer
46、 to ensure that the equipment proposed meets the design intent of the specification. The design process commonly used is in the form of the PDR/FDR process. Where possible all of the engineering electrical components should be subject to: Drawings control Visual inspections (general aspect, tagging,
47、 connectors integrity, harnesses protection ) Non-conformances/deviations reports Interfaces control Electrical continuity checks (usually performed by the electrical supplier) ATEX (or equivalent) certificates if applicable Functional checks: o Control System (I/O checks) o Instrumentation (Full or
48、 Pre-calibration in two points) o Power supplies System (UPS, protection devices) o Earthing connections CoCs (Certificate of Conformity) Declaration of Conformity to legal requirements (e.g., CE marking) All of the above checks should be supported by documentation in the form of reports and certifi
49、cates, Certificates of Conformity (CoCs), validation reports, Factory Acceptance Test (FAT) procedure reports as agreed with the End User. All documentation for each of the electrical components should be retained within the facility handover file that will be submitted to the end user at facility handover. 3.4 Software The engineering software components of the new
