PUR Eair Systems For Helicopter Engine Protection

PUREair Systems
for Helicopter Engine
Protection
ADF Symposium,
November 2015
Click to edit Master text styles
Disclaimer
This presentation is the Confidential work product of
Pall Corporation and no portion of this presentation
may be copied, published, performed, or
redistributed without the express written authority of
a Pall corporate officer.
© 2015 Pall Corporation
Presentation Content
 Theory
 Design
 Operation & Maintenance
 Case Studies
 Application
Theory What does an engine really want!
 No upstream restriction.
 Clean air.
Then we really mess things up by hanging an aircraft on it….
which….
 Generates Loss
 Creates Distortion
Credit AgustaWestland
Theory Helicopter Operating Environment
Threats to Helicopter Engines
Challenges
 Engine power loss (compressor
erosion or damage)
 Blade corrosion
 Turbine blade glazing
 FOD or bird strike damage
Solution – the PUREair System
 Increased operational availability &
reduced downtime
 Increased engine reliability
 Safe operation
 Protection against engine erosion
 Reduced maintenance &
operational costs
Theory –
Vortex System Principle
Scavenge Ejector
Scavenge Fan
Theory PUREair Barrier Principle of Operation
Filter losses
Pleat
Form
Entrance Losses: 30%
Media Losses:40%
Mitigating
filter
losses
Exit Losses: 30%
Geometry matters
60% of losses driven by pleat form
Pleat Stability
Fewer pleats can equal
more performance
Media & Materials
1 MM
Oil Wetted
Deformed Pleats
Impede flow,
degrade power
Dry Media
Stable Pleats for
better air flow,
more power
Cotton Gauze
Open and Fraying,
reduced protection
1 MM
Advanced Synthetic
Uniform and Stable,
consistent protection
TheoryEvolution of PUREair Systems
1st generation designs
1970’s
Dr. Pall patented
vortex tube
1980’s
Composite materials
2000’s
1990’s
“Simple” box or
flat designs
.
2010’s
2015’s
Design –
PUREair Reduced Scavenge Power
Next Generation
2013 - on
Bleed Air Flow: Low
Efficiency: 95+%
Constant operation
Existing Systems
2000’s
Bleed Air Flow: Medium
Efficiency: 95%
Legacy Design
1980’s
Bleed Air Flow: High
Efficiency: 90%
Think Dust Penetration!
90 to 95% Improvement =
2:1 reduction in dust entering engine
Design –
Vortex Tube Design
Design –
How do we meet what the customer wants?
Working closely with manufacturers (OEM) and operators the correct
product specifications for each helicopter type are defined.
Designs for:
EACH DESIGN IS UNIQUE
But needs to know:
 High removal efficiency
Pressure loss limits (power penalty)
 FOD protection
Allowable filter space claim
 Min weight
Engine intake geometry
 Min pressure drop
Engine flow distortion limits
 Smallest space envelope
Electrical power availability
OEM = Original Equipment Manufacturers
Engine bleed air availability
Design –
“The Complex Conundrum”
 What has to be considered in our PUREair designs?
Low ∆P
 Optimised Restrictions
Photo ©Craig Hoyle Flight International.
FOD Screen
 Location
 ∆P Penalty
Integrity
 Load balancing
 Material Selection
Design –
Vortex System vs Barrier
Pall Inlet Barrier Filter
(IBF)
Fit and maintain (air
cleaning)
Varying performance
High initial efficiency
protection
In flight FOD protection
Good for prepared
landing areas
Icing
Pall Vortex System
Self-Cleaning, fit and forget
Constant performance
High efficiency protection
In flight FOD protection
Excellent in brownout and
unprepared landing areas
All weather certified
Design, Analysis and Test Capabilities
Designing a helicopter intake protection system
is a complex process that requires significant
knowledge and experience.
Every PUREair design is tailored to a specific
helicopter model. The steps include:
Define specifications
Generate engineering design and analyse flow
Create prototypes
Perform qualification testing
Perform flight testing
Design Engine Distortion at Compressor Entry Plane
Downstream view of the simulated flow through the CEP for a
specific helicopter application
Intake Only
Intake With PUREair
Vortex Panel
Design –
Helicopter Flow analysis on Air Intake
CFD Results: Axial section through intake
EAPS Outlet Panel
Velocity Distribution
Improved flow distribution
Design Flow analysis using CFD
CFD Analysis enables prediction of performance
Hover.
Forward
Flow
Design
Design
– –
Composite
Materials
/ Additive
Manufacturing
Composite
Materials
/ Additive
Manufacturing
Programmes
Advantages




Photo Courtesy R. Criniti
Design Challenges



Requires special tooling and fixtures
Requires process control to effect in
field repairs.
Requires significant up-front
investment
Can be formed into complex shapes
Offers a total weight reduction
Improves the distribution of loads therefore
enhancing product life.
Reduce assembly parts count and complexity
Case Study 1 PUREair Performance (Tiger helicopter)
Background:
French Army Aviation experience during desert operations in Chad, Africa with
Gazelle and Puma helicopters:
– Frequent engine removal due to erosion wear, related to sand exposure
Tiger Requirements:
- Ten hours operation under brownout conditions with an engine power loss not
to exceed 5 %
Test Parameters:
Engine testing performed with Tiger engine equipped with PUREair system.
 PUREair gravimetric efficiency (laboratory) : 96.7 %
 Contaminant Concentration: ISO Coarse Test Dust, 1.5 g/m3
 Test Duration: 10 hours
 Flow Rate: 173.3 m3/minute
 Total dust ingested in 10 hours: 156 Kg (156000g)
Case Study 1 PUREair Performance (Tiger helicopter)
Test Results:
Total Dust Fed: 156 Kg (344 lbs)
Power Loss after test: only 3%
Result
3% Power loss
TEST P
ASSED
This shows only 1/10 of the test dust actually injected
into engine air inlet (156 kg).
Trial was equivalent to a minimum of 300 landings under brownout conditions!
Case Study 2 PUREair Performance (RTM322)
Background:
RTM322 developed as an alternative to the T700 engine, powering
Blackhawk, Apache and NH90 helicopters
The U.S. Army required an Inlet Particle Separator (IPS) system,
present in the T700 engine
Turbomeca evaluated a PUREair unit against the IPS.
Test parameters:
Inspect the engine 1st compressor wheel (most prone to erosion).
 Test duration: 50 hours
 Test Contaminant: ISO Coarse Test Dust
 Test Contaminant Concentration: 53 mg/m3
Results:
Based on the evaluation the PUREair system was qualified as an
alternate option to the IPS system. It is standard option on the NH90
helicopter
Case Study 2 PUREair Performance
PUREair Systems vs. Inlet Particle Separators (IPS)
Compressor blade “as good as new”
with PUREair system
Compressor blade erosion with IPS
Test Contaminant
MIL-E5007C
ISO Coarse Test
Dust
Typical PUREair Efficiency (%)
96.5
95.5
92
75
2.3
5.5
Typical IPS System Efficiency (%)
Compressor wheel service life increase with PUREair system
compared to IPS
Case Study 3 –
Paris Dakar Rally – AS350 aircraft
Compressor Inspection concluded no degradation after 100 hours and 98
landings on unprepared sites in the Sahara desert with PUREair.
Operation and Maintenance
On a PUREair Vortex system there are 5 main areas to inspect:
1) Module structure 2) Vortex tubes
3) Scavenge System
4 + 5) Seals and FOD Screen
On a Pall PUREair Dry
Barrier Filter:
1) Oil Wetted – Pleat maintenance and clean =
wash, dry, re-oil
2) Dry – No pleat maintenance and clean = wash then dry
(this cycle is about 5 time shorter than an oil wetted
cleaning)
Application In Service Support
 Installation OEMs / Retrofit
 High Utilisation: Integrated Logistics Support
 Maintenance Support provides enhanced life:
Barrier cleaning technique's and structural /
vortex performance
 FOD Analysis
Credit: Airbus Helicopters
Application Over 50 Helicopter Air Intake Solutions
Images Courtesy of Airbus Helicopters, Agusta Westland, Bell Helicopters,
U.S Army, Boeing, Martin Eadie, Marshall LaPlante, 2015
Any Questions?
ADS symposium, November 2015
Click to edit Master text styles