SAE ARP 5435A-2016 APU Gas Turbine Engine Test Cell Correlation.pdf

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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 theref

2、rom, 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 2016 SAE InternationalAll rights reserved. No part of this publi

3、cation 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: +1 724-776-4970 (out

4、side USA)Fax: 724-776-0790Email: CustomerServicesae.orgSAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedbackon this Technical Report, please visithttp:/www.sae.org/technical/standards/ARP5435AAEROSPACERECOMMENDED PRACTICEARP5435 REV. AIssued 2007-12Revised 2016-08Superseding A

5、RP5435APU Gas Turbine Engine Test Cell CorrelationRATIONALEARP5435 update per the five year review requirement.The SAE EG-1E committee is composed of a cross section of representatives from OEMs, commercial users, repair stations, and military depots. Based on the inputs from representatives of thes

6、e various areas of interest, it was concluded that there was a need for a standardized procedure for correlating an APU gas turbine test cell. This paper represents the committees best effort to satisfy the interest of all parties concerned and arrive at a valid realistic correlation procedure. It i

7、s the belief of the committee members that this document meets that objective.TABLE OF CONTENTS1. SCOPE 3 1.1 General 3 1.2 Beneficiaries 3 1.3 Limitations . 3 2. REFERENCES 3 2.1 Applicable Documents 3 2.1.1 SAE Publications. 3 2.1.2 ASTM Publications 4 2.1.3 Other Publications. 4 2.2 Definitions .

8、 4 3. FACTORS AFFECTING CORRELATION 5 4. PERFORMANCE MEASUREMENTS. 5 4.1 General 5 4.2 Performance Parameters 6 4.3 Instrumentation Calibration . 6 4.3.1 Hierarchy/Secondary Standards . 6 4.3.2 Traceability 6 4.4 Power Extraction Determination . 7 4.5 Factors Affecting Performance Measurement 7 4.5.

9、1 Humidity 7 4.5.2 Engine Inlet Temperature and Pressure. 7 4.5.3 Fuel Properties 9 4.5.4 Dress Kit Hardware . 9 4.5.5 Data Acquisition 10 4.6 Software Verification . 10 SAE INTERNATIONAL ARP5435A Page 2 of 205. DESIGNATION OF BASELINE AND REFERENCE FACILITIES 11 5.1 General 11 5.2 Identification of

10、 a Suitable Reference Facility. 11 5.2.1 Alternative Reference Facilities 11 5.3 Uncertainty Stack-Up 11 5.3.1 Reducing Uncertainty 11 5.4 Engine Test Hardware Configuration for Reference Testing 11 6. REFERENCE TEST 12 6.1 General 12 6.2 Preparation and Engine Running 12 6.2.1 Establishing Appropri

11、ate Dialogue 12 6.2.2 Ensuring Test Cell Suitability 12 6.2.3 Identifying an Acceptable Correlation Engine and Dress Kit Configuration 12 6.2.4 Ensuring Validity of Calibration of Test Cell Instruments 12 6.2.5 Reference Facility Engine Performance Test . 12 6.2.6 Shutdown Period. 13 6.2.7 Repeating

12、 the Reference Test 13 6.2.8 Repeating the Reference Test with Customer Dress Kit Installed 13 6.2.9 Correcting and Analyzing the Correlation Data 14 6.3 Shipping the Engine to the Customer Facility. 14 7. TEST CELL CORRELATION (CUSTOMER FACILITY). 14 7.1 General 14 7.2 Preparation and Engine Runnin

13、g 14 7.2.1 Establishing Appropriate Dialogue 15 7.2.2 Ensuring Test Cell Suitability 15 7.2.3 Calibrating the Instrumentation . 15 7.2.4 Pre-Correlation Procedure 15 7.2.5 Performing the Correlation Procedure 15 7.2.6 Shutdown Period. 16 7.2.7 Repeating the Correlation Test. 16 7.2.8 Post-Correlatio

14、n Procedure 16 7.3 Correcting and Analyzing the Correlation Data 16 7.3.1 Data Validation 16 7.3.2 Performance Shift Determination 17 7.3.3 Correlation Factors Determination 17 8. CORRELATION REPORT 17 8.1 General 17 9. MAINTENANCE OF TEST CELL CORRELATION 18 9.1 General 18 9.2 Engine and Test Cell

15、Configuration Control 18 9.3 Correlation Monitoring and Maintenance 18 9.3.1 Trending 19 9.3.2 Periodic Checks 19 9.3.3 Re-Correlation. 19 9.4 Instrumentation Calibration . 19 9.5 Controlling Changes 19 9.5.1 Record Keeping 19 9.5.2 Back-to-Back Testing 19 9.6 Test Cell Equipment and Facility Mainte

16、nance. 20 10. NOTES 20 10.1 Revision Indicator 20 SAE INTERNATIONAL ARP5435A Page 3 of 201. SCOPE1.1 GeneralThis paper describes a recommended practice and procedure for the correlation of test cells that are used for the performance testing of APU (auxiliary power unit) engines. Test cell correlati

17、on is performed to determine the effect of any given test cell enclosure and equipment on the performance of an engine relative to the baseline performance of that engine. The baseline performance is generally determined at the original equipment manufacturer (OEM) designated test facility.Although

18、no original equipment manufacturer (OEM) documents are actually referenced, the experience and knowledge of several OEMs contributed to the development of this document. Each engine Manufacturer has their own practices relating to correlation and they will be used by those OEMs for the purpose of es

19、tablishing certified test facilities.1.2 BeneficiariesThis recommended practice will benefit the OEM, commercial users, repair stations, and military depots as well as intermediate level maintenance activities. Specific cases in which the information contained herein will be beneficial are: a. As an

20、 aid for providing correlation of test cell data between engine and airframe companies supporting commercial and military requirements. b. As an aid for providing military maintenance facilities and commercial repair stations a method by which to correlate test cells. c. As an aid in establishing co

21、rrelation practices for new test cells, for updating, and maintaining existing test cells. d. As an aid to an engine manufacturers facility in correlation of test cells used for engine development and acceptance in accordance with the applicable engine model specification. 1.3 LimitationsKnown metho

22、ds of determining test cell correlation factors include, but are not limited to, the following: a. Back-to-back b. Cross-cell c. Correlation engine The “correlation engine“ procedure is the recommended and most common method for the correlation of an engine test cell. This paper is limited to the di

23、scussion of this one method.2. REFERENCES2.1 Applicable DocumentsThe 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 purcha

24、se order. In the event of conflict between 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 PublicationsAvailable fr

25、om SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org.ARP741 Turbofan and Turbojet Gas Turbine Engine Test Cell CorrelationSAE INTERNATIONAL ARP5435A Page 4 of 20ARP4755 Turboshaft/Turboprop Ga

26、s Turbine Engine Test Cell CorrelationARP4990 Turbine Flowmeter Fuel Flow Calculations AIR5026 Test Cell Instrumentation ARP5758 Trend Analysis for Maintaining Correlation of Gas Turbine Engine Test CellsARP6028 Configuration Control for Maintaining Correlation of Gas Turbine Engine Test CellsARP619

27、6 Gas Turbine Engine Test Facility Audit ProcessWebb, W., “A Forward Look at Gas Turbine Testing Facilities,“ SAE Technical Paper 801124, 1980, doi:10.4271/801124.2.1.2 ASTM PublicationsAvailable from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 61

28、0-832-9585, www.astm.org.Annual Book of ASTM (American Society for Testing Materials) Standards. 1992. Section 5, Petroleum Products, Lubricants, and Fossil Fuels. Volumes 05.01, 05.02, and 05.03.2.1.3 Other PublicationsAdvisory Group for Aerospace Research and Development (AGARD). Operation and Per

29、formance Measurement on Engines in Sea Level Test Facilities. AGARD-LS-132. Krengel, J.H. Air-Breathing Engine Test Facilities Register. AGARD-AG-269The Aerospace Industries Division of Instrument Society of America. Measurement Uncertainty Handbook. AEDC-TR-73-5United States Air Force. Test Cell Co

30、rrelation Set Technical Manual: Operation, Maintenance and Parts Breakdown. United States Air Force Technical Order (TO) 33DA-6- 261. 2.2 DefinitionsThe following list defines the terms and phrases used in this document: BACK-TO-BACK: A test performed with the same engine before and after a modifica

31、tion to the facility or associated equipment. BASELINE FACILITY: A facility designated as the standard for certification of an engine. CALIBRATION: The comparison of a particular instrument or system with a standard of known accuracy. CORRELATION: The comparison of engine performance parameters meas

32、ured on a common engine tested in two test facilities, where one facility is the reference. CORRELATION ENGINE: An engine of known and repeatable performance used for test cell correlation. CORRELATION FACTOR: A multiplier or delta used where appropriate to adjust for the difference in performance b

33、etween the customer facility and a reference facility, also known as a “correction factor“ or a “facility modifier“. SAE INTERNATIONAL ARP5435A Page 5 of 20CROSS-CELL: The comparison of engine performance parameters measured on a common engine, which is not necessarily a correlation engine, in at le

34、ast two previously correlated test cells for the purpose of checking facility correlation of a third test cell. CUSTOMER FACILITY: The test facility which is to be correlated against the reference facility. ENGINE DRESS KIT: Typically consists of aerodynamic hardware, accessories, and test instrumen

35、tation required to permit operation of the engine in the test cell. INDOOR TEST CELL: A facility for the testing of gas turbine engines in a restricted environment. OUTDOOR TEST STAND: An open air facility, without any enclosure, for testing engines. REFERENCE FACILITY: A test facility of known perf

36、ormance, traceable to the designated baseline facility, against which the customers facility is compared. TEST FACILITY (TEST CELL): An area in which a gas turbine engine is operated to determine its performance and other information as required by a given test. 3. FACTORS AFFECTING CORRELATIONThe f

37、ollowing factors may affect the correlation of an engine test cell: a. Configuration of the test cell, particularly the inlet, augmenter tube and exhaust stack configurations b. Engine position in the test cell c. Ambient conditionsd. Instrumentation: calibration, location, measurement accuracy, and

38、 quantity e. Test cell power measurement system consisting of bleed air and/or shaft powerf. Testing procedures g. Data acquisition system h. Fuel properties i. Engine dress kit 4. PERFORMANCE MEASUREMENTS4.1 GeneralThe primary function of the engine test facility is to obtain proper performance eva

39、luation of an engine. The test facility andtest configuration must provide a stable test environment conducive to stable operation of the engine. All test facilities create an environment which influences the data obtained during testing. This is particularly true of indoor ground level test cells.

40、In addition, the engine test configuration including the engine dress kit influences the data taken during testing. Variation in test facilities and engine test configurations cause differences, in measured engine performance. The test cell correlation provides the means to quantify these difference

41、s, to understand them, to reduce them whenever possible, and to establish the appropriate cell correlation factors. SAE INTERNATIONAL ARP5435A Page 6 of 204.2 Performance ParametersA variety of performance parameters should be examined in the process of test cell correlation. This list may include,

42、but is not limited to: a. Engine fuel flow b. Engine power extraction consisting of bleed air and/or shaft powerc. Engine speed(s) d. Engine pressures and temperatures e. Engine inlet conditions f. Test cell temperatures and pressures g. Engine vibrationsh. Engine variable geometry system (where app

43、licable)4.3 Instrumentation CalibrationThe engine test facility is an article of test equipment and as such requires appropriate design and calibration of measurement systems. The importance of proper calibration of the test cell and its instruments cannot be overemphasized. A calibration procedure

44、firmly establishes the uncertainty of the individual instrument and system measurements. Rather than accept the reading of an instrument, it is essential to make a calibration check to verify the validity of the measurements.In most cases an end-to-end calibration of a measurement system is better t

45、han removing an instrument from the test cell and calibrating it in an instrument shop. However, periodic calibration of individual instruments, either performed in place or in the instrumentation shop is necessary. For example, a pressure measurement may be affected by a leak or liquids in a pressu

46、re line; electrical measurements may be disturbed by noise, or by wiring flaws; liquid flowmeters are affected by turbulence in the liquid. Many such conditions can be detected during calibration, and should be corrected before the final calibration curves are established. 4.3.1 Hierarchy/Secondary

47、StandardsIn the United States of America, the National Institute of Standards and Technology (NIST) has the primary responsibility for maintaining the standard units of length, mass, time, temperature, and electrical quantities. Other nations have comparable standards bodies. Instruments used as tra

48、nsfer standards should have calibrations traceable to a national standard. Prior common practice required a secondary or transfer standard have an uncertainty at least four times better than the instrument being calibrated. It is increasingly more difficult to achieve this hierarchy of secondary sta

49、ndards with the development of low uncertainty electronic equipment. The transfer standard, in this case, should have an uncertainty equal to or better than the working instrument. 4.3.2 TraceabilityTraceability establishes the calibration hierarchy for a particular measurement. It identifies all possible error contributions between the test facility measurement system and the national standard. Traceability does not reduce the uncertaint