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Carrying out test bed runs on aircraft engines (uninstalled)

URN: SEMAE3161
Business Sectors (Suites): Aeronautical Engineering Suite 3
Developed by: Enginuity
Approved on: 2021

Overview

This standard identifies the competences you need to carry out test bed runs on aircraft engines, as appropriate to the engine type, in accordance with approved procedures. The engines to be tested will include turbo prop, turbo jet, turbo fan, ducted fan, turbo shaft, piston engines, auxiliary power units (APU), and ground turbine start units (GTS).

You will be required to carry out all necessary preparations to the engine, in readiness for the tests to be carried out and these will include ensuring that the engine is correctly mounted to the test bed/pylon, that all ancillary equipment is fitted to the engine, appropriate blanking plates are fitted, test instrumentation is correctly connected and that all necessary electrical checks are carried out.

In carrying out the tests, you will be required to follow laid-down procedures to ensure that the working area is clear, appropriate guards and notices are displayed, engine runs/tests are carried out in accordance with the appropriate schedule, monitoring procedures are complied with, analysis of results is made, and that test documentation is completed, accurately and legibly.

Your responsibilities will require you to comply with organisational policy and procedures for the tests undertaken and to report any problems with the testing activities that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to undertaking the engine test procedures. You will understand the engine being tested, the specific test schedule to be followed and will know what the various instruments and readings mean, in adequate depth to provide a sound basis for carrying out the tests to the required specification.

You will understand the safety precautions required when carrying out the testing activities, in particular those involved with fuelling and running the engines. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.

Performance criteria

You must be able to:

  1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
  2. follow the appropriate procedures for use of tools and equipment to carry out the required tests
  3. set up and carry out the tests using the correct procedures and within agreed timescales
  4. record the results of the tests in the appropriate format
  5. review and analyse the results and carry out further tests if necessary
  6. de-rig and leave the engine in a safe and appropriate condition, free from foreign object debris

Knowledge and Understanding

You need to know and understand:

  1. the specific safety practices and procedures that you need to observe when testing aircraft engines (including any specific legislation, regulations/codes of practice required for the activities, equipment or materials used)
  2. the importance of maintenance on, and impact upon (extended twin operations procedures) ETOpS systems, legislation and local procedures
  3. the health and safety requirements of the work area in which you are carrying out the activities and the responsibility these requirements place on you
  4. the safety procedures that must be carried out before tests are started on the engine (such as the lock guard system is functioning, test cell is empty of people, bed doors are closed, all personnel are clear of the test area)
  5. the requirements and importance of understanding and applying human factors as defined by the regulatory requirements and the potential impact if these are not adhered to
  6. the protective clothing and equipment (PPE) to be worn during the testing activities
  7. the hazards associated with testing aircraft engines and how to minimise them and reduce any risks
  8. the preparations to be carried out on the engine prior to starting the engine tests (such as attaching to the test pylon, fitting test instrumentation, fitting ancillary equipment, fitting blanking plates, filling the engine with oil, making fuel connections, attaching electrical power and making final electrical checks of all systems)
  9. how to obtain the required test schedules and specifications for the aircraft and engine type being tested, and how to check their currency and validity
  10. how to read and interpret the specifications and from whom you can seek assistance if you have problems or issues regarding the test schedules or specifications
  11. the correct operating procedures for the engines being tested
  12. the principle of operation of the engines under test and the function of the individual units within the system
  13. the methods and procedures to be used to carry out the various engine tests
  14. the need to apply engine power in incremental stages and to check all readings, temperatures and pressures at each stage
  15. how to record the results of each individual test and the documentation that must be used for this
  16. from whom to seek authorisation if you need to alter or change the test procedures
  17. how to analyse the test results and how to make valid decisions about the acceptability of the engine
  18. the procedures to be followed if the engine or system fails to meet the test specification
  19. potential problems that can occur with the testing activities and how they can be overcome
  20. problems that may cause errors or discrepancies in/with the test results and how to avoid them
  21. any required environmental controls relating to the testing
  22. why equipment and tool control is critical and what to do if a piece of equipment/tools are unaccounted for on completion of the activities
  23. the documentation to be completed at the end of the testing activities
  24. the extent of your own authority and to whom you should report if you have a problem that you cannot resolve

Scope/range

Scope Performance

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  1. Prepare the engine for testing by carrying out all of the following, as applicable to the engine type:

    1. obtain and use the correct issue of engine test schedule, test procedures and quality documentation
    2. adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
    3. attach and secure the engine to the test pylon
    4. fit all the required test instrumentation to the engine
    5. fit all required ancillary equipment (to include starter motors, control valves, slave oil filters, magnetic chip detectors and strainers)
    6. fit appropriate blanks (to include bleed off-take, anti-icing, generator and hydraulic)
    7. make all required connections to the engine (to include fuel connections, electrical and instrumentation)
    8. carry out all necessary electrical checks and confirm that the engine is ready for testing
    9. ensure that all personal are clear of the test facility and that safe working distance procedures are maintained

  2. Carry out tests to appropriate schedules, on one of the following types of engine:

    1. turbo prop          
    2. ducted fan   
    3. auxiliary power unit (APU)
    4. turbo jet                   
    5. turbo-shaft    
    6. ground turbine start (GTS)
    7. turbo-fan                    
    8. piston engines

  3. Carry out tests to appropriate schedules on one of the following categories of engines:

    1. production engines       
    2. repaired/overhauled engines 
    3. development engines

  4. Undertake engine tests, as listed in the appropriate engine test schedule, to include all of the following:

    1. visually checking that the engine is free from any damage or obvious defects
    2. filling the engine with oil
    3. checking that engine igniter mechanisms operate correctly
    4. carrying out ground idle checks
    5. checking that fuel flow is operating correctly
    6. carrying out running and handling checks
    7. carrying out performance curves
    8. carrying out vibration surveys
    9. checking that engine pressure ratios are within specification
    10. checking that engine temperature is within specification
    11. checking that throttle/high pressure fuel flow operates smoothly
    12. checking that the bleed air system functions correctly
    13. ensuring that maximum thrust/power is achieved
    14. checking that fire detection and protection equipment is functioning

  5. Deal with two of the following complexities during the engine tests:

    1. engine runs with no faults    
    2. engine runs with faults 
    3. engine with intermittent faults

  6. De-rig the engine on completion of the testing procedures, to include carrying out all of the following:

    1. removing and checking magnetic chip detectors for contamination
    2. removing and checking slave filters for contamination
    3. installing the engine's own magnetic chip detectors and filters
    4. draining all oil and fuel from the engine
    5. removing all blanks and test instrumentation
    6. removing the engine from the pylon, safely and correctly
    7. passing the engine to dispatch (where applicable)

  7. Review, record and analyse the results of the test run, using two of the following:

    1. engine test schedule
    2. data sheets
    3. calibration records
    4. log cards/history sheet
    5. fault records
    6. maintenance manuals and records
    7. company-specific documentation

  8. Carry out tests in compliance with one of the following:

    1. Civil Aviation Authority (CAA)/European Aviation Safety Agency (EASA)
    2. Ministry of Defence (MoD)
    3. Military Aviation Authority (MAA)
    4. Aerospace Quality Management Standards (AS)
    5. Federal Aviation Authority (FAA)
    6. Joint Airworthiness Authority (JAA)
    7. extended twin operations procedures (ETOpS)
    8. BS, ISO or BSEN standards and procedures
    9. customer standards and requirements
    10. company standards and procedures
    11. power plant manufacturer's specific requirements

Scope Knowledge

Values

Behaviours

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You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:

  • strong work ethic
  • positive attitude
  • team player
  • dependability
  • responsibility
  • honesty
  • integrity
  • motivation
  • commitment

Skills

Glossary

Links To Other NOS

External Links

Version Number

3

Indicative Review Date

2024

Validity

Current

Status

Original

Originating Organisation

Enginuity

Original URN

SEMAE3161

Relevant Occupations

Engineer, Engineering, Engineering and Manufacturing Technologies, Engineering Technicians

SOC Code

5234

Keywords

aircraft engines; turbo prop; turbo jet; turbo fan; ducted fan; turbo shaft; piston engines; auxiliary power units (APU); ground turbine start units (GTS)