Introduction
The kingdom of Saudi Arabia is one of the most important countries not only in the Middle East, but also in the globe. This is because this country is known for the quantity of oil that it produces in the world. Furthermore, this nation is recognized for two important mosques and key in the lives of the Muslims across the globe.
Due to this, this republic is working towards ensuring that it bears a sufficiency in all fields. Especially in this time and age, this country is working towards ensuring that the defense and security sectors are catered for. In order to achieve this, this nation has entered into agreements with the British aerospace in order to supply the kingdom with the most modern technology in the defense.
During my cooperative training I had the opportunity to work with the British Aerospace. During this period I was able to get more information about the tornado Aircraft. This aircraft is the nucleus of Royal Saudi Air Force (RSAF).
This report consists of a summary of my experience during this training period. It provides details about the Tornado engine, its maintenance, and some of the problems that were encountered and suggestions to set them right.
Organizational history
The British Aerospace Company is a company which is located in Europe. It is a company which is regarded as Europe’s largest and it is the third largest aerospace company in the world. This company has a turnover of 10 million pounds and booked orders which are worth more than 11 billion pounds. The number of staff who is working in this company total to 88,300 qualified personnel.
The main operations of this company dwell in the commercial and defense aircrafts. Alongside this, the company is also involved in aircraft maintenance, flight training, advanced navigation and communication systems, rockets, arms and ammunition, civil engineering, optical systems, satellites, ground defense systems, and the ship services.
The company has or is divided in three divisions. These divisions are the helicopter systems, naval systems and the Al- Yamamah project. Tornado Aircraft
This aircraft is a two seat supersonic combat aircraft which is capable of great flexibility of purpose and design to fulfill a wide range of operational requirements. It has variable geometry wings, multi – spool, reheated turbofan engines, giving it a speed in excess of Mach 2 at high altitude. The variable geometry wings together with high lift devices, ensures that it can land and take off at slow speeds at dispersed sites.
During the time I was in this company, I realized that there are two kinds of Tornado Aircrafts. That is the Tornado Air Defense Variant (ADV), and the Tornado Interdictor Strike (IDS). The difference that exists between these two aircrafts is that the ADV and IDS, is based in the reheat section.
Furthermore, the IDS is 1.39 m longer than the ADV which is the main external difference in front fuselage section to accommodate the AL radar, Sky flash missiles, avionics and extra fuel tank. It also has wing nips which sweep at 68 degrees rather than 60 degrees as on the IDS aircraft.
The Tornado is not a pure British design, but Italy and Germany also joined in designing and producing this aircraft. The Tornado weapon system represents the closet approach yet to an ideal multi –m role combat aircraft, sought by military aircraft design engineers. Its success is attributable to the skilled application of a number of high technology features incorporated into a basic airborne vehicle. The major roles of Tornado
The Tornado is designed to fulfill a number of roles. These roles include close air support, interdictor strike, air strike superiority, interception, land based maritime strike and reconnaissance.
Characteristics of the Tornado
The Tornado has got specific characteristics which make it stand out from the other aircrafts. This is based on the fact that it is designed in order to fulfill the above stated functions.
The main characteristics of this aircraft include the short takeoff or landing and the ability to accelerate rapidly to a high subsonic speed to permit operation from dispersed or damaged airfields in forward areas and immediate reaction to quickly changing battlefield conditions. High speeds at low level so that the enemy defense receives little warning during the time of attack.
The smoothness of the low gust with the wings swept at low levels ensures that the crew maintain their fighting efficiency. High specific excess power or rate of climb and good acceleration ensure efficient interception or, in the reconnaissance role, evasion. All weather capability enables the Tornado to maintain round the clock pressure on enemy targets and to intercept enemy aircraft by day or night, or in bad weather.
Good load carrying ability and flexible weapon or fuel load interchange ensures that most effective interdictor or close air supervision use over a wide range of target distance combinations. This plane has a good sustained maneuverability which ensures excellent self defense and attack capability against enemy aircraft.
Lastly the multi – spool engines ensure that the aircraft has got a good specific fuel consumption which produces a long range in the strike reconnaissance roles and a prolonged loiter capability in the air superiority role. The table below gives a summary of the IDS and the ADV aircrafts in terms of their specifics. (See Table 1 and Diagram 1)
Tornado Aircraft dimensions: The aircraft construction
During the study, I discovered that the aircraft has got an elaborate structure which demands the construction process to be elaborate. In essence, the aircraft structure can be divided into a number of major components. These parts include the Fuselage, wings and the tail unit. The fuselage is further divided into the front, center and rear fuselage sections.
The method which is used in the construction of this aircraft known as the, “Semi – Monocoque.” This method utilizes frames, sub-frames, lonegrons, diaphragms, webs, beams and skins in the construction of the fuselage, with spars and ribs used in the construction of the wings, fin, ailerons and flaps.
The frames, longerons, spars, ribs and skins are designed to withstand the bending, twisting, compression and torsion loads that an aircraft feels during flight. It is worth noting that the materials which are used in utilizing this aircraft should be able to withstand the loads which the aircraft feels and at the same time be light.
Front Fuselage
The fuselage consists of frames, diaphragms, webs and skins, manufactured to form an assembly consisting of pressurized structure, forwards equipment compartment, the left hand gun avionics compartments, left hand gun compartment, liquid oxygen compartment, rear equipment compartment, right hand avionics compartments, right hand gun compartments, nose landing gear compartment and the spent cases compartments.
The center fuselage
This extends from the forward transport joint at the frame 9 to the rear transport joint at frame 16, and it is constructed of closely spaced frames and skin assemblies. The frames vary depending on their functions. The wing box contains the wing pivot bearings which are mounted in the top structure. This wing box is usually manufactured from high strength machined titanium alloy.
The internal frames are located between the forward and the rear face walls to provide additional strength to the structure. The wing slots seals exist to maintain the fuselage shape. They are also used in order to reduce drag. These pockets are closed by inflatable seals. The wing pocket has got two seals, that is, the upper and lower seals on each side of the Tornado.
There are usually interconnected to allow for pressure variations due to the various altitudes which are attained during flight. The main landing gear is usually placed in two compartments. These compartments are located on the underside structure of the center fuselage.
The main landing gear retracts forward and inward, the struts being rotated to allow the wheels to be housed flat within the shadow compartments. Fuel is usually stored in the fuselage which is located in the center of the tornado. There are a total of 16 fuel cells in two groups, six in the front fuel group and 10 in the rear fuel group.
Rear fuselage
This fuselage extends from the transport joint which is located at frame 16 and extends to the frame 19. This is done so that two engines can be mounted in the compartments which are on each side.
In addition to the makeup of the engine, the rear fuselage also provides fittings for the fin, air brakes the engine doors and the arrester hook. The rear fuselage consists of frames which are divided by beams. The hydraulic system components are located in these regions.
The engine bay is a part of the Tornado which is enclosed by two doors. These doors are locked in position using a mechanism which is known as the release shoot-bolt. Air breaks are also mounted in the recesses of the fuselage. They are made up of aluminum alloy. The air breaks are located in a closed position sustained by a hydraulically operated lock units.
Wings
Wings are crucial components of the Tornado Aircraft. Their ability to sweep wing and rotate a pivot axis by means of an actuator is one of the aspects of this aircraft that makes it outstanding. The wings are designed in such a manner that they can carry two wing pylons for the carriage of external stores.
The wings are attached to the trailing edge flaps which are installed on the lower side of the trailing edge. These flaps are equipped with carriage rib and a roller system which has two screw jacks.
Damage evaluation and inspections
There are two main categories of this section. These include the reference system and the inspection of damages. The reference system is a method which is used in defining surfaces, positions and contours. It is a system which operates using a basic system which is supplemented by an auxiliary system. This system is used to locate places on the plane which might be having repair issues.
On the other hand the inspection of damage is an action which takes place when a person seeks to establish if there are aspects of the aircraft which are not in good working condition. There are several aspects which are taken when carrying out this inspection. These include the access for inspection. In this case, it is necessary to ensure that the structural damage of the aircraft is assessed.
The preliminary visual inspection is the process which involves the visual inspection of the exterior surfaces of the aircraft. Detailed visual inspection involves the deliberate process of establishing the actual problems which may be noticed on the airplane.
Tornado systems
The Tornado has got several systems. These systems include the fuel system, the environmental system, the electric system, and the wheel or tires system. The fuel system; the aircraft fuel load is usually located in the front fuselage, the center fuselage, the fin and in the wings. The main fuel tank is usually located in the center fuselage.
The main fuselage consists of numerous fuel cells which are interconnected in a way that form two separate groups which are designated in the front fuselage. The environmental system; the main task associated with this system is to convert the liquid oxygen into a form that can enable the pilot to breathe in flight.
The oxygen system is made up of two parts. These parts are the main oxygen system and the oxygen emergency system. During the emergency cases when the pilot needs to come of the plane, this system ensures that the pilots get 100% oxygen.
Tornado Engine
The study process made me realize that the Tornado has got a very unique engine. This engine matches the unique characteristics which are used by the engine. The Engine KB 199 was developed by Turbo Union in order to ensure that the Multi – Role Combat Aircraft is realized.
The required characteristics demanded the engine to have a bypass engine. This should have a capability of reheat for both the hot and cold gas streams. The thrust reverser is basically fitted with the intention of short landings.
In addition, for the sake of maintenance, the engine is divided into several basic modules. These modules enable one to be able to note what they are working on at any given point.
It is worth to mention that when removing a module, its identification plate must be kept with its own module, and when refitting a module, that plate must be refitted to the carrier. This eases the process of maintenance. See (Table 2: Table of engine modules, Diagram of the engine and the attached diagram)
Types of engine modules
During my experience I learnt that the Tornado has got sixteen modules. Some of these modules include the Low pressure compressor module. This is a three stage axial flow unit which comprises two main assemblies, that is, the engine and the rotor. See (Diagram 2 Compressor module (M01).
The intermediate pressure compressor module is a compressor which comprises alternative rows or rotor and stator blades. These consist of an integral disc assembly to which the blades are secured by dove tail roots and retained in the discs by the segmented plates.
The high pressure compressor module consists of an outer casing and an inner casing. The outer casing is a part of the intermediate casing module. The inner casing consists of a number of rings bolted together in each pairs. See (Diagram 3 Intermediate pressure compressor module (M02)).
The intermediate casing module is a module which forms the foundation unit of the engine which is known as the Master base Module. Their thrusts are attached to the outer case of the module. Engine performance parameters
There are several parameters which are used in establishing the functionality of an engine. In this case the parameters include the engine thrust and the specific fuel consumption. The thrust is a gas jet exhausting at a high velocity from a nozzle in the opposite direction of the jet. I later realized that the aim of the designers of these natures of engines is to aim at having engines which have higher thrusts.
The specific fuel consumption may be considered to be what is next to thrust. This is because it is one of the most important aspects regarding the performance of the engine. This aspect is used to determine the amount of fuel which is used to achieve pone unit of thrust over a finite period of time.
Engine maintenance procedure
The maintenance of the Tornado engine is carried out at the engine shop. When the engine arrives at the engine shop it is subjected to various diagnostic tests to check on its functionality. In this case they include the baroscopic, hardness test and the MCD check.
Conclusion
Just like any other machine or aircraft, the Tornado engine has got its share of the problems which have solutions. When I was under training in this company I realized that some of the problems which are associated with this engine include the interference with the foreign objects which damage the engine (FOD). The high hours can also lead to bearing debris circulating in the engine oil system.
This leads to massive wear and tear of the engine. Other problems are associated with thermal fatigue and operating in an environmentally hostile environment.
Despite the challenges and problems, one of the sure ways of maintenance of these engines is through subjecting them to thorough inspection and system evaluation. Consistent servicing of these aircraft reduces the risk of the problems which are associated with them thus they are able to function properly for a much longer period of time.
Works Cited
Rouhollah, K. Ramazani and Joseph A. Kechichian. The Gulf Cooperation Council: Record and Analysis, Virginia: University of Virginia Press, 1988. Print.