Aircraft Systems

ATPL AGK - Aircraft Systems Reference Guide

ATPL Aircraft General Knowledge

Aircraft Systems - Comprehensive Reference Guide

Quick Reference - Critical Values

115/200V
AC System Voltage
28V
DC System Voltage
3000 PSI
Typical Hydraulic Pressure
8.1 PSI
Max Cabin Differential Pressure
400 Hz
AC Frequency
35-45 PSI
Pneumatic Bleed Air Pressure

SYSTEM Electrical Systems

Primary Purpose: Modern aircraft use 115/200V AC at 400 Hz as the primary electrical power source. The higher frequency allows for lighter and more compact electrical equipment compared to 50/60 Hz ground power.

Integrated Drive Generators (IDG)

The IDG combines a Constant Speed Drive (CSD) and a generator in a single unit. The CSD uses a hydraulic transmission to maintain constant generator speed (6000-8000 RPM) regardless of engine speed variations.

Key Features:

  • Outputs 90 kVA or 120 kVA (typical)
  • Maintains ±0.5 Hz frequency stability
  • Oil-cooled system with separate reservoir
  • Cannot be reset in flight once disconnected
⚠️ CRITICAL LIMITATION: Once an IDG is disconnected in flight using the disconnect switch, it CANNOT BE RECONNECTED until maintenance performs a ground reset. This is because the dog clutch mechanism requires the drive to be at rest for re-engagement.

Generator Control Unit (GCU)

The GCU monitors and protects the generator system:

  • Voltage Regulation: Maintains 115V ±3V
  • Frequency Control: Keeps output at 400 Hz ±5 Hz
  • Load Sharing: Balances load between generators (within 10%)
  • Overload Protection: Trips generator if load exceeds 150% rated capacity
  • Differential Protection: Detects internal generator faults

DC power at 28V is supplied by:

  • Transformer Rectifier Units (TRUs): Convert 115V AC to 28V DC
  • Batteries: Backup power and APU start capability
  • External Power: Ground operations

Battery Systems

Nickel-Cadmium (NiCd) Batteries
  • Traditional aircraft battery type
  • Nominal voltage: 24-28V
  • Capacity: 25-40 Ah typical
  • Can provide 30 minutes emergency power
  • Susceptible to thermal runaway if overcharged
Lithium-Ion Batteries (Modern Aircraft)
  • Higher energy density
  • Lighter weight (up to 40% reduction)
  • No memory effect
  • Requires sophisticated thermal management
  • Fire containment systems mandatory
⚠️ THERMAL RUNAWAY: If a lithium battery enters thermal runaway, temperature can exceed 800°C. Modern systems include thermal sensors, fire suppression, and containment systems. Battery temperature monitoring shows EICAS/ECAM warnings above 70°C.

Battery Charger

Maintains battery charge and provides 28V DC to essential buses. Typical charging rate is C/10 (10-hour charge rate). Overcharge protection prevents exceeding 30.8V for NiCd batteries.

Bus Architecture

Bus Priority Hierarchy: Aircraft electrical systems are organized in a hierarchical structure to ensure critical systems remain powered during electrical failures.
Bus Type Power Source Systems Supplied Priority
Main AC Bus Engine Generators Non-essential AC loads Lowest
Essential AC Bus Generator/Static Inverter Flight instruments, autopilot High
Main DC Bus TRUs/Battery General DC loads Medium
Essential DC Bus Battery/TRU Critical avionics, standby instruments Very High
Battery Bus Battery Direct Emergency lighting, critical systems Highest

Bus Tie Contactors (BTCs)

BTCs allow connection between buses for load sharing or backup power. Logic prevents paralleling of out-of-phase generators. Automatic load shedding occurs if single generator powers entire system.

Load Shedding: If operating on single generator or APU generator, non-essential loads are automatically shed to prevent generator overload. Galley power typically first to disconnect.

Ram Air Turbine (RAT)

⚠️ EMERGENCY POWER: The RAT automatically deploys when:
  • Complete electrical failure detected
  • Both engines fail or are shut down
  • Airspeed above 100 knots (typical)

Deployment time: 8 seconds typical. Generates 5-15 kVA depending on aircraft speed and altitude.

RAT Performance:

  • Powers essential AC and DC buses
  • Provides hydraulic pressure (some aircraft)
  • Output increases with airspeed
  • Cannot be retracted once deployed
  • Minimum operating speed: 130 knots (typical)

Static Inverter

Converts 28V DC to 115V AC at 400 Hz. Used to power essential AC bus when generators fail. Capacity typically 1 kVA. Powers standby instruments and essential avionics.

External Power Unit (EPU) Specifications:

  • Voltage: 115/200V AC at 400 Hz
  • Also provides 28V DC
  • Interlocked with generators - cannot parallel
  • Voltage must be within ±5% of nominal
  • Frequency tolerance: ±5 Hz
Ground Power Connection: Before connecting external power:
  • Verify voltage and frequency within limits
  • Ensure generators are off or will auto-disconnect
  • Check phase rotation correct (3-phase AC)
  • GPUs typically provide 90 kVA capacity

SYSTEM Hydraulic Systems

Purpose: Hydraulic systems transmit power to operate flight controls, landing gear, brakes, and other systems. Modern transport aircraft typically have 3 independent systems for redundancy.

Hydraulic Fluid

Skydrol (Phosphate-Ester Base):

  • Most common in modern aircraft
  • Fire resistant
  • Operating range: -40°C to +135°C
  • Purple/red color
  • Attacks paint, plastics, human skin
  • Specific gravity: 1.04-1.06
⚠️ FLUID INCOMPATIBILITY: Different hydraulic fluid types MUST NEVER BE MIXED. Contamination can cause system failure. Skydrol and mineral-based fluids are completely incompatible. Color coding prevents mixing:
  • Skydrol: Purple/Red
  • Mineral Oil: Blue

Operating Pressure: Typical systems operate at 3000 PSI (207 bar). Some modern aircraft use 5000 PSI systems for reduced weight.

Engine Driven Pumps (EDP)

  • Type: Variable displacement axial piston pump
  • Driven from engine accessory gearbox
  • Output: 20-30 GPM at 3000 PSI
  • Swashplate angle varies to maintain constant pressure
  • Automatic compensation for load changes
  • Case drain returns leakage fluid to reservoir

Electric Motor Driven Pumps (EMDP)

Provide backup and ground operation capability:

  • Power: 115V AC 400 Hz
  • Flow rate: 8-15 GPM typical
  • Used for: Engine start, ground ops, backup in flight
  • Lower capacity than EDPs
  • Thermal protection prevents overheating
Electric Pump Limitations: EMDPs have limited duty cycle. Continuous operation may cause overheating. Typical limit: 30-60 minutes continuous use. Auto-shutoff at 130-150°C.

Accumulators

Gas-charged accumulators serve multiple functions:

  • Pressure Storage: Provides instant pressure for system needs
  • Shock Absorption: Dampens pressure surges
  • Thermal Expansion: Compensates for fluid expansion
  • Emergency Power: Multiple brake applications without pump

Precharged with nitrogen to 1000-1500 PSI. System pressure compresses gas to 3000 PSI, storing energy.

Component Function Critical Values
Reservoir Fluid storage, air separation Pressurized to 35-50 PSI
Filters Remove contamination 10-25 micron filtration
Heat Exchanger Cool hydraulic fluid Max temp: 135°C
PTU Power Transfer Unit - connects systems Equalizes pressure between systems

Three System Configuration

System A (Green)
  • Engine 1 EDP
  • Electric pump backup
  • Powers: Primary flight controls
  • Landing gear normal extension
  • Normal brakes
System B (Yellow)
  • Engine 2 EDP
  • Electric pump backup
  • Powers: Primary flight controls
  • Cargo doors
  • Alternate brakes
System C (Blue)
  • Electric pump only
  • Powers: Standby controls
  • Emergency gear extension
  • Backup systems

Power Transfer Unit (PTU):

The PTU is a hydraulic motor-pump combination that allows one system to power another. Typical configuration: System A can power System B loads through PTU.

  • Automatically activates on pressure differential > 500 PSI
  • Characteristic barking sound during operation
  • Used primarily for landing gear operation if one system fails
  • Does not transfer fluid - only mechanical energy
⚠️ TOTAL HYDRAULIC FAILURE: Loss of all hydraulic systems results in:
  • Reversion to mechanical backup or manual reversion flight controls
  • Landing gear free-fall extension via gravity
  • Accumulator pressure for limited brake applications (5-8 applications)
  • RAT deployment may provide emergency hydraulic pressure (aircraft dependent)

Pressure Monitoring

Normal operating pressure: 3000 PSI

Low pressure warning: 2200-2400 PSI

Overpressure relief: 3600-3800 PSI

Temperature Monitoring

Temperature Limits:
  • Normal: 40-70°C
  • Caution: 90°C
  • Maximum: 135°C
  • Above max temp causes fluid degradation and seal damage

Quantity Monitoring

Reservoir quantity displayed as percentage or level. Low level warnings typically at:

  • Caution: 40% remaining
  • Warning: 20% remaining
  • Minimum for operation: 10-15%
⚠️ CAVITATION: Low fluid level causes pump cavitation. Symptoms:
  • Erratic pressure indications
  • Unusual pump noise
  • Elevated fluid temperature
  • Can cause pump damage in 30 seconds
Purpose: Hydraulic fuses automatically isolate failed components to prevent complete system fluid loss. Critical for safety in case of line rupture.

Operation:

  • Spring-loaded piston mechanism
  • Activates on excessive flow rate (indicating rupture)
  • Closes within 0.1 seconds
  • Limits fluid loss to 1-2 quarts
  • Located at actuator inlets
  • Cannot be reset in flight
Fire Shutoff Valves: In event of engine fire, hydraulic shutoff valves close to prevent fluid feeding fire. Operated by fire handle. Isolates all hydraulic lines in engine fire zone.

SYSTEM Pneumatic Systems

Primary Function: Engine bleed air provides high-pressure, high-temperature air for:
  • Air conditioning and pressurization
  • Ice protection (wing and engine anti-ice)
  • Engine starting
  • Hydraulic reservoir pressurization
  • Water system pressurization

Bleed Air Sources

Engine Bleed

Air extracted from engine compressor:

  • Low Stage: 5th-7th stage, lower pressure
  • High Stage: 10th-14th stage, higher pressure
  • Pressure: 35-45 PSI (typical)
  • Temperature: 200-250°C
  • Automatic changeover based on demand
APU Bleed
  • Available on ground and in flight
  • Max altitude: FL200-FL250 typical
  • Pressure: 40-50 PSI
  • Limited capacity vs engine bleed
  • Can supply full air conditioning
  • Cannot supply anti-ice in most aircraft
⚠️ ENGINE PERFORMANCE PENALTY: Using engine bleed air reduces engine performance:
  • Thrust loss: 5-10% with packs on
  • Additional 3-5% loss with anti-ice on
  • Takeoff performance calculated with packs consideration
  • Hot/high airports may require packs off for takeoff

Bleed Air Regulation

Pressure Regulating Valve (PRV):

  • Reduces bleed air to 35-45 PSI
  • Maintains constant pressure regardless of engine power
  • Protects downstream components from over-pressure
  • Pneumatically operated with electronic control

Precooler (Heat Exchanger):

  • Cools bleed air from 250°C to 150-200°C
  • Uses fan air for cooling
  • Essential for downstream component protection
  • Over-temp protection closes bleed valve at 290°C

Bleed Air Manifold

Central distribution system connecting all bleed sources. Includes crossbleed capability allowing:

  • Single engine operation of all systems
  • APU bleed to supply both sides
  • Ground cart connection
  • Engine cross-start capability
System User Pressure Required Priority
Engine Anti-Ice 35-45 PSI Highest
Wing Anti-Ice 35-45 PSI Very High
Air Conditioning Packs 35-45 PSI High
Engine Start 40-50 PSI Medium
Hydraulic Reservoir 35-50 PSI Low
Priority Logic: If bleed air pressure insufficient for all demands:
  1. Engine anti-ice maintained (safety critical)
  2. Wing anti-ice reduced or cycled
  3. Pack flow reduced to economy mode
  4. One pack may be shed automatically

Leak Detection

⚠️ BLEED AIR LEAK: High temperature bleed air leak in wing or fuselage is serious fire risk:
  • Dual loop leak detection in all bleed ducts
  • Warning at 260°C duct temperature
  • Alerts crew via EICAS/ECAM
  • Requires immediate bleed source shutdown
  • QRH procedure includes landing consideration

Over-Pressure Protection

  • Relief valve opens at 75-80 PSI
  • Prevents downstream component damage
  • Vents overboard through dedicated duct
  • Automatic reset when pressure normalizes

Over-Temperature Protection

Multiple temperature sensors monitor bleed air:

  • Caution: 260°C - advisory message
  • Warning: 290°C - automatic bleed valve closure
  • Critical: +300°C - potential fire condition
Air Start System: Modern turbine aircraft use pneumatic starting. Bleed air drives air turbine starter connected to engine HP spool via accessory gearbox.

Start Sequence

Ground Start (APU Bleed):

  1. APU started and supplying bleed air
  2. Start valve opened - air to starter
  3. Engine accelerates to 20% N2
  4. Fuel introduced and ignition activated
  5. Light-off at 20-25% N2
  6. Self-sustaining at 50-56% N2
  7. Start valve closes automatically
  8. Idle speed: 60-65% N2

Cross-Bleed Start

Starting second engine using first engine's bleed air:

  • Engine 1 at stable idle
  • Crossbleed valve opened
  • Engine 2 start initiated
  • Engine 1 automatically increases to 70% N1
  • Provides adequate bleed air pressure
  • Start time slightly longer than APU start
⚠️ START LIMITATIONS:
  • Starter Duty Cycle: After 2 start attempts, wait 30 minutes for starter cooling
  • Hot Start: ITT exceeds 725°C (typical) - abort start immediately
  • Hung Start: Engine fails to accelerate to idle - N2 stagnates below 50%
  • No Light-Off: No ITT rise after fuel introduction - dry motor to purge fuel

In-Flight Start

If engine shutdown in flight, restart procedure:

  • Minimum windmill speed: 15% N2
  • Optimum altitude: FL200-FL250
  • Maximum altitude: FL300-FL350 (aircraft dependent)
  • Windmilling provides sufficient N2 for fuel ignition
  • No starter required if adequate windmill speed
  • APU provides bleed if windmill insufficient

SYSTEM Fuel Systems

Jet Fuel Characteristics: Aviation turbine fuel must meet strict specifications for safety, performance, and engine protection.
Jet A / Jet A-1 (Common)
  • Kerosene-type fuel
  • Flash point: 38°C minimum
  • Freeze point: -40°C (A) / -47°C (A-1)
  • Specific gravity: 0.775-0.840
  • Energy content: 43.2 MJ/kg
  • Most common worldwide
Jet B (Wide-Cut)
  • Naphtha-kerosene blend
  • Freeze point: -60°C
  • Lower flash point (more volatile)
  • Better cold weather performance
  • Used in Canada and Alaska
  • Higher fire risk on ground
⚠️ FUEL CONTAMINATION: Water in fuel is dangerous:
  • Freezes at cruise altitude forming ice crystals
  • Ice blocks fuel filters causing engine flame-out
  • Water detection critical during pre-flight
  • Fuel contains additives to prevent microbial growth in water
  • Daily fuel tank water draining mandatory

Fuel Additives

Additive Type Purpose Typical Concentration
Fuel System Icing Inhibitor (FSII) Prevents ice crystal formation 0.10-0.15%
Anti-Oxidant Prevents gum formation 17-24 mg/L
Metal Deactivator Prevents catalytic oxidation 2-6 mg/L
Static Dissipator Improves electrical conductivity 1-3 mg/L
Biocide Prevents microbial growth As needed

Wing Tanks

Primary fuel storage in integral wing structure:

  • Left and right main tanks
  • Surge tanks at wingtips (expansion space)
  • Vent system prevents pressure buildup
  • Sealed with sealant, not separate bladders
  • Structure serves as tank walls

Center Tank

Located in fuselage center section:

  • Used for additional capacity on longer flights
  • Fuel used first to unload wing structure
  • Contains 2 boost pumps
  • Automatic pump shutoff when tank empty
  • May have fuel temperature limitations (heated area)
Center Tank Temperature: Center tank located above hot air ducts. If fuel temperature exceeds 49°C, center tank pumps must be OFF to prevent vapor formation and pump cavitation. Monitored by fuel temperature sensors.

Auxiliary Tanks (Optional)

Tail Tank (Trim Tank)
  • Located in horizontal stabilizer
  • Used for CG control in flight
  • Improves cruise efficiency
  • Transfer system moves fuel aft
  • Large aircraft only (747, A380)
Fuselage Auxiliary Tanks
  • Additional tanks for extended range
  • May reduce cargo capacity
  • Transfer to main tanks required
  • Often removable/optional

Fuel Pumps

Redundant Pump System: Each main tank has 2 electric boost pumps plus engine-driven pump capability. Ensures continuous fuel supply even with multiple failures.

AC Electric Boost Pumps:

  • Submerged in fuel tank
  • Pressure: 30-50 PSI
  • Flow rate: 700-900 GPH each
  • Provide positive pressure to engine fuel pump
  • Prevent vapor lock at altitude
  • Cooled by surrounding fuel

Engine-Driven Fuel Pump:

  • Gear-type positive displacement pump
  • Mounted on engine accessory gearbox
  • Final pressure boost to 300-700 PSI
  • Supplies fuel to FCU (Fuel Control Unit)
  • Can operate with failed electric pumps
  • Suction feed capability up to FL250-FL300
⚠️ LOW PRESSURE WARNING: If both boost pumps in a tank fail:
  • Low pressure light illuminates
  • Engine-driven pump continues to supply fuel
  • At altitude, vapor lock risk increases
  • Consider descent below FL250
  • Landing as soon as practical recommended

Fuel Heating

Fuel/oil heat exchangers prevent fuel freeze:

  • Hot engine oil heats cold fuel
  • Also cools engine oil
  • Maintains fuel above -40°C (Jet A)
  • No pilot control - automatic operation
  • Critical for preventing fuel system icing

Cross-Feed System

Allows any engine to receive fuel from any tank:

  • Cross-feed valve connects fuel manifolds
  • Used for: Engine failure, fuel imbalance, single engine taxi
  • Can feed both engines from one tank
  • Normal position: CLOSED (each engine feeds from its tank)
Fuel Imbalance: Typical imbalance limit: 1000-1500 lbs or 200 gallons. Excessive imbalance causes:
  • Lateral CG shift requiring aileron trim
  • Wing bending stress
  • Increased drag
  • Requires cross-feed to balance

Fuel Quantity Indication

Capacitance-Type Probes:

  • Multiple probes in each tank
  • Measure fuel dielectric constant
  • Compensate for fuel density variations
  • Display in pounds or kilograms
  • Accuracy: ±1% typical

Totalizer: Calculates total fuel remaining by summing all tank quantities. Includes:

  • Fuel used indication
  • Fuel flow rate per engine
  • Range remaining calculation
  • Predicted fuel at destination

Fuel Jettison (Dump)

⚠️ EMERGENCY FUEL JETTISON: Used to reduce weight for emergency landing:
  • Maximum landing weight may be 200,000+ lbs below MTOW
  • Jettison rate: 2000-4000 lbs/min typical
  • Dumps from outer wing tanks
  • Minimum jettison altitude: 5000 ft AGL
  • Fuel vaporizes before reaching ground
  • Cannot jettison below minimum fuel quantity

Fire Protection

⚠️ ENGINE FIRE PROCEDURE: Fire handle closes:
  • Engine fuel shutoff valve (spar valve)
  • Engine hydraulic shutoff valve
  • Engine bleed air valve
  • Fuel pump supply to that engine
  • Cannot be reopened in flight

Fuel Filter

  • Removes particles down to 10-25 microns
  • Bypass valve opens if filter clogs
  • Impending bypass indication alerts crew
  • Water separator included in filter assembly
  • Filters must be drained regularly

Vent System

Maintains atmospheric pressure in tanks:

  • Prevents tank collapse as fuel consumed
  • Allows thermal expansion
  • Surge tanks capture overflow fuel
  • NACA vents prevent icing
  • Flame arrestors prevent external ignition
Vent Blockage: Blocked vent causes:
  • Tank pressure decrease (vacuum)
  • Possible tank structural damage
  • Fuel starvation if severe
  • Pre-flight inspection critical

Pressure Refueling

Standard method for large aircraft:

  • Single point connection under fuselage
  • Refueling rate: 600-1000 GPM
  • Pressure: 50-55 PSI
  • Automated fuel distribution to tanks
  • Preset quantity shutoff
  • Full fuel load in 15-30 minutes

Over-Wing Refueling

Gravity feed through tank filler caps:

  • Backup method or small aircraft
  • Much slower than pressure refuel
  • Manual monitoring required
  • Risk of overfill if not monitored
⚠️ REFUELING SAFETY:
  • Bonding cable connected before fueling begins
  • No passengers during refueling (some jurisdictions)
  • Fire extinguisher readily available
  • No electrical equipment operation
  • Fuel spills must be cleaned immediately
  • APU may run during refuel (ops dependent)

Defueling

Removing fuel from aircraft tanks:

  • Uses boost pumps in reverse
  • Or dedicated defuel pump
  • Rate: 300-500 GPM
  • Required for heavy maintenance or CG issues
  • Same safety precautions as refueling

SYSTEM Landing Gear Systems

Tricycle Configuration: Modern transport aircraft use nose gear plus two main gear assemblies. Provides stability on ground and better visibility during takeoff and landing.
Main Landing Gear
  • Carries 90-95% of aircraft weight
  • Multiple wheels per assembly (2-6 typical)
  • Equipped with multi-disc brakes
  • Shock strut (oleo-pneumatic)
  • Retracts into wing or fuselage
  • Tire pressure: 180-220 PSI typical
Nose Landing Gear
  • Carries 5-10% of aircraft weight
  • Provides steering control
  • Typically 2 wheels
  • Usually not braked
  • Retracts forward or aft
  • Contains tow bar attachment

Shock Strut (Oleo Strut)

Two-Chamber Design:

  • Upper Chamber: Compressed nitrogen gas (1800-2200 PSI)
  • Lower Chamber: Hydraulic fluid
  • Compression forces fluid through orifice
  • Energy dissipated as heat
  • Nitrogen spring returns strut to extension
  • Proper servicing: 2-4 inches exposed piston typical
Strut Servicing: Incorrect servicing causes:
  • Over-serviced: Hard landing, gear damage risk
  • Under-serviced: Bottoms out, tail strike risk
  • Check strut extension with aircraft at operating weight
  • Service pressure adjusted for actual aircraft weight

Normal Extension/Retraction

Hydraulic System Operation:

  • Gear selector lever commands extension/retraction
  • Hydraulic pressure moves actuators
  • Sequence valves ensure proper timing
  • Doors open before gear moves
  • Gear locks in position with mechanical over-center locks
  • Extension time: 15-30 seconds
  • Retraction time: 10-20 seconds

Landing Gear Doors

Protect gear wells and reduce drag:

  • Open before gear extends/retracts
  • Close after gear fully extended/retracted
  • Some aircraft leave MLG doors open with gear down
  • Hydraulically actuated
  • Blown open by gear during emergency extension
⚠️ GEAR OPERATING LIMITATIONS:
  • VLO (Landing gear Operating speed): 220-270 KIAS typical
  • VLE (Landing gear Extended speed): 250-285 KIAS typical
  • Exceed VLO: possible door/actuator damage
  • Exceed VLE: structural damage, increased drag

Gear Position Indication

Three Green Lights: Gear down and locked

No Lights: Gear up and locked

Red Light: Gear in transit or disagree

Position sensors (typically 3 per gear leg):

  • Proximity switches detect lock position
  • Redundant sensing for reliability
  • All sensors must agree for green light
Alternate/Emergency Systems: Designed to extend gear even with complete hydraulic failure. Uses gravity, mechanical linkage, or stored hydraulic pressure.

Gravity/Free-Fall Extension

Most Common Method:

  • Emergency gear handle pulled
  • Releases hydraulic pressure from up side
  • Mechanical uplock releases
  • Gear falls under own weight
  • Airflow and gravity assist extension
  • Extension time: 30-90 seconds
  • Airspeed required: 140-180 KIAS minimum
Free-Fall Considerations:
  • Gear may not lock down properly
  • Visual check by other aircraft recommended
  • G-loading may affect extension (pull ~1.2-1.5G)
  • Nose gear most likely to have issue
  • Yaw aircraft if nose gear fails to extend
  • Cannot retract after emergency extension

Accumulator Pressure Extension

Some aircraft use stored hydraulic pressure:

  • Accumulator charged to 3000 PSI
  • Sufficient for 1-3 gear extensions
  • More reliable than gravity alone
  • Provides positive down-lock
  • Independent of main hydraulic systems
⚠️ GEAR UNSAFE INDICATION: If gear does not indicate down and locked:
  • Attempt normal extension again
  • Use alternate/emergency system
  • Fly-by tower for visual check
  • Consider higher approach speed
  • Plan for possible gear collapse
  • Emergency services standby
  • Burn off fuel to reduce landing weight

Ground Safety Systems

Squat Switches (Weight-On-Wheels):

  • Located on main gear struts
  • Detect aircraft on ground vs. in air
  • Control multiple systems:
    • Prevents gear retraction on ground
    • Enables ground spoiler deployment
    • Activates autobrakes
    • Inhibits TCAS/GPWS on ground
    • Changes flight control logic
  • Redundant switches for reliability

Gear Warning System

Configuration Warnings: Aural and visual warnings if:
  • Landing gear not down with:
    • Flaps beyond 25-30°
    • Power levers at idle
    • Below 800-1500 ft RA (radio altitude)
  • Warning: Continuous horn and red light
  • Can be silenced but light remains
  • Test button verifies system function

Steering Disconnect Safety

Nose gear steering automatically disconnects:

  • During takeoff at 60-80 knots
  • Prevents excessive nose gear loads
  • Rudder becomes primary directional control
  • Reconnects during landing rollout
  • Manual override available for ground ops

Anti-Skid System

Prevents wheel lock-up during braking:

  • Wheel speed sensors on each main wheel
  • Compare wheel speeds continuously
  • Reduce brake pressure if wheel decelerating too rapidly
  • Optimizes braking efficiency
  • Prevents tire blow-out from flat spots
  • Inoperative below 20 knots
⚠️ ANTI-SKID FAILURE: With anti-skid inoperative:
  • Use caution with brake application
  • Landing distance increases 25-50%
  • Hydroplaning risk greatly increased
  • Consider dry runway for landing
  • Gentle brake application required
  • Use maximum reverse thrust

Normal Brakes

Hydraulic Multi-Disc Brakes:

  • Multiple steel discs (rotors and stators)
  • Hydraulic pressure forces discs together
  • Typical pressure: 3000 PSI
  • Heat generated: up to 500°C during rejected takeoff
  • Brake temperature monitoring critical
  • Cooling time required after heavy use

Alternate Brakes

Backup system using different hydraulic source:

  • Separate hydraulic system
  • May have reduced effectiveness
  • Anti-skid typically still available
  • Autobrakes may be unavailable

Parking Brake

Mechanically traps hydraulic pressure:

  • Lever/button sets parking brake
  • Isolates brake hydraulics
  • Pressure maintained even with pumps off
  • Will slowly release as fluid leaks internally
  • Chocks required for long-term parking
Brake Overheating: After heavy brake use (rejected takeoff):
  • Temperature may reach 500-900°C
  • Fuse plugs melt at 177°C to deflate tire
  • Prevents explosive tire failure
  • Brake fire risk if extremely hot
  • Cooling time: 30-60 minutes before flight
  • Fire crews must inspect if fuse plugs blown

Autobrakes

Automatic brake application during landing or rejected takeoff:

Landing Settings:

  • LOW: Gentle deceleration, long runways
  • MEDIUM: Normal operations
  • MAX: Short runway, contaminated surface
  • Activated at main gear touchdown
  • Deactivated by pilot brake application

Rejected Takeoff (RTO):

  • Maximum brake pressure immediately
  • Activates above 85 knots
  • Requires throttle reduction to idle
  • Cannot be overridden

Tire Specifications

Aircraft Tire Characteristics:

  • Pressure: 180-220 PSI (much higher than car tires)
  • Rated for specific loads and speeds
  • Speed rating: up to 225 mph
  • Tread depth minimum: 1/32 inch in grooves
  • Inflation with nitrogen (not air)
  • Life: 200-300 landings typical
Tire Inspection Required:
  • Cuts, bulges, or bald spots = replacement
  • Foreign object damage (FOD) common
  • Pressure check every flight
  • Wear patterns indicate alignment issues
  • Nose tire wears faster than main tires

Hydroplaning

⚠️ DYNAMIC HYDROPLANING: Tire rides on film of water, losing all braking action.

Hydroplaning Speed Formula:

9 × √Tire Pressure (PSI) = Speed in knots

Example: 200 PSI tire: 9 × √200 = 127 knots

Prevention:

  • Good tire tread depth
  • Proper tire inflation
  • Grooved runways
  • Maximum reverse thrust
  • Avoid heavy braking until speed reduced

SYSTEM Flight Control Systems

Control Surfaces: Ailerons (roll), elevators (pitch), and rudder (yaw) are the primary flight controls. Modern aircraft use hydraulically-powered control surfaces with multiple levels of redundancy.
Ailerons
  • Control roll about longitudinal axis
  • Outboard and inboard sections
  • Outboard: low-speed flight
  • Inboard: high-speed (locked out)
  • Powered by multiple hydraulic systems
  • Deflection: ±25° typical
Elevators
  • Control pitch about lateral axis
  • Typically 2 sections (L/R)
  • Work in conjunction with stabilizer
  • Redundant hydraulic power
  • Deflection: ±30° typical
  • May have lockout protection
Rudder
  • Controls yaw about vertical axis
  • Often multiple sections
  • Upper/lower or main/auxiliary
  • Yaw damper auto-coordination
  • Deflection: ±30° typical
  • Travel reduced with speed

Hydraulic Power Control Units (PCUs)

Convert pilot input into hydraulic surface movement:

  • Servo valve directs hydraulic pressure
  • Main actuator moves control surface
  • Feedback mechanism ensures precise control
  • Multiple hydraulic systems for redundancy
  • Force: 20,000-50,000 lbs per actuator
⚠️ CONTROL SURFACE RUNAWAY: Uncommanded surface movement due to PCU failure:
  • Immediate action required
  • Isolate affected hydraulic system
  • May require manual reversion
  • Reduced control authority
  • Higher control forces
  • Emergency descent may be necessary

Triple Redundancy

Each primary control surface typically powered by:

  • System A hydraulic
  • System B hydraulic
  • System C hydraulic (backup)
  • Loss of any two systems still allows control
  • Degraded handling with system failures

Manual Reversion

Total Hydraulic Failure Backup:
  • Direct mechanical linkage to flight controls
  • Extremely high control forces required
  • Limited to specific surfaces (usually elevator/aileron)
  • Rudder may have limited authority
  • Speed must be kept low (250 knots typical)
  • Two pilots may be required for control
⚠️ MANUAL REVERSION LIMITATIONS:
  • No autopilot available
  • No yaw damper
  • Greatly increased control forces
  • Reduced control surface deflection
  • Landing requires 2 pilots on controls
  • Approach speed increased
  • Consider crew fatigue - expedite landing

Spoilers/Speed Brakes

Multiple Functions:

  • Flight Spoilers: Assist ailerons in roll control
  • Speed Brakes: Increase drag for descent/deceleration
  • Ground Spoilers: Dump lift on landing, increase braking
  • Typically 5-8 panels per wing
  • Hydraulically actuated
  • Deflection: up to 60°

Ground Spoiler Logic:

  • Armed before landing
  • Auto-deploy when:
    • Main wheels spin up (wheel speed sensors)
    • AND throttles at idle
    • OR reverse thrust selected
  • Immediate lift dump on touchdown
  • Transfers weight to wheels for braking
  • Improves stopping distance by 30-40%
Speed Brake Limitations:
  • Maximum speed: 280-320 KIAS (aircraft dependent)
  • Automatically retract with flap extension
  • Auto-retract with certain autopilot modes
  • Do not extend with ice accumulation

Flaps & Slats

High-Lift Devices: Increase camber and wing area to reduce stall speed and improve low-speed handling.
Leading Edge Slats
  • Extend forward and down
  • Increase wing camber
  • Delay stall to higher angle of attack
  • Operate automatically with flaps
  • Can extend independently for maneuvers
Trailing Edge Flaps
  • Multiple sections per wing
  • Fowler flaps (move aft and down)
  • Increase lift and drag
  • Positions: 0°, 1°, 5°, 10°, 15°, 20°, 25°, 30°, 40°
  • Extension speed limits decrease with setting
Flap Setting Typical Use Speed Limit (KIAS)
Cruise, Clean Config -
1° / 5° Takeoff, Go-Around 250
10° / 15° Takeoff, Initial Approach 220
20° / 25° Final Approach 200
30° / 40° Landing (Full Flaps) 180
⚠️ FLAP ASYMMETRY: Unequal flap extension causes severe roll:
  • Automatic flap asymmetry detection
  • System stops flap movement if detected
  • Asymmetry > creates significant roll moment
  • May require opposite aileron and spoiler
  • Land with existing flap configuration
  • Do not attempt to retract if asymmetric

Horizontal Stabilizer (Trim System)

Adjusts entire horizontal stabilizer angle:

  • Electric motor drives jackscrew
  • Backup: alternate trim system
  • Range: 0° to 13° nose-up typical
  • Trim speed: 0.2°/second
  • Autopilot controls for hands-off flight
  • Position indicator in cockpit
⚠️ STABILIZER RUNAWAY: Uncommanded trim movement:
  • Immediate cutout switches activation
  • Control column force may be extreme
  • Manual trim wheel always available
  • May require unusual aircraft attitude
  • QRH memory item procedure
Electronic Flight Control: Pilot inputs sent to flight computers which command actuators. No direct mechanical linkage. Provides envelope protection and improved handling.

System Architecture

Components:

  • Sidestick or control column (with sensors)
  • Multiple redundant flight control computers (3-7 computers)
  • Electro-hydraulic actuators at control surfaces
  • Multiple data buses for communication
  • Voting logic resolves computer disagreement

Control Laws

Normal Law (Full Protection)
  • Load factor limiting
  • Angle of attack protection
  • High speed protection
  • Bank angle limitation (67°)
  • Automatic pitch trim
  • Cannot stall aircraft
Alternate/Direct Law (Degraded)
  • Reduced or no envelope protection
  • Results from sensor failures
  • More conventional handling
  • Stall protection may be lost
  • Manual pitch trim required

Envelope Protection Features

Angle of Attack Protection:

  • Maximum AoA: α-max
  • Computer prevents exceeding limit
  • Full aft stick commands α-max, not stall
  • Automatic nose-down if approaching stall

Load Factor Protection:

  • Positive limit: +2.5g (clean), +2.0g (config)
  • Negative limit: -1.0g (clean), 0g (config)
  • Prevents structural overstress

High Speed Protection:

  • VMO/MMO protection
  • Automatic nose-up at VMO+6 / MMO+0.01
  • Cannot be overridden by pilot
⚠️ REVERSION TO DIRECT LAW: Loss of normal protections due to:
  • Multiple computer failures
  • Air data sensor failures
  • Flight control surface faults
  • Electrical power degradation

Pilot Actions:

  • Increased awareness required
  • Manual speed/AoA management
  • Can stall aircraft - monitor speed closely
  • Pitch trim required manually
  • Limit maneuvering

SYSTEM Pressurization & Air Conditioning

Purpose: Maintain comfortable cabin pressure and oxygen levels at high altitude. Typical cabin altitude at cruise: 6000-8000 feet at FL350-FL430.

Pressurization Parameters

Maximum Differential Pressure: 8.1-9.1 PSI

This is the difference between cabin pressure and outside pressure. Limits:

  • Normal operation: up to 8.1 PSI
  • Relief valve opens: 8.6-9.1 PSI
  • Structure designed for: ~10 PSI (safety margin)
Aircraft Altitude Cabin Altitude Differential Pressure
Sea Level Sea Level 0 PSI
FL250 5000 ft 5.5 PSI
FL350 6500 ft 7.8 PSI
FL410 8000 ft 8.1 PSI (max normal)
Above FL410 Increases above 8000 ft 8.1 PSI (constant)

Pressurization Control

Cabin Pressure Controller:

  • Automatically controls outflow valve position
  • Inputs: destination field elevation, cruise altitude
  • Controls climb/descent rates
  • Typical rate: 300-500 ft/min cabin altitude change
  • Provides smooth pressure changes for passenger comfort

Outflow Valves

Control cabin pressure by regulating air exhaust:

  • Located in aft fuselage (typically 2 valves)
  • Motor-driven for position control
  • Automatic and manual modes
  • Fully open: no pressurization
  • Fully closed: maximum pressurization (limited by relief)
Pressurization Rates:
  • Climb: Cabin climbs slower than aircraft
  • Descent: Cabin descends before aircraft
  • Prevents ear discomfort
  • Maximum rate typically: 500 ft/min
  • Can be manually adjusted if passengers uncomfortable

Relief Valves

⚠️ OVERPRESSURE PROTECTION:
  • Positive Relief: Opens at 8.6-9.1 PSI differential
  • Prevents excessive cabin pressure
  • Spring-loaded, automatic operation
  • Cannot be closed manually
  • Negative Relief: Opens at -0.3 to -0.5 PSI
  • Prevents cabin depressurization below outside pressure
  • Protects structure from negative loads

Rapid Depressurization

⚠️ EMERGENCY DESCENT REQUIRED:

Rapid depressurization causes:

  • Loud noise (explosive if sudden structural failure)
  • Temperature drop (adiabatic cooling)
  • Fog formation in cabin
  • Oxygen masks auto-deploy at 14,000 ft cabin altitude

Time of Useful Consciousness at Altitude:

  • FL250: 3-5 minutes
  • FL300: 1-2 minutes
  • FL350: 30-60 seconds
  • FL400: 15-20 seconds
  • FL450+: 9-12 seconds

Immediate Actions:

  1. Don oxygen masks (crew)
  2. Establish crew communications
  3. Passenger oxygen verify ON
  4. Emergency descent - target 10,000 ft
  5. Descend at maximum rate (may exceed 250 KIAS below FL100)

Safety/Dump Valve

Manual valve to depressurize cabin:

  • Used for: smoke/fumes elimination, emergency
  • Opens outflow valves fully
  • Cabin altitude equalizes with aircraft altitude
  • Oxygen masks required above 10,000 ft
Air Cycle Machine (ACM): Cools and conditions bleed air for cabin use. No refrigerant - uses air expansion for cooling. Also called "pack" (Pressurization and Air Conditioning Kit).

Pack Operation

Three-Wheel Boot Cycle:

  1. Compressor: Further compress bleed air
  2. Heat Exchanger: Cool air using ram air
  3. Turbine: Expand air (temperature drops significantly)
  4. Water Separator: Remove condensed moisture

Output air: 5-15°C, mixed with hot bleed air for final temperature control

Pack Configuration

Typical transport aircraft: 2 packs (left and right)

  • Each pack can condition entire cabin (reduced capacity)
  • Pack flow: AUTO, HIGH, LOW
  • AUTO: Varies based on demand
  • HIGH: Maximum cooling/heating
  • LOW: Reduced flow (engine performance)
Pack Trip-Off: Pack automatically shuts down if:
  • Compressor overspeed
  • Overtemperature (>230°C output)
  • Turbine overspeed
  • Loss of bleed air supply
  • Can be reset after cooling period

Temperature Control

Zone temperature control:

  • Cockpit zone: independent control
  • Forward cabin zone
  • Aft cabin zone
  • Cargo compartments (if heated)
  • Trim air valves add hot bleed air to reach desired temp
  • Range: 18-30°C typical

Air Distribution

Cabin Airflow Pattern:

  • Fresh air enters from overhead
  • Flows downward along cabin walls
  • Exits at floor level
  • Minimizes mixing between rows
  • Improves air quality and comfort

Air Quality

Air Composition:

  • 50% fresh air from packs
  • 50% recirculated cabin air
  • Recirculated air filtered (HEPA filters typical)
  • Filters remove 99.97% of particles
  • Complete air change every 2-3 minutes

Gaspers & Equipment Cooling

Gasper Outlets:

  • Individual passenger air nozzles
  • Supply from recirculation system
  • Temperature not individually controlled

Equipment Cooling:

  • Avionics cooling fan
  • Draws cabin air through electronic bays
  • Exhausts overboard
  • Smoke detection in avionics bay

Cargo Heating/Ventilation

Cargo compartments:

  • Forward: heated and ventilated (pets, perishables)
  • Aft: may be heated and ventilated
  • Bulk: typically not heated
  • Temperature: 7-24°C
  • Smoke detectors in all compartments
  • Fire suppression in Class C/E holds

SYSTEM Ice and Rain Protection

Anti-Ice: Prevents ice formation. Used on critical surfaces continuously when icing conditions exist. De-Ice: Removes ice after formation. Typically pneumatic boots on propeller aircraft or some older jets.
Anti-Ice Systems (Jets)
  • Engine hot bleed air
  • Continuous operation in icing
  • Engine cowl anti-ice
  • Wing leading edge anti-ice
  • Prevents ice accumulation
De-Ice Systems (Props)
  • Pneumatic boots (wing/tail)
  • Inflate to crack accumulated ice
  • Cyclic operation
  • Less effective than anti-ice
  • Must accumulate ice before activation

Engine Cowl Anti-Ice

⚠️ CRITICAL FOR SAFETY: Engine cowl anti-ice prevents ice buildup on engine inlet that could cause:
  • Compressor stall/surge
  • Engine flame-out
  • Ingestion damage
  • Vibration from ice shedding

System Operation:

  • Hot bleed air (200-250°C) directed to inlet cowl
  • Heats leading edge structure
  • Each engine independently controlled
  • Thrust loss: 3-5% when operating
  • Mandatory in icing conditions

When to Use Engine Anti-Ice

Operate Engine Anti-Ice when:
  • OAT ≤ 10°C AND visible moisture
  • This includes: rain, fog, mist, sleet, snow, ice crystals
  • On ground with OAT ≤ 10°C AND:
    • Operating in falling snow or ice crystals
    • Standing water, slush, or ice on taxiways/runways
  • Exception: OAT below -40°C, moisture extremely limited

Takeoff Considerations:

  • Engine anti-ice: ON for takeoff in icing conditions
  • Performance penalty considered in calculations
  • Improved takeoff safety outweighs thrust loss
  • N1 indication may be slightly lower with anti-ice on

Wing Leading Edge Anti-Ice

Hot Bleed Air System:

  • Piccolo tubes distribute air inside wing leading edge
  • Heats first 3-8% of chord
  • Covers 3-4 inboard slats typically
  • Outboard wing not protected (no ice in these areas)
  • Temperature: 150-200°C
⚠️ WING ANTI-ICE LIMITATIONS:
  • DO NOT use on ground except for:
    • Pre-takeoff check (30 seconds max)
    • Heavy freezing rain/snow during taxi
  • Reason: Can overheat and damage wing structure on ground
  • No cooling airflow when stationary
  • USE in flight whenever icing conditions exist

Wing Anti-Ice Operation

Icing Conditions Requiring Wing Anti-Ice:
  • Same criteria as engine anti-ice
  • OAT ≤ 10°C with visible moisture
  • In flight only (except brief test/heavy precip)
  • Can be used in light to severe icing
  • Turn on before entering icing

Ice Detection

Ice Detection Methods:

  • Visual: Accumulation on wipers, mirrors, wings
  • Ice Detector Probe: Senses ice accretion, alerts crew
  • Advisory: Amber light when ice detected
  • Some aircraft have automatic anti-ice activation

Airframe Icing Effects:

  • Increased drag: up to 50%
  • Reduced lift: up to 30%
  • Increased weight
  • Stall speed increase: 10-20 knots
  • Stick shaker/pusher activation speed increases
  • Reduced control effectiveness
⚠️ SEVERE ICING - IMMEDIATE EXIT REQUIRED:

Indications of severe icing:

  • Ice accumulation 1/4 inch in 5 minutes
  • Ice aft of protected surfaces
  • Lateral or directional control problems
  • Uncommanded roll excursions
  • Abnormal vibration
  • Flap/slat extension abnormalities
  • Airspeed unreliable

Actions: Request immediate altitude/route change to exit icing. Do not continue flight in severe icing.

Pitot & Static Probe Heat

Electrically Heated Probes:

  • Pitot tubes heated to prevent ice blockage
  • Static ports heated
  • AOA vanes heated
  • TAT probes heated
  • Power: 115V AC
  • Heating element in probe structure
  • Auto-activation with engine start (some aircraft)
⚠️ BLOCKED PITOT/STATIC:
  • Pitot blocked: airspeed unreliable, altimeter/VSI work
  • Static blocked: all three instruments unreliable
  • Can cause controlled flight into terrain
  • Always activate probe heat before flight into clouds/precip
  • Leave on throughout flight in IMC

Windshield Heat

Electrical Heating:

  • Conductive film in windshield glass
  • Power: 115V AC
  • Each windshield panel independently heated
  • Temperature: 40-50°C typical
  • Prevents ice/fog formation
  • Also prevents bird strike shattering
Window Heat Precautions:
  • High current draw (5-10 amps per window)
  • Overheat protection at 65-70°C
  • Cracked windshield: heat OFF (may worsen crack)
  • System monitors temperature continuously

Wiper Systems

Rain Removal:

  • Electric or hydraulic motor drive
  • Multiple speed settings
  • Intermittent mode available
  • Park position when off
  • Rain repellent application option

Rain Repellent:

  • Chemical applied to windshield
  • Causes water to bead and blow off
  • Effective above 150 knots
  • Lasts 15-30 minutes
  • Reduces need for wipers in heavy rain
  • Improves visibility significantly

SYSTEM Fire Protection Systems

Fire Zones: Critical areas monitored for fire/overheat:
  • Engine compartments (each engine)
  • APU compartment
  • Main landing gear bays (on some aircraft)
  • Cargo compartments
  • Lavatories (smoke detection only)

Engine Fire Detection

Continuous Loop Detection:

  • Pneumatic or electronic sensing elements
  • Dual loop system (Loop A & Loop B)
  • Detects overheat or fire
  • Fire warning if either loop detects fire
  • Fault warning if one loop fails
  • Detection temperature: 200-260°C
Fire Loop Failure:
  • Single loop failure: fire protection degraded but operational
  • Dual loop failure: no fire detection for that zone
  • FAULT light illuminates
  • Flight may continue with limitations
  • Operational restrictions apply

Cargo Fire Detection

Smoke Detectors:

  • Optical sensors detect smoke particles
  • Multiple detectors per compartment
  • Test button verifies system
  • Immediate crew alert on detection
  • Class B/E compartments have fire suppression
⚠️ CARGO FIRE WARNING:
  • Master warning + aural alert
  • EICAS/ECAM warning message
  • Immediate suppression activation
  • Oxygen to cargo area shut off
  • Diversion to nearest suitable airport
  • Fire may continue to smolder despite suppression
  • Land as soon as possible

Lavatory Smoke Detectors

  • Required in all lavatories
  • Aural warning in lavatory and cockpit
  • Automatic fire extinguisher in waste bin
  • Halon cartridge activates automatically
  • No crew action required for bin extinguisher

Fire Extinguisher Bottles

Halon 1301 System:

  • Each engine: 2 fire bottles
  • APU: 1 fire bottle
  • Bottles pressurized with nitrogen
  • Discharge pressure: 600 PSI
  • Agent distributed via piping in fire zone
  • Discharge time: 1-2 seconds
  • Effective immediately

Fire Handle Procedure

⚠️ MEMORY ITEMS - ENGINE FIRE:
  1. Thrust Lever: Idle
  2. Fire Handle: Pull (after confirmation)
    • Shuts off fuel (spar valve)
    • Shuts off hydraulic fluid
    • Closes bleed air valve
    • De-energizes generator
    • Arms fire bottles
  3. Fire Bottle: Discharge (rotate handle)
  4. If fire persists (30 seconds): Discharge second bottle
Post-Discharge Actions:
  • Verify fire extinguished (warning light out)
  • Monitor engine parameters
  • If fire persists: consider continued discharge
  • Assess aircraft controllability
  • Declare emergency
  • Land at nearest suitable airport
  • Brief flight attendants

APU Fire Protection

Automatic System:

  • Fire detected: APU auto-shuts down
  • Fire bottle auto-discharges (on ground only)
  • In flight: manual discharge required
  • APU automatically shuts down 10 seconds after fire detect
  • Bottle should extinguish fire before significant damage

Class B/E Cargo Compartments

Requirements:

  • Smoke detection system
  • Built-in fire suppression
  • Controlled ventilation
  • Class B: accessible to crew
  • Class E: not accessible but suppression available

Halon Suppression System

Two-Shot System:

  • First bottle: Immediate discharge (knockdown)
  • Second bottle: Metered discharge over 60-90 minutes
  • Maintains suppressive concentration
  • Prevents re-ignition
  • Ventilation system shut off to maintain concentration
⚠️ CARGO FIRE SUPPRESSION LIMITATIONS:
  • Halon concentration effective for 60-90 minutes only
  • Cannot extinguish deep-seated fires in dense cargo
  • May suppress flames but smoldering continues
  • Temperature in compartment continues to rise
  • MUST LAND within suppression time
  • Structural damage may occur from heat
  • Time to land is critical consideration

Cargo Fire Decision Making

Considerations:
  • Time to nearest suitable airport
  • Weather at diversion airport
  • Suppression time remaining
  • Overweight landing may be necessary
  • Request priority handling
  • Emergency services on standby
  • Brief cabin crew - possible evacuation

Lithium Battery Fires

⚠️ SPECIAL HAZARD: Lithium batteries in cargo:
  • Can cause intense, difficult-to-extinguish fires
  • Thermal runaway generates 600-800°C
  • May produce explosive gas
  • Halon may be less effective
  • Regulations limit quantity in cargo
  • Special packaging required
  • Crew notification mandatory for large quantities

Cockpit & Cabin Extinguishers

Halon BCF (Halon 1211):

  • Most common type in aircraft
  • Effective on Class A, B, C fires
  • Non-conductive (safe for electrical fires)
  • Capacity: 2-5 lbs
  • Discharge time: 8-15 seconds
  • Use in confined space: caution (displaces oxygen)

Water Extinguishers (Some Aircraft)

  • Used for Class A fires (paper, wood, cloth)
  • More effective for deep-seated fires
  • Never use on electrical fires
  • Never use on lithium fires (makes worse)
Fire Extinguisher Limitations:
  • Short discharge duration
  • Multiple extinguishers may be needed
  • Watch for re-ignition
  • Halon can cause health effects in confined space
  • Ventilate area after discharge if possible

Location Requirements

Minimum extinguishers required:

  • 1 in cockpit (readily accessible)
  • 1 per galley
  • 1 per cabin section (large aircraft)
  • Additional in cargo compartments (Class B only)
  • Mounted in brackets or compartments
  • Regular inspection required
  • Pressure check before each flight

SYSTEM Oxygen Systems

Purpose: Provide breathable oxygen to flight crew for:
  • Depressurization emergencies
  • Smoke/fumes incidents
  • Prolonged flight above FL250

Crew Oxygen System Components

High-Pressure Gaseous System:

  • Storage: 1800-2200 PSI
  • Cylinder capacity: 77-115 cubic feet
  • Duration: 2+ hours for 2 crew
  • Pressure regulator reduces to 70-85 PSI
  • Quick-don masks at each crew station
  • 100% oxygen on demand
  • Built-in microphone and headset connections

Quick-Don Mask

Features:

  • Donning time: <5 seconds
  • One-hand operation
  • Automatic seal inflation
  • Smoke goggle provision
  • Selector: NORMAL, 100%, EMERGENCY
  • EMERGENCY: positive pressure, prevents smoke inhalation
⚠️ OXYGEN REQUIREMENTS - FLIGHT CREW:
  • Above FL250: One pilot on oxygen at all times
  • Above FL350: One pilot on oxygen continuously
  • Above FL410: One pilot wearing mask continuously
  • Depressurization: All crew on oxygen immediately
  • Smoke/Fumes: Masks to EMERGENCY (positive pressure)

Portable Oxygen Bottles

Supplemental portable oxygen for:

  • Flight attendants during emergency
  • Medical emergencies (passenger use)
  • Crew moving in cabin during depressurization
  • Capacity: 15-30 minute duration
  • Pressure: 1800 PSI
  • Regulators provide continuous flow or demand

Chemical Oxygen Generators

System Type: Most aircraft use chemical oxygen generators rather than stored gas.

How They Work:

  • Sodium chlorate canister
  • Mechanical pull-pin activation
  • Exothermic chemical reaction produces oxygen
  • Generates heat: 200-260°C
  • Duration: 12-22 minutes depending on cabin altitude
  • Cannot be shut off once started
  • One generator per group of 2-4 seats
Chemical Generator Characteristics:
  • Canister becomes very hot - do not touch
  • May emit slight odor or smoke (normal)
  • Flow decreases as generator depletes
  • Duration sufficient to descend to 10,000 ft
  • Cannot be tested without replacement
  • Expiration date - must be replaced periodically

Automatic Deployment

Deployment Logic:

  • Automatic at 14,000 ft cabin altitude
  • All overhead panels drop simultaneously
  • Oxygen flows only when mask pulled and generator pin extracted
  • Manual deployment available to crew
  • Cockpit switch overrides automatic system
⚠️ PASSENGER OXYGEN BRIEFING POINTS:
  • Pull mask toward you to start flow
  • Place mask over nose and mouth
  • Breathe normally
  • Secure own mask before helping others
  • Bag may not inflate (doesn't indicate malfunction)
  • Keep mask on until crew advises removal

Passenger Oxygen Duration

Duration varies with cabin altitude:

  • At 25,000 ft cabin: 22 minutes
  • At 30,000 ft cabin: 18 minutes
  • At 35,000 ft cabin: 15 minutes
  • At 40,000 ft cabin: 12 minutes

Sufficient time to descend to 10,000 ft at maximum descent rate.

Therapeutic Oxygen

For passenger medical use:

  • Separate system from emergency oxygen
  • Stored gas cylinders (not chemical)
  • Continuous low-flow delivery
  • Typically 2-4 liters/minute
  • Must be airline-supplied (personal oxygen prohibited)
  • Medical clearance may be required

Fire Hazard

⚠️ OXYGEN FIRE HAZARD:
  • Pure oxygen greatly accelerates combustion
  • Materials normally non-flammable can burn in oxygen
  • Keep oxygen systems away from:
    • Oil and grease
    • Solvents
    • Any ignition source
  • Passenger oxygen generator fire extremely dangerous
  • Cannot extinguish chemical generator once started

Oxygen System Maintenance

  • Pressure check before each flight
  • Minimum pressure: 1600 PSI typical
  • Service to 1800-1850 PSI
  • Contamination check periodically
  • Mask inspection and cleaning
  • Generator replacement per schedule
  • Regulator functional test
Oxygen System Precautions:
  • Smoking prohibited during oxygen use
  • Keep oils away from system components
  • Use only approved cleaning materials
  • High-pressure system: leak can cause rapid depletion
  • Contaminated oxygen can cause illness
  • Regular system inspections mandatory

SYSTEM Auxiliary Power Unit (APU)

APU Purpose: Small gas turbine engine providing:
  • Electrical power (generator)
  • Pneumatic power (bleed air)
  • Engine starting capability
  • Ground operations independence
  • Emergency in-flight backup power

APU Components

  • Gas turbine engine: Single-shaft design
  • Generator: 90 kVA typical (115V AC 400Hz)
  • Bleed air system: Supplies air conditioning/pressurization
  • Fuel system: Uses main aircraft fuel
  • Oil system: Self-contained lubrication
  • Fire detection/suppression: Dedicated system

APU Start Sequence

Normal Start:

  1. Master switch: ON
  2. Start button: Press
  3. Starter motor accelerates APU
  4. Fuel introduced at 10% RPM
  5. Ignition activated
  6. Self-sustaining at 50-60% RPM
  7. Idle speed: 95-102% RPM
  8. Generator available at 95% RPM
  9. Bleed air available at 95% RPM

Total start time: 60-90 seconds typical

Power Source for Start:

  • Battery (always available)
  • External power (if connected)
  • Main aircraft generators (in flight)

Altitude Limitations

APU Start Altitude Limit:

  • Maximum start: FL250-FL300 (aircraft dependent)
  • Above limit: insufficient air density for combustion
  • Plan APU start before reaching maximum altitude

APU Operating Altitude Limit:

  • Electrical load only: FL410-FL430 typical
  • With bleed air extraction: FL200-FL250 typical
  • Limitation due to reduced air density
  • Bleed air demand increases turbine temperature

Ground Operations

Run-Time Limitations:

  • Continuous operation: Unlimited on ground (with cooling)
  • High ambient temperature may require reduced bleed load
  • Maximum ambient: 45-50°C for start
  • APU can run during refueling (check company policy)

In-Flight Use

  • Can be started and operated at any altitude within limits
  • Provides backup electrical power
  • Can assist with engine restart
  • Bleed air available below FL200-FL250
  • Fuel penalty: 1-2% of total fuel burn
⚠️ APU LIMITATIONS:
  • Cannot start both engines simultaneously
  • Electrical load shedding if generator overloaded
  • Bleed and electrical together may exceed capacity
  • Do not taxi on APU bleed alone (hot conditions)
  • APU fire requires immediate shutdown

APU Parameters

Normal Operating Values:

  • RPM: 95-102%
  • EGT: 600-650°C normal, 750°C max
  • Oil Temperature: 80-100°C normal, 155°C max
  • Oil Pressure: 25-60 PSI
  • Generator Load: 90 kVA maximum

Automatic Shutdown

⚠️ APU AUTO-SHUTDOWN: APU will shut down automatically if:
  • Fire detected in APU compartment
  • EGT exceeds 750°C
  • Low oil pressure below 10 PSI
  • Overspeed above 107%
  • No start within time limit
  • Loss of electrical control power

After auto-shutdown, wait 60 seconds before attempting restart.

APU Fire Protection

Fire Detection:

  • Dual-loop system in APU compartment
  • Detects fire or overheat
  • Triggers automatic shutdown on ground
  • Triggers automatic fire bottle discharge on ground
  • In flight: manual shutdown and bottle discharge required

Fire Suppression:

  • Single Halon 1301 bottle
  • On ground: auto-discharge after shutdown
  • In flight: manual discharge via APU fire button
  • Bottle pressure monitored
  • Low pressure indicates discharge or leak

Operational Benefits

  • Ground Independence: No GPU/air cart required
  • Climate Control: Packs for passenger comfort during boarding
  • Fast Turnaround: Pre-cool/heat cabin before engine start
  • Engine Start: Can start engines without external power
  • Emergency Backup: In-flight electrical/pneumatic backup
  • ETOPS: Required for extended overwater operations

Cost Considerations

Fuel Consumption:

  • Ground operation: 100-200 lbs/hour
  • In-flight operation: 200-300 lbs/hour
  • Trade-off vs. ground power unit
  • Some airports require GPU use (environmental)

Maintenance

  • Oil service: every 200-300 hours
  • Inspection: part of regular aircraft checks
  • Inlet door check (prevents FOD)
  • Fire bottle pressure check
  • Generator and bleed valve functional test
  • APU hours tracked separately from engine hours
APU MEL Considerations:
  • May be dispatched inoperative with restrictions
  • GPU required for engine start
  • Pre-conditioned air or open doors for cooling
  • ETOPS operations may be restricted
  • Landing at remote airports may be limited