Technical Training Manual Boeing 737-600/-700/-800/-900

BOSTONAIR Technical Training Manual

BOEING 737-600/-700/-800/-900 Overview

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900

Table of Contents

Nitrogen Generation System Introduction

1 Nitrogen generation system - introduction - 6 -

Purpose of the Nitrogen Generation System

1.1 Purpose - 6 -

General Description of the Nitrogen Generation System

1.2 General description - 8 -

General System Information

1.2.1 General - 8 -

System Operation

1.2.2 Operation. - 8 -

Component Locations

2 Component locations 10 -

Thermal Control Unit Location

2.1 Thermal Control Unit 10 -

Nitrogen Generation System Location

2.2 Nitrogen Generation System 10 -

Bite Display Unit (BDU) Location

2.3 Bite Display Unit (BDU) - 10 -

Operability Indicator Location

2.4 Operability Indicator 10 -

NGS Control System Location

2.5 NGS Control System 10 -

Nitrogen Enriched Air Distribution System (NEADS) Ram Air Duct Compartment Location

2.6 Nitrogen Enriched Air Distribution System (NEADS) Ram Air Duct Compartment .. 12 -

NEADS Center Tank and Wing Structure Location

2.7 Nitrogen Enriched Air Distribution System (NEADS) Center Tank and Wing Structure - 12 -

Component Descriptions

3 Component descriptions 14 -

Operability Indicator Description

3.1 Operability indicator 14 -

Operability Indicator Purpose

3.1.1 Purpose 14 -

Operability Indicator Location

3.1.2 Location 14 -

Operability Indicator Physical Characteristics

3.1.3 Physical 14 -

Thermal Control Unit Description

3.2 Thermal control unit - 15 -

Thermal Control Unit Purpose

3.2.1 Purpose - 15 -

Thermal Control Unit Description Details

3.2.2 Description - 15 -

Bleed Pressure Sensor Description

3.3 Bleed pressure sensor - 17 -

Bleed Pressure Sensor Purpose

3.3.1 Purpose 17 -

Bleed Pressure Sensor Location

3.3.2 Location - 17 -

Bleed Pressure Sensor General Description

3.3.3 General Description 17

Nitrogen Generation System Shutoff Valve Description

3.4 Nitrogen generation system shutoff valve. 18 -

NGS Shutoff Valve Purpose

3.4.1 Purpose 18 -

NGS Shutoff Valve Location

3.4.2 Location 18 -

NGS Shutoff Valve Physical Description

3.4.3 Physical Description - 18 -

NGS Shutoff Valve Functional Description

3.4.4 Functional description 20 -

Ozone Converter Description

3.5 Ozone converter 22 -

Ozone Converter Purpose

3.5.1 Purpose 22 -

Ozone Converter Location

3.5.2 Location 22 -

Ozone Converter General Description

3.5.3 General Description .22 -

Heat Exchanger Description

3.6 Heat exchanger 24 -

Heat Exchanger Purpose

3.6.1 Purpose. 24 -

Heat Exchanger Location

3.6.2 Location 24 -

Heat Exchanger General Description

3.6.3 General Description 24 -

Ram Air Valve Description

3.7 Ram air valve - 26 -

Ram Air Valve Purpose

3.7.1 Purpose 26

- 1 - Maintenance Course B1/B2 ATA 47 NITROGEN GENERATION SYSTEM Issue 4 - October 2024

BOSTONAIR Technical Training Manual (Continued)

BOEING 737-600/-700/-800/-900 Component Descriptions (Continued)

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900

Ram Air Valve Location

3.7.2 Location 26

Ram Air Valve Physical Description

3.7.3 Physical Description - 26 -

Ram Air Valve Functional Description

3.7.4 Functional description 28 -

Air Filter Description

3.8 Air filter 30 -

Air Filter Purpose

3.8.1 Purpose 30 -

Air Filter Location

3.8.2 Location 30 -

Air Filter Functional Description

3.8.3 Functional Description - 30 -

Air Separation Module Physical Description

3.13.3 Physical Description. - 38 -

Filter Differential Pressure Switch Description

3.9 Filter differential pressure switch. - 32 -

Air Separation Module Functional Description

3.13.4 Functional Description. - 38 -

High Flow Valve Description

3.14 High flow valve - 40 -

High Flow Valve Purpose

- 40 - 3.14.1 Purpose 40 -

Filter Differential Pressure Switch Physical Description

3.9.3 Physical Description 32 -

Filter Differential Pressure Switch Functional Description

3.9.4 Functional Description - 32 -

High Flow Valve Physical Description

3.14.3 Physical Description. - 40 -

High Flow Valve Functional Description

3.14.4 Functional Description. . 40 -

NEADS Distribution

4 NEADS Distribution 42 -

NEADS Distribution Description

4.1 Description . 42 -

NEADS Distribution Purpose

4.1.1 Purpose 42 -

NEADS Distribution Description Details

4.1.2 Description - 42 -

NEADS Drain Cap

4.1.3 Drain Cap. 42 -

NEADS Float Valve

4.1.4 Float Valve 42 -

NEADS Cross Vent Check Valve

4.1.5 Cross Vent Check Valve - 42 -

Thermal Switch Functional Description

3.11.4 Functional Description 35

NEADS Backflow Prevention Check Valves

4.1.6 Backflow Prevention Check Valves 42

NEADS Duct

4.1.7 NEADS Duct - 43 -

Overtemperature Shutoff Valve Purpose

3.12.1 Purpose - 36 -

Overtemperature Shutoff Valve Location

3.12.2 Location 36

Overtemperature Shutoff Valve Physical Description

3.12.3 Physical Description. - 36 -

Overtemperature Shutoff Valve Functional Description

3.12.4 Functional Description. 36 -

Air Separation Module Description

3.13 Air separation module - 38 -

Air Separation Module Purpose

· 38 - 3.13.1 Purpose 38 -

Air Separation Module Location

3.13.2 Location 38 -

NEADS Dielectric Isolator Hose

4.1.8 Dielectric Isolator Hose 43 -

Filter Differential Pressure Switch Purpose

3.9.1 Purpose 32 -

Filter Differential Pressure Switch Location

3.9.2 Location 32 -

Temperature Sensor Description

3.10 Temperature sensor 34 -

Temperature Sensor Purpose

3.10.1 Purpose 34 -

Temperature Sensor Location

3.10.2 Location 34 -

Temperature Sensor Physical Description

3.10.3 Physical Description 34 -

Thermal Switch Description

3.11 Thermal switch - 35 -

Thermal Switch Purpose

3.11.1 Purpose 35 -

Thermal Switch Location

3.11.2 Location 35 -

Thermal Switch Physical Description

3.11.3 Physical Description 35 -

- 2 - Maintenance Course B1/B2 ATA 47 NITROGEN GENERATION SYSTEM Issue 4 - October 2024

BOSTONAIR Technical Training Manual (Continued)

BOEING 737-600/-700/-800/-900 NEADS Distribution (Continued)

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900

NEADS Flame Arrestor

4.1.9 Flame Arrestor - 43 -

NEADS Ejector Nozzle

4.1.10 Ejector Nozzle - 43 -

NEADS Component Locations

4.2 Component locations. 44 -

NEADS General Component Locations

4.2.1 General 44 -

NEADS Components - Left Ram Air Compartment

4.2.2 Components - Left Ram Air Compartiment 44 -

NEADS Components - Left Wheel Well

4.2.3 Components - Left Wheel Well 44 -

NEADS Components - Center Tank - Left Cheek

4.2.4 Components - Center Tank - Left Cheek - 44 -

NEADS Components - Center Tank - Right Cheek

4.2.5 Components - Center Tank - Right Cheek .46 -

NGS System Controller

5 NGS system controller 48 -

NGS System Controller Description

5.1 Description 48 -

NGS System Controller Purpose

5.1.1 Purpose 48 -

NGS System Controller Location

5.1.2 Location - 48 -

NGS System Controller Physical Description

5.1.3 Physical Description 48 -

NGS System Controller Functional Description

5.1.4 Functional Description 48 -

NGS System Controller Interface

5.2 Interface 50 -

Indication

6 Indication 53

Operability Indicator

6.1 Operability indicator - 53 -

Operability Indicator Purpose

6.1.1 Purpose 53

Operability Indicator Location

6.1.2 Location 53 -

Operability Indicator Physical Description

6.1.3 Physical Description 53 -

BITE Display Unit

6.2 BITE display unit 55

BITE Display Unit Purpose

6.2.1 Purpose - 55 -

BITE Display Unit Location

6.2.2 Location - 55 -

BITE Display Unit Physical Description

6.2.3 Physical Description. 55 -

BITE Functionality

6.2.4 BITE 55 -

BITE Operation

6.3 BITE operation 57 -

BITE General Operation

6.3.1 General 57 -

BITE Continuous Monitor

6.3.2 Continuous Monitor 57 -

BITE Tests

6.3.3 BITE Tests 57 -

BITE Operation Details

6.3.4 BITE operation. - 57 -

BITE Main Menu

6.3.5 Main Menu. 57 -

Maintenance Course B1/B2 ATA 47 NITROGEN GENERATION SYSTEM Issue 4 - October 2024 - 3 -

BOSTONAIR Technical Training Manual (Continued)

BOEING 737-600/-700/-800/-900 List of Figures

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900

LIST OF FIGURES

• Figure 1: Nitrogen generation system - introduction - 7 -
• Figure 2: NGS - General description - 9 -
• Figure 3: NGS - component locations 11 -
• Figure 4: NGS - Component locations (2) 13 -
• Figure 5: NGS operability indicator. 14 -
• Figure 6: NGS thermal control unit 16 -
• Figure 7: Bleed pressure sensor 17 -
• Figure 8: NGS Shutoff valve 19 -
• Figure 9: NGS - functional description 21
• Figure 10: Ozone converter 23 -
• Figure 11: Heat exchanger 25 -
• Figure 12: Ram air valve 27 -
• Figure 13: Ram air actuator - functional description 29 -
• Figure 14: Air filter. 31 -
• Figure 15: Temperature sensor 34 -
• Figure 16: Thermal switch 35 -
• Figure 17: Overtemperature shutoff valve 37 -
• Figure 18: Air separation module 39
• Figure 19: High flow valve 41 -
• Figure 20: NEAS - component locations 45 -
• Figure 21: NEAS - Component locations (2) 46
• Figure 22: NEAS - Component locations (3) 47
• Figure 23: NGS Controller 49 -
• Figure 24: NGS controller - interfaces. 51 -
• Figure 25: NGS Controller - discrete inputs 52 -
• Figure 26: Operability indicator 54 -
• Figure 27: BITE display module 56 -
• Figure 28: BITE operation - 58 -
• Figure 29: NGS system schematic 59 -

Maintenance Course B1/B2 ATA 47 NITROGEN GENERATION SYSTEM - 4 - Issue 4 - October 2024

BOSTONAIR Technical Training Manual (Continued)

BOEING 737-600/-700/-800/-900 Abbreviations and Acronyms

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900

ABBREVIATIONS AND ACRONYMS

• ASM air separation module
• BDU BITE display unit
• BITE built in test equipment
• CWT center wing tank
• GSE ground support equipment
• NEA nitrogen enriched air
• NEADS nitrogen enriched air distribution system
• NGS nitrogen generation system
• PRSOV pressure regulating and shutoff valve
• OEA oxygen enriched air
• OTSOV overtemperature shutoff valve
• RAV ram air valve
• TCU thermal control unit

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Nitrogen Generation System Introduction

Purpose of the Nitrogen Generation System (NGS)

1 Nitrogen generation system - introduction 1.1 Purpose The purpose of the Nitrogen Generation System (NGS) is to reduce the oxygen content in the center tank to a level which will not support combustion. The system has been developed and introduced in the aircraft systems due to previous accidents with fuel tank explosions. The system does these functions: . Controls the air pressure into the system. · Changes ozone in the air in to oxygen. · Cooling of the bleed air. · Removes contamination of the air. · Supplies Nitrogen Enriched Air (NEA) to the center tank. . Check of system performance. · Blow Oxygen Enriched Air (OEA) overboard.

NGS System Warnings

WARNING: Several components of the NGS system can get very hot during operation or testing. WARNING: When in use the system produces Nitrogen by eliminating oxygen from the air, creating a potential lethal environment. During operation, leaks in the system can fill up certain compartments with nitrogen. Symptoms of oxygen deprivation are: Headache • • Feeling light headed · Feeling dizzy · Getting unconcious During maintenance on the system, when displaying one of the these symptoms, try immediately to get some fresh air, and warn others from a potential dangerous situation and shut down the system.

- 6 - Maintenance Course B1/B2 ATA 47 NITROGEN GENERATION SYSTEM Issue 4 - October 2024

Nitrogen Generation System Overview

NGS System Diagram

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900 AIRCONDITIONING & PRESSURISATION WING & ENGINE ANTI ICE SYSTEMS PNEUMATIC SYSTEM ENGINE START + WATER PRESSURE HYDRAULIC SYSTEM RESERVOIRS SURGE TANK BLEED AIR MAIN TANK NUMBER TWO TANK END RIB (TYPICAL) CENTER TANK TANK END RIB (TYPICAL) NITROGEN GENERATION SYSTEM MAIN TANK NUMBER ONE SURGE TANK Figure 1: Nitrogen generation system - introduction - 7 - Maintenance Course B1/B2 ATA 47 NITROGEN GENERATION SYSTEM Issue 4 - October 2024

Nitrogen Generation System General Description

General Description of NGS Subsystems

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900 1.2 General description 1.2.1 General The Nitrogen Generation System has these subsystems: · Thermal control unit (TCU) · Nitrogen generation · Distribution • Control • Indication The TCU has components in the left ECS compartment and in the left ram air duct compartment. The nitrogen generation components are in the left ram air duct compartment. The nitrogen enriched air distribution system (NEADS) has components in the left ram air duct compartment, in the center tank, in the right surge tank, and in the left wheel well. The controller is installed in the aft forward cargo area. The BITE display unit is in the right ECS compartment. The operability indicator is in the right wheel well, adjacent to the APU shutoff switch. The nitrogen generation system uses bleed air from the left side of the pneumatic manifold. The NGS shutoff valve controls the airflow from the manifold. The NGS controller uses system pressure and voltage to control the NGS shutoff valve.

NGS System Operation

1.2.2 Operation. The nitrogen generation system gets bleed air from the left side of the pneumatic manifold. A sensor on the bleed air duct sends pressure data to the NGS controller. The controller adjusts the NGS shutoff valve. The NGS shutoff valve controls the pressure that comes into the system. Bleed air goes through the catalytic converter to change the ozone in the air to oxygen. Ozone can decrease the performance and mechanical properties of the air separation module. The heat exchanger uses ram air to decrease the bleed air temperature to 160 degrees +/- 10 deg F. The ram air valve adjusts the quantity of cool air that goes through the heat exchanger. The temperature sensor sends temperature data to the controller. The controller adjusts the ram air valve. The filter removes contamination before the air goes into the air separation module. A differential pressure sensor monitors the filter. The air separation module decreases the oxygen in the air below the quantity necessary to support combustion. The air separation module removes oxygen from the air and releases it overboard. Nitrogen enriched air (NEA) goes through the high flow valve to the center tank. The high flow valve controls the quantity of NEA that goes to the center tank. The controller uses data from the altitude sensor, differential pressure sensor, and airplane systems to open or close the valve. The controller monitors and controls system operating temperatures and pressures. An operability indicator gives a visual indication of the condition of the system. You use the BITE display unit to do a test of the system. You use the GSE connection to do a test of the oxygen quantity of the air downstream of the ASM. The NEA distribution system (NEADS) sends NEA to the center wing tank. NEA goes into the tank through an ejector nozzle in the climb vent in the left part of the tank. A float valve in the right part of the tank makes sure that the concentration of NEA is constant. A cross vent check valve makes sure that ambient air does not dilute the nitrogen concentration in the center tank during the descent.

Maintenance Course B1/B2 ATA 47 NITROGEN GENERATION SYSTEM - 8 - Issue 4 - October 2024