SOA-PRC06

APPROVED
SCHOOL OF AVIATION Rev: 0
BASIC
STUDENT REPORT FORM Date: JAN
TRAINING
+ 2021

MODULE: M13 SUB-MODULE Air-conditioner

SERIAL NO. 022 HANGAR WORKSHOP ✘ LABORATORY

1. TYPE 2. AIRCRAFT/ENGINE/ 3. AIRCRAFT/ENGINE/ 4. TRADE 5. LEVEL OF

EQUIPMENT EQUIPMENT TYPE STUDY
IDENTIFICATION

AIRCRAFT HNTEC in
Aircraft
ENGINE AeroTrain Model AS-44 B2
Maintenance
✘ EQUIPMENT
Engineering

TASK: Carry out inspection and functional test for air conditioner.

REPORT

Introduction
In the aviation industry, the air conditioning system plays a critical role in maintaining the safety, health,
and efficiency of both passengers and crew. Aircraft are designed to operate at high altitudes, where
external temperatures can be extremely cold and the atmospheric pressure is low. To encounter these
challenges, air conditioning systems are essential for regulating the cabin environment, ensuring
passenger's comfort, and supporting the proper functioning of sensitive equipment.

THE PURPOSE

One of the benefits of air conditioning inspections in aviation is to prevent failures. Aircraft operate with
frequent temperature changes, high altitudes, and varying pressure conditions. Air conditioning systems
are exposed to extreme wear and tear, regular inspection is necessary to maintain system reliability. To
ensures that the aircraft operates smoothly, reduce unexpected breakdowns during a flight and
preventing such failures not only improves operational safety but also enhances passenger satisfaction
by providing a comfortable in-flight environment.
Procedure

SAFETY PRECAUTIONS FOR FUNCTIONAL TESTING AND INSPECTION OF AIR CYCLE

MACHINE CONDITIONING SYSTEM TRAINER

Before beginning the inspection, it is essential to ensure that the system is powered off. Follow the
procedures to prevent accidental power activation, which could cause electrical shock or moving part
injuries. During the inspection, it is critical to handle all components with care. Refrigerant lines can be
extremely cold or hot, posing a risk of burns. Additionally, follow manufacturer guidelines to ensure safe
handling of air conditioning components and always wear personal protective equipment (PPE) such as
safety boots should be worn to protect against any hazards.

When conducting functional tests, safety is the top priority. Power should be applied gradually to avoid
electrical surges. Technicians must closely monitor pressure gauges to prevent over-pressurization,
which could lead to system failure or even explosions. Moving parts, such as fans and compressors,
pose a significant hazard, so it is important to stay clear of these components while the system is
running.

Figure 1: Air Cycle Machine Conditioning System Trainer

Inspection and Functional Testing on Air Cycle Machine
Conditioning System Trainer
Visual Inspection

The first step in inspecting an ACM conditioning system trainer is through visual inspection. This
involves checking all components, including:

 The air cycle machine,

 heat exchangers,
 ducts,
 valves, and
 sensors

Visual inspection is used to check for any signs of wear, corrosion, or damage. Refrigerant lines and air
ducts should be inspected for leaks, blockages, or other irregularities that may affect system
performance.

Functional Testing Procedures

Once the visual inspection is complete, the functional testing begins. This involves powering on the
system and monitoring its operation. The following steps are typically involved in the functional testing
of an ACM conditioning system trainer:

1. Initial Startup - Power is applied to the system to avoid electrical spikes.

2. System Monitoring - The air cycle machine’s operation is monitored, including compressor
speed, turbine operation, and heat exchanger efficiency.
3. Pressure and Temperature Checks - Pressure gauges and temperature sensors are used to
ensure that the system operates within specified parameters. Any deviations from expected
values are noted for further investigation.
4. Airflow Testing - Airflow through the ducts and outlets is measured to ensure that the system
provides adequate ventilation and cooling.
5. Control System Testing - The system’s control panel and sensors are tested to ensure they
respond correctly to user inputs and environmental changes.
Findings from Functional Testing of Air Cycle Machine Conditioning System Trainer

During the functional testing of the Air Cycle Machine (ACM) Conditioning System Trainer, leak was
identified in the area surrounding the cooling turbine assembly. Upon close inspection, the leak
appeared to originate from the connections between the turbine housing and the attached ducting. This
area is critical, as the cooling turbine plays a vital role in reducing the temperature of the compressed
air before it is distributed into the aircraft cabin.

Figure 2: Finding - leak 1

A leak in the system allows conditioned air to escape, reducing the overall efficiency of the cooling
process. This can lead to:

 Inadequate cooling of the cabin - especially during high-temperature operations.

 Uneven cabin temperatures - making certain areas warmer than others.
 Overheating of avionics - which rely on proper cooling for optimal performance.

With air escaping through the leak, the ACM has to work harder to maintain the desired cabin
conditions. This can result in:

 Increased wear and tear on the air cycle machine components, including the turbine and
compressor.
 Higher energy consumption which can lead to reduced fuel efficiency in the aircraft.

If the leak occurs near or in the heat exchangers or ducting, there is a risk of external contaminants
entering the system. This can:

 Compromise the quality of cabin air, leading to discomfort or health issues for passengers and
crew.
 Allow unfiltered air to circulate through the cabin, potentially introducing odours or harmful
particles.
A leak was also found between the overheat sensor and the shutoff valve in an aircraft's air conditioning
system trainer.

Figure 3: Finding - Leak 2

There are several potential consequences:

1. Loss of Air Conditioning Control: The overheat sensor and shutoff valve are integral components
in the system's ability to regulate temperature and airflow. A leak between them could disrupt
the normal operation of the system and lead to inadequate cooling or heating within the cabin.
2. Risk of Overheating: The overheat sensor is designed to monitor the temperature and prevent
overheating. If the sensor's ability to detect temperature is compromised by a leak, it may fail to
detect overheating conditions, which could affect the safety of the aircraft by contributing to
cabin temperature issues.
3. Airflow Disruptions: The shutoff valve controls the flow of conditioned air. A leak in this area
could lead to a loss of air pressure or improper distribution of conditioned air, impacting
passenger comfort and lead to cabin pressure issues.

Overall, Aircraft air conditioning systems are subject to strict safety standards. A leak in this critical area
could violate maintenance or operational requirements, leading to delays in flights, safety inspections,
or even grounding of the aircraft until the issue is resolved.
Conclusion

The leaks identified in both the Air Cycle Machine (ACM) cooling turbine assembly and between the
overheat sensor and shutoff valve present significant risks to the aircraft's air conditioning system. The
leak around the cooling turbine reduces cooling efficiency, leading to uneven cabin temperatures,
potential overheating of avionics, and increased wear on ACM components. This also results in higher
energy consumption and reduced fuel efficiency. The leak near the overheat sensor could disrupt
temperature regulation can lead to inadequate cabin conditions and potential overheating. Both leaks
compromise system performance, cabin comfort, and safety. Immediate repairs are necessary to
restore system functionality and meet safety standards, preventing operational delays or grounding of
the aircraft. These issues not only affect passenger comfort but also pose risks to the overall safety of
the aircraft. Immediate inspection, repairs, and corrective actions are essential to restore the air
conditioning system to optimal functionality and ensure compliance with safety standards.

REFLECTION ON THE ACTIVITY

This activity reinforced the importance of safety precautions during maintenance, such as powering off
the system, wearing personal protective equipment (PPE), and closely monitoring pressure levels to
prevent hazards. It also demonstrated how even minor leaks can increase fuel consumption, reduce
system efficiency, and potentially violate safety regulations, the need for immediate repairs to maintain
operational efficiency and ensure compliance with aviation standards.

VERIFIED
STUDENT’S NAME Norshafinaz Binti Morsidi
BY

DATE 19/02/2025 DATE