section

9 Auxiliary
Power Unit

www.flyaoamedia.com
 The material covered in this document is based off information obtained from
the original manufacturers’ Pilot and Maintenance manuals. It is to be used
for simulation purposes only.

Copyright © 2011 by Angle of Attack Productions, LLC

All rights reserved

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Table of Contents Table of Illustrations
APU Overview 3 Figure 9-1. Auxiliary Power Unit Diagram 6
APU Engine Primary Components 4 Figure 9-2. Fuel Supply Diagram 8
APU Fuel Supply 7 Figure 9-3. Inlet Guide Vanes 13
APU Start 9
APU Operational Modes 11
APU Altitude Operational Limits 14
APU Shutdown 15
APU Normal Shutdown 15
APU Protective Shutdown 15
APU Automatic Load Shedding 17

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APU Overview
The Auxiliary Power Unit, or APU, is a gas turbine engine After combustion, the APU exhausts gases through a muffler
capable of providing electrical and pneumatic services and out of the tailcone.
on the ground and in the air. It allows the aircraft to be self-
sufficient on the ground without the need for ground power. The high speed flow of the APU exhaust forms a low
pressure area inside the APU compartment which pulls
The 737NG uses the AlliedSignal, now Honeywell, 131-9B outside air in through a second hole in the tailcone. This
APU. is called the eductor inlet, and draws outside air into the
APU compartment, cooling the APU oil.
The 131-9B is able to start and operate up to the
aircraft’s maximum certified altitude of 41,000 feet. This is an efficient means of cooling and removes the need
The APU is installed within a fireproof compartment in the for a separate cooling fan, eliminating another moving part.
tail of the aircraft. An Electronic Control Unit, or ECU, continuously monitors
and controls the APU from start to shutdown. It also
A firewall isolates the APU compartment from the aircraft provides shutdown protection in the event that any one of
fuselage and the horizontal stabilizer assembly. several parameters goes out of limits.

The APU air inlet door is located on the right side of the aft Shutdown protection is discussued in more detail later.
fuselage and is automatically controlled. This is a NACA
type inlet, a concept originally developed by the US
National Advisory Committee for Aeronautics in 1945.

It is a low drag inlet, designed to allow air to flow into the

duct in flight. There is an inlet flow deflector that modifies
the airflow into the intake to ensure that it is laminar and
appropriate for ingestion into the APU.

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APU Engine Primary Components
The APU is very different to the two CFM56 engines on the pneumatic load compressor.
737. It has three primary engine components (see figure 8.1) :
●● The power section. The purpose of the pneumatic load compressor is to
●● The load compressor. supply bleed air to aircraft systems that require it, such as
air conditioning, pressurization, ice protection, and for
●● The accessory gearbox.
engine start.
The power section drives the load compressor and the
The key difference here is that the two main engines supply
accessory gearbox. The power section consists of:
bleed air from the power section, while the APU has a
●● A single stage centrifugal compressor. dedicated compressor for the job.
●● A combustion chamber.
●● A two stage axial flow turbine. Because the pneumatic load compressor is attached to
the same shaft as the engine compressor, they both spin at
Air enters the APU through the air inlet, and is directed the same RPM.
into the centrifugal compressor which throws it outwards,
compressing it. In order to vary the amount of bleed air taken from the
APU, the ECU opens and closes Inlet Guide Vanes in the
The compressed air is directed into the combustion load compressor inlet. These control the amount of air that
chamber where it is mixed with fuel and ignited. Ignition and enters the load compressor, and consequently the amount
expansion of the gas in the combustion chamber forces it of air taken from the APU for aircraft systems.
through the turbines, spinning them.
The Inlet Guide Vanes move from 15 degrees to 110
The turbines are connected to a single shaft, which in turn degrees as bleed air demand changes.
is connected to the centrifugal compressor. Also attached
to this same shaft are a starter-generator, gearbox, and the The accessory gearbox is also mounted to the APU shaft.

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APU Eng.Prim. Components (Cont.)
This reduces the high rotational speed of the shaft to a Notes
lower speed for the accessories mounted on the gearbox.
The gearbox turns the APU starter-generator, and other
components.

The starter-generator is used when starting the APU and

generates electrical power once it is running.

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 COMPRESSOR
AIR INLET

APU BLEED AIR SURGE CONTROL

VALVE VALVE

EDUCTOR INLET

STARTER
GENERATOR

FROM FUEL FCU

SYSTEM

FROM EDUCTOR
INLET

OIL COOLER

Figure 9-1. Auxiliary Power Unit Diagram

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APU Fuel Supply
Fuel supply to the APU is controlled by the APU Fuel Under normal conditions once the APU is running, an AC
Control Unit. The Fuel Control Unit regulates the fuel supply Fuel Pump is used to pressurize the system. There are two
for different running conditions, and uses a motor driven by AC Pumps for each fuel tank.
the accessory gearbox.
The fuel system features a Crossfeed Valve that effectively
The APU uses the same fuel supply as the two main engines. isolates each side of the fuel system from the other. With the
Fuel piping is arranged such that the APU normally takes Crossfeed Valve closed, any of the three AC pumps on the
fuel from the left side of the fuel system. (see figure 8.2) left side of the system can supply the APU. This includes the
two Main Tank 1 pumps and the left Center Tank pump.
The APU is capable of drawing fuel without positive
pressure from the fuel pumps. When no fuel pumps are The Main Tank 1 Aft Fuel Pump is normally used to feed the
operational, fuel is suction fed from Main Tank 1 using the APU on the ground. If the APU will be run for an extended
Fuel Control Unit’s own motor. period, the left Center Tank pump may be used to prevent
a fuel imbalance.
Operating without the assistance of a fuel pump can
reduce the service life of the Fuel Control Unit motor With the Crossfeed Valve open, fuel may also be fed from
however. To address this, an automatically operated DC Main Tank 2. Operation of the DC Fuel Boost Pump is
Fuel Boost Pump is installed. This pump draws fuel from Main automatic, but the AC Pumps must be manually selected
Tank 1 when the APU Fuel Control Unit senses low fuel ON or OFF on the Forward Overhead Panel. When an
pressure. This provides positive pressure and preserves the AC pump is used and pressurizes the system, the DC pump
service life of the Fuel Control Unit. automatically shuts off.

The DC Fuel Boost Pump is usually used during APU startup APU fuel consumption is roughly 225 pounds per hour
when no AC power source is available to power the AC running both packs. This is very much a ballpark figure – fuel
Pumps. consumption varies depending on a variety of conditions.

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 TO APU

Figure 9-2. Fuel Supply Diagram

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APU Start
APU start is controlled by the ECU, Electronic Control Unit. The Start Power Unit forwards this to the Start Converter
It is a fully automatic start sequence. Unit which converts it to AC power for the starter-generator
on the APU gearbox.
The Battery Switch on the Forward Overhead Panel must
be set ON before the APU can be started. As the name implies, the starter-generator performs two
main functions:
The APU Fire Switch on the Aft Electronics Panel must ●● It supplies the initial rotation of the APU during the start
also be IN, and the APU Fire Control Handle in the main cycle.
landing gear wheel well must be in the UP position. ●● And provides a source of electrical power for aircraft
systems once the APU is running.
Controls and indications for the APU are located on the
Forward Overhead Panel. If starting on the battery, there will be a significant
amperage draw indicated on the AC/DC Metering Panel
The start sequence is commenced by holding the APU when the starter-generator kicks in. This is usually in the
switch momentarily to START. The switch is spring loaded region of a 400 amps draw – it takes a lot of power to get
back to the ON position, and will return there when that APU turning.
released. When the switch is selected to START, the
Electronic Control Unit opens the APU Fuel Shut-off Valve Additionally to the negative amps indication, the BAT
and the APU Air Inlet Door. DISCHARGE light will illuminate.

Either 28v DC power from the battery or 115v AC power The APU draws power from the Main Battery for startup, so
from AC Transfer Bus #1 may be used to start the APU. This the Auxiliary Battery is automatically isolated during APU
passes through the Start Power Unit which converts it to start.
270v DC power.
The LOW OIL PRESS light will illuminate during the start

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APU Start (Cont.)
process, and will extinguish once APU oil pressure reaches This minute of idle running is intended as a stabilization
normal levels. period to extend the service life of the APU. Although the
start cycle itself takes a minute or so, if powered from the
The APU’s Exhaust Gas Temperature indication may battery at this point it uses the equivalent of approximately
fluctuate throughout its entire range during start prior to 7 minutes of battery life.
normal EGT rise. This is normal, and has no adverse effect
on starting the APU. Once the start cycle is complete, and the APU has
reached 95% speed, the ECU gives a ‘Ready to Load’
Note that there are no limitation indications on the EGT signal to other aircraft systems. This signals that the APU is
gauge – EGT is monitored automatically by the ECU, and ready to accept pneumatic and electrical loads.
the APU will be shut down automatically if it exceeds limits.
It is therefore not necessary to monitor EGT during APU The electrical system indicates this to the crew by way of
start. the APU GEN OFF BUS light, which illuminates blue when
the APU is capable of powering an AC bus but is not yet
The ECU commands ignition and fuel injection during doing so.
startup automatically as the APU reaches the appropriate
speeds. There is no direct equivalent indication for the air system.

The start cycle will terminate automatically after 120

seconds if the APU has not yet reached the required RPM
to disengage the starter.

The start cycle may therefore take as long as 120 seconds,

and the APU should be run for a further minute after start
before it is used as a bleed air source.

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APU Operational Modes
We have already stated that the APU should be run the APU power section components.
for at least one minute after start before it is used as a
bleed air source. Taking bleed air from the APU places a To keep the load compressor cool, the Inlet Guide Vanes
considerable load on it, far more demanding than taking do not close fully, even in ‘no bleed mode’ with no bleed
electrical power from the starter-generator. air demand. They close only as far as 15 degrees.

The ECU selects from four bleed air modes depending on The ECU sets ‘Duct pressurization mode’ when the APU
demand from aircraft systems: Bleed Air Valve is open, but there is no actual demand
●● No bleed mode from the air system. In this case, the Inlet Guide Vanes open
●● Duct pressurization mode further to allow the load compressor to pressurize the
pneumatic system air ducts.
●● Main engine start mode
●● Air conditioning system mode ‘Main engine start mode’ opens the Inlet Guide Vanes
as needed to meet the high airflow requirement of main
The ‘no bleed mode’ is set when there is no bleed air engine start.
demand from the pneumatic system and the APU Bleed Air
Valve is closed. Air conditioning system, or ACS mode sets the Inlet Guide
Vane position as necessary to supply air to the air
When the pilot selects the APU Bleed Air switch OFF on conditioning system.
the Forward Overhead Panel, the APU Bleed Air Valve
closes. The air conditioning system itself has four modes of
operation:
The ECU closes the Inlet Guide Vanes to 15 degrees.
●● One pack inflight.
Even without any bleed air demand, the load compressor
will still be spinning as it is attached to the shaft along with ●● One pack ground.

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APU Operational Modes (Cont.)
●● Two packs, normal. pressure than two packs would, it requires less actual
●● Two packs, high. quantity of airflow.

The ECU opens the Inlet Guide Vanes to the appropriate There is therefore a considerable excess of bleed air
position for each of these modes so as to supply the produced that is not required.
required airflow.
This excess bleed air is exhausted through a Surge
APU fuel consumption is considerably greater when Control Valve, which ducts it through the APU exhaust. This
operating a single pack than when operating both. increases exhaust gas temperatures, and the additional
airflow through the exhaust can increase the noise
A single pack must work much harder than two packs to signature of the APU by approximately 2 decibels.
cool the cabin to a given temperature. The APU must
therefore supply higher pressure bleed air to allow the Running both packs on the ground therefore reduces noise,
single pack to function. reduces fuel consumption and extends the life of the APU
hot section. This is the recommended practice.
To supply higher pressure bleed air, the APU Inlet Guide
Vanes must open further than they would otherwise have
to to supply both packs. The further open the Inlet Guide
Vanes are, the greater the torque required to keep the
APU rotating at a constant speed (see figure 8.3).

This requires the Fuel Control Unit to inject more fuel,

increasing fuel consumption.

Additionally, although a single pack requires greater

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 16 1
15 2
14 3
13 4
12 5
11 6
10 7
9 8

Figure 9-3. Inlet Guide Vanes

16 Inlet Guide Vanes Load Compressor IGVs
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APU Altitude Operational Limits
The APU is able to start and operate up to the aircraft’s Notes
maximum certified altitude of 41,000 feet.

There are limitations on the services it can provide

however, both electrical and pneumatic, that vary with
altitude.

The APU can provide 90 kilovolt amp electrical power up

to 32,000 feet. Between 32,000 feet and 41,000 feet,
only 66 kilovolt amp electrical power is assured.

The APU can provide both electrical and pneumatic

power simultaneously up to 10,000 feet.

Pneumatic power alone is available up to 17,000 feet.

These operational limits are a result of reducing air density

with altitude. The higher the altitude, the less oxygen per
unit volume there is for combustion by the APU. This limits its
performance, and thus its ability to handle pneumatic and
electrical loads.

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APU Shutdown
Like the start process, the Electronic Control Unit, or The cool down period preserves the life of the APU hot
ECU, controls the shutdown. There are two types of APU section, and prevents coke accumulating in the turbine
shutdowns: bearing and fuel nozzles.
●● Normal shutdown
●● Protective shutdown As the APU speed decreases below 30%, the APU Fuel
Shutoff Valve and inlet door start to close.
APU Normal Shutdown
The ‘normal shutdown’ is initiated by placing the APU switch If the APU Fuel Shutoff Valve does not close, the FAULT
to the OFF position. light will illuminate after approximately 30 seconds.

This signals the ECU to begin the shutdown process. The Below 7%, an APU restart can be initiated if desired by
normal shutdown is preceded by a 60 second cool down moving the APU switch back to START.
period, which begins as soon as the APU switch is set OFF.
The APU can be shut down immediately without the 60
When the APU switch is set OFF, the ECU performs several second cool down period by pulling the APU Fire Switch.
actions: Clearly this is not standard practice, and should only be
●● It removes the ‘Ready to Load’ signal, thus indicating
done in an emergency.
to aircraft systems that the APU is no longer ready to
accept pneumatic or electric load. APU Protective Shutdown
Under certain conditions the APU will shut down
●● It closes the APU Bleed Air Valve.
automatically to prevent damage to itself or other aircraft
●● Closes the Inlet Guide Vanes to 15 degrees. components.
●● Opens the Surge Control Valve.
●● De-energizes the APU starter-generator. There are three different indications in the cockpit that
●● Starts the 60 second timer for the cool down period. indicate a protective shutdown; all three are on the APU

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APU Shutdown (Cont.)
Panel. ○○ Inlet temperature failure,
●● The LOW OIL PRESSURE light illuminates when oil ○○ APU underspeed.
pressure drops below limits for 20 seconds or more.
○○ This causes a protective shutdown. Any one of these will trigger a protective shutdown.
●● The FAULT light illuminates for a large number of
conditions: Finally, the OVER SPEED light will illuminate for a further
○○ Fuel shutoff valve not in the commanded position, three conditions:
○○ Inlet door not in the commanded position, ●● Fuel Control Unit solenoid valve fails in the open position,
○○ Loss of DC power, ●● Loss of overspeed protection,
○○ Electronic Control Unit failure, ●● APU overspeed.
○○ APU fire,
Any one of these will trigger a protective shutdown.
○○ APU inlet overheat,
○○ Loss of both Exhaust Gas Temperature signals, The LOW OIL PRESSURE, FAULT and OVER SPEED lights
○○ No APU speed signal, will extinguish when the APU switch is cycled to OFF, then
○○ No APU acceleration, back to ON again with APU speed less than 7%. Why 7%?
○○ No APU rotation, Because that’s the speed below which the APU can be
restarted again.
○○ Low Exhaust Gas Temperature after introduction of fuel,
○○ Generator filter clogged, The MAINT light illuminates when oil pressure drops below
○○ High oil temperature, a specified level, or if the starter-generator has a shorted
○○ APU overtemperature, rotating diode. In both cases the APU may continue to run,
○○ Reverse flow through the load compressor, but will require maintenance as soon as possible.
○○ Oil temperature sensor failure,

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APU Automatic Load Shedding
The APU is of course only capable of supplying a finite Notes
amount of electrical power to aircraft systems.

When the APU is the only source of AC power, system

logic automatically removes electrical loads to prevent an
overload of the APU. This is called ‘load shedding’, and
may occur both on the ground and in flight.

In flight, if the APU is the only source of electrical power,

all galley busses are automatically shed. If electrical load
still exceeds design limits, both main AC busses are also
automatically shed.

The APU will also shed load on the ground if it is the only
source of electrical power.

If an overload condition is sensed, the APU sheds the

galley buses first, then the main buses until the load is within
limits.

The APU can take on more load on the ground than in

the air due to better airflow cooling on the ground. It
is therefore capable of handling more demand on the
ground than in the air, so the threshold for load shedding
will be higher.

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