SECOND QUARTER 2011
VOLUME ELEVEN, ISSUE two

Extensive MRO network provides time- and cost-saving GE, CFM overhaul solutions

Five decades-plus of overhaul and repair experience with GE and CFM International engines has enabled GE to build an inventory of expertise in these technologies that benefits customers on several fronts. The company’s vast history of maintenance and remote diagnostics data on its GE and CFM engine base results in:

  • Optimized workscopes and more predictable maintenance actions
  • Which, in turn, lead to cost-efficient overhauls with faster turntimes

Whether a customer is looking for a shorter-term time and material (T&M) overhaul or a longer-term collaborative, consultative arrangement, GE has a solution that meets each operator’s evolving business requirements.

“GE is well positioned to meet any and every overhaul need,” says Paul McElhinney, newly appointed president and CEO of GE Aviation, Services. “As the OEM, GE Aviation engineers have designed, supported, serviced and monitored these engines since day one—they know them inside out.

“GE also continues to look into ways to save the customer money—whether it is through new repair introduction, used material or other innovative technologies, early-pay incentive programs or intelligent workscoping tools.”

GE overhaul and repair facilities are located worldwide, in North America, South America, Europe, China and in North and South Asia. Providing customers breadth of services and extensive capacity to provide OEM (original equipment manufacturer) solutions that meet their maintenance, repair and overhaul (MRO) needs, GE delivers these services via:

  • Five dedicated GE overhaul facilities in Brazil, Malaysia, Scotland, Wales and the United States
  • Seven dedicated GE repair facilities
  • An expansive network of 12 MRO alliance partners

Base engine overhaul, onwing support, accessory repair and availability, diagnostics, technology upgrades—there is no “one plan fits all” engine overhaul solution.

OnPoint solutions can also be tailored for leasing companies as well as operators. From integrated spare engine support to agreements with a true firm, fixed price, these solutions are designed to meet customers’ specific operational and financial maintenance targets for fleets of any size.

One of the linchpins in GE’s OnPoint overhaul solutions is the company’s inventory of GE and CFM new, used serviceable and repair material.

Readily available through four distribution channels, this material is on hand when and where it is needed. GE Aviation’s materials business outside Dallas, Texas and the recently formed CFM Materials business are leading suppliers of used material. In addition, GE has material distribution centers in Amsterdam and Singapore. Access to this GE-owned OEM inventory reduces risk of turntime delays and enables GE to offer varying levels of used serviceable material content guarantees for significant customer cost savings.

A fixed-price labor schedule contract with a 90% guarantee of used serviceable material could save an engine owner up to $250,000 for an average, full-performance workscope on a CFM56-3 engine compared to replacing the same level of scrapped parts with new.

Overhaul guarantees: GE backs up its service agreements with overhaul performance guarantees, including the industry’s first-ever customer service guarantees:

  • Customer service standards: From receipt through final invoice, GE provides critical overhaul documentation via digital communications. These information packages allow customers to track their engines’ overhaul progress and schedule their return to revenue service. GE guarantees delivery to these customer service standards, or remedies will be provided at the time of issue of the final invoice.
  • Overhaul turnaround time (TAT): GE customers receive industry-leading turnaround times. Lean manufacturing techniques and flow technology used in each shop reduce variation in TAT and improve speed. These best practices enable GE to guarantee TAT based on predictable shop performance.
  • Exhaust gas temperature (EGT) margin: By incorporating best practices across its overhaul shops to optimize workscopes and improve predictability, GE is able to offer test cell EGT margin guarantees. In fact, GE shops have significantly improved the EGT margin of the CFM56-3 engine following overhaul, consistently achieving levels 20% better than any other provider.

Information and communication innovations: “To further innovate the customer communication and information retrieval process, last year GE initiated myEngines* digital services—which includes suites of applications accessible at the touch of a button,” says Huntley Myrie, general manager of GE’s Services Solutions division. “Customers can now monitor overhaul data by logging into the secure myEngines portal via their smartphone, tablet, desktop or laptop.


myEngines' Overhaul application makes it possible for our customers to track their assets as they progress through overhaul gates, view activity logs and get real-time delivery updates to optimize fleet planning.

GE has five dedicated, world-class aircraft engine overhaul shops located in Strother, Kansas (USA); Malaysia; Celma (Brazil); Caledonian (Scotland); and Wales -- as well as 12 alliance shop partners within GE's global MRO network. Click on the video screen to view a capabilities tour of the GE Aviation, Services-Wales overhaul facility.

OEM expertise to optimize workscopes. Flexible overhaul agreements. Two dozen repair and overhaul locations worldwide. The most extensive access to OEM new, used serviceable and repair material in the world. myEngines real-time communication and tracking technology. GE’s overhaul capabilities provide the highest level of customer service, engine performance and reliability at an industry-competitive investment.

Kristen Kalonick kristen.mayrhofer@ge.com
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Recognizing the value of a true originalTRUEngine program expanded to include GE engines

Building on the well-received CFM56* engine program offering, GE Aviation has now extended the TRUEngine* program to GE engine lines—beginning with its CF6* and GEnx* powerplants.

As part of the launch, GE has granted TRUEngine designation to Nippon Cargo Airlines' fleet of 43 CF6-80C2 engines powering its Boeing 747* fleet and Air India’s GEnx-1B engine fleet. Air India has ordered GEnx-1B engines for its 27 Boeing 787-8 aircraft.

Additionally, as part of a recently signed GE Branded Services Agreement (GBSA), Air India will be licensed to perform maintenance and overhaul work on the GEnx-1B, which means the carrier will follow GE-issued engine maintenance, service bulletins and other maintenance recommendations.

The TRUEngine designation, introduced in 2008, has become a common and recognized status for identifying engines maintained per CFM International-issued manuals and other maintenance recommendations, which consider the affect that each component or system has on the engine.

In addition to optimized support and enhanced marketability, TRUEngine qualification provides other valuable benefits, such as extended new part warranty and complimentary days access to the GE or CFM engine lease pool.

"Achieving optimum performance and reliability won't happen if you treat your hardware purely as a commodity," says Chuck Williams, general manager of the CF6 engine program. "It's about leveraging the unique engine system design knowledge and field experience, combined with the latest technology, into an optimized material and maintenance strategy."

To qualify for TRUEngine status, an engine’s overhaul practices, spare parts and repairs used to service the engine must be consistent with GE or CFM requirements and submitted to GE or CFM for review.

Upon meeting the criteria, TRUEngine status will be available to each of the CFM56 and CF6 engines in service as well as ordered GEnx engines. Visit www.geaviation.com/services/truengine for additional information on the TRUEngine program for GE engine lines.

Contact: Your GE representative or the TRUEngine team directly at TRUEngine@ge.com

Quick facts

TRUEngine status:

  • Is a free program, with no cost to qualify or receive benefits
  • Ensures optimal technical and product support
  • Is not permanent or contractual—status remains in effect until next shop visit (requalification) or owner/operator choice to decline
  • Is granted on a per engine serial number (ESN) basis, not by customer or fleet
  • Is based on maintenance records to the latest exposure of each module
  • Is fully transferable in the event of an engine sale or new lease

CF6 engine notes

  • The CF6 engine line has been in service for 40+ years.
  • The engine line has logged more than 350 million flight hours and has the lowest cost of ownership compared to comparable engines in its class.
  • More than 70% of CF6-powered aircraft remain in service today.
  • Backed by GE, the CF6 engine’s global maintenance, repair and overhaul (MRO) network offers owner/operators 24/7 support.
  • CF6 technology improvements—such as a low emissions combustor and advancements in the high pressure turbine technology—will maximize customer value well into the 21st century.

GEnx engine notes

  • The GEnx engine will be the workhorse engine of the 21st century for medium-capacity, long-range aircraft.
  • Selected to power the Boeing 787 Dreamliner* and Boeing 747-8 aircraft, GEnx is scheduled to enter service this year with the GEnx-2B engine powering 747-8 aircraft for Cargolux Airlines International S.A. of Luxembourg. The GEnx-1B engine is scheduled to enter service later in 2011.
  • The engine uses the latest-generation materials and design processes to reduce weight, improve performance and lower maintenance.
  • A product of ecomagination*, the engine’s advanced technologies result in best-in-class NOx emissions.
  • Once in service, the engine will be backed by GE’s global MRO network for around-the-clock support.
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Air China, CFM finalize engine MRO joint venture; expand engineering, maintenance capabilities

Air China and CFM International have cleared the final hurdle and received Chinese government approval for the formation of Sichuan Services Aero Engines Maintenance Company (SSAMC), a 60/40 joint venture between the two companies.

Located in Chengdu, China, this innovative maintenance, repair and overhaul (MRO) joint venture will combine Air China's capabilities with CFM’s, merging their expertise to provide optimal service for their Chinese and worldwide customers.

The facility, which previously operated as a dedicated overhaul shop, completes 60 to 80 engine overhauls annually. The new joint venture will expand Air China’s engineering offerings, which already include aircraft maintenance, repair and overhaul services.

“Bringing Air China and CFM together in this joint venture relationship is a winning solution,” says Jean-Paul Ebanga, president and CEO of CFM International.

“Benefitting from Air China and CFM’s combined expertise, SSAMC will be able to offer best-in-service level of performance in terms of quality, turnaround time, restored EGT margin and cost.”

Contact: Brian Ovington brian.ovington@ge.com

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CFM completes successful LEAP blade-out, rig testing

Development of CFM International's LEAP* engine is on track for first full engine to test in early 2013 and certification in 2014. CFM launched LEAP as a completely new centerline engine in 2008 and has been developing advanced technologies for the engine for more than 15 years.

Completed earlier this year, successful blade-out testing at CFM's development center in Villaroche, France, confirmed that the engine's 18-blade 3-D woven, resin transfer molding (RTM) composite fan and composite fan case can contain the loss of one or more blades and continue operating for a period simulating a return to ground.

These fan blades have been identified as the LEAP engine's 1,001st technology innovation. Their patented, revolutionary technology uses woven carbon fibers and a unique manufacturing process to create maintenance-free, highly durable blades. The light-weight fan, combined with a composite fan case, reduces aircraft weight by 1,000 pounds compared to the same size fan manufactured using all-metal materials. This lower weight, along with state-of-the-art blade design, contributes about half of the 15% fuel efficiency improvement the LEAP engine will provide.

In May, CFM conducted extensive rig testing of its ultra-high-efficiency LEAP low-pressure turbine with outstanding results. The rig, which included the full low-pressure turbine (LPT) and turbine rear frame, validated the technical innovations in the design, including the advanced 3-D designed airfoils and blade and vane alignment. Initial results confirmed very high efficiency levels and matched results achieved in pre-test simulations.

The LEAP-X1C is the sole Western powerplant of the Commercial Aircraft Corporation of China's C919*.

In addition, Airbus has announced the selection of the LEAP-X1A engine as part of its offering for the A320neo* (new engine option), a new aircraft/engine combination scheduled to enter commercial service in 2016. Earlier this month, Virgin America officially launched CFM's advanced LEAP engine with an order to power 30 new Airbus A320neo aircraft.

At the Paris Air Show in Le Bourget, France, CFM has booked firm orders for 910 LEAP-X1A engines to power 455 Airbus A320neo aircraft.

  • AirAsia placed the single largest order in aviation history, selecting the advanced LEAP engine to power 200 Airbus A320neo aircraft.
  • CIT Aerospace placed an order for LEAP engines to power 15 A320neos.
  • GE Capital Aviation Services (GECAS) ordered engines to power 60 A320neos.
  • ILFC selected the LEAP engine to power 40 A320s.
  • Republic Airways Holdings, the parent company of U.S.-based Frontier Airlines, selected the LEAP-X1A to power 40 A319neo and 40 A320neo aircraft.
  • SAS chose the LEAP engine to power 30 A320neos.

CFM Materials recently celebrated the official grand opening of its new, 48,000-square-foot facility in Grand Prairie, Texas.

Contact: Bill Brown bill.h.brown@ge.com

LEAP advantages

Designed to power the next-generation of short-to-medium range aircraft, the LEAP turbofan’s revolutionary technologies will create a powerplant that is expected to:

  • Produce 50% fewer NOX emissions#
  • Emit 15% fewer CO2 emissions#
  • Run on up to 15% less fuel#
  • Reduce noise by 10 to 15 dB#

Heavily rooted in CFM’s proven advanced aerodynamics, environmental and materials technologies and backed by the most extensive support network in the industry, engines in the LEAP program will benefit from best-in-industry CFM56* reliability and maintainability.

The LEAP engine is being readied for 2014 certification to coincide with the entry into commercial service of the COMAC C919 and the A320neo in 2016.

#Compared to the current production engines the LEAP will replace as well as current and proposed environmental regulations

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CF34 newsTAME signs five-year GE OnPoint solutions agreement

TAME, or Línea Aérea del Ecuador, recently signed a five-year OnPoint* solutions agreement with GE Aviation for the maintenance of its CF34-10E engine fleet powering its three EMBRAER 190* aircraft.

"TAME appreciates how GE tailored this agreement to meet our unique maintenance needs," says TAME President, Brigadier General Gustavo Cuesta. "By having GE maintain our engines, TAME is confident the engines will be in excellent performing condition to help us serve our flying customers."

"They have served Ecuador for close to 50 years, and GE is looking forward to providing TAME with high-quality OEM material and services to ensure it can continue offering its customers the same high level of service that they have come to expect," says Doug Izarra, vice president, GE Aviation.

The airline is headquartered in Quito, Ecuador, and has offered passenger, charter and freight services within Ecuador as well as to Colombia, Cuba, the Dominican Republic and Panama since 1962.

GE’s OnPoint solutions are customized service agreements tailored to the operational and financial needs of each customer for any size fleet. These agreements are designed to lower customers’ cost of ownership and maximize the use of their assets. Backed by GE’s global support network, OnPoint solutions may include overhaul, on wing support, new and used serviceable parts, component repair, technology upgrades, engine leasing, integrated systems support and diagnostics and integrated systems.

Contact: André Robert andre.robert@ge.com

The CF34-10E file

  • At 20,000 lbs. of thrust, the CF34-10E has the CF34* engine family’s highest thrust rating.
  • By this July, 1,000 CF34-10E engines will be in service with 43 customers.
  • The CF34 has accumulated more than 5 million flight-hours and 3 million cycles.
  • Features include:
    • A wide-chord fan blade for higher thrust and high tolerance to foreign object damage
    • 3-D aerodynamic design airfoils throughout the entire flowpath, providing highly efficient, stall-free operation as well as better fuel burn and higher exhaust gas temperature margins
    • A highly durable single annular, low-emissions combustor that meets or surpasses the most stringent emissions standards
    • A single-stage high-pressure turbine for lower operating cost
  • CF34 engines power the EMBRAER 190/195* aircraft and EMBRAER Lineage 1000* business jet.
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Component repair highlights

Development of new engine repairs by original equipment manufacturer (OEM) engineers provides GE Aviation customers with the experience, resources and cost-effective solutions required to keep their aircraft flying while reducing cost of powerplant ownership. Following are a few of the recently released repairs and programs for CF34-10E, CF34-3 and GE90-115B engines.

Part: CF34-10E stage 4 LPT blade
Repair: Interlock wear repair

This repair addresses the excessive wear on the low-pressure turbine (LPT) stage 4 blade interlock region. Due to the relative motion of the two adjacent blades, this region typically wears over time. The repair involves material deposition in the interlock region and subsequent machining and heat treat operations to restore final design geometry. Pre-twist and coating is performed to restore serviceability.

Part: CF34-3 stage 3 LPT nozzle
Repair: Outer band wire mesh restoration

The outer band of the LPT stage 3 nozzle typically experiences significant metal loss due to corrosion and thermal distress. This repair is an extension of the full repair. The previous repair process was limited to surface buildup using weld material only. This repair builds up the eroded outer band surface by utilizing a specialized wire mesh and welding/brazing process that enables a much higher salvation rate. This new repair process has increased repair LPT nozzle yields significantly.

Part: GE90-115B combustor inner liner
Repair: Inner liner multi-hole panel repair

Distress in the multi-hole panel region of the combustor’s inner liner is a common occurrence. This repair involves stripping the thermal barrier coating (TBC), machining away the multi-hole panel region and replacing it with a new panel. Dimensional restoration and installation of new nut plates completes the repair. Also a G05 configuration is upgraded to a G06 configuration with the newer aft ring geometry. This repair also restores the wear coating on the aft seal surface as necessary.

Contact: Bobby Sohi bobby.sohi@ge.com

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Did you know?

GE’s long-serving Boeing 747-100 flying testbed (at left) will soon be retired. In its place, GE Aviation is refurbishing a GE CF6-80C2-powered Boeing 747-400, purchased late last year from Japan Airlines (foreground). GE is making a $60 million investment in the aircraft, which is to be home-based at GE’s Flight Test Operation in Victorville, Calif.

To prepare the 747* for flight-testing, its left wing and strut are being redesigned and strengthened to accommodate experimental engines of varying sizes and weights. The plane’s interior is also being modified, and GE is installing data systems for testing and systems integration equipment that will transform the aircraft into a state-of-the-art flying testbed for the next generation of jet engines. The process will take about two years before the aircraft is ready to make its inaugural test flight with the new CFM LEAP engine.

The retiring 747-100 aircraft celebrated 40 years of flight in 2009 and has been operating as GE’s flying testbed since 1992. Most test missions are flown within the Edwards Air Force Base Restricted Test Area, restricted airspace for test flights located around the Lancaster, Calif., base.

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