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Five- to six-digit savings/SV potential Restoring serviceability and value through component repair technologies
Reclaiming aircraft engine components that would otherwise have to be replaced helps operators extend an engine’s service life, while positively affecting the bottom line.
With in-depth expertise in a wide range of technical fields, GE’s repair technology specialists continually develop and support world-class component repair solutions with the same rigor as new-make original equipment manufacturer (OEM) parts. In 2010 alone, there were more than 1,000 repairs introduced, and the 2011 pipeline for new repair development is full.
$40M R&D investment: “Within the aviation business alone, GE invests approximately $40 million each year in new repair development and industrialization,” says Anna Nabb, general manager of Component Repair, GE Aviation, Services. “These repairs are key to GE and CFM56* powerplant owners’ ability to maintain their engine fleets at optimal and extended performance levels. For customers, the longer time on wing and significant shop savings equate to lower cost of ownership and improved competitive position.”
OEM synergy equates to better repairs: Repairing engine parts utilizing the OEM repair process is one of the most cost-effective ways to preserve reliability and performance, while the use of proven and durable materials ensures configuration control, integrity and support.
- The component repair team has dedicated resources working with GE’s new engine design teams to better understand new technologies going into GE and CFM International engines.
- This OEM knowledge and synergy with other GE teams helps the component repair team address root causes of component distress, resulting in reliable and faster repairs.
Current component repair focus
- Flowpath: While GE is focused on several specific areas that the company believes will be important for customer cost of ownership over the next five to 10 years, processes to repair flowpath hardware, such as high-pressure turbine (HPT) airfoils and low-pressure turbine (LPT) and HPT nozzles, are a primary focus. Typically, these parts see the most wear and tear. There are extensive efforts to understand and develop repair technologies in the areas of welding techniques, coatings, cleaning and inspection processes for these components.
- Turnaround times: Increased aircraft utilization rates since 2010 have resulted in more shop visits for GE and CFM engines. Customers need repairs and overhaul completed and their engines back into service as quickly as possible.
“GE is addressing turnaround times by investing in both human and industrial resources—hiring more experts across all six core repair shops and adding additional equipment and automation capabilities,” says Nabb. Improving turnaround times is a critical factor for customers, and there is an extensive focus on optimizing repair processes and eliminating waste. - Advanced technology materials: GE’s repair technology specialists are continually developing and supporting cost-saving repair solutions in seven critical categories: inspection, joining, specialized welding, cleaning, coating, advanced materials and metal addition.
Click on the video screen to view a demonstration of GE’s advanced component repair techniques.
From carbon fiber and ceramic matrix composites to titanium aluminide and the most advanced alloys in use today, repairs for parts created utilizing progressive technologies and materials are developed leveraging the same rigorous OEM standards (design analysis, testing on component and system effects) that are employed when designing GE and CFM56 engines. - Leading-edge communication tools: “The myEngines digital services group is expanding its offerings with a Repair Status suite of applications focused on enhancing the customer service experience,” says Nabb. Currently in development, the Repair app will provide the status of orders at GE’s component repair shops. Customers will be able to track turnaround times, filtering data by shop and engine serial number, and have the capability to view details on each individual component being repaired.
The new Repair app will complement GE’s other myEngines suites of engine and system apps, all of which allow customers to view the progress of their individual engines during the overhaul process, providing an enhanced and more flexible customer service experience. - Other areas of focus: Some of GE’s current activities are centered on new coatings and new coating processes for HPT airfoils that will provide enhanced protection at higher temperatures. The company is also developing more accurate inspection methods that provide greater levels of information relating to how the repaired part will operate in the engine system.
Significant per-shop-visit savings: Advanced repair solutions reduce the requirement for a complete infusion of new material, thus lowering operators’ overall cost of ownership. The savings impact of these innovative technologies can be seen across GE’s component repair portfolio.
Customer input, proactive repairs: Customers are an integral part of the component repair development process. The environment in which the engine operates can have a big influence on the distress seen in the individual components. For example, hot and harsh environments can accelerate HPT airfoil distress.
GE’s technical team leverages customer insights and data to develop proactive repair solutions for specific issues—extending the life of affected parts, reducing ownership costs and improving customers’ competitive position.
Contact: Bobby Sohi bobby.sohi@ge.com
ClearCore Engine Wash system now ecomagination certified
GE Aviation’s ClearCore* Engine Wash system, an on-wing engine wash and effluent collection system, recently joined GE’s distinguished list of ecomagination* products and services.
An engine’s performance deteriorates over time due to mechanical wear and environmental contamination, such as dust and sand. The deterioration caused by these environmental factors can be lessened with the ClearCore service.
The amount of performance recovered varies based on operating conditions and wash interval cycle. To maximize the benefits, GE utilizes its diagnostic technology to determine the ClearCore system’s optimal wash interval. Diagnostics are also used after a wash is completed to determine the effectiveness of the process.
The ClearCore service provides a full effluent capture system, which allows the engines to be washed at the gate or in the hangar. The water collected from the wash is micro-filtered and can be reused, and an integrated vacuum system eliminates water pooling.
Ecomagination is GE’s commitment to imagine and build innovative solutions to today’s environmental challenges.
“Aviation’s impact on the environment is a leading concern for our business,” says David Joyce, GE Aviation president and chief executive officer. “That’s why our engineering team focuses its development efforts on ensuring our new products and services help to further reduce fuel burn, emissions and noise.”
Contact: Jeff Wiseman jeffrey.wiseman@ge.com
TAM Airlines signs GE Fuel and Carbon Solutions agreement—targets significantly reducing fuel costs, increasing overall operational efficiency
TAM Airlines has tapped into GE’s expanded services portfolio, signing a Fuel and Carbon Solutions agreement that will bring the airline in-depth analyses on its GE- and CFM-powered aircraft.
Using proprietary decision software and fuel-consulting expertise, GE's Fuel and Carbon Solutions team will work with TAM to identify and track operational improvements that could reduce the airline's fuel spend by an average of 3%.
"We are focusing our efforts on reducing costs and increasing efficiency to offer our clients high-quality services,” says José Zaidan Maluf, TAM's supply and contract vice president. “Managing our jet fuel consumption efficiently will not only enable us to reduce financial impact of our most significant expense, but will also improve our CO2 emission footprint, coping with our sustainability objectives. GE's expertise in this field will help us fulfill our goals.”
Based in Sao Paulo, Brazil, TAM operates domestic flights throughout Brazil and internationally, to 19 cities in South America, Europe and the United States. Its fleet includes CF6-80C2/-80E1, GE90* and CFM56* engines.
"TAM has selected GE and CFM56 engines for their emission performance and fuel efficiency," says John Gough, leader of GE Aviation's Fuel and Carbon Solutions. "Now, by using GE's Fuel and Carbon Solutions, TAM can further reduce its fuel usage and help further reduce emissions."
Contact: Jeff Wiseman jeffrey.wiseman@ge.com
Eight application suites now featured myEngines digital services: Secure data access for 24/7 fleet and engine management
Building on the original set of applications, GE recently released myEngines* digital services version 4, adding three new suites of apps to the initial five. These latest—Fleet, Fuel and TRUEngine*—bring even greater scope and capability to the myEngines fleet and engine management tools.
“This latest expansion of myEngines’ services will help customers monitor engine health from a multiple GE and/or CFM International engine fleet perspective, analyze fuel burn and carbon emissions trending, and track TRUEngine OEM-configuration status,” says Huntley Myrie, general manager of GE’s Services Solutions division. “Further to this latest release, we will continue to expand myEngines capabilities, working with customers to design new apps to meet their diverse information needs.”
Eight apps, countless pieces of data
With the original myEngines digital services offering launched in 2010, the now eight major application suites provide customers even greater access to critical engine and fleet data.
“Our goal is to help customers resolve issues that they may have related to data overload, rising fuel costs and environmental concerns,” adds Myrie. “GE’s myEngines digital services allow operators to manage their fleets from virtually anywhere. Having 24/7 access to critical information means they can make real-time decisions that help drive down operating costs and improve productivity.”
At the touch of a button—from desktops, laptops and leading smartphones and tablets—customers can access multiple fleet and engine databases through a single, secure myEngines portal. The program’s applications provide a direct link to GE and CFM original equipment manufacturer (OEM) data and expertise and keep customers connected to maintenance activities, engine performance and asset configuration—even while away from the office.
Contact: Eduardo Cocozza eduardo.cocozza@ge.com
Expanded facility opens TEXL now offering comprehensive GE90 engines MRO services
On June 30, GE and Taikoo Engine Services (Xiamen) Company Limited (TEXL) held a special ceremony commemorating the opening of TEXL’s expanded engine overhaul facility and the start-up of TEXL’s full overhaul and engine test services on GE90* engines.
Located in Xiamen, China, the facility now includes a new two-story, 17,500-square-meter building in which TEXL will perform module strip and build and component repair.
“The larger facility will help us better service our GE90 engine customers and effectively respond to the growing demand for quality GE90 overhaul services,” says Paul McElhinney, president and chief executive officer of GE Aviation’s services operation.
TEXL completed the facility expansion with GE’s assistance and has received Part 145 certificates from the European Aviation Safety Agency (EASA), U.S. Federal Aviation Administration (FAA) and Civil Aviation Administration of China (CAAC) that allow the facility to perform complete overhaul on the GE90-110B and GE90-115B engine models.
The company is the sole holder of a GE90 GE Branded Service Agreement (GBSA) in Asia, operating under a 22-year arrangement with GE to perform authorized GE90 repair services. The GBSA affords TEXL enhanced access to GE’s technology, inventory, resources and training.
Since July 2010, TEXL has been performing quick-turn engine repairs, including modifications and repairs to the compressor outlet guide vane leaf seals, turbine center frame and high-pressure turbine module shrouds.
The new expansion is adjacent to TEXL’s existing 3,500-square-meter facility, where full engine tests are performed in an engine test cell rated at 150,000 pounds of thrust.
Contact: Brian Ovington brian.ovington@ge.com
Recent GE Aviation, CFM news
GE names ST Aerospace as first independent TRUEngine MRO shop
In a unique agreement signed at the Paris Air Show, ST Aerospace has become the first independent maintenance, repair and overhaul (MRO) company to be formally designated a TRUEngine* service provider. ST Aerospace joins GE Aviation Services and Snecma in having this distinction.
Operating a global MRO network with facilities in the Americas, Asia Pacific and Europe, ST Aerospace is the world’s largest aircraft MRO provider, with a global customer base that includes leading airlines, airfreight and military operators. Now, as a TRUEngine MRO provider, any CFM56* engines overhauled by ST Aerospace are eligible for TRUEngine status.
Until recently, the TRUEngine program had only been open to airline customers. The program serves as a method for identifying engines that have been maintained in accordance with GE- and CFM-issued recommendations and provides a valuable database to industry appraisers and potential buyers. The TRUEngine program for CFM56 engine lines and operators launched in 2008.
In 2008, GE and ST Aerospace signed a series of agreements to support CFM56 engine MRO operations. The agreements include a comprehensive long-term materials services agreement that encompasses component repairs and the provision of both new and used serviceable original equipment manufacturer materials for life-limited and non-life-limited parts for the CFM56 engine.
Contact: Brian Ovington brian.ovington@ge.com
GE Aviation, Aviall enter CF6 parts distribution agreement
Aviall, Inc. has entered into an exclusive worldwide aftermarket distribution agreement with GE Aviation for unique spare parts for CF6-80C2/-80E engines. The agreement, which excludes life-limited parts and flow path hardware, extends the life of the engine. This extension is currently certified on 11 widebody aircraft models, including the Boeing 747*, Boeing 767* and the Airbus A330*.
A wholly owned subsidiary of The Boeing Company and headquartered in Dallas, Texas, Aviall is one of the world’s largest providers of new aviation parts and related aftermarket operations, serving its customer base from 40 global locations. Aviall will assume the CF6* distribution responsibilities by end of summer 2011, including forecasting, ordering and delivering all original equipment manufacturer genuine replacement parts unique to the CF6-80C2/-80E engines.
Contact: Chris Gilmore chris.gilmore@ge.com
GE Aviation to design new Dubai engine repair and overhaul facility for Emirates
Emirates Airline has announced plans to build a technologically advanced engine overhaul shop in Dubai. Targeting a 2012 construction start and 2014 opening, the shop will be located on the same campus as the airline’s test cell facility and will create more than 500 new jobs for the region.
Per a signed letter of intent, GE Aviation will oversee the design and construction of the new engine shop, employing the most advanced technology, equipment and best practices in the industry.
To provide the most cost-effective and efficient engine maintenance, the growth of the Emirates fleet and its subsequent number of operating engines have necessitated the addition of the in-house engine shop. The facility will provide Emirates with the capability to annually service 300 GE90* and GP7200* engines powering the Boeing 777* and Airbus A380* respectively.
This announcement represents another milestone for Emirates Engineering in its efforts to increase engine maintenance capability in terms of volume and repairs. “We are pleased to be working with Emirates in supporting the building of the engine shop using GE expertise in this field to introduce best industry practices in managing engine repairs,” says Muhammad Al-Lamadani, senior executive sales, vice president GE International Inc.
Contact: Brian Ovington brian.ovington@ge.com
