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Enhanced service supportGEnx-2B engine enters service on 747-8 with launch customer Cargolux
GE’s GEnx* engine entered into service this fall with the first delivery of
GEnx-2B engines on the new Boeing
747-8 to launch customer Luxembourg-based cargo carrier Cargolux.
With 13 Boeing 747-8 freighter aircraft on firm order, Cargolux took delivery of its first two aircraft October 12 and 13. Since that time, the cargo carrier has taken delivery of four more GEnx-2B-powered 747-8 aircraft. And, with less than two months in service, the GEnx-2B engine has already completed more than 1,700 engine flight cycles.
Support-ready
While the GEnx-2B is five years out from the first shop overhaul visit, the GE Aviation services team’s multifaceted effort to establish best practices and procedures is well underway.
“We have one chance to make a great first impression, and we plan to do so,” says Bill Fitzgerald, vice president and general manager of the GEnx engine program at GE Aviation. “We’ve dedicated a lot of time and energy up front ensuring that available maintenance efforts are underway.”
- GE has established a worldwide network of GEnx engine maintenance, repair and overhaul providers, including five GEnx on-wing support sites around the world.
- Customers will benefit by a significant increase in field service engineer support over earlier programs, with a team of support personnel that is GEnx-trained and ready for quick-turn deployment to in-the-field locations.
- Development, testing and confirmation of overhaul and repair processes is an ongoing effort.
“The day the GEnx entered service, our team had training and familiarity regarding how we will support this new engine program,” says Fitzgerald, noting that the GE services operation has worked closely with Boeing on support preparedness.
GE’s Cincinnati Technical Education Center (CTEC) in Evendale, Ohio, has already trained more than 1,000 professionals—both external customers as well as GE employees—in maintenance and technical training on the GEnx engine prior to entry into service.
A product of ecomagination*
The GEnx’s performance is helping define GE’s next generation of commercial engines. Quieter and more fuel-efficient compared to the powerplants they replace, GEnx engines dramatically reduce NOx emissions.
At the time of the Cargolux delivery, the GEnx was already the fastest-selling high-thrust jet engine in GE’s history, with 1,300-plus engines sold to 45 customers. In addition to powering the Boeing 747-8, GEnx-1B engines will power Boeing’s new 787 Dreamliner*.
"This is a huge year for the GEnx," says David Joyce, president and CEO of GE Aviation. "Its technical features make it a very unique jet engine, resulting from more than a decade of concentrated focus on its development. Now, the engine can prove itself in operational service first with Cargolux and then with many more customers over the next few years."
Contact: Jennifer Farrell Emerich jennifer.farrell@ge.com
Dynamic customer training servicesGE Aviation launches CTEC University: One-stop conduit to maintenance training information and services
GE Aviation’s Customer Technical Education Center (CTEC) has launched CTEC University, providing GE customers a one-stop online conduit to GE’s robust menu of aviation maintenance training modules, materials and more.
Engine maintenance knowledge and skills and employing OEM best practices are key to extending engine life and managing cost of ownership. Through CTEC, each year thousands of GE customers worldwide take advantage of an all-encompassing portfolio of maintenance training opportunities.
Now, with the introduction of CTEC University, GE customers with applicable signed General Terms Agreements in place need only a computer and access to GE’s Customer Web Center portal to tap into CTEC’s multiple service offerings. For CFM International customers, access to CTEC University is scheduled to be up and running in mid-2012. Until then, CFM customers can access CTEC educational opportunities via the established channels.
“CTEC University is the foundation on which all of our learning is going to be based going forward,” says Tim Meyers, who leads GE Aviation’s aircraft engine training services division. “It is composed of six components—it is a catalog, a scheduler, a registration device, an online learning platform, a material ordering conduit and, last but not least, it has a student course records and reporting functionality.
“These six attributes are what makes CTEC University special,” says Meyers, noting that the concept really boils down to two things:
- Through CTEC University, GE is able to provide one-stop customer training, while offering flexibility and enhanced learning for which customers are not required to call a variety of people to access.
- And customers can now go to one location to enroll students at one of GE’s training centers, take online courses, review newsletters, order course materials, track training progress and generate reports for their regulatory reporting authorities.
Value, productivity
There is no cost to GE customers for CTEC University. Customers access the functionality through GE’s Customer Web Center. Depending on their customer contract, there may be a cost for some of the courses for which they register or take online or the materials they order. However, there is no cost to access CTEC University to research what is available, to whom, when and where.
Says Meyers, “With all of GE Aviation’s technical training offerings and information now gathered together and accessible via this single contact point, what CTEC University offers translates into value and productivity for our customers.
“Once a customer registers via CTEC University, the system determines what GE engine products they fly and provides them access to the maintenance training instruction information and services geared specifically to those commercial or military engine lines.”
Dynamic customer training services
Meyers adds that CTEC’s training services are a significant piece of the support package customers receive when they buy GE engines. Maintenance training allows customers to keep their cost of ownership down. The goal is to keep their engines in motion for revenue service. GE believes CTEC University now simplifies and enhances customers’ access to maintenance education, while allowing technical training to be delivered with ease and flexibility via multiple avenues into the hands of those who need it.
“GE Aviation’s technical training group delivers a quality product,” says Meyers. “We deliver world-class materials that are updated on a regular basis to ensure they are timely, accurate and professional. Our number one intent in launching CTEC University is to bring this value to our customers in the most current, efficient and convenient manner available.”
Contact: Tim Meyers tim.meyers@ge.com
WestJet taps into TRUEngine benefits, gains significant savings
When 100 of WestJet’s CFM56-7B engines qualified for the CFM TRUEngine* program in 2010, the Canadian airline also became eligible for up to 100 complimentary days of spare engine support annually from the CFM International lease pool in the event of any unscheduled removals. Earlier this year, WestJet found itself in just such a position, and CFM was able to help them stay in service through a period of low engine availability.
Experiencing multiple engine removals in a relatively short time span, WestJet had real concerns that it would have enough spare engines to avoid disruption to its operations.
“This is an instance where we really saw the benefits of the TRUEngine program,” says Russ White, vice president of Technical Operations for WestJet. “Having access to the lease pool enabled us to avoid an AOG [aircraft on the ground] situation and other disruptions.
“Plus,” White emphasizes, “the complimentary days saved us well over $300,000 in engine leasing expenses. We are really pleased with our decision to qualify our CFM56-7B fleet as TRUEngine.”
TRUEngine value
Launched in mid-2008, the TRUEngine designation is available for all CFM56* engines and recently expanded to include GE’s CF6* and GEnx* engines as well.
The TRUEngine designation serves as a method for identifying engines with GE- or CFM-approved content and facilitates product support of these engine systems. Industry stakeholders use the engine content knowledge to evaluate engine value and re-marketability.
To qualify, a customer submits engine serial numbers along with a combination of fleet operational and maintenance records. The information is reviewed to ensure each engine’s content, overhaul practices and repairs are consistent with GE- and CFM-issued recommendations.
Contact: Your GE or CFM representative or the TRUEngine team directly at TRUEngine@ge.com
GE Aviation, Iberia expand MRO relationships to bring OEM expertise to the customer
GE Aviation and Iberia continue to expand their longtime working relationship to bring new engine overhaul capabilities and OEM expertise to Spain’s largest air transport group and its maintenance arm.
Enhanced CF34* overhaul capabilities: A recently inked agreement between GE and Iberia Maintenance expands the service provider’s current overhaul capabilities for the CF34 engine family to now include maintenance and repair services on CF34-8C/E engines.
The agreement also licenses GE's engine maintenance technology and provides GE’s OEM technical support for the Iberia Maintenance customer base, which includes Iberia and another 100 customers around the world.
“Iberia Maintenance has demonstrated its quality workmanship as an MRO provider for many years,” says Paul McElhinney, president and chief executive officer of GE Aviation’s services operations. “Iberia has served as a GE Designated Fulfillment Center on the CFM56-5A for several years, and GE Aviation welcomes Iberia’s effort to further expand its MRO capabilities to include the CF34-8C/E engine, which has more than 2,000 engines in operation around the world.”- New CFM56* repair shop: Iberia is also working with GE to develop a new high-pressure compressor blade repair shop in Madrid, Spain, for CFM International’s CFM56-5/-7 engine families. The airline is in the final stages of GE certification on this project.
Contact: Brian Ovington brian.ovington@ge.com
Iberia first to select all three of GE’s ‘beyond-the-core’ engine services offerings
Iberia has become the first customer to utilize GE Aviation’s full portfolio of beyond-the-core engine services offerings for its aircraft—adding myEngines* digital services, Fuel and Carbon Solutions and the ClearCore* engine wash system to help better manage its fleet, improve productivity, reduce operational costs and extend its engines’ time on wing.
myEngines digital services: From desktops, laptops and leading smartphones and tablets—customers can access multiple fleet and engine databases through a single, secure myEngines portal, allowing operators to manage their fleets from virtually anywhere. The program’s applications provide a direct link to GE and CFM International OEM data and expertise and keep customers connected to maintenance activities, engine performance and asset configuration. Having 24/7 access to critical information helps customers make real-time decisions to drive down operating costs and improve productivity.
Fuel and Carbon Solutions: Through the use of proprietary decision software and fuel-consulting expertise, GE’s Fuel and Carbon Solutions help aircraft owners and operators reduce their fuel spend by an average of 3% on given segments. A product of GE’s ecomagination* portfolio, Fuel and Carbon Solutions involves a three-step process:
- Operational evaluation: Identify and collect data on the airline's current fuel and carbon reduction programs, and quantify where the customer is today.
- Customized solution design: Further analyze data to isolate and prioritize potential fuel management solutions.
- Implementation support and verification: Work with customers to implement changes, and then measure and validate savings.
ClearCore engine wash system: Also a GE ecomagination product, the ClearCore service provides a full effluent capture system, which allows the engines to be washed on wing, 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. The water collection system can be used with existing front-end washing systems. Customers can purchase the equipment or purchase a full-service package, with GE providing the washes.
Contact: Jeff Wiseman jeffrey.wiseman@ge.com
Component repair highlights
Development of new repairs has the dual goal of increasing engines’ time on wing while reducing GE Aviation customers’ cost of ownership. Following are a few of the recently released repairs and programs for CF6-6, CF6-80C and CF34-10E engines.
Part: CF6-6 low-pressure turbine (LPT) case
Repair: Forward corner replacement
The CF6-6 engine line is a mature engine line, and introducing repairs signifies an important commitment to ensure lower cost of customer ownership. LPT cases have been found to exhibit cracking in the forward end weld joint between the horizontal flange and the case skin. This repair installs new, wrought spads at the four forward corners. The new material replaces the high-stress weld joint at the intersection of the horizontal flange and the case skin with wrought material and no weld joint, which results in greatly reduced stress and elimination of cracking in this area. As a result of this repair, LPT cases can now be overhauled every other shop visit, thereby reducing customer costs.
Parts: CF6-80C2/80E stage 1 and 2 high-pressure turbine (HPT) blades
Repair: HPT blade shank corrosion repair
The area beneath the HPT stage 1 and 2 blades platform is prone to corrosion attack. This distress mode is driven by the temperature and environment to which the blades are exposed. As the blades corrode, the protective coating breaks down, further accelerating the corrosion process. This repair removes the corrosion underneath the platform and reconditions the chromium content of the coating to restore the blade to a serviceable condition. The repair also offers improved and enhanced protection from future corrosion attack.
Parts: CF34-10E high-pressure compressor (HPC) vane sectors stages 4 through 8
Repair: Standard repair
This repair addresses distress on stages 4 through 8 of the HPC vane sector. The repair includes blend repair of the leading and trailing edges of the airfoils, seal slot crimp weld repair and honeycomb replacement. After the re-braze process, the coating on the outer platform is replaced. The vane sectors are restored to original design intent dimensions, thereby maximizing engine performance and operability.
Contact: Bobby Sohi bobby.sohi@ge.com
