MTU - Engine Condition Monitoring (ECM)
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1 MTU - Engine Condition Monitoring (ECM) Dipl.-Ing. Matthias Binner Dr.-Ing. Jens Friedrichs MTU Maintenance Hannover GmbH Hannover Messe April 2009
2 Agenda Introduction MTU - MTU Plus Engine Trend Monitoring MTU ECM track record MTU ECM service levels Engine health monitoring Summary 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 2
3 Introduction Agenda Introduction MTU - MTU Plus Engine Trend Monitoring MTU ECM track record MTU ECM service levels Engine health monitoring Summary 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 3
4 Aircraft condition monitoring Aircraft Condition Monitoring APM ECM AHMS Aircraft Performance Monitoring Engine Condition Monitoring APU Health Monitoring ECM is part of the aircraft condition monitoring system 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 4
5 MTU - MTU Engine Trend Monitoring Agenda Introduction MTU - MTU Plus Engine Trend Monitoring MTU ECM track record MTU ECM service levels Engine health monitoring Summary 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 5
6 Engine Condition Monitoring (ECM) On-wing electronically readable data (Semi)-manually readable data Via ACARS, SATCOM, DFDR,... Via , Fax ECM department MTU Plus ETM Processing & database Analyzing & advising Operations/ Line maintenance Internet access to database Reports, advises, alerts Maintenance data (findings, T/S results..) Internet Access Portal to MTU network 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 6
7 MTU Plus ETM MTU s Engine Trend Monitoring tool for ECM Data snap-shots 1 MTU Plus ETM DATAFLOW Input filter Manual ARINC Database Calibration Engine model MOPS system* TAKO / Cruise snapshots Engine specific models Trends calculated by MOPS (MOdular Performance Synthesis) 2 Trending Trend plotting MTU Plus ETM MONITORING Visualization & warning Warning logic - standard -customized 3 MTU FEEDBACK* * Service Level II or III MTU engineering know-how & MRO experience Analyzing Communication with customer - Recommendations - Corrective actions 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 7
8 Performance model MOPS within MTU Plus ETM Calibrated performance model Measured parameters EPR*, ALT, Ma, TAT EGT, FF, N2, N1* Engine model specific performance model Calibration mode (one-time calibration): - Healthy engine - MOPS calibrated to measured parameters ESN specific performance model Trending mode (ongoing): - Calibrated MOPS calculates expected parameters - Residuals vs. expected and measured parameters plotted Expected / estimated EGT,FF,N2 + - = measured - estimated * Depending on engine control principle 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 8
9 ECM current applications* CF6-50/-80C2 V2500 PW2000 CFM56-7 CF34-10 *All other engine types can be supported on request One single platform for various engine types 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 9
10 MTU Plus ETM Capabilities & advantages Common platform for all engine and aircraft types Graphic interface Full thermodynamic model Monitoring of different operations (TO,climb,cruise) ESN related calibration (also re-calibration ) Automated alerts and reports Engine performance analysis and management Individual alert levels Alarm flag indication based on free rules (logical and/or arithmetical calculation) Free combination of parameters allows early failure detection Free adjustable sensitivity allows Expert mode 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 10
11 MTU ECM track record Agenda Introduction MTU - MTU Plus Engine Trend Monitoring MTU ECM track record MTU ECM service levels Engine health monitoring Summary 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 11
12 ECM Track record (1) EGT thermocouple change HPC stg.11 vane liberation Engine inspected within one leg after MTU recommendation (A/C relocated) BSI confirmed the failure Engine was removed and replaced re-calibration HPC damage 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 12
13 ECM Track record (2) HPC stage 5 lever arm failure/ liberation After visual inspection engine was removed and replaced Lever arm failure 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 13
14 ECM Track record (3) Bolt broken L/H core VSV master beam aft hinge bolt broken Engine visually inspected Returned to service after bolt replacement 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 14
15 ECM Performance management Engine performance management tool Δ EGT (C ) Monitoring of EGT deterioration Determination of most effective point for core cleaning based on individual engine performance water wash water wash Determination of effective cleaning method (soft / hard) Monitoring of performance improvement, re-scheduling if needed Extended On-wing time Pro-active engine removal planning a) Water wash b) Coke cleaning 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 15
16 MTU ECM service levels Agenda Introduction MTU - MTU Plus Engine Trend Monitoring MTU ECM track record MTU ECM service levels Engine health monitoring Summary 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 16
17 ECM - Customer service levels Automatic data collection & processing (24 hours / 7 days) Service Level I WEB-based MTU Plus ETM system access, including alerting, trending and diagnostic tools, alarm notification Operator performs monitoring and keeps full responsibility Service Level II ECM service provider performs trend monitoring & engineering support incl: - Watchlist management - Performance reports - Fault diagnostic and troubleshooting support ECM service provider does the monitoring on behalf of the operator, but the operator keeps full airworthiness responsibility Service Level I and Service Level II in combination, Service Level III providing also operator access to the MTU Plus ETM system 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 17
18 Summary Agenda Introduction MTU - MTU Plus Engine Trend Monitoring MTU ECM track record MTU ECM service levels Engine health monitoring Summary 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 18
19 ECM operational benefits Gives predictive information about engine abnormal behavior and helps to avoid unexpected failures Supports early line maintenance decisions to avoid secondary damages and AOG s Supports performance prediction & optimum aircraft operational planning Allows better engine removal planning & optimized spare engine management Leads to early known damage pattern Allows optimized off-wing maintenance planning 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 19
20 ECM financial benefits Optimized usage of engine fleet Minimized unscheduled downtime, and optimized on-wing times Reduced spare engine level requirements Increased fuel efficiency and overall fuel consumption thanks optimized core engine wash timing Lower maintenance cost 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 20
21 MTU Plus ETM benefits One single ECM system - for all engine types No additional cost for IT & software Complete real-time visibility thanks to a 24/7 webaccess via secure customer log-in Customized trend analysis based on engine type and history Immediate automatic alarm notification when performance trend shifts detected, not when OEM limits are exceeded Adjustable sensitivity for expert-mode 23 April 2009 MTU Engine Condition Monitoring (ECM) Hannover Messe 2009 MTU Aero Engines GmbH 21
22 Thanks you for your attention! Special thanks to Ulf Godehardt and Ivo Krastev for their participation Contact: Engineering: Sales:
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