mtu engine condition monitoring (ecm) hannover...
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MTU - Engine Condition Monitoring (ECM)
Dipl.-Ing. Matthias BinnerDr.-Ing. Jens FriedrichsMTU Maintenance Hannover GmbH
Hannover Messe 2009
23 April 2009
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 2© MTU Aero Engines GmbH
Agenda
• Introduction
• ECM @ MTU - MTU Engine Trend Monitoring
• MTU ECM track record
• MTU ECM service levels
• Engine health monitoring
• Summary
Plus
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 3© MTU Aero Engines GmbHIntroduction
• Introduction
• ECM @ MTU - MTU Engine Trend Monitoring
• MTU ECM track record
• MTU ECM service levels
• Engine health monitoring
• Summary
Agenda
Plus
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 4© MTU Aero Engines GmbH
APM ECM AHMS
Aircraft Condition Monitoring
Aircraft condition monitoring
Aircraft Performance Monitoring
EngineCondition Monitoring
APUHealth Monitoring
ECM is part of the aircraft condition monitoring system
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 5© MTU Aero Engines GmbHECM @ MTU - MTU Engine Trend Monitoring
• Introduction
• ECM @ MTU - MTU Engine Trend Monitoring
• MTU ECM track record
• MTU ECM service levels
• Engine health monitoring
• Summary
Agenda
Plus
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 6© MTU Aero Engines GmbH
Via ACARS, SATCOM, DFDR,....
ECM department
MTUPlus ETM Processing &
database
Reports, advises, alerts
Engine Condition Monitoring (ECM)
On-wing electronicallyreadable data
(Semi)-manuallyreadable data
Analyzing &advising
Internet PortalAccess to MTU network
Operations/Line maintenance
Internet access to database
Maintenance data (findings, T/S results..)
Via E-mail, Fax
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 7© MTU Aero Engines GmbH
MTUPlus ETM – MTU’s Engine Trend Monitoring tool for ECM
• Manual• E-Mail• ARINC
Inputfilter
Calibration
Engine model
MOPS –system*
• TAKO / Cruise snapshots
• Engine specific models
• Trends calculated by MOPS(MOdular Performance Synthesis)
• Trend plotting
• Warning logic - standard- customized
• Analyzing
• Communication with customer- Recommendations- Corrective actions
Trending
Visualization & warning
Data snap-shots
1
2
3
MTUPlus ETMDATAFLOW
MTUPlus ETMMONITORING
MTU engineeringknow-how &MRO experience
Database
MTUFEEDBACK** Service Level II or III
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 8© MTU Aero Engines GmbH
Calibrated performance
model
Expected /estimated
EGT,FF,N2+ -
∆ = measured - estimated
* Depending on engine control principle
Performance model “MOPS” within MTUPlus ETM
• 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
Measured parameters
EPR*, ALT, Ma, TAT EGT, FF, N2, N1*
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 9© MTU Aero Engines GmbH
ECM – current applications*
CF6-50/-80C2 V2500 PW2000 CFM56-7 CF34-10
One single platform for various engine types
*All other engine types can be supported on request
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 10© MTU Aero Engines GmbH
MTUPlus 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 11© MTU Aero Engines GmbHMTU ECM track record
• Introduction
• ECM @ MTU - MTU Engine Trend Monitoring
• MTU ECM track record
• MTU ECM service levels
• Engine health monitoring
• Summary
Agenda
Plus
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 12© MTU Aero Engines GmbH
ECM – Track record (1)
EGT thermocouple
change
re-calibration
HPC damage
• 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
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 13© MTU Aero Engines GmbH
ECM – Track record (2)
Lever armfailure
• HPC stage 5 lever arm failure/liberation
• After visual inspection engine was removed and replaced
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 14© MTU Aero Engines GmbH
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 15© MTU Aero Engines GmbH
ECM – Performance management
• Engine performance management tool
• Monitoring of EGT deterioration
• Determination of most effective pointfor core cleaning based on individual engine performance
• Determination of effective cleaningmethod (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
wat
er w
ash
wat
er w
ash
-10°
0°
20°30°
10°
Δ EGT (C°)
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 16© MTU Aero Engines GmbHMTU ECM service levels
• Introduction
• ECM @ MTU - MTU Engine Trend Monitoring
• MTU ECM track record
• MTU ECM service levels
• Engine health monitoring
• Summary
Agenda
Plus
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 17© MTU Aero Engines GmbH
Service Level I
Service Level II
Service Level III
ECM - Customer service levels
• Automatic data collection & processing (24 hours / 7 days)
• WEB-based MTUPlus ETM system access, including alerting, trending and diagnostic tools, alarm notification
• Operator performs monitoring and keeps full responsibility
• 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, providing also operator access to the MTUPlus ETM system
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 18© MTU Aero Engines GmbHSummary
• Introduction
• ECM @ MTU - MTU Engine Trend Monitoring
• MTU ECM track record
• MTU ECM service levels
• Engine health monitoring
• Summary
Agenda
Plus
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 19© MTU Aero Engines GmbH
• 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
ECM operational benefits
23 April 2009 MTU – Engine Condition Monitoring (ECM) Hannover Messe 2009 20© MTU Aero Engines GmbH
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 21© MTU Aero Engines GmbH
MTUPlus 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 web-access 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
Thanks you for your attention!Special thanks to Ulf Godehardt and Ivo Krastevfor their participation
Contact:Engineering: [email protected]: [email protected]