Stockholm, May 23, 2007, Roland Arntz - sasCommunity · Stockholm, May 23, 2007, Roland Arntz ......

© SR Technics 2007

Engine Condition Monitoring at SR TechnicsStockholm, May 23, 2007, Roland Arntz

2© SR Technics 2007

Objectives

● SR Technics Introduction

● Engine Condition Monitoring (ECM)

● Problem

● Solution

● Benefit

● Future

● Questions


Who are we today

● Leading independent airline technical solutions provider with capabilities covering most Airbus and Boeing aircraft types

● Diversified global customer base – major airlines, low cost carriers, aircraft leasing companies and Original Equipment Manufacturers (OEM)

● Around 750 aircraft supported

● Around 5,000 employees, more than 435,000 sqm in facilities including 11 hangars

● A growing number of partnerships, acquisitions and joint ventures worldwide

● Extensive network of line stations at 20 locations across Europe and Asia as well as logistics centres at London-Heathrow, London-Luton, Zurich and Hong Kong


Recent Company Developments

2006 Mubadala Development, Dubai Aerospace Enterprise and Istithmar became the new owners of SR Technics.

Completion of the transition from a traditional MRO (Maintenance, Repair and Overhaul) company to a global total services provider. Successful market introduction of the three key integrated solutions service packages: Integrated Airline Solutions (IAS), Integrated Component Solutions (ICS) and Integrated Engine Solutions (IES).

2005 Continued to significantly strengthen market position and build-up of a truly global presence, with over 750 aircraft under contract from customers all over the world. The contract with easyJet marked a significant milestone in the industry.

2004 SR Technics acquired FLS Aerospace and integrated it into the Group.

2002 SR Technics transferred to new ownership (3i and Star Capital as major shareholders).

1997 SR Technics - formerly the technical department of Swissair since its establishment in 1931 -established as a separate subsidiary within SAirGroup.


Our Presence

● Major Facilities Switzerland: Zurich (company headquarters)

Ireland: DublinUK: London-Stansted

● Other Operations Ireland: Cork (Airfoil Services)

● Joint Ventures Spain: Palma de MallorcaUK: London-Luton (easyTech)China: Shanghai SR Aircraft Technics Company

● Logistic Centres London-Heathrow, London-Luton, Hong Kong, Zurich

● Line Stations UK, Ireland, mainland Europe, Scandinavia, China


Our Integrated Solutions Offering

Integrated Airline Solutions (IAS)The IAS concept provides a tailor-made solution, consisting of various

Aircraft, Component, Engine and Fleet Technical Management services

Integrated Component Solutions (ICS)

Component Services● Component Maintenance● Component Management● Component Financing● Component Logistics

Integrated Engine Solutions (IES)

Engine Services● Engine Maintenance● Engine Management● Engine Financing● Additional Services

(Logistics and storage, consulting)

Aircraft Services● Aircraft Maintenance● Aircraft Technical Fleet

Management● Aircraft Training● Additional Services

(Aircraft recovery, incident and accident report, consulting)

Fleet Technical Management


Engine Condition Monitoring (ECM) – Why?

● Monitor Engine Performance in flight

● Meet authority requirements (ETOPS)

● Meet economical targets● Avoid unscheduled downtimes● Avoid high cost failures● Reduce fuel consumption● Maximum on-wing life at minimum cost

● Reliability targets● Monitor engine parameters● Improve engine reliability ● Extend engine on-wing life ● Identify weak engines

ECM – Part of the Engine Fleet Management


On Wing Monitoring

Test Cell

Watch ListTrend Report

PilotComplaints

EngineeringExperience

MaintenanceActions

MaintenanceProgram

SAP

ReliabilityMonitoring

ACARSFALCON

OpticalDisk Data

EMSdb Trouble-

shooting

ARTOS

Exceedances

ECMTools


History of ECM

● Single Systems with specific infrastructures and outputs

● High amount of ECM manpower required

● Get rid of ”paper trash”


Standardized GUI

Goals:

● Unified output reduces training / workload up to 90%

● Automated data processing reduces manpower to a minimum

● KISS philosophy for users

● Monitoring of different aircraft / engine applications via one tool

StandardizedGraphical

UserInterface

FALCON


FALCON Overview

Parameter

Plot Area

VariousOptions

Applications


FALCON Data Source

733438,00828,03512,00127,2F688,06064,029

733425,00828,00424,00127,2EE88,06064

1.288,1.288,084.23,087.8,077.4,0428,06.760,02974,05.131

1.288,1.288,083.76,088.1,077.6,0429,06.710,02959,05.101

15.516,093.6,110.4,137.9,469.8,043.3,049.9,089.01,N01.1

15.124,085.5,113.8,137.1,469.3,042.2,048.7,089.78,N00.8

024.5,32,099,209,125.5,0,03.5,0.01,0.04,00.9

027.7,32,100,195,124.0,0,01.0,0.04,0.14,00.1

Aircraft Data:● Automatically collected, processed

and sent via communication system

● Immediate data transfer to home base


FALCON Data Processing and Interface0011100111001010010010011

0001011010010010110011101

0100100010000111100011010

0101101001100101010110100

1010001010110101010101001

0101010001110010101011010

1010101001011000111010101

1010101100100001101010101

1111100011000101101001001

0010001011000111000101100

1110011011010101010110100

0100101010001001100010101

1100100101010101101010101

0100010100101101010001111

1001010101001010101010010

0100100101010110001010100

0101010010101010001010001

733425,00828,00424,00127,2EE88,06064

1.288,1.288,084.23,087.8,077.4,0428,06.760,02974,05.131

1.288,1.288,083.76,088.1,077.6,0429,06.710,02959,05.101

15.516,093.6,110.4,137.9,469.8,043.3,049.9,089.01,N01.1

15.124,085.5,113.8,137.1,469.3,042.2,048.7,089.78,N00.8

024.5,32,099,209,125.5,0,03.5,0.01,0.04,00.9

027.7,32,100,195,124.0,0,01.0,0.04,0.14,00.1

SAS Software on UNIX:● BASE SAS, SAS/AF, SAS/CONECT

SAS/GRAPH, SAS/IntrNet, SAS/SHARESAS/ACCESS to R3

Raw Data:● Text-File, various Formats and content● Immediate data processing

Interface:● Internet Web Server or SR Technics Intranet● Microsoft .net


FALCON Data Limit Monitoring and Alerting

Automatic Data Monitoring:● Trend Changes● Limit Exceedance● E-mail Alerting

Engineering Actions:● Detailed Data Analysis● Aircraft Inspection● Hardware Replacement


An ECM Example (Event)

„Hello ZRH MCC, this is Flight 123 fromZRH to LAX. We have a vibration and exhaust gas temperature alert in the cockpiton engine 2. Please give us support.“

Maintenance Control Center contactsEngine Troubleshooting and Engine Engineeringfor analysis and support.


An ECM Example (Analysis & Action)

The automatic on-line data download via ACARS allows immediate review of engine data and aircraftexceedance reports by Engineering.


An ECM Example (Consequence & Saving)

„Flight 123, this is ZRH calling. Unfortunately weconfirm an engine problem and ask you to comeback to ZRH for troubleshooting.“

Engine removed in ZRH. Shop inspection revealed turbinedamage (about USD 2 million), butdue to immediate action, costexceedance up to USD 5 million oreven engine write off avoided.


FALCON “The User’s View”

● KISS philosophy / user friendly interface

● No user training required

● Quick & professional support in background

● Software changes faster than from OEM’s

● User/Customer requests are understood and fulfilled

● Software helps and is no obstacle

● Software can be maintained in house


FALCON in general

● Internet allows global 24-hour access

● On-time data and E-mail alerting for immediate maintenance action

● Self definable alert limits for individual setup

● Concentration on weak engines reduces workload

● Automatic data processing reduces manpower

● Fleet survey shows status of complete engine fleet

● 2006 Frost & Sullivan Product Differentiation Innovation Award


Savings and Cost

● Cost Savings● 3 FTE’s● Technical Problems avoided

- A320 Variable Bleed Valve Faults / Fuel Costs saved / 15 cases- A330 High Pressure Turbine Case Cooling Valve Faults / Fuel Costs saved / 16 cases - A340 Aircraft Bleed System Faults / Fuel Costs saved / 2 cases- A340 High Press Turbine Shroud Defects / Major damage avoided / 2 cases

USD 7,6 million since 2004

● Development Costs / Infrastructure Costs to be accounted● 0,5 FTE● IT costs (SAS License, Hardware, Infrastructure)

USD 200,000 per year


Competitive Advantage

● Engine Condition Monitoring realized via the Graphical User Interface FALCON, developed by SR Technics

● FALCON can monitor complete aircraft fleets with a mix of different engine types, and display comparative engine data on one screen

● Input data format can be customised as per individual airline requirements

● FALCON uses state of the art technologyand SR Technics’ Engine ConditionMonitoring experience to monitor a fleetmore efficiently

http://www.rolls-royce.com/civil_aerospace/products/airlines/trent1000/engine.jsp

http://www.rolls-royce.com/media/gallery/civil/lrg_trent1000_01.htm

http://www.aircraftenginedesign.com/pictures/Pw6000.JPG


FALCON planned Extensions

● Testcell Data integration

● Aircraft Data Monitoring(APU, Bleed System, Landing Gear)

● Integration of Pilot Complaintsand Maintenance Actions ex SAP


Glossary

● ACARS: Aircraft Communication Addressing and Reporting System

● ECM: Engine Condition Monitoring

● EFM: Engine Fleet Management

● ETOPS: Extended-range Twin-engine Operation Performance Standards

● FALCON: Flight data Analysis Combined with Network


Questions?

Stockholm, May 23, 2007, Roland Arntz - sasCommunity · Stockholm, May 23, 2007, Roland Arntz ......

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