mtu ecm brochure

8/13/2019 MTU ECM Brochure

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Engine Condition Monitoring

MTU Maintenance Hannover

An MTU Aero Engines Company


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The MTU Maintenance group, a business seg-

ment of MTU Aero Engines, Germanys leading

engine manufacturer, has been providing the

aviation industry with quality engine mainte-

nance services for almost three decades.

Today, MTU Maintenance has become the

worlds largest and most experienced inde-

pendent provider of commercial engine main-

tenance services.

As a leading company in both engine develop-

ment and manufacturing as well as mainte-

nance, repair and overhaul, MTU puts a strong

focus on the development of new maintenance

and repair technologies.

Engine Condition Monitoring (ECM) is an inno-

vative system that constantly and remotely

monitors various aircraft engine parameters

and helps detect engine abnormalities and

problems in due time before a critical failure

occurs. This translates into higher engine effi-

ciency and lower cost of ownership through

prevention of potential damage.

Furthermore, ECM helps operators optimally

plan the maintenance of their engine fleets.

ECM complements MTUs Total Engine Care

(TECTM) program and provides for carefree

engine operation.

Via the Engine Trend Monitoring (MTUPlus ETM)

software tool, engineers collect and analyze

engine data that allows them to monitor EGT

deterioration and to detect abnormal engine

behavior. With the system, performance devia-

tions can be detected early and preventive

Your partner for carefree

engine operations

measures can be implemented before serious

problems occur. This can help customers save

substantial amounts of money they would

have to spend, for example, in case of engine

in-flight shut-down or serious failure. Further-

more, the tool can be used to optimize the

timing for a core engine wash.

The MTUPlus ETM system allows engineers to

track engine operations and also to make

recommendations as to corrective actions,

inspections, LRU replacement as necessary, asa variety of other potential measures.

On-line access to the web-based MTUPlus ETM

system provides an overview of the engine

fleet performance worldwide, 24 hours a

day, 7 days a week, with complete real-time

visibility to the customer.

PW2000 CF6 CFM56

V2500 CF34


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In-flight engine data is collected by MTU

Maintenance for processing and analysis.

Automated data acquisition and transfer via

onboard air-to-ground communication (e.g.

ACARS) allow real-time condition monitoring,

if the aircraft is equipped for the purpose. The

MTUPlus ETM system utilizes the existing net-

work of onboard sensors. Thus no extra equip-

ment costs are incurred.

Manual data transfer is also possible around

the clock via a secure internet portal. In-flight

data can also be sent to MTU by fax or e-mail.

The MTUPlus ETM software uses mathematical

modeling to build a parametric engine model

that is based on historical data recorded du-

ring normal operation. The model is customized

to the specific engine serial number and the

specific operating conditions. Statistical mod-

eling allows to use MTUPlus ETM on any engine,

regardless of manufacturer or type. This brings

greater simplicity to the customers operations,as all engine types can be monitored using

one single tool.

The trend plots are derived from the differences

between the model and the actual measured

data. The engine parameters are depicted in a

graphic form rather than in plain numbers.

The MTUPlus ETM system Therefore, MTU engineers are able to identifydeviations from the normal operating mode in

a very timely manner. In the event of signifi-

cant changes an immediate alert is sent to

the operator.

Via MTUs web-accessible portal, ECM service

operators have 24/7 access to the trend plots

of their respective engines via a secure cus-

tomer login.

The engine watchlist permits an efficient

appraisal of the condition of all engines oper-

ated in the customers fleet and highlights

critical parameters.

In addition, customers can receive reports and

advice from MTUs engineering department on

a regular basis.

Currently supported engine types are:

CFM56-7

CF6-50

CF6-80C2 PW2000

V2500

CF34

All other engine types can be supported on

request.


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MTU currently provides Service Levels I, II

and III, including engineering services.

The 24/7 hours/days a week service is

offered for Service Level I only.

Service levels 24/7 automatic data collection and

processing

Web-based alerting and trending tools,

access to diagnostic tools, alarm notifica-

tion via MTUPlus ETM system

Operator performs engine monitoring and

retains full airworthiness responsibility

Service Level I

Service Level II

MTU performs trend monitoring and

engineering support:

Watchlist management

Performance reports

Fault diagnostics

Troubleshooting support

MTU performs the monitoring on behalf of

the operator, but the operator retains full

airworthiness responsibility

Service Level III

Service Level I and Service Level II in

combination

User also has access to the data via

MTUPlus ETM system


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9590

85

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75

70

65

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55

50

45

40

35

30

25

20

15

105

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d_EGT d_FF d_N2 TO_EGTM

CF6-80C2/B747: Stage 5 lever arm fracture. The engine was replaced after visual inspection.

0 0 10 20 30 40 50 60 70 800 0-0,01 0,01-0,02 0,0210 20 30 40 0,95 1,05-10-20-30-40

Examples of ECM events

Event 1: CF6-80C2 engine

Finding:

The EGT and fuel flow parameters

showed a trend shift which generated an

alarm

Investigation:

MTU informed the operator and recom-

mended a visual inspection Diagnosis:

Stage 5 lever arm fracture (see photograph)

Result:

The engine was removed, an expensive

damage and an AOG situation was avoided.

Event 2: V2500 engine

Finding:

A trend shift in EGT and fuel flow data

generated an alarm

Investigation:


mended an inspection

Diagnosis:Compressor stage 6 blade fracture

Result:

The finding was acknowledged but ignored

by the airline. Two months later consequen-

tial damage occurred which resulted in an

in-flight event, an AOG situation and a high-

cost shop visit.


Finding:

Parameter N2 showed a trend shift which

generated an alarm

Investigation:

MTU informed the operator and recom-mended a visual inspection

Diagnosis:

Broken bolt of the L/H VSV actuating

mechanism

Result:

The bolt was replaced and the engine

returned to service.

Engineering support


Finding:

The EGT and fuel flow parameters

showed a trend shift which generated an

alarm

Investigation:


mended a borescope inspection. The

engine was inspected following the next

landing

Diagnosis:

Stage 11 vane fracture Result:

The engine was replaced and the aircraft

returned to service after a short interruption

only.


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ECM ensures improved and practically care-

free engine operations.

Early identification of problems reduces the

risk of unscheduled downtimes and delays.

ECM can help to increase engine fuel efficien-

cy as it enables the operator to determine the

optimal timing for an engine core wash. Opti-

mized core washing can increase the EGTmargin by10 to12 percent, which equals to

a one-percent reduction in specific fuel con-

sumption (SFC).

The improved understanding of the engines

condition makes maintenance planning more

predictable and accurate, resulting in optimized

on-wing times.

MTUs services are designed to provide oper-

ational and financial benefits to our customers.

MTU customers benefit from our strong global

presence. The MTU Maintenance group has

an extensive network of shops located in

Hannover and Berlin (Germany), Vancouver

(Canada), Zhuhai (China), Kuala Lumpur

(Malaysia) and Rzeszcw (Poland). Thus MTUs

AOG teams can rapidly intervene on-site if

necessary.

No matter where our support is needed, we

are available anytime, anywhere.

Customer benefits

MTU Maintenance

Canada Ltd.

MTU Maintenance

Zhuhai Co. Ltd.

Airfoil Services Sdn.Bhd.

MTU Aero Engines PolskaMTU Aero Engines GmbH MTU Maintenance

Berlin-Brandenburg GmbH

Financial benefits:

Optimized usage of engine fleet

Minimized unscheduled downtime

Lower maintenance cost

Reduced fuel consumption

Reduced spare engine requirements

No extra cost for IT and software

Operational benefits:

One single ECM system forall engine types Early identification of operating problems

Reliable engine performance

Optimized maintenance management

Longer on-wing times

Closed loop maintenance

MTU Maintenance

Hannover GmbH


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Full overview of your engine fleet

performance:

Monitoring of dedicated operating modes

(take-off, climb, cruise)

24/7 automated alerts and reports

Customized trend analysis based on engine

type and history

Illustrated engine data and performance

trends

Documentation of engine performance(engine history)

MTUs expert engineering support:

Years of experience in aircraft engine

maintenance

Qualified maintenance recommendations

and planning

State-of-the-art technology

MRO capabilities for all major commercial

aircraft engines

Your advantages:

The MTUPlus Engine Trend Monitoring (ETM)

is suitable for different engine types Immediate alert when performance trend

shifts are detected, not when OEM limits

are exceeded

Graphic interface (trend plots) for fast

identification of performance abnormalties

instead of analyzing long tables of data

No extra cost for IT and software

Web-based data access via a secure

connection

Reduction of MRO process time (TAT) based

upon diagnostic data availability

Early fault detection

Reduction of unscheduled engine removals

and AOG situations Fuel savings and emission reduction thanks

to optimized timing of core engine washing

based on fuel flow and EGT monitoring.

Our services

30

20

10

0

-10

EGT (C)

Water wash timing can be optimized by using MTUPlus

ETM.

Waterwash

Waterwash


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GER09/08/H/01000/DE/EB/E

An MTU Aero Engines Company

MTU Maintenance Hannover GmbHMnchner Strae 3130855 Langenhagen GermanyTel. +49 511 7806-0Fax +49 511 7806-111AOG +49 171 4314333E-mail [email protected]

Engineering Support:E-mail [email protected]

Sales Support:E-mail [email protected]

mtu ecm brochure

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