GE Aviation’s Caledonian Shop Service-Ready by GENX Engine EIS

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GE Aviation’s Caledonian Shop Service-Ready by GENX Engine EIS
GE Aviation’s Caledonian services facility in Prestwick, Ayrshire, Scotland, is gearing up in preparation for entry into service (EIS) of GE’s next generation turbofan—the GEnx* engine.
Designed for medium-capacity, long-range aircraft, the GEnx engine represents a giant leap forward in propulsion technology. Part of GE’s “ecomagination” product portfolio, it uses latest-generation materials and design processes to reduce weight, improve performance and lower maintenance costs.
Ground-testing on the engine began in March 2006, and it took to the skies for flight-testing on GE’s 747* flying testbed in February 2007. Following a rigorous two-year ground- and flight-test program, the GEnx-1B engine received
U.S. Federal Aviation Administration (FAA)
Additional Benefits
The top-down repair station certification
process includes validation of the:
.  
GEnx-1B Engine Manual
.  
GEnx-1B Clean-Inspect-Repair Manual
.  
3-D Illustrated Parts Catalog (IPC)
.  
Overhaul tooling used

“As we go through the process,” says
GE’s Leo Gallick, “we will be reviewing all
support documents, hardware, tooling and
procedures, making improvements where
we can to ensure everything is in place for
our customers from day one.”
airworthiness engine certification in March 2008.
Certification Under Way
As preparations for the engine’s EIS continues, the Caledonian shop is working toward GEnx engine repair station certification. European Aviation Safety Agency (EASA) Part 145 certification is currently under way, to be followed by FAA FAR Part 145 certification. Both should be complete by second quarter 2009.
Certification is a multi-step undertaking. To achieve the green light, the shop will be reviewed, evaluated and tested on several measures, including:
.  
Organizational structure
.  
Technical expertise and experience
of personnel
.  
Facility requirements
.  
Processes and controls

.  
Test and inspection equipment

The shop is following a demanding timeline and is, says Leo Gallick, turbo machinery leader, GEnx Product Support Engineering, “ahead of schedule to be up, running and service-ready when the first GEnx engines enter service on the Boeing 747-8 and 787 Dreamliner*.”
.  
May 2008: Caledonian shop personnel spent several weeks this past May on GEnx engine-specific training at the Evendale, Ohio,

Development Assembly Engine Operation; the Customer Training and Education Center (CTEC), also in Evendale; the Peebles, Ohio, Test Center; and the Durham, North Carolina, assembly plant.
.  August 2008: The Caledonian shop received its first GEnx engine—one of the nine development engines used to FAR 33 certify the engine—and shop personnel began full teardown to the piece-part condition. In this step, and all that follow, work is done in accordance with the GEnx-1B Engine Manual and Caledonian shop procedures.
continued on page 2


CF34 Engine Program Reaches Major Milestones
.  MTU Maintenance Berlin-Brandenburg Receives GE CF34-10E Certification: GE’s CF34-10E engines are the newest addition to the Ludwigsfelde, Germany-based maintenance, repair and overhaul (MRO) center’s services portfolio. A unit of MTU Aero Engines and offering its services on a global basis, the MRO is now an authorized CF34* service provider to the entire in-service CF34 engine family.
CF34-10E engines entered service on the
EMBRAER 190/195* in 2005. On receiving
U.S. Federal Aviation Administration certification covering support for the CF34-10E, the Ludwigsfelde MRO becomes the powerplant’s first independent maintenance services provider.
“We’ve extensively prepared for the CF34-10E version and will be sure to offer our clients custom-made solutions, the same as we do elsewhere,” says André Sinanian, vice president, CF34 Program at Ludwigsfeldeis. The first engines are due in before year-end 2008.
Today, more than 4,200 CF34 engines power regional jets. Based on the strong demand for GE-powered regional aircraft, GE expects this fleet to surpass 8,600 CF34 engines by 2018.
The Ludwigsfelde MRO specializes in the maintenance of engines in the small- to medium-thrust and power categories as well as industrial gas turbines.
.  GE-powered CRJ1000 NextGen Jetliner Prototype Completes First Flight:
Bombardier Aerospace
and GE Aviation added
another milestone to their
long collaboration in regional
jet airliners when Bombardier’s
prototype CRJ1000 NextGen* jetliner completed its flight at the Bombardier facility in Mirabel, Québec, on September 3. Powered by GE’s CF34-8C5 engine series, the 100-seat jetliner is scheduled to enter commercial service in late 2009.
Designed for medium-haul routes in the 500- to 1,300-nautical mile range, the CRJ1000 NextGen has attracted 63 firm orders, conditional orders and options from four airlines, including Brit Air of France, myair.com of Italy and Adria Airways of Slovenia.
The aircraft will be offered with the CF34-8C5, -8C5A1 and -8C5A2 engine models. For the CRJ1000, the engines feature a new first-stage, high-pressure turbine nozzle and other enhancements
for durability, up to 12% lower engine

.  ARJ21 Regional Prepares for Flight Testing: Powered by two GE CF34-10A engines, the ARJ21-700* regional jet is in final preparations to make its inaugural test flight by year’s end.
Developed by the Shanghai-based Commercial Aircraft Corporation of China, Ltd. (COMAC), the 90-seat ARJ21-700 is the first medium- to short-range regional airframe designed entirely within China. The powerful CF34-10A engines are ideally suited for China’s diverse environment, including the hot temperature and high-altitude conditions on many routes in western China.
The 70- to 90-passenger aircraft is expected to obtain its airworthiness certificate next year. There are now announced orders for 206 of these aircraft, with the first production ARJ21-700 slated to be delivered to Shandong Airlines in fall 2009.
Contact: André Robert andre.robert@ge.com
GE Caledonian Shop to be GEnx Service-Ready . . . continued from page 1  
.  By end of year 2008: Following the full  As the Caledonian shop progresses  Once the shop receives its FAR 145 repair  
disassembly, now complete, all engine  through each step, representatives from  station certification, it will be approved for  
parts are currently undergoing thorough  several organizations are on site to support  maintenance and alterations of the  
cleaning and inspection (including fluorescent  the manuals and tooling validation effort,  GEnx powerplant.  
penetrant inspection), a process that is  including Product Support Engineers, Field  
scheduled for completion by year-end.  Service Engineers, Support Equipment Tooling  Says Gallick, “Validating the processes,  
.  Scheduled to begin January 2009: The next step in the process is reassembly of the engine, wrapping up the shop certification  Engineers and Technical Publication experts. Already an active maintenance, repair and overhaul facility, the GE-owned Caledonian  manuals and tooling at this stage of the program will lead to improved throughput in the overhaul process and a streamlined workflow.”  
process by spring 2009.  shop currently services the CF6* engine family.  Contact: Leo Gallick leo.gallick@ge.com  
2 / Service Solutions 8.4
CF6-80C2 Engine Milestone

150 Million Flight-Hours and Counting
GE Aviation is celebrating 150 million flight-hours on the CF6-80C2 engine fleet— that’s nearly 18,000 flight-hours per day for the 23 years these engines have been in service.
CF6-80C2 Engine File
.  
Entered service October 1985
.  
Most popular CF6 engine model—
more than 3,700 engines in operation,
more than 140 customers

.  
Powers Boeing 747*, 767* and MD-11*;
Airbus A300* and A310*


“We are proud to celebrate this significant achievement that was made possible by our CF6-80C2 customers,” says Colleen Athans, general manager for the CF6* engine program. compressor advancements are available as “The engine has consistently demonstrated an upgrade option to incorporate into existing the lowest specific fuel consumption of any CF6-80C2 fleets. commercial engine in its thrust class. And

in 2006, we launched our new Tech CF6 engine program, which offers new advanced technologies to further improve the engine’s fuel burn retention and operational reliability and lower our customers’ cost of ownership.”
The new Tech CF6 high-pressure turbine technologies include airfoil-cooling advancements that are now standard on all new CF6-80C2 production engines. The Tech CF6 combustor and high-pressure
For 35 years, GE’s CF6 family of engines has been among the most utilized in the industry. With 7,000-plus engines in service powering more than 10 models of wide-body aircraft, the engine family has established an unparalleled record of reliability—compiling more than 325 million flight-hours in service with more than 260 customers worldwide.
Contact: Hadley Bowling hadley.bowling@ge.com
CF6-80C2 Engine Marks Time-on-Wing Record
Logging more than 40,000 flight-hours and nearly 10 years of continuous on-wing operation on a Boeing 767* aircraft, American Airlines recently set a time-on-wing record for a GE CF6-80C2 engine. This record is equivalent to making 2,000 round trips from Dallas, Texas, to London, England, without ever removing the CF6-80C2 engine from the wing of the aircraft.
In addition to this record-setting engine, American has several other CF6-80C2 engines in its fleet that have surpassed 35,000 continuous hours on wing.
“This record is an outstanding achievement for American Airlines and our CF6-80C2 engine,” says Colleen Athans, general manager for the CF6* engine program. “American Airlines’ strong maintenance program, combined with the use of GE’s diagnostic tools, enabled the engine to attain this record, and we commend the airline staff.”
Recent CFM International and CF34* repair releases reduce customer costs and increase engines’ time on wing:
CFM56-3 Combustion Case Aft End Replacement: A repair that replaces a distressed section with new material, salvaging parts previously unserviceable and reducing the scrap rate by up to 60%.
CFM56-5A, -5B, -5C, -7 Combustion Chamber Aft Datum Flange Replacement:
This repair uses the new Tech Insertion flange as an upgrade to the current design, improving durability. This is accomplished through reduced cracking and separation from the combustor case.
CF34-8 Low-Pressure Turbine (LPT) Stage 4 Blade Light Repair: This repair addresses missing or depleted coating, minor dents and scratches and repairs the airfoil twist. The repaired coating provides for an additional repair cycle and achieves a yield of 96%.
Contact: Scott Welsh scott.welsh@ge.com
Service Solutions 8.4 / 3

Sharing Best Practices
GE Celma Shop Studies Engine
Benefits: There are several benefits to Transportation Costs removing the exhaust cone prior to shipping to a service center:
With operational costs on the rise along with a slowdown in the global economy, a
.  Freight costs can be reduced by up to
logistics team at GE Celma in Petrópolis,
10%, offsetting fuel surcharges. (Note:
Brazil, took a look at what could be done
The cost of labor to remove the cone—two
to reduce transportation costs charged to
to three hours by a certified mechanic—is
ship engines from customers to the Celma
significantly less than the reduction in

overhaul shop.
transportation costs.)
Situation: In much the same way carry-on
.  During peak shipping seasons (for example, luggage must meet both weight and size
end-of-the-year holidays), the more compact requirements, airlines calculate freight based
shipping size makes it easier to find space on not only on how much it weighs, but also
cargo aircraft. on how much space it will take up in their silva@ge.com
aircraft’s cargo area. Freight is then charged .  The more compact shape lessens the possibility
by the higher of the two, actual weight or of damage to the engine during shipment.

BEFORE

the container’s size—a factor called the “volumetric,” or “dimensional,” weight. Sharing best practice: Implemented in fall
2008, wherever the opportunity exists, the Solution: The Celma team studied the Celma team is sharing this best practice across volumetric weight of the CFM56* engine GE. (Note: Once they understood the benefits models that come into their shop—the of shipping engines in this manner, the Celma CFM56-3, -5 and -7. Their review found team reviewed other GE engine lines to see if that removing the exhaust cone prior to this process would apply to them as well. shipping and packing it alongside the engine Due to size and weight parameters, however, body made for a more compact shape they determined the exhaust cone removal that significantly reduced the chargeable process is most advantageous for the CFM56 volumetric weight. engine line.)
THE AMERICAS  EUROPE/AFRICA  ASIA  CHINA  MIDDLE EAST  
Mike Munz  Jack Lutze  Chaker Chahrour  Mike Wilking  Muhammad Al-Lamadani  
michael.munz@ge.com  jack.lutze@ge.com  chaker.chahrour@ge.com  mike.wilking@ge.com  muhammad.al-lamadani@ge.com  
The purpose of Service Solutions is to enhance communication with our customers. Please contact us if we can be of further service to you. View Service Solutions online at www.geaviation.com/services/information/servicesolutions.

GE Aviation
General Electric Company
One Neumann Way
Mail Drop J4
Cincinnati, OH 45215 U.S.A.
Phone:  +1.513.552.3272 (Internationally) +1.877.432.3272 (Within U.S.)
Fax:  +1.513.552.3329
www.geaviation.com/onpoint
E-mail: servicesolutions@ge.com
. 2008 General Electric Company. All rights reserved. GE Engine Services, Inc. is a wholly owned subsidiary of General Electric Company. GE and
are trademarks of General Electric Company.
*
CF34, CF6, GEnx and TRUEngine are trademarks of General Electric Company.
*
CFM56 is a trademark of CFM International, a 50/50 joint company of Snecma and General Electric Company.
*
A300 and A310 are trademarks of Airbus.
*
747, 767, 787 Dreamliner and MD-11 are trademarks of The Boeing Company.
*
CRJ1000 NextGen is a trademark of Bombardier Inc.
*
ARJ21-700 is a trademark of Commercial Aircraft Corporation of China, Ltd. (COMAC).

*EMBRAER 190/195 are trademarks of Embraer S.A. AE-54619 (11/08) Printed in U.S.A.

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GE Aviation’s Caledonian Shop Service-Ready by GENX Engine EIS  

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