AHS International Helicopter Safety Symposium International Helicopter Safety Symposium Peter Watson ... XXXXXXX XXXXXX XXXXXXX XXXXXX XXXXXX XXXXX Automated trend data capture expedited

United Technologies / Altair Avionics Corp. Proprietary Information

AHS International Helicopter Safety Symposium

Peter WatsonAltair Avionics Corp.

United Technologies Corp.Montreal, Quebec, Canada

September 26-29, 2005

““Better Product Better Product Life Cycle SafetyLife Cycle Safety

Using Diagnostics”Using Diagnostics”


Generic Aircraft Product LifecycleGeneric Aircraft Product LifecycleTime (in years)

ProductionDiscovery

DefinitionDesign

Development

Testing

Retire

Initial ProductFielding

20-30 years

FieldUsage

ResidualLife

Requirements,Architecture,

Plan documents.

Reviews & acceleratedlife tested

Maj

or

Act

iviti

es

Scope document

ProductTesting &

Certification

Design Documents.

Continuous Innovation and Development

Life

cycl

ePr

oces

s

Continuous Refinement

Con

tinuo

us

Act

iviti

es

Product Configuration Management

Requirements & Scope Change Management

Reviews

Project Management Cycle

Support Processes (Change Management, Training, Daily Flight Ops…


How do we maximize the component on-wing time?

When should we remove the components?

How do we better plan

the next shop visit?I need more information so we can make the best

business decision?

How do we proactively detect and mitigate emerging global fleet trends

and failure modes?

Whe

n sh

ould

we

dow

n th

e ai

rcra

ft?

What was that?I didn’t hear anything!

OK, tell me what happened?

You did what tomy aircraft?

This will help our This will help our maintenance planningmaintenance planning

decision processdecision process

Why You Need Diagnostics!Why You Need Diagnostics!

The reg’s require it!Improved

Dispatch Reliability

Safety of flight begins with a properly maintained aircraft. Safety of flight begins with a properly maintained aircraft.


Health Management Value Stream- It depends on what phase of the product’s life cycle you’re currently in- There are different HMVS customers during the different Life Cycle phases.

Maintenance PlanningDecision Support

Operational Usage Data

DATAACQUISITION

DATAMANAGEMENT INVESTIGATE / ANALYSIS DECISION

MAKING

Requirements & Design: Optimized Product Design

Test & Certification: Pre-Service Validation

Entry into Service: Confidence / Peace of mind

Production: Maintenance Planning & Timely Decision Support Tools / FOQA…

Removal from Service: Residual Component Life Reuse

Diagnostics = Predictability: no matter what phase of the products life cycle

Product Life Phase :Product Life Phase : Desired OutcomeDesired Outcome

Maintenance Planning Decision SupportMaintenance Planning Decision Support


Cell Tower

Internet

WLAN AccessPoint

WirelessHandheld

CellularProviders

Altair Avionics Aircraft Usage Monitoring TechnologyData Management

Integrated WebECTM(R)

Reporting

Fleet Usage ReportsExceedance ReportsE-mail/Pager Alerts

Acquire Data Transmit & Distribute Actionable Information

MLPLaptop

CableHook-up

ISPProviders

XX-XXXXX-XXX

TurbineTracker(TM)

Servers

Certified & Flying Today!


• opening the door to continuous health monitoringcontinuous health monitoring• allowing for more accurate preventative servicing

and remote troubleshooting • optimizing engine/component on-wing time• offering new level of service to our customers• warranty & reliability enhancements• competitive advantage provided by using

DPHM technology• improved safety factors• improving R&M• driving costs

A Step-Change in Service


Value Example: Full vs Partial Cycle CountingValue Example: Full vs Partial Cycle CountingAccurate Component Usage Adds Immediate Value Accurate Component Usage Adds Immediate Value

Full CycleFull CycleFull Cycle

Partial CyclePartial CyclePartial Cycle

55--toto--10% additional component10% additional componentusage life identified when usage life identified when

tracked electronicallytracked electronically

Mea

sure

dPa

ram

eter

sM

easu

red

Para

met

ers

TO

Idle

TimeTime


OPTIMIZING REMOVALS AND WORKSCOPE$$

$’s

OV

ER

HA

UL

CO

STS

(% R

educ

tion)

OVERHAULOVERHAULTODAYTODAY

EXTENDED TIME ON WING

WITH DIAGNOSTICSWITH DIAGNOSTICS% SAVINGS% SAVINGS

EarlyRemoval

LateRemoval

OPTIMIZEDOPTIMIZEDUSAGE POINTUSAGE POINT

We need to shift from time-based to condition-based maintenance where appropriateREDUCED O/H COST

TIME ON WING (% Increase)

Monitor Health -- Reduced Unscheduled Maintenance / RemovalsProactively Manage Product Configuration – Extend Time On WingPlan Removals -- Minimize Service DisruptionsOptimized Work Scopes – Minimize Turn Around TimeContinuous Usage Monitoring – Component Deterioration predictability


Example: Where Can Diagnostics Help HEMS Operators?Example: Where Can Diagnostics Help HEMS Operators?

SCENE

HOSP XFER SEE EXAMPLE 3A

DAY OR NIGHT

OP?

DAY

WX ABV MINS & STABLE

PREBRIEFED

NO INFO

WX AT MINS OR UNSTABLE

DETERMINE IF ANY OF

THE FOLLOWING

EXIST

FLIGHT REQUEST

PROCEED WITH

CAUTION

PROCEED WITH EXTRA

CAUTION

Yes

NIGHT

WX ABV MINS & STABLE

WX AT MINS OR UNSTABLE

No

Green = NORMAL OPS

Yellow = EXTRA CAUTION ZONERed = CRITICAL

SAFETY DECISION

PREBRIEFED

NO INFOPROCEED WITH

FLIGHT

CRITICAL SAFETY DECISION REQUIRED

EDGE OF ENVELOPE

PWR/PERF/FUEL/ RANGE

VISIBILITY RESTRICTIONS

FOG/RAIN/SNOW/ ICE

WX NEAR/AT MINSTEMP/DEW PT < 3O

DUTY TIME LIMIT/DIST FROM HOME

MINIMUM EQUIP. LIST ITEMS

LANDING ZONE CONCERNS

FLIGHTCREW OPERATIONAL

CONCERNS

MEDICAL CREW CONCERN

From FAA Notice 8000.301 dated 8/1/05APPENDIX 2. EXAMPLES OF TRAINING-WEIGHTED RISK ASSESSMENT AND MANAGEMENT PROCESSES

REQUIRED


•• ToTo

Ex

am

ple

: A

lert

No

tifi

ca

tio

nE

xa

mp

le:

Ale

rt N

oti

fic

ati

on


Blade Rub

SegmentRub

Correlation of Measured FieldEvents and then Performing

Focused MaintenanceCan Save Many Thousands of $$$’s

While Improving A/C Reliability Enabling Info

Data Management Maintenance Planning and

Decision SupportMaintenance Execution

Diagnostics can help drive the

cost of ownership down!


This single flight with both an over-temp & over-torque engine

event cost the operator $100K+

As Measured On AircraftAs Measured On AircraftExceedence detected at [06/16/2003 08:45:19]:

Duration = 2680 (=67 secs)Engine 2 - ITT: Max = 00812.2749, Ave = 00808.4173

Exceedence detected at [06/16/2003 08:54:55]:Duration = 1680 (=42 secs)Engine 2 - Torque: Max = 03990.4150, Ave = 03975.8030

Exceedence detected at [06/16/2003 09:41:12]:Duration = 12880 (=322 secs)Processor 2 - Airspeed: Max = 00257.1400, Ave = 00251.8467

Results of an Eventful FlightResults of an Eventful Flight

Opportunity for inOpportunity for in--flight flight notification tonotification to

help prevent this help prevent this now availablenow available


ITT

N1

Rotor Speed

Airspeed

Feb 17, 2004 Total Duration= 27 seconds

<97% (3 sec) Min = 96.9%

Max = 106.39 ktsMin = 102.48 ktsAvg. = 104.4 kts

>101.8% (9 sec) Max = 102.58%

Max = 852ºC>810ºC (22 sec)

Actual B412 N1 OverspeedXXX

We need to help the operators maximize usage while We need to help the operators maximize usage while not exceeding the aircraft capabilitiesnot exceeding the aircraft capabilities


Customer Value Customer Value –– IFSD / UER avoidanceIFSD / UER avoidancePT6A-67D engine removed prior to additional damage occurring

TurbineTracker™ event alert and DAC notification

Event Name Detection Time Event Duration Valid Report Time History

Left Eng ITT > 800 20-May-05 18:52:42. 00:00:20

Engine 1 - Ng Max = 63.2129 % Avg = 40.4976 % Engine 1 - ITT Max = 883.2482 C Avg = 856.8231 C Left Eng ITT > 870 20-May-05 18:52:32. 00:00:05

Engine 1 - ITT Max = 883.2482 C Avg = 880.065 C Engine 1 - Ng Max = 38.5788 % Avg = 35.5131 % Left Eng ITT > 850 ON START 20-May-05 18:52:30. 00:00:09

Engine 1 - Ng Max = 28.2315 % Avg = 34.717 % Engine 1 - ITT Max = 883.2482 C Avg = 869.9468 C

- Engine removed for event and ECTM ® trend shift / performance degradation- Investigation revealed CT blade and segment rub- DAC service provided customer with maintenance recommendations based on engine performance indications

P&WC FMP - Regional Air Lines Description Engine S/N Late Data Status Last Review Date Last Upload Date Notes CN-RLA PS0106 RED 10-Jun-05 16-Jun-05 very hot start ATR-42-1 120689 GREEN 16-May-05 No Data New Installation

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Automated trend data capture expedited removal / repair process

Estimated Savings:Estimated Savings: This had the potential cost of ~$250K to repair


DATACAPTURE

DATADATACAPTURECAPTURE

ASSETMANAGEMENT

DATAMANAGEMENT

DATADATAMANAGEMENTMANAGEMENT

PREVENTATIVEACTION

PREVENTATIVEPREVENTATIVEACTIONACTION

Predictive AnalysisAircraft Availability

Component Reliability Cost of Ownership

Reliably Captured Accurate DataConfiguration FlexibilityReduced Pilot Workload

Secured Data Centrally LocatedIntegrated Multi-User Solution

Subject Matter Expertise

Aircraft Health ManagementTurning concepts into $ saving reliability improvements


Conclusions:Conclusions:-- Data recording is an extremely Data recording is an extremely valuable toolvaluable tool-- The implementation cost can be small relative to the The implementation cost can be small relative to the ROIROI-- Helps improve Helps improve communicationcommunication between Operations and Maintenancebetween Operations and Maintenance-- Use the dataUse the data as an element of your overas an element of your over--all Safety Management Systemall Safety Management System-- If you do not use the data then you will not derive the If you do not use the data then you will not derive the full benefitfull benefit of the systemof the system

Remember:Remember:Mission First - Safety Always!

Any Questions?