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8/13/2019 MTU ECM Brochure
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Engine Condition Monitoring
MTU Maintenance Hannover
An MTU Aero Engines Company
8/13/2019 MTU ECM Brochure
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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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100
9590
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
105
0
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:
MTU informed the operator and recom-
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.
Event 3: CF6-80C2 engine
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
Event 4: 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 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.
8/13/2019 MTU ECM Brochure
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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]