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Tutorial IEEE PHM SAFRAN AIRCRAFT ENGINES Dallas 2017 Tutorial IEEE PHM SAFRAN AIRCRAFT ENGINES Dallas 2017 Marion Jedruszek, François Demaison, Jerome Lacaille, Josselin Coupard, Guillaume Bastard, Yacine Stouky Prognostics & Health Monitoring @ Safran Safran Aircraft Engines, 77550 Moissy-Cramayel, France This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran SAFRAN AIRCRAFT ENGINES PHM / TUTORIAL CONTENTS Global PHM System Architecture Operational realizations System perimeter PHM Systems on CFM56 & Silvercrest engine Engine dysfunction analysis Gaining in confidence in a PHM System Engine wear modes Predictive & Effective maintenance System architecture 1 2 3 4 Introduction & Context Embedding a PHM System Why PHM for Aircraft Engines ? Constraints on airborne systems Harsh environment & monitoring Chapter progress bar 2 June 2017 / R& T 1 2 3 4 Q This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran 443 0,121 0,062 ABOUT US 0,062 3 June 2017 / R& T 1 2 3 4 Q This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran About us SAFRAN GROUP IN BRIEF 1/4 More than 70 successful 1 single-aisle commercial jet takes Ariane5 launches in a raw off every 2 seconds, powered by our engines 1 out of 3 helicopter Over 35,000 turbine engines sold power worlwide 17,300 nacelle transmissions, components in totaling over 850 service million flight-hours More than 40,000 500km of electrical wiring on an landings a day using our Airbus A380 equipment 4 June 2017 / R& T 2 3 4 Q This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran About us OVERVIEW OF SAFRAN GROUP 2/4 SAFRAN AERO SAFRAN AIRCRAFT SAFRAN CERAMICS SAFRAN ELECTRICAL SAFRAN ELECTRONICS BOOSTERS ENGINES & POWER & DEFENSE - Partner to major engine- - a world leader in aircraft - specialist in advanced - a world leader in aircraft - a global leader in aerospace makers engines ceramic materials electrical systems and defense electronics SAFRAN HELICOPTER SAFRAN IDENTITY SAFRAN LANDING SAFRAN NACELLES SAFRAN TRANSMISSION ENGINES & SECURITY SYSTEM SYSTEMS - The power transmission - The world leader in aircraft - A world leader in aircraft - The world leader in - Security solutions for people specialist landing and braking systems helicopter turbine engines around the world engine nacelles 5 June 2017 / R& T 2 3 4 Q This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran About us SAFRAN AIRCRAFT ENGINES 3/4 LEAP -15% of FUEL 99,9% of reliability CONSUMPTION rate versus today’s Over 1h30 average flight engines leg SAM146 15,000 -50% of NOX 500,000 flight employees emissions versus SAM146 hours with SSJ100 CAEPI6 standards Engines -15% of CO2 emissions versus for commercial and 35 todays engines military facilities aircrafts worldwide LEAP* M53 More than 30,000 produced since the outset Recognized for its unrivaled reliability M88 and low operating and maintenance Maintenance, Electric costs propulsion Repair and systems for The benchmark powerplant in the CFM56 Overhaul (MRO) satellites and PPS & TMA single-aisle services space commercial jet vehicles Plasmic propulsion CFM56* market Partners with GE in CFM International since 1974: design and production of the CFM56 and LEAP engines 6 June 2017 / R& T 1 2 3 4 Q This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran About us CFM International 4/4 A 50/50 joint company between GE(U.S.A) and Safran Aircraft Engines (France), we develop, produce and sell the new advanced-technology LEAP engine and the world’s best-selling CFM56 engine since 1974 2009-2011 – LEAP selected 30,000 CFM56 by three major aircraft manufacturers: Airbus engines delivered (as of December 31, 2016) (LEAP-1A), Boeing (LEAP- 1B) and COMAC (LEAP-1C) 74% of the global LEAP: more than market for engines 12,200 engine powering single-aisle orders and commercial jets commitments at January 31, 2017 7 June 2017 / R& T 1 2 3 4 Q This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran Chapter1 1/20 Global PHM System Architecture Operational realizations System perimeter PHM Systems on CFM56 & Silvercrest engine Introduction Engine dysfunction analysis Gaining in confidence in a PHM System Engine wear modes Predictive & Effective maintenance & Context System architecture Why PHM for Aircraft Engines ? 2 3 4 Embedding a PHM System Constraints on airborne systems Harsh environment & monitoring 8 June 2017 / R& T 1 2 3 4 Q This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran Chapter 1 CHAPTER 1 ON “WHY PHM IN AIRCRAFT ENGINES ?” CONTENTS 2/20 Part 2 : Engines operation Usage & Operational life 1 Part 1 : Aircraft Engines Part 3 : Engines Maintenance Engines : from design to production Maintenance type and Engine maintenance owner 9 June 2017 / R& T 1 2 3 4 Q This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran Chapter 1 Part 1 CHAPTER 1 CONTENTS 3/20 Part 2 : Engines operation Usage & Operational life Aircraft Engines: Short introduction from design to production Part 3 : Engines Maintenance Maintenance type and Engine maintenance owner 10 June 2017 / R& T 1/3 2 3 4 Q This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran Chapter 1 Part 1 About … Aircraft ENGINES 4/20 Can be more expensive Engine are Over than an designed with $1,5 billion aircraft total trade based Development development on Specific costs cost around 25% Fuel of the aircraft’s Support for engine for a 15- Consumption, price when sold year rate per flight hours with Thrust, Fan Over Catalog price for 20 years Aircraft engines are an essential part of the leap-1A is an airline of 20 leaps costs Diameter and product cycles aircraft as fuel burn is one of the main key $13,9 $3,000 per engine Direct span driver for an airline millions per day Maintenance costs with EASA and . FAA have respect to Turbofan aircraft engines specific range consumes oil with a ratio defined Specific regulations / Flight legs of 0,1 liter per hour materials during cruise phase with respect to (Ceramic the conception, matrix the Today’s engines such as composites , manufacturing LEAP provide 15% fuel 3D Woven and the burn difference with older Carbon maintenance of an engine. Specific test means may be developed with a generation of engines. Fibers) new engine 11 June 2017 / R& T 1/3 2 3 4 Q This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran Chapter 1 Part 1 Technical layout of an engine (Leap-1A) 5/20 Take-off Thrust : Fan Bypass Ratio Leap-1A23 : 106.80 kN, Size : 78’’ or 198cm between veins Leap-1A30 143.05 kN (or 18 Composites Fan blades BPR: 11:1 32,160 lbf) Max RPM ~ 4,000 2 stages HP Turbine Length: 3.328 m With 3D aero and advanced Max Width : ~2.5m cooling Max Height 2.37 m Max RPM : ~20,000 Weight : 2,990-3,153 kg / 6,592-6,951 lbs 7 stages LP 2 Rotors : 1 high pressure, Lean Turbine annular 1 low pressure combustor Fan Case: Direct Drive engine Active Composite & Noise 3 Stages Low Pressure clearance 10 stages High Pressure Compressor control with t treatment Compressor or Booster with Pressure ratio 22:1 HPTACC and FADEC is on fan case VBV Doors LPTACC actuators 12 June 2017 / R& T 1/3 2 3 4 Q This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran Chapter 1 Part 1 Characteristics of a PHM System 6/20 PHM – Prognostics & Health Monitoring Monitor and forecast the health status of an engine. • Integration from the Start of the On Board Development Cycle. From the beginning Data • The Challenge of the Automatic and Adaptable Data Transmission and Automatic & Adaptable Transmission connection. • A new PHM Standard for an Optimal Agile, Based on Standard On Ground Workflow. And Web accessible 13 June 2017 / R& T 1/3 2 3 4 Q This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran Chapter 1 Part 1 PHM Life Cycle 7/20 At SAFRAN Aircraft Engines PHM is about monitoring and predicting the health of an engine, using operational data to enable our clients to have a continuity of service while keeping a maintainability of the engine that is cost-oriented and optimal. Development of PHM System Signal Capture & & data base detection process on engine PHM System PHM System Operational Phase OSA-CBM approach: Design Phase • DM – data PHM manipulation models • SD – state detection • HA – health estimation • PA - RUL & prognostics Analysis are done to Needs collection provide maintenance & Risk analysis Accurate trouble-shooting Engine Failures & support to build CNR of PHM System and maintenance support Degradations analysis advice 14 June 2017 / R& T 1/3 2 3 4 Q This document and the information therein are the property of Safran.
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