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Reliable APU Is Critical for Italian Carrier's Boeing 777-200ER ETOPS

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Reliable APU Is Critical for Italian Carrier's Boeing 777-200ER ETOPS CUSTOMER SUCCESS STORY Reliable APU is critical for Italian carrier’s Boeing 777-200ER ETOPS Honeywell 331-500B APU remains uninterrupted on wing more than ten years after aircraft entered service AT A GLANCE Customer Name: Alitalia – Compagnia Aerea Italiana S.p.A. Location: Rome, Italy Industry: Airline Website: www.alitalia.com Honeywell solution 331-500B APU Why Alitalia CAI chose Honeywell w Alitalia wanted to fly extended twin-engine operations (ETOPS) and minimise airport handling charges. Reliable APUs are critical for this w Outstanding dedicated technical and field service support w APU capability and certification for ETOPS operations Customer results w Original APU fitted to Alitalia’s first Boeing 777-200ER Overview remains on wing ten years later w High reliability has limited Alitalia’s maintenance and Aviation regulators insist that airlines follow strict criteria to fly extended twin-engine operations repair costs (ETOPS) and APUs are considered a safety-critical device that must be w APU’s reliability for ETOPS means Alitalia has been able to fly the most efficient routes, saving fuel, limiting environmental available for these flights. Alitalia CAI has experienced extremely high reliability from the impact and improving passenger service Honeywell 331-500B APU – the original component fitted to the airline’s first Boeing 777-200ER remains uninterrupted on wing more than ten years after the aircraft first took to the sky. Background Alitalia’s first Boeing 777-200ER, which carries the name ETOPS approval is dependent on the airframe and engine, as of the Sicilian coastal town of Taormina, was delivered in well as the operational excellence of the airline. Certification is Italy’s flag carrier Alitalia CAI (Alitalia) debuted in January 2009 August 2002. It forms part of a fleet that operates routes governed by the airline’s own country’s aviation regulators. when Air One and Alitalia began the process of merging their between Italy and North America, South America (Argentina networks, their fleets and their administrative and commercial Auxiliary power units (APUs) that are fitted to ETOPS aircraft and Brazil) and the Far East (China and Japan). structures. are considered a safety-critical device as they supply backup Most of these services operate as ETOPS (extended range, electricity and compressed air in case of main engine or The airline now serves 92 destinations around the world with twin-engined operations) flights across areas such as the electrical generator failure. up to 5,000 flights a week from its base at Rome Fiumicino Atlantic and Russia. This means Alitalia can use the airport and major operations in Catania, Milan, Naples, Turin APUs that are certified for ETOPS must be able to start at twin-engined aircraft on flights that would have previously and Venice. altitudes up to the aircraft’s service ceiling and they are regularly required the use of less fuel efficient aircraft fitted with three tested during commercial flights. Alitalia, run by private entrepreneurs, is also committed to a or four main engines. major renewal of the fleet which consists of upgraded aircraft If the APU is unserviceable, then the aircraft cannot conduct Business Need that will have reduced environmental impact and provide an ETOPS flight and must take a longer route that can lead to reliable and comfortable flights. While ETOPS has enabled airlines to fly new, fuel efficient and additional fuel costs, delays and passenger inconvenience. faster routes with twin-engined aircraft, aviation regulators lay Key aircraft in the fleet include 100 Airbus A320-family down strict criteria to ensure the safety of the aircraft, their narrow-bodied jets, 12 Airbus A330-200s and 10 Boeing crew and passengers. 777-200ERs. Its regional carrier, Alitalia CityLiner, focuses on regional flights and will operate 15 ERJ-175s and For example, if an aircraft is certified for 120 minutes then 5 ERJ-190s. its route must never take it more than two hours from the nearest airport. Solution Environmentally adjusting By eliminating reliance on ground-based power units to start Air inlet on top for reduction engine control system main engines, the aircraft-mounted APU revolutionised the of debris ingestion commercial airline industry, enabling aircraft to fly to remote Air turbine starter for improved cold soak starting locations around the world. APUs provide: • Starting power for the main engines • Air supply for environmental and control systems • Power source for other pneumatic and hydraulic systems • Backup electrical and pneumatic power for inflight operations • Electrical and pneumatic backup power for inflight start reliability Today, Honeywell APUs are found on most aircraft worldwide and since 1952 the company has delivered more than 64,800 units. Honeywell’s 331-500 APU was first fitted to Boeing 777 aircraft, where its highly reliable inflight operability enables operators to use the aircraft for ETOPS flights. It was Honeywell’s first APU to use an eductor to cool oil by using the vacuum created by exhaust air flow to draw air across it and the unit also incorporates both an electrical starter and an air turbine starter for improved inflight starting reliability. The engine was also designed with fuel efficiency in mind. Load compressor design The 331-500 APU’s mean time between repairs (MTBR) is more with adjustable Inlet Guide than 7,400 hours worldwide, providing operators with a low Vane (IGV) for efficiency Air cooled cost of maintenance and ownership. hot section Eductor system, reducing moving parts for oil cooling With approaching 20 million hours of service, the 331-500 is ago to remain on the aircraft today. The duration on wing is backed up by Honeywell’s global network of service centres. Its beyond any predictable expectation. reliability has increased ever since it was released into operation “This reliability has helped us keep maintenance and repair “We are extremely as a result of a regular servicing and maintenance programme costs down and ensure the availability of the aeroplane for and monitoring of the APU’s use. satisfied by ETOPS services to long-haul destinations around the world. Alitalia’s entire fleet of Boeing 777-200ERs were fitted with “Furthermore, because of such high performance, we have the reliability 331-500 APUs and the airline continues to rely on the product been able to reduce the frequency of the inflight engine starts more than ten years later. of Honeywell’s that we are required to carry out. Benefits “Alitalia has been so pleased with the performance of APU. I don’t think Alitalia has been delighted with both the performance and Honeywell’s products and the global support that the company anyone would have believed reliability of Honeywell’s 331-500B APU. provides, that it recently signed a ten-year deal for the firm to manage the APUs across almost its entire fleet of around 140 The airline’s first Boeing 777 first flew on August 1, 2002 and it possible for an APU which narrow and wide-bodied aircraft in order to further strengthen was delivered to the carrier a few weeks later. Ten years after the already strict business relationship. entered service ten years ago entering the service, the original 331-500B remains on wing, which is close to a record length of service for an APU fitted to “Together with Honeywell, Alitalia is very proud of this to remain on wing today. The a commercial airliner. impressive performance on our B777 fleet. It has been a small but important contribution to improving new Alitalia operations duration on wing is beyond “We are extremely satisfied with the reliability of Honeywell’s over the past few years. APU,” said Livio Donatiello, Senior Vice President Engineering any predictable expectation.” and Maintenance, Alitalia. “I don’t think anyone would have “In this period the Engineering and Maintenance Department has successfully completed a big turnaround, achieving the believed it possible for an APU which entered service ten years Livio Donatiello, best results ever for Alitalia in technical reliability. This has helped Alitalia to regain its rightful place among the best airlines SVP Engineering and Maintenance for punctuality.” Alitalia Honeywell Aerospace Honeywell 1944 E. Sky Harbor Circle Phoenix, AZ 85034 Telephone: 1.800.601.3099 International: 1.602.365.3099 C61-1193-000-000 www.honeywell.com September 2012 © 2012 Honeywell International Inc..
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