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AIR INDIA MRO
HYDERABAD AIR SHOW
MARCH 2012
AIR INDIA LIMITED
Air India is the National Flag Carrier, wholly
owned by Government of India.
Started operations in 1932.
Operates in both Domestic and International
Sectors.
Fleet includes both Wide Body & Narrow Body
Aircraft – B777-200LR, B777-300ER, B747-400,
B737NG, A 310, A319, A320, A321,A330, CRJs
and ATRs.
AIR INDIA LIMITED
Domestic Operation covers a wide network of
64 Destinations.
International Operation includes 35
destinations spanning over 3 Continents.
Air India – MRO comprises of huge
infrastructure to cater to Line Maintenance,
Base Maintenance, Engine Overhaul,
Accessories Overhaul and Component
Overhaul activities.
AIR INDIA - MRO
In addition to maintaining its own fleet, the
MRO offers exclusive services to Third Party
Customers.
The repair and overhaul services include ENGINE &
APU OVERHAUL, ACCESSORIES & AVIONICS
COMPONENTS OVERHAUL, BASE MAINTENANCE,
LINE MAINTENANCE, STRUCTURAL AND COMPOSITE
REPAIRS, NDT, BORESCOPE INSPECTION,
ECOPOWER ENGINE WASH & TECHNICAL TRAINING.
ENGINE & APU
OVERHAUL AND REPAIR
AIR INDIA - MRO
ENGINE OVERHAUL FACILITY
Mumbai: Built in 1963, the Facility serves as a single-site
source for the maintenance, repair, overhaul and testing of aircraft engines and APUs for more than 48 years.
Manned by a highly skilled and experienced work force of around 400 personnel
State-Of-The-Art Facility spread over 25,280 Sq.M. Caters to following engine models:
CFM56-7B Series/ GE90 -100/PW 4000-94 Series/ GE CF6-80C2 Series/GE CF6-50 Series
Delhi……To be filled……
AIR INDIA was adjudged as BEST ENGINE MRO IN INDIA for 2011 by MRO ASSOCIATION OF INDIA
ENGINE SHOP
Assembly / Disassembly:
CFM56-7B Series Engines
GE CF6-80 C2 Series Engines
GE CF6-50 Series Engines
V2500 A1
GE90-100 Engines
PW 4000 Engines
Module Overhaul
GE CF6-50 Engine Modules
GE CF6-80 C2 Engine Modules
CFM56-7B Engines Modules
V2500 A1 Engine Modules
PW 4000 Engine Modules
Computerized Static/ Dynamic Balancing
Machine
NDT
Cleaning Bays
Spare Parts Warehouse
ENGINE SHOP
Chemical & Mechanical Cleaning(GE & PW Specification)
Chemical Cleaning
Grit Blasting
Glass-bead Peening
Sweco Cleaning
Non –Destructive Testing
Electrostatic FPI Line
Eddy Current Inspection
Ultrasonic Inspection ( Contact Type)
Specialized Inspection
Normal/Video Borescope Inspection with
measurement feature using LASER.
Boro Blending on engines
Piece Part Repairs Processes
TIG Welding
Rework Set up
Machine Shop
Heat-treatment Furnaces
Shot-peening Machines
Plating Shop
Plasma Shop
Piece Part Repairs Processes
Heat Treatment:
Air Furnace
Shot-Peening :
Automated Shot-peening
Manual Shot-peening
Plating Processes:
Nickel Plating
Ni-cadmium Plating
Titanium-cadmium Plating
Cadmium Plating
Silver Plating
Chromium Plating
Electro-less Nickel Plating
Plasma Coat:
Robotic Plasma Spray System
M 1100 Plasma
Unicoat Plasma
APU OVERHAUL FACILITY
APU Overhaul:
Honeywell GTCP 331-250 APU
Honeywell 131-9B APU
PW 901 APU
To be filled
TEST HOUSE
Engine Test Houses equipped with
Automatic Data Acquisition System
and capable of testing Engines up to
100000 lbs. of thrust at Delhi and
Mumbai.
Engine Test House:
• GE CF6-50 Series Engines
• GE CF6-80 C2 Series Engines
• PW4000 Series Engines
• CFM56-7B Series Engines
• V2500 A1
• JT- 8D Series
APU Test House
• Honeywell GTCP331-250 APU
• PWC901 APU
• To be filled
ENGINE SHOP CAPABILITY
Machine Shop:
5 Axis CNC Milling Machine
Co-ordinate Measuring Machine
CNC Vertical Turret Lathe
Horizontal Boring Machine
Jig Boring Machine
Cylindrical & surface grinding machine
MK3 - Computerised Measuring Systems
AIR INDIA MRO ADVANTAGE
Advantage:
Highly skilled and well trained manpower.
Location advantage
Modern Infrastructure
Strong emphasis on Quality Assurance - Proven and tested Quality System.
Experience in handling Third Party Customers
Lower TAT
Low labor Cost.
More than 45 years experience in maintenance of airframes, components, jet engines and APUs
FAA and EASA approved Repair Stations
ISO9001-2008 certified.
AIR INDIA MRO ADVANTAGE
Attributes that make Air India MRO the preferred
Choice are:
High Quality & Reliability
Minimum Downtime
Lowest Maintenance Costs
Superior Customer Service
Cost Effective labour
Portfolio of Spare Engines
Expertise in maintenance of airframe, engines and components
Certifications
Certifications:
Approved by DGCA (India) as CAR-145 Maintenance Organization
Approved by FAA as FAR-145 Repair Station
Approved by EASA as EASA-145 Maintenance Organization
ISO 9001: 2008 Certified Facility
OEM Support:
OEM Field Representatives permanently stationed in Mumbai to facilitate Air India’s need:
Boeing
Airbus Industries
Pratt & Whitney
GE Aircraft Engines
Honeywell
Hamilton Sunstrand
IAE
CFM
GLOBAL CUSTOMERS
GE
P&W Engine Leasing, USA
Bangladesh Biman
Star Aviation FZC, UAE
Kellstrom Industries, USA
Chromalloy , USA
Israel Aircraft Industries, ISRAEL
CUSTOMERS – LEASED AIRCRAFT FLEET
KOREAN AIR
SINGAPORE AIRLINES
BOEING AIRCRAFT HOLDING CO
GECAS
GUGGENHEIM AVIATION PARTNERS
ALAFCO
VELING
AIRBUS FINNACIAL CO
AIR CASTLE
STRENGTHS
TRAINED MANPOWER
SELF-SUFFICIENT INFRASTRUCTURE
STRONG QUALITY ASSURANCE ORGANIZATION
PROVEN CAPABILITY TO HANDLE THIRD PARTY CUSTOMERS
VAST EXPERIENCE IN MAINTENANCE, REPAIR AND OVERHAULOF ENGINES AND APUs
FAA AND EASA APPROVED REPAIR STATION
FUTURE PLANS
GE Branded AI Owned GEnx Engine shop at
Nagpur – one of the few in the world
New GE90 Engine Overhaul Facility at Nagpur
New Test Cell for GE90 and GEnx Engines at
Nagpur.
ON WINGBORESCOPE INSPECTION
&
BORO-BLEND REPAIR
AIR INDIA - MRO
We do
Routine
Event Based (AOG, FOD,
EGT EXCEEDENCE, HIGH
VIBRATION ETC)
Borescope Inspection
to evaluate
Engine/APU
Serviceability
BORESCOPE INSPECTION
BOREBLEND REPAIR
In case of Aircraft on Ground
(AOG) situation due to
Boro-distress ……???
We can do Boro-blend
repair on damaged
Compressor Airfoils
per AMM to restore
engine serviceability.
A dedicated team of
highly skilled Borescope
Inspectors manage the
Complete operation,
inspection, repair and
certification.
15 years average
Experience
Trained by OEM
Prompt Service
BORESCOPE TEAM
Wide range of Accessories
and Attachments:
Rigid and Flex Scopes of
varied diameter, length
& direction of view.
Light Source of different
intensities.
Video recording
Measurement capability
BORESCOPE EQUIPMENT
Laser Technology
used for accurate
measurement of
defect.
Video Recording of
BSI Inspection
findings.
Borescope Report in
Hardcopy/ Softcopy
format.
VIDEO BORESCOPE EQUIPMENT
Additional Feature:
Equipped with CHANEL VIDEO SCOPE.
Helps to remove any loose object lying in
gas path.
Can prevent possible engine removal.
Excellent record of retrieving liberated HPC
Stage 9 OGV Forward Leaf Seal on wing to
put GE90 Engines back into service using
this special feature.
CHANEL VIDEO SCOPE
BORESCOPE EQUIPMENT
UNIQUE ADVANTAGE
One of the very few facilities
to have a portable GENSET
to supply power for the
BORESCOPE equipment.
No dependance on Aircraft
power
No need to operate APU or
GPU to source power for BSI.
Customer can save 90% of
cost vis-à-vis APU Operation
We provide Comprehensive Solution to
Customer’s BSI need;
On Wing Facilitation
Inspection
Blend Repair
Certification
BSI Reports With Video Recording
BORESCOPE CAPABILITY
Facility approved by FAA, EASA AND DGCA,
INDIA to perform BSI and boroblend on;
GE90-100 Series Engines
GE CF6-80C2 Series Engines
CFM56–7B Series Engines
PW4000-94 Engines (Inspection only)
Honeywell GTCP331-250H, 131-9B and
PWC 901A APUs
CERTIFICATION
SALIENT FEATURES
OUR USP:
Provide comprehensive solution for borescope
inspection need.
Boro-blending capability may prevent a possible
AOG situation.
Customer saves on Labor Cost as many of the tasks
are either not required or managed by Service
Provider.
Self-contained Borescope Unit that helps Customer
to reduce cost by 90% vis-à-vis APU usage cost.
Completion of task in shortest possible time
AIR INDIA - MRO
Accessories & Avionics Components
Overhaul and Repair
ELECTRICAL ACCESSORIES
Major Test Stations:
o Avtron ATE K825B
o Testek ATE TS 1650 S
o Electromechanical Test Stations
o IDG Test Stand Avtron K738XL
Testek ATE TS 1650S
Test Facility for :
•Pack and Zone Temperature Controller
•GCU
•BPCU
• APU Controller
•Back Up Converter
•Cabin Temperature Controller
• APU Controller
AVTRON ATE K825B
Test Facility For:
•Main Generator Control Units(GCU)
•APU GCU
•Bus Control Unit(BCU)
•Window heat Controllers
•Brake System controllers.
Avtron IDG Test Stand K738XL
Test Facility for :
•IDGs
• APU generators
•Starter Generators
• Back-up Generators(VSCF)
ELECTRICAL ACCESSORIES
Capability:
o Electrical Power System Component & Aircraft Batteries
o Auto Brake & Anti Skid System Components
o Pneumatic & Air Conditioning System Components
o Electromechanical Actuators
o Cockpit Panels & Modules
o Galley & Lavatory Equipments
o Emergency Power Supply Units
o Ice & Rain System Components
o APU & Engine Accessories
o Cockpit Chairs & Passenger Seats
o Fire Detectors, Smoke Detectors & their Controllers
o PDUs & Cargo Door Actuator
PNEUMATIC ACCESSORIES
Major Test Stations:
o Bauer Universal Low Flow Test Stand
o Air Chiller Test Rig
o Starter Test Rig
o LEFD Test Rig
o ADP Test Rig
BE Aerospace Tester 410-2
Test facility For:
•Galley Chiller
BE Aerospace Part No:
267-5 / 100
Bauer Universal Low Flow Test Stand
Test Facility for:
• Engine Bleed Components
• Check Valves
• PRSOV
• Airframe pneumatic Components
• Safety Valve
• outflow Valve
• PRV
• HP Bleed Valves
Pneumatics Accessories
Capability:
o Engine Bleed Components
o Airframe pneumatic Components
o Safety Valve
o LEFD
o PRV & HP Bleed Valves
o PRSOV
o Air Chillers
o Engine Starters
o Starter Shut off Valve
o Check Valves & Pressure Sensor
o Flow Control Valves
o Wing & Engine Anti Ice Valves
HYDRAULIC ACCESSORIES
Major Test Stations:
o Universal Linear Test Stand (Testek)
o Universal Servo Test Stand (Testek)
o Red Oil Test Stand
Testek Universal Linear Test Stand .
Test Facility For:
•Hydraulic System Valves
& Actuators
Testek Universal Servo Test Stand
Test Facility
For:
Mechanical /
Flight Control
Servo LRUs.
HYDRAULIC ACCESSORIES
Capability:
o Landing Gear Components ( Up-lock & Down-lock Assemblies,
L/G Retract Actuator, NLG Steering Metering Valve)
o Flight Control Components ( Elevator Feel Unit, Elevator , Ruder,
Aileron Power Control Unit)
o Hydraulic Power (Hydraulic Pump, Reservoir, System Pressure
Module)
o Auto Pilot Component
o T/R Hydraulic Components
FUEL ACCESSORIES
Major Test Stations:
o Universal Fuel Component Test Stand (Bauer)
o Universal Major Fuel Accessories Test Stand (Testek)
o Fuel Operated Bleed Component Test Stand (Testek)
o Nozzle Test Stand (Testek)
o Oil Test Stand (AMS)
Test Facility
For:
•Engine FMU
•MEC
•APU FMU
•FCU
Bauer Universal Fuel Component Test Stand
Testek Fuel Operated Bleed Component Test Stand
Test Facility For:
•VSV Actuator
•2.5 Bleed actuators
•TCC Actuator
•Engine / IDG Air Oil
Heat exchanger valve
Universal Major Fuel Accessories Test Stand
(Testek)
Test Facility for:
•Engine / APU Fuel
Pumps
• APU FMU
• FCU
Testek Nozzle Test Stand
Test Facility For:
• Engine Fuel
Nozzles
• APU Fuel
Nozzles
FUEL ACCESSORIES
Capability:
o MEC ( Main Engine Control)
o FCOC ( Fuel Cooled Oil Cooler)
o APU FCU
o Pumps
o Bleed System Components
o APU Components
o Engine & APU Nozzles
INSTRUMENTS OVERHAUL
Major Test Stations:
o ATEC 6
o IRS Test Station
o Flight Management Test Station
o Flight Data Test Station
o Flight Management Computer Test Station
o Data Management Unit Test Station
CASSIDIAN ATEC series 6
Test Facility for:
•737 / 777 ADM (Air Data Module)
•737 Display Unit
•737 Engine Accessories Unit
•737 LCD CDU
•737 FMC
•737 EFIS Control Panel
•737 DEU (Display Electronics Unit)•777 Video Display Unit
•777 ISFD
(Integrated Standby Flight Display)
• 777 FQPU
(Fuel Quantity Processor unit)
•777 WEU (Warning Electronics Unit)
•777 PFC (Primary Flight Computer)
Test Station-L3 SSDFDR
INSTRUMENTS OVERHAUL FACILITY OVERVIEW
INSTRUMENTS OVERHAUL
Capability:
o Flight Management System Components
o Inertial Reference System Components
o Oxygen System Components
o Display Units
o Cockpit Instruments
o Gyroscopic Instruments
o Fuel System Components
o Flight Data Recorders
o Data Management Unit
ELECTRONICS OVERHAUL
Major Test Stations:
o ATEC 5000
o Teradyne CTS
o THALES IFE TEST Stations TB3, TB 4+
o Weather Radar System Test stations
o Honeywell TCAS Test Stations
o SATCOM Honeywell MTS
o Honeywell & Rockwell HF Test Stations
o Honeywell & Rockwell Radio Navigation Test Stations
o Audio / Video Component Test Stations
HONEYWELL WEATHER RADAR TEST STATION
Test Facility for:
•Weather Radar
Receiver / Transmitter
•Antenna Drive &
Control Panel
ELECTRONICS OVERHAUL FACILITY OVERVIEW
Test Station for Honeywell HF Transceivers &
Antenna Couplers
Honeywell SATCOM Manual Test
Station(MTS)
Test Facility for:
•B777/B747-400
Satellite Data
Unit(SDU)
•High Power Amplifier
(HPA)
•Radio Frequency Unit
Interface Adapter
(RFUIA)
ATE Hall for Teradyne CTS , ATEC 5000 &
TPT-81A
ATEC 5000
TCAS / MODE S Test Station TPT-81A
Test Facility for:
Honeywell TCAS / MODE-S
System Components.
Testing Rockwell Collins DU 7000 on ATEC 5000
Head End Equipment Test Station TB4+
Test Facility for:
Thales Top series IFE Systems
Components of B747-400, B777
and A319/A320 airplanes
•SEBs
•Media Servers & Controllers
•Area Distribution Boxes
•Ethernet Switching Units etc
High Volume Test Station TB3
Test Facility for:
Thales Top series IFE System
components of B747-400, B777
and A319/A320 airplanes.
•TPCUs
•Seat Displays
•Crew Terminals
ELECTRONICS OVERHAUL
Capability:
o Audio & Video Components
o Communication & Navigation Components
(ILS components)
o Weather Radar Components
o Multiplex Systems
o ECAM System Components
o TCAS/ MODE-S System Components
o IFE System Components
o DCAS – Access System Components
o ATEC Components
LINE & BASE MAINTENANCE
SERVICES
AIR INDIA - MRO
LINE MAINTENANCE SERVICE
Provides strategic Line
Maintenance Services at major
network stations in India.
Services managed by well
trained and highly experienced
personnel.
Line & Base Maintenance
Services covers all checks up to
and including “D”/“C” Check
,troubleshooting & defect
rectification.
LINE & BASE MAINTENANCE SERVICE
Our Services include Airframes of A320 family, A310, A330, B737NG, B747-400, B777 and Engines models such as V2500, CFM56-5B,CFM56-7B, PW4000-94, PW4000-100, GE CF6-80C2 and GE 90-110.
Hangar facility available in all major airports in Mumbai, Delhi, Chennai, Hyderabad and Trivandrum.
Back-Shop capability exist for
Structural Repair
Landing Gear Repair
Engine Repair
Components Repair
Composite Repair
CVR/ DFDR read out facility
Service available 24X7
LINE MAINTENANCE SERVICE
Efficient Logistic support
including manpower, spare
parts, specialised equipments
available in shortest possible
time through 64 network
Stations.
The only Airline in the region
equipped with Aircraft
Recovery Kit to take care of
emergencies.
IATP approved provider of
Aircraft Recovery kit and
services for India and
neighboring countries.
®
ON-WING ENGINE WATER WASH
Reduce airline operating
costs the green way
Mumbai International Airport
India
g Engine Pratt & Whitney
CHALLENGES
INCREASING FUEL COST
HIGH OPERATING COST
HARSH OPERATING ENVIRONMENT
REDUCED ENGINE ON-WING TIME
HIGH MAINTENANCE COST
LOOKING FOR SOLUTION ?
ENGINE GASPATH CLEANING/ ENGINE CORE WASH at Regular Interval.
Use P&W Patented, Cutting Edge Next Generation Technology “EcoPower” Engine Wash System to Maximize Benefits.
EcoPower’s Operational Efficiency Enables Frequent Washing That Produces Maximum Benefit versus Washing On-Condition Only.
ECOPOWER SERVICE IN INDIA
AIR INDIA partners with Pratt & Whitney to launch EcoPower service
Presently the service is available in MUMBAI INTERNATIONAL AIRPORT.
AIR INDIA – the only EcoPower Service Provider in India.
MANAGED by a highly dedicated team Professionals, trained by OEM
SERVICE available 24 X 7
ECOPOWER SERVICE
OUR USP
We complete wash in ~ 2 hours after engine
cool down
Wash can be done at the gate
Competitive Rate
Flexible to meet customer need
Service available 24X7
All engines become contaminated in normal operations leading to: Restricted airflow
Engines working harder and hotter
Increased fuel burn and EGT
Regular EcoPower® engine washing proven to restore engine health Improved fuel consumption
Decreased CO2 emissions
Decreased maintenance costs
Pratt & Whitney Proprietary
Value of On-Wing Engine Washing
engine washing uses the latest technology for optimal results with minimal impact on airline operations and the environment
®
Contaminated compressor
Clean compressor
Issues with Conventional Engine Wash Methods
Methods: Shepherd’s Hook / Fire Hose
Pratt & Whitney Proprietary
No effective effluent capture
Detergents and harsh chemicals
High volume water utilization
Fuel wasted moving aircraft
Noise
Time consuming (~ 4 - 6 hrs)
Aircraft movement to wash/run-up bay
Leads to fewer engines being washed
• Operational:
• Environmental:
Pratt & Whitney Proprietary
Next Gen Collector
Integrated Wash Unit
Water Filtration System
Wash Manifold
CLOSED-LOOP
ENGINE WASH SYSTEM
®
Wash
System
Effluent
Collection
Water
Purification
System
Atomized
Water
Cleaning
Engine Washing Re-defined with ®
Fully Integrated and Technically Advanced Engine Wash Procedure
Efficiency Redefined : Operations & Performance
Pratt & Whitney Proprietary
Fast & ConvenientNo tools to setup
Fast - typically 60-90 min total time Wash during regular aircraft operationsMobile - no movement of aircraftClosed Loop - can wash at the gate Scalable – wash all engine types
Highly Effective CleaningSpecially designed nozzles for every engine type Pure, heated atomized waterMaximized component wetting, contaminant removalWash fan and core - overall engine performanceProven performance benefits and retention Precise repeatable process - consistent results
Environmental Benefits
Reduces fuel burn and CO2 footprint
EcoPower cleans with pure, atomized water
No toxic chemicals = no special handling or storage
Safe for Employees, Engine and Environment
Effluent collected / purified in closed-loop system
90% of water is recycled
EcoPower has received environmental approval to operate at airports worldwide
Pratt & Whitney Proprietary
EcoPower improves engine performance while protecting the environment
®
Fuel burn trend - regular washing
• Jet fuel price volatile, 30-40% of airline operating cost.
• Specific fuel consumption (SFC) reduced by 0.5%-1.0% on average after an EcoPower engine wash.
• Regular EcoPower washing significantly decreases deterioration rate and keep EGT, Turbine Inlet
Temp, and Fuel Flow low.
Pratt & Whitney Proprietary:
Cycles
Incr
ease
in
Fu
el F
low
Sin
ce I
nst
alla
tio
n [
%]
Average Fuel Burn
Deterioration for High
Thrust Utilization
PW4060 Engine
WASH
WASHWASH
WASH
0 500 1000 2000 2500 3000
B
A
®
A: Fuel burn savings due to
reduced deterioration.
B: Fuel burn savings due to
cleaning of the compression
system.
Additional Maintenance Savings
Engines washed with EcoPower operate cooler
Intervals between overhauls increased
Maintenance materials costs decreased
Pratt & Whitney Proprietary
05
10
152025
3035
4045
50
Cycles
EGT
Ma
rgin
C
Washed EngineUnwashed Engine
Time On-Wing Extension
Typical engine overhaulExtended interval
Typical EGT, Fuel benefits by model
EcoPower technology consistently delivers enhanced EGT and TSFC improvements washing with only pure
water
EcoPower®Engine Wash - Global Experience
Performed more than 22,300 washes in 103 locations for 124 different customers on 68 engine models
Pratt & Whitney Proprietary
Mobile Operations
Service Locations
As of July 2011BR71
5A
CF34
CF6
CFM56
-3
CFM56
-5
CFM56
-7
F11
7
GE90
GP70
00
JT8D
JT9D
PW
125
PW
2000
PW
4000
-94
PW
4000
-112
PW
4000
-100
RB21
1-53
5
Tay
600
TF3
3
Tre
nt 50
0
Tre
nt 80
0
Tre
nt 90
0
V25
00
Tot
al
7 43 652 118 104 3560 3649 46 1 253 20 2 440 1291 162 150 149 83 4 52 314 1 1179 12280
Benefits of EcoPower® Engine Wash
Improved recovery of performance in fuel burn and EGT
Proven excellent benefits and retention
Faster and safer than Shepherd’s hook
Reduces post-wash run requirements
Eliminates detergent issues
Environmentally and mechanic friendly
Saves fuel, manpower and time
Successfully used at airports around the world
Business Related Queries
Contact :
Mr. S. Rotkar
Executive Director (Sales & Marketing), MRO SBU
Tel: + 91 22 26263555
Cell: +91 9821081504.
E-mail: [email protected]
Fax: +91-22-26157068
