AHS International Helicopter Safety Symposium Better Product Life Cycle Safety Using Diagnostics

Transcription

1 AHS International Helicopter Safety Symposium Better Product Life Cycle Safety Using Diagnostics Peter Watson Altair Avionics Corp. United Technologies Corp. Montreal, Quebec, Canada September 26-29, 2005

2 Generic Aircraft Product Lifecycle Time (in years) Major Activities Scope document Requirements, Architecture, Plan documents. Design Documents. Reviews & accelerated life tested Product Testing & Certification Initial Product Fielding Continuous Innovation and Development years Field Usage Residual Life Definition Retire Lifecycle Process Discovery Design Development Testing Continuous Refinement Production Continuous Activities Project Management Cycle Requirements & Scope Change Management Product Configuration Management Reviews Support Processes (Change Management, Training, Daily Flight Ops

3 I need more information so we can make the best business decision? Improved Dispatch Reliability How do we better plan the next shop visit? When should we down the aircraft? Why You Need Diagnostics! Safety of flight begins with a properly maintained aircraft. What was that? I didn t hear anything! When should we remove the components? This will help our maintenance planning decision process OK, tell me what happened? The reg s require it! How do we maximize the component on-wing time? You did what to my aircraft? How do we proactively detect and mitigate emerging global fleet trends and failure modes?

4 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. Operational Usage Data Maintenance DATA Planning DATA ACQUISITION MANAGEMENT Decision Support INVESTIGATE / ANALYSIS Maintenance Planning Decision Support DECISION MAKING Product Life Phase : Desired Outcome 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

5 Altair Avionics Aircraft Usage Monitoring Technology Certified & Flying Today! Data Management Cellular Providers Cable Hook-up Integrated WebECTM(R) XX-XXX WLAN Access Point Cell Tower Reporting Wireless Handheld ISP Providers Turbine Tracker(TM) Servers MLP Laptop Internet Fleet Usage Reports Exceedance Reports /Pager Alerts Acquire Data Transmit & Distribute Actionable Information

6 A Step-Change in Service opening the door to continuous 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

7 Value Example: Full vs Partial Cycle Counting Accurate Component Usage Adds Immediate Value TO 5-to-10% additional component usage life identified when tracked electronically Measured Parameters Idle Partial Cycle Time Full Cycle

8 OPTIMIZING REMOVALS AND WORKSCOPE We need to shift from time-based to condition-based maintenance where appropriate $$$ s OVERHAUL COSTS (% Reduction) Early Removal OVERHAUL TODAY EXTENDED TIME ON WING OPTIMIZED USAGE POINT Late Removal REDUCED O/H COST TIME ON WING (% Increase) WITH DIAGNOSTICS % SAVINGS Monitor Health -- Reduced Unscheduled Maintenance / Removals Proactively Manage Product Configuration Extend Time On Wing Plan Removals -- Minimize Service Disruptions Optimized Work Scopes Minimize Turn Around Time Continuous Usage Monitoring Component Deterioration predictability

9 Example: Where Can Diagnostics Help HEMS Operators? From FAA Notice dated 8/1/05 APPENDIX 2. EXAMPLES OF TRAINING-WEIGHTED RISK ASSESSMENT AND MANAGEMENT PROCESSES FLIGHT REQUEST HOSP XFER SEE EXAMPLE 3A SCENE DAY PREBRIEFED WX ABV MINS & STABLE WX AT MINS OR UNSTABLE PROCEED WITH CAUTION WX NEAR/AT MINS TEMP/DEW PT < 3 O EDGE OF ENVELOPE PWR/PERF/FUEL/ RANGE DAY OR NIGHT OP? NO INFO PREBRIEFED PROCEED WITH EXTRA CAUTION WX ABV MINS & STABLE DETERMINE IF ANY OF THE FOLLOWING EXIST VISIBILITY RESTRICTIONS FOG/RAIN/SNOW/ ICE DUTY TIME LIMIT/ DIST FROM HOME MINIMUM EQUIP. LIST ITEMS LANDING ZONE CONCERNS Green = NORMAL OPS Yellow = EXTRA CAUTION ZONE Red = CRITICAL SAFETY DECISION REQUIRED NIGHT NO INFO WX AT MINS OR UNSTABLE CRITICAL SAFETY DECISION REQUIRED PROCEED WITH FLIGHT No FLIGHTCREW OPERATIONAL CONCERNS MEDICAL CREW CONCERN Yes

10 To Example: Alert Notification Example: Alert Notification

11 Blade Rub Correlation of Measured Field Events and then Performing Focused Maintenance Can Save Many Thousands of $$$ s While Improving A/C Reliability Enabling Info Data Management Maintenance Planning and Decision Support Maintenance Execution Diagnostics can help drive the cost of ownership down! Segment Rub

12 Results of an Eventful Flight As Measured On Aircraft Exceedence detected at [06/16/ :45:19]: Duration = 2680 (=67 secs) Engine 2 - ITT: Max = , Ave = Exceedence detected at [06/16/ :54:55]: Duration = 1680 (=42 secs) Engine 2 - Torque: Max = , Ave = Exceedence detected at [06/16/ :41:12]: Duration = (=322 secs) Processor 2 - Airspeed: Max = , Ave = This single flight with both an over-temp & over-torque engine event cost the operator $100K+ Opportunity for in-flight notification to help prevent this now available

13 Actual B412 N1 Overspeed XXX Feb 17, 2004 Total Duration = 27 seconds N1 >101.8% (9 sec) Max = % ITT >810ºC (22 sec) Max = 852ºC Rotor Speed <97% (3 sec) Min = 96.9% Airspeed Max = kts Min = kts Avg. = kts We need to help the operators maximize usage while not exceeding the aircraft capabilities

14 Customer Value IFSD / UER avoidance PT6A-67D engine removed prior to additional damage occurring TurbineTracker event alert and DAC notification P&WC FMP - Regional Air Lines Description Engine S/N Late Data Status Last Review Date Last Upload Date Notes XXXXXXX CN-RLA PS0106 XXXXXX RED 10-Jun Jun-05 very hot start XXXXXXX ATR XXXXXX GREEN 16-May-05 No Data New Installation Event Name Detection Time Event Duration Valid Report Left Eng ITT > May-05 18:52:42. 00:00:20 Engine 1 - Ng Max = % Avg = % Engine 1 - ITT Max = C Avg = C Left Eng ITT > May-05 18:52:32. 00:00:05 Engine 1 - ITT Max = C Avg = C Engine 1 - Ng Max = % Avg = % Left Eng ITT > 850 ON START 20-May-05 18:52:30. 00:00:09 Engine 1 - Ng Max = % Avg = % Engine 1 - ITT Max = C Avg = C Time History Automated trend data capture expedited removal / repair process - 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 XXXXXX XXXXX Estimated Savings: This had the potential cost of ~$250K to repair

15 Aircraft Health Management Turning concepts into $ saving reliability improvements DATA CAPTURE Secured Data Centrally Located Integrated Multi-User Solution Subject Matter Expertise DATA MANAGEMENT Reliably Captured Accurate Data Configuration Flexibility Reduced Pilot Workload ASSET MANAGEMENT PREVENTATIVE ACTION Predictive Analysis Aircraft Availability Component Reliability Cost of Ownership

16 Conclusions: - Data recording is an extremely valuable tool - The implementation cost can be small relative to the ROI - Helps improve communication between Operations and Maintenance - Use the data as an element of your over-all Safety Management System - If you do not use the data then you will not derive the full benefit of the system Remember: Mission First - Safety Always! Any Questions?