Aero Engine Reliability Improvement & Maintenance Cost Optimization

8 - 12 April 2013, Singapore

About The Trainer

Mr. S.Nadeem Ahmed has 20 years plus of diverse engineering experience in Industrial sectors as a Mechanical Engineer with Manufacturing and Engineering MRO Industry. For the past 15 years, he has worked with PK Engineering MRO facility on Maintenance Repair, Overhaul, Testing and Evaluation of Turbo Machinery including Aero and Aero derivative Gas Turbine Power Plants and has diversified experience on General Electric, Rolls Royce and Pratt & Whitney Machines. As an international conference speaker & trainer globally addressing Gas Turbine Power Plants, Rotating equipment, Reliability engineering & lean Six Sigma topics, he has also trained numerous professionals in the same area within and outside his organization. Nadeem has also provisioned Process companies (Power Generation, Oil and Gas etc) on Effective Reliability Improvement Programs, Maintenance Management Strategies, Lean Maintenance and Six Sigma Process Improvement Strategies integrating the same with reliability solutions. He holds a Masters in Mechanical Engineering with Major in Thermal Power Systems Engineering, is a Certified Six Sigma Master Black Belt from USA & is well versed with the Quality, Six Sigma and Power Plant Equipment Reliability Analysis Softwares. He has also conducted training for the following companies : Lao Airlines, Miat Mongolian Airlines, ST Aerospace Supplies Pte Ltd, Air Niugini Limited, Myanmar Airways International, Berjaya Air Sdn Bhd and Brunei Department of Civil Aviation.

About The Organizer

T.U.N International was formed with the objective of truly understanding the needs of each individual organizations training requirements. Our strength lies in our ability to listen to our clients, understand their unique business issues and assisting them to deliver the appropriate training solution based on the business challenges in the current market situation. Our vision is to be the No. 1 preferred training provider for all corporate companies by providing an innovative approach to your training requirements. We facilitate a training solution that is not only cost effective, but tailored to yield maximum benefits. We deeply value our working relationship with our clients and constantly dedicate ourselves to exceed your expectations of us. Besides customizing in-house training solutions for corporate companies, we also offer public courses and conferences in various industries.

TEL: +65 9743 4606 FAX: +65 6271 9029 EMAIL: LINDA@TUN.SG ONLINE: WWW.TUN.SG

Aero Engine Reliability Improvement & Maintenance Cost Optimization 8 - 12 April 2013, Singapore
Aero Engines are the most important components in Aircraft and generates the propulsive force for the flight. This comprehensive Five Day Interactive course is designed to achieve an in depth understanding into effective reliability and maintenance management of Aero Engine ( Aero gas turbine ) throughout life cycle. The Basics to advanced level operational issues will be focused with case studies for current variant of models will supplement the course. The design upgrades and thrust growth for various engine models will be discussed in detail with respect to reliability growth trends and maintenance cost optimization. Examining the performance and life assessments for aero gas turbines aimed at improving Operational performance and Integrating best maintenance practices, minimizing the likelihood of failures, ensuring higher reliability thus prolonging asset life and reducing maintenance costs per hour of operation .The detailed services agreements including fleet hour agreements , Fleet management plans along with life extension studies , warranties and insurance issues , evaluation for various aircraft applications will be discussed .

Key Learning Outcomes

Aero Engine Basics, Design Philosophy and Applications. Develop a detailed knowledge on material systems employed in gas turbines. Examine recent advances in materials for creep and fatigue failures. Understanding the manufacturing technology for Hot sections. Understand degradation mechanisms and how to predict them. Trend / Condition Monitoring of Aero Engines. Performance Analysis, Thermal, Mechanical etc. Condition assessments techniques including Non Destructive Evaluation. Practical management of Aero Engines Components Risk management mechanisms in relation to repair and maintenance Management decision making on overhaul scheduling and condition assessment techniques

Work-scoping (Various levels ) in Aero Gas Turbine with emphasis on maintenance cost reduction. Warranty and Insurances related to Aero Engines. Maintenance Services agreements with OEMs and MROs for various applications

Who Should Attend

Aero Engine / Power Plant Sr Maintenance Managers Maintenance Managers Engineers Technicians Aero Engines Reliability Engineers Technical Finance people Life extension Engineers Asset Management Managers / Engineers

Testimonials
Good Basic Reliability training who would like to establish reliability program in their organization. Berjaya Air SDN BHD Very good sharing of knowledge and enlightening. ST Aerospace Supplies Pte Ltd A Better insight to how operator operates and what is in place. ST Aerospace Supplies Pte Ltd It was a good experience and useful. MIAT Mongolian Airlines The Training is very useful & highly recommended. The training was clear and helped me understand the importance of having a good reliability programme, and how to do proper calculation and evalutation of our current reliability programme. Air Niugini Limited I get a lot of knowledge on aviation & Aircraft Reliability. Myanmar Airways International

TEL: +65 9743 4606 FAX: +65 6271 9029 EMAIL: LINDA@TUN.SG ONLINE: WWW.TUN.SG

Aero Engine Reliability Improvement & Maintenance Cost Optimization 8 - 12 April 2013, Singapore

Course Outline
Day 1
Aero Engine Basics. Layout of Systems Pneumatic , Hydraulic Fuel , Oil , Electrical , Control Systems Videos Modular Concepts for Maintenance Design Philosophy Critical Components / Parts Aero Engine OEM Manuals Specific Operating Instructions Manual Maintenance / Trouble Shooting Manual Overhaul Manual Standard Practices Manual NDT ( Non Destructive Testing ) Design, Operation, Materials and Integrity/ Life Issues Control Systems ( Typical Aero / Aero Derivatives ) FADEC / EEC Engines ETOPs Considerations / Requirements Bearing Seals and Drives. Bearing Sumps Philosophy Turbine Mechanical Design & Aero Overview Compressor Mechanical Design Static Structures Combustor Aero Design Design of hot gas path components, Materials, coatings, cooling, life and deformation models.

Performance & Certification Issues Performance Standards / Certifications Typical Failure Modes / Trouble shooting / Diagnostics Compressor operation issues , Deterioration in compressor performance and prevention. Combustion Effect on Hot section Materials Aero Engine performance mapping. LCF and HCF Issues in Aero gas turbines Emissions standards ( CAEP Standards) Certification Standards FAA / EASA ( Test Examples )

Day 4
Vibration Analysis in Aero Gas turbines Vibration Data Analysis Vibration Sensor Types Typical Mechanical Problems Vibration Severity Limits Fundamentals of Combustion Model Specific Combustion Sequential Combustion Combustion Analysis Advanced Combustor designs , Current technology Aero Engine Operational Monitoring and Analysis Systems Blade Temperature Measurement and Monitoring System (BTMMS) Debris Monitoring System / Oil Analysis Functional and Performance Data Collection and analysis Results and Conclusions from Initial Test Data Methodology for Aero Engine Performance Analysis / Condition Monitoring ISO Conditions / Rated Values of Performance Parameters Correcting Performance Parameters to Standard Conditions Thrust Output Exhaust Gas Temperature (EGT) Air Mass Flow Rate (Exhaust) Compressor Efficiency (%) ASME PTC 55 Aero Engine Performance Standard Aero Engine Base Line Performance assessment and Degradation Thrust Output Exhaust Gas Temperature Air Mass Flow Rate Specific Fuel Consumption Performance Degradation / factors

Day 2
Hot Gas Path Materials and Degradation Mechanisms Hot Gas Path Importance Alloy development for Various Aero Engines Models Development in Thermal Barrier Coatings. Coatings life aspects. Materials degradation mechanisms Creep, fatigue and oxidation. Type I and II oxidations Principles of life assessment. Analytical and condition based life assessment. 3D Blade designs, Manufacturing Technology. Design to meet LCF and HCF in Blade Technology Coarse grain, directionally solidified and single crystal types. Life extension of Aero Gas Turbine hot section Extending the intervals ( Case Study ) Hot Gas Path Parts Management Achieving best performance and life Repair vs. Replace decision Advantages of performance trending Optimizing maintenance scheduling

Day 5
LTSAs ( Long Term Service Agreements ) Understanding the Common pitfalls in LTSAs LTSA from a Technical perspective Insurance , Risks and LTSAs Warranty Issues FHA , FMPs , MCPH Agreements Developing a Reliability Program Reliability Model development for aero engines Compressor and turbine reliability Systems reliability Components reliability with ETOPS consideration Reliability standards background Reliability Reports for Aero Engines Auditing Gas Turbine Overhauls Major aims of the audit process. Components of effective audits. Benefits of Auditing Major Aero Engine overhauls Determining key outcomes for overhauls Performance Targets vs Investments Advantages of assessing overhauls before, during and after. Integrating the Performance Together Module Efficiencies and Performance Combustion Analysis of Aero Engines Performance Curves and Interpretation. Achieving Optimum Point for all Thrust condition Using soft-wares for Analysis and Model Building for Performance Additional Reliability Factors for Aero Engines. Exercises Conclusion & Questions

Day 3
Condition and Life Assessment in Aero Engine Modules Condition and life assessment. Condition Monitoring / Trend Monitoring Life assessment of Parts and how to achieve. Optimization of Component Life and Repair cycles Life assessment analysis( Use of Six Sigma Techniques) Case Study ( Aero Engines ) Repair Techniques for Aero Engine Turbine / Compressors Parts Repair of hot / Cold gas path components. Turbine / Compressors Understand the Repair Processes The various Re-Coating options available Examining which repairs extend life and which dont. Auditing the repair process with vendors ( Case Study ) Turbine Discs Life Assessment Turbine discs / LLPs ( Life Limited Parts ) Understand LLP Damage Mechanisms Contained / Uncontained Failures Industry Examples , ATSB reports Importance of Thermo-Mechanical Stress Analysis. Time based versus condition based remaining life NDT requirements and techniques Disc life Assessment Process ( Level I , II , III )

TEL: +65 9743 4606 FAX: +65 6271 9029 EMAIL: LINDA@TUN.SG ONLINE: WWW.TUN.SG

Aero Engine Reliability Improvement & Maintenance Cost Optimization 8 - 12 April 2013, Singapore 4 EASY WAYS TO REGISTER
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Aero Engine Reliability Improvement & Maintenance Cost Optimization 8 - 12 April 2013, Singapore

SGD 5,399
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SGD 5,899

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TEL: +65 9743 4606 FAX: +65 6271 9029 EMAIL: LINDA@TUN.SG ONLINE: WWW.TUN.SG