Implementation of an Engine Condition Monitoring tool for Airbus Aircraft Aerospace Engineering

102 Pages·2015·14.45 MB·English

by  Sergio Ribeiro

Implementation of an Engine Condition Monitoring tool for
Airbus Aircraft
Sérgio da Cruz Ribeiro
Thesis to obtain the Master of Science Degree in
Aerospace Engineering
Supervisors: Prof. António José Nobre Martins Aguiar
Eng. Hélder António Silva Mendes
Examination Committee
Chairperson: Prof. Fernando José Parracho Lau
Supervisor: Prof. António José Nobre Martins Aguiar
Member of the Committee: Prof. Pedro da Graça Tavares Alvares Serrão
June 2015
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“If i have seen further than others, it is by standing upon the shoulders of giants.”
Sir Isaac Newton
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Acknowledgments
IwouldlikethankProf. Anto´nioJose´ NobreMartinsAguiarfortheopportunityofdevelopingthecurrent
dissertation at TAP, which was a truly an enriching experience, and for all the support and hours spent
reviewing the work developed. I would also like to give a special thanks and a word of appreciation to
Eng. He´lder Anto´nio Silva Mendes for all the guidance, patience, sympathy and without whom I would
not have achieved the same results.The friendships made during my internship, could not go without
mention, thank you Andre´ Simo˜es, Lu´ıs Vargas, Tiago Duarte and Pedro Soares. I would also like to
mentionthecontributionsfromAlexandreGarrinhasandDulceMontez.
To all my college friends for all the support and shared experiences. A special thanks to Joa˜o Silva for
thetimespentreviewingsomematerialsandkeepingmemotivated.
Tomyfamilyfortheunconditionalloveandsupport.
Last,butnotleast,toCarolinaOliveiraforallthesupportandsacrificesmade.
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Resumo
Com o crescimento da indu´stria aerona´utica o transporte ae´reo tornou-se acess´ıvel a uma populac¸a˜o
mais vasta o que tem levantado crescente preocupac¸a˜o com a seguranc¸a deste sector. Para ale´m
disso,devidoa`smargensdelucroreduzidasea` intensacompetic¸a˜ocaracter´ısticasdestemercado,as
companhias ae´reas tem procurado medidas que melhorem a eficieˆncia dos seus processos
operacionais de modo a reduzir custos e trazer benef´ıcios a n´ıvel ambiental. O crescimento e
desenvolvimentodaindu´striaimplicatambe´mumaumentonaquantidadededadosdevoodispon´ıveis
paraserutilizadosnarealizac¸a˜odeestudoscomavistaamelhorartodaaoperac¸a˜o. Osdadosdevoo
sa˜o recolhidos atrave´s de sistemas a bordo da aeronave, sendo posteriormente descodificados e
armazenados na estac¸a˜o de dados de voo. Com estes dados podem ser conduzidas ana´lises
estat´ısticas como a que e´ realizada pela aplicac¸a˜o desenvolvida durante a presente dissertac¸a˜o. A
ferramenta desenvolvida permite analisar a evoluc¸a˜o no tempo da performance dos motores e
identificar situac¸o˜es que necessitem de intervenc¸a˜o ou que possam indicar mau funcionamento de
algum componente. Foi desenvolvido um algoritmo para optimizar o tratamento de dados assim como
uma aplicac¸a˜o interactiva que permite uma ana´lise mais dinaˆmica da evoluc¸a˜o dos paraˆmetros de
performance dos motores. Esta aplicac¸a˜o online esta´ acess´ıvel a qualquer altura pondo a` disposic¸a˜o
dosva´riosdepartamentosdaempresainformac¸a˜oquedeoutraformaseriamaisdif´ıcildeobter.
Palavras-chave:
Dados de voo, Engine Condition Monitoring, Evoluc¸a˜o de performance,
Correcc¸a˜odeparaˆmetrosdeturbinasaga´s,Pontosdeestabilidade.
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Abstract
The growth of the aviation industry implies its accessibility to a broader population and this raises
particular concerns about air transport safety. Also, due to the low profit margins and intense
competitivenessofthismarket,airlinecompaniesarefocusingonmakingtheiroperationmoreefficient
in order to reduce costs and become more environmentally friendly. The growth and development of
the industry also means an increase in the existing on-flight data available to perform studies with the
objective of improving existing processes. Data is collected through systems aboard the aircraft, being
posteriorlydecodedandstoredattheFDdepartment. Statisticalanalysis,suchastheonedonebythe
applicationdevelopedduringthecurrentdissertation,canbeperformedusingthisdata. Thedeveloped
tool allows the analysis of engine performance parameters through time and identifies situations that
require intervention or may indicate malfunction of some engine component. An algorithm that
optimizes data processing in terms of time and computational resources required was also developed,
aswellasaninteractiveapplicationthatallowsadynamicanalysisoftheevolutionofsaidparameters.
Thisisanonlineapplicationthatcanbeaccessedanywhereneeded,makingavailableinformationthat
wouldotherwisebedifficulttoobtain.
Keywords:
Flight Data, , Engine Condition Monitoring, Performance Trends, Corrected Gas
TurbineParameters,StabilityPoints.
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Contents
Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Resumo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
ListofTables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
ListofFigures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
Glossary xviii
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi
1 Introduction 1
1.1 Motivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Structureofthedocument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 EngineConditionMonitoring 4
2.1 Condition-basedMaintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 TurbofanEngine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 DataSourcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3.1 RecordinganddisplayofData . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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2.3.2 SystemsforDataCollection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 TrendMonitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4.1 TrendMonitoringParameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4.2 EGTMargin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.3 CruisePerformanceTrending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.4 Baselinemodelandtrendmonitoring. . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.5 Performancedeteriorationdetection . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 EngineParameterCorrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3 TAPPortugal 25
3.1 TheFleet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 FlightDataDepartmentatTAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.1 AnalysisGroundStation(AGS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2.2 FlightPhaseIdentification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2.3 DataExporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4 DevelopinganECMTool 32
4.1 ECMandcruisetrendanalysisconsiderations. . . . . . . . . . . . . . . . . . . . . . . . . 32
4.1.1 StabilityPointsearchcriteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.1.2 ParameterFiltering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1.3 FixedWindowandGlidingWindowstableframesearch . . . . . . . . . . . . . . . 36
4.1.4 QualityNumber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1.5 Applicationofparametercorrections . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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4.1.6 EngineBleedanditseffects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1.7 BaselineDefinition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.1.8 TrendMonitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2 Algorithmforin-flightperformanceanalysis . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.3 Improvementsdeveloped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.3.1 LoadingFlightsfromtheFlightDB . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.3.2 Optimizationofdataprocessing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.3.3 BasicConditionsandstabilitycriteriadefinition . . . . . . . . . . . . . . . . . . . . 51
4.3.4 MinimumandnormalPackFlowBaselines . . . . . . . . . . . . . . . . . . . . . . 52
4.3.5 DevelopmentofaWeb-basedUserInterface . . . . . . . . . . . . . . . . . . . . . 53
4.4 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5 Results 56
5.1 Validatingthealgorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.2 CaseStudy-HPTCCvalvefailure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.3 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6 Conclusions 66
6.1 Achievements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.2 FutureWork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Bibliography 70
A ExportedParameters 71
B PackFlowSelection 73
C BaselinesFirstanalysis 74
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D BaselinesSecondanalysis 76
E BaselinesCaseStudy 78
F FlightPhaseIdentification 80
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