Thanks to the latest technologies, we provide service for the GTF aircraft engines
At EME Aero, we provide the maintenance, repair and overhaul (MRO) of the latest generation of Pratt & Whitney GTF aircraft engines. Each engine that is inducted in our shop, goes through a service cycle, which may vary depending on the type of visit and the work complexity.
A service visit begins when the customer’s engine arrives at the plant. After its induction, the work and process schedule is planned. Before disassembly, mechanics prepare the engine based on the commissioned repair plan. At this stage, an engine induction inspection is carried out, and we assess its general condition.
The next step is disassemble. At EME Aero we disassembly each engine from the PW1000 family into modules and individual parts. The process is carried out with the usage of the most modern technological solutions, designed for EME Aero – FOS (Fixed Overhaul System). During the initial inspection, the engine is checked for any damages. A boroscopic inspection is carried out. It includes the diagnosis of irregularities, during which the repair plan may be changed.
After disassembly and initial inspection, the disassembled parts are cleaned. EME Aero is equipped with an automated cleaning line that includes tanks for degreasing, descaling, paint and rust removal. The area is also equipped with a closed water circuit, which allows the water resources to be reused in the cleaning process. Manual workstations enable the individual cleaning of all components.
The EME Aero is equipped with a non-destructive testing laboratory where engine parts are inspected. Activities carried out in the service center include tests and examinations with the computer measuring devices and advanced non-destructive testing (NDT) procedures, including FPI (Fluorescent Penetrant Inspection), MPI (Magnetic Particle Inspection) and ultrasound analysis. EDDY current research is also planned.
Based on the visual inspection, a pre-inspection report is prepared. At this stage, all disassembly orders are checked for correctness and compliance with the scope of the repair. This stage completes the inspection status of all disassembled parts. It is here that all parts and components are compared with the permissible limit values and assessed for further usage. Based on the detected damage, our employees select the necessary repair processes. If the part is intact, it is used in the assembly process. If repair is required, the relevant part is transported to an in-house repair shop or sent for external processing and repair.
In addition to the maintenance of all engine components, EME Aero performs repairs for engine parts and components resulting from a service visit. After the inspection, a decision is made whether the part is to be replaced, repaired or overhauled. Repairs include repairing parts, components, on a module or a super module. After their completion, the parts are verified for the correctness of the repair. A positive result allows the given part for further assembly.
All undamaged, new and repaired parts are assembled in modules, grinding and balancing, and then assembly individually to the engine. Final assembly takes place with EME Aero’s distinctive tooling technology systems. These are FOS and MTOS systems for lifting and mounting all types of engines in our portfolio. When the entire engine is assembled, our employees review all service activities performed and compare them to the producer’s specifications, plans and requirements.
The EME Aero test cell is one of the largest and most modern in the world. During the test, the data necessary for determining the performance characteristics and examining the engine parameters are obtained. The results obtained during the test are carefully analyzed. The approved for serviceability engine is packaged and prepared for shipment to client. After the test, we verify that all service activities ordered by the customer have been properly performed and documented in accordance with the applicable procedures. The service visit ends with an airworthiness confirmation issued in the form of a certificate, and the engine itself is released for operation.
Fixed Overhaul System is for lifting, assembly and disassembly of engines serviced at the EME Aero. It allows the standardization of the disassembly and assembly processes in relation to the procedures applicable to the PW1000 engine family. Such solutions have a positive effect on the ergonomics and service time.
Mobile Transport and Overhaul System is a mobile stand for assembling and disassembling PW1100, PW1500 and PW1900 engines. It is one of the most modern technological solutions for flow lines, designed and implemented for EME Aero by MTU Aero Engines Technology Department in Munich.
EME Aero has been approved by the European Union Aviation Safety Agency (EASA) as a service center for the GTF Pratt & Whitney engines family, including the PW1100G-JM and PW1500G models. The EASA Part-145 certification (as part of the Lufthansa Technik Group approval) covers the inspection, repair and modification of almost all engine components.
It is regularly inspected by the German Federal Aviation Authority (LBA) as the national aviation authority.
The EASA Part-145 certification for EME Aero covers all processes related to the commercial engine maintenance process: disassembly, assembly, inspection, CMM, repair, tool storage, NDT, cleaning and testing.