Aircraft Engine Overhaul - 300 hours around the world: Before a commercial aircraft engine is serviced for the first time, it travels around 12 million kilometres. With experience, expertise and precision, we will ensure that it continues to perform reliably.
A Rolls-Royce engine has more than 15,000 individual parts. In a structured and strictly controlled process, we analyze, clean, repair or replace as necessary and make the engine in good condition for reliable flight operations for years to come.
Aircraft Engine Overhaul
The scope of our maintenance work always depends on the customer's order. Our production planners convert these into detailed work plans after the initial inspection of the engine, taking into account legal requirements and manufacturing requirements.
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In a U-shaped bell flow line, engine parts travel from station to station. The optimized arrangement of all functional areas, tool stations and materials ensures efficient material flow, maximum flexibility, short distances and maximum transparency.
In our workshop, the Repair and Maintenance Workshop, each engine is carefully disassembled into individual parts. During the initial inspection, the engine is first checked for hidden damage.
After this, all non-modular parts are removed, e.g. pipes. The crane then moves the engine to the vertical position. This vertical method, unique to the N3, allows for material-friendly disassembly of the engine modules. The mechanics work particularly efficiently and ergonomically in each of the four engine types with the help of special lifting platforms that are electronically controlled. After that, the modules are disassembled into individual parts or module disassembly parts.
The heart of the area is the cleaning plant, which has a total of 28 cleaning tanks for degradation, lime removal, paint removal and rust removal. Each tank is approximately twelve and a half cubic meters and components up to 2 meters in diameter and weighing 500 kg can be machined.
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The entire cleaning area is closed. The exhaust air is extracted and prepared in the basement for reuse. The process water remains in the cleaning line and is used repeatedly in a multi-stage cycle. By adding several blow machines and flexible manual workstations, almost every component can be cleaned individually.
After cleaning, our team will check the engine parts for possible damage. Then NDT methods are used. These include fluorescent penetrant examination (FPI), magnetic particle inspection (MPI) and X-ray imaging.
For particularly critical engine components, such as blades or welds, other non-destructive testing methods have been introduced: FPI, MPI and X-ray analyzes are based on user experience and a trained eye assessment, turbulent flow and ultrasonic tests provide measurement accurate result.
Here, all engine parts and components are compared to the approved limits and their reusability and/or repairability is assessed. Based on the detected damage, our team selects the necessary repair processes, taking into account technical and economic aspects.
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In observational reports, they document each pattern of consumption with the utmost precision. If the part is intact, it is redirected to the "Reservations" area. If repair is required, the corresponding part is transported to N3's internal repair shop or sent for external processing and repair. We will keep replacement parts in our warehouse until proper disposal is available.
As well as servicing all engine components, N3 carries out repairs as well as quality new parts. We also do reliable one-off repairs for international customers.
After the inspection, it is determined whether the part needs to be replaced, repaired or restored. Our repair planners convert each order into detailed workflows in accordance with legal requirements and manufacturing specifications. We guarantee fast and reliable implementation for our customers.
Our state-of-the-art machinery enables complete restorations, repairs and complex modifications. More detailed information about each repair process can be found here.
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All parts - undamaged, new and repaired - are assembled separately for engine installation. Mechanics assemble, grind and balance the modules and, after internal inspection, forward them to engine assembly.
By grinding the rotor tips with a high speed grinder, the gap between the rotor and the stator (casing) is optimized. As a result, the efficiency of the engine is improved and its kerosene consumption is reduced.
Since even the smallest imbalances can cause strong vibrations in the system at certain frequencies, N3 also balances fast-rotating engine turbines and compressors. This extends their service life and ultimately improves the safety of the motor.
The final assembly of the engine is also done with vertical suspension. It requires a lot of discipline, because even the slightest damage can make an expensive engine part unusable. That's why here at N3 we work according to the most modern quality assurance procedures: Every process and every assembled part is checked and recorded in the assembly documents. Continuous control measurements and the simultaneous performance of additional visual inspections in accordance with the principle of double control ensure additional protection.
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After the complete engine has been installed, authorized personnel inspect all the maintenance steps performed and compare them to the manufacturer's specifications, work plans and requirements.
In a test cell with a cross-section of 14 x 14 meters, we check the performance of each engine, no matter how many are machined in the N3.
The test drive is carried out according to the strictest safety regulations in different stages, determined by the Rolls-Royce manufacturer: It must be proven precisely that the engine has the required mechanical function and the specified performance.
The test cell was equipped with sound insulation according to the latest results of the acoustic study with several attenuation systems.
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If the engine has passed the test drive, a final comparison is made between the engine's pre-delivery specifications and Rolls-Royce and returned to the customer. The Ludwigsfelde site, located near Brandenburg Airport in the German capital, has so far focused on smaller aircraft engines and industrial gas turbines. It is used to service Pratt & Whitney PT6A, PW200, PW300, PW500 and GE Aviation CF34 series engines, according to the MTU website.
The Boeing 737NG-powered CFM56-7Bs are currently being serviced in Hannover and at the Zhuhai facility, which MTU owns together with parent company China Southern Airlines.
MTU Vice President of MRO Programs Martin Friis-Petersen tells Cirium that CFM56-7B services are due to start at the Berlin plant in the middle of this year. He says the expansion amid the pandemic reflects the company's confidence in the recovery and post-Covid MRO outlook for lean body engines.
Despite the crisis, MTU is continuing to expand its Zhuhai facility - including building a new PW1000G service shop next to the current site - and setting up a component repair shop outside the Serbian capital, Belgrade, he adds noticed.
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The Munich-headquartered engine parts and MRO supplier expects synergies from overhauling the CFM56-7B and CF34 at the same location, as the latest CF34 versions share technology with the 737NG powerplant.
MTU says the additional CFM56-7B supply line will increase the flexibility and reactivity of the network - something the company sees as "very important" in today's environment.
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