INTRODUCTION TO

ENGINE FLEET MANAGEMENT

(EFM) WORKBOOK

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 ABOUT THIS GUIDE

© 2022 Raytheon Technologies Corporation. All rights reserved.

THIS CONTENT IS ISSUED BY PRATT & WHITNEY, EAST HARTFORD, CONNECTICUT, U.S.A., A DIVISION OF
RAYTHEON TECHNOLOGIES CORPORATION.

UNLESS FAIR USE OR SOME STATUTORY EXEMPTION APPLIES, YOU MAY NOT REPRODUCE OR DISTRIBUTE
COPIES OF ANY PORTIONS OF THIS CONTENT WITHOUT THE PRIOR EXPRESS WRITTEN PERMISSION OF
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THE INFORMATION AND INSTRUCTIONS IN THIS CONTENT ARE FOR GENERAL TRAINING PURPOSES ONLY.
THIS CONTENT DOES NOT REPLACE OR SUPERSEDE THE INFORMATION CONTAINED IN THE APPROPRIATE
MAINTENANCE OR ENGINE MANUALS OR OTHER OFFICIAL PUBLICATIONS.

Proprietary Statement:
This document is the property of Pratt & Whitney, a division of Raytheon Technologies Corporation (RTC), and contains
confidential and / or proprietary information. You may not possess, use, copy or disclose this document or any information in
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permission is not authorized and may result in criminal and/or civil liability.

Note that due to engine production schedules, some discrepancies may exist between actual production components and
course content.

U.S. Export Classification:

EAR ECCN 9E991, Classification Request #1181365

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 TASK 1-1:

WORKSHEET

GIVEN: EXCLUDE:
1. FLEET SIZE = 40 ENGINES 1. COST OF OIL
2. AVG COST PER D&C = $25,000 2. COST OF FUEL
3. AVG COST PER OD = $150,000 3. COST OF MONEY
4. AC ANNUAL UTILIZATION = 4,000 HOURS 4. COST OF L&B MAINTENANCE
5. AVG SHOP VISIT COST = $1,200,000

ESTIMATE THE FOLLOWING ENGINE VARIABLE COSTS FOR THE SPECIFIED THRESHOLD
(RATE) LEVEL.
$ per EFH $ per Yr-Fleet

1. MAINTENANCE COST (SHOP COST): _________ __________

2. PROBABLE (RISK) EVENT COST (OD COST) _________ __________

3. PROBABLE INTERRUPTION COST (D&C COST) _________ __________

4. TOTAL ENGINE OPERATING COST _________ _________

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 TASK 1-2 : Calculate EMC/Hour for XYZ if the average SVC is $750,000.

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HvC EFM Class 217c 219 SVR.pptx
TASK 1-2 : What can be said about the length of XYZ’s flight legs?

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 Task 2-1

Given the information below, estimate:

the required number of spare engines
to support the current SVR and TAT

AIP = # Shop visits * # AC * # Eng * # hours * # days = Avg # Eng-days

Eng-hr fleet AC year-AC visit-eng 365

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 Task 2-1

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 Task 2-2
Given the information below, estimate the following:
• The required 1- and 5-year Maintenance Cost budget for the fleet.
• The impact on the Engine Maintenance Budget due to improper engine stagger plan.
Worksheet

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 Task 2-2

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 Task 2-3 : POWERPLANT SPARE REQUIREMENT

GIVEN: 12 B767 AIRCRAFT FLY 4,000 HOURS/YEAR

SVR = 0.1/1000 HOURS , TAT = 60 DAYS

HOW MANY ENGINE SPARES ARE REQUIRED FOR THIS FLEET?

HOW MANY ENGINE HOURS ARE FLOWN PER YEAR FOR THE FLEET?

HOW MANY FLYING HOURS DOES AN ENGINE HAVE BEFORE IT HAS A SHOP VISIT?

HOW MANY ENGINE SHOP VISITS ARE REQUIRED FOR THIS FLEET IN AN AVERAGE YEAR?

HOW MANY DAYS OUT OF SERVICE ARE EXPERIENCED PER YEAR,

AND WHAT IS THE AVERAGE IN PROCESS (AIP) NUMBER?

HOW MANY SPARE ENGINES DOES THE FLEET REQUIRE? IS IT THE SAME EVERY YEAR?

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 Task 2-4 : ENGINE STAGGERING EXERCISE

1. What is the spacing (in engine cycles) required between engine changes so that only one engine is away at
overhaul at any time?

A330 / PW4168 ENGINE STAGGERING EXERCISE

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 Task 2-4

2. Will there be any problems with the proposed engine changes? Which engines are the most troublesome?
3. During which aircraft’s next C check do you want to make the first swap, and with which spare engine?

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 Task 3-1

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 Task 3-1

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 Task 3-1

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 Task 3-1

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 Task 3-1

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 Task 3-1

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TASK 3-2: PW4056 Phase 3 Engine’s Performance Assessment

Comment on the condition of the modules of the engine that is highlighted

by 3 blue squares (representing the different power settings) on each plot:

ΔN1- ΔN2 versus LPC Pressure Ratio:______________________________________

Thrust versus ΔN1:______________________________________________________

LPC Exit Temperature versus LPC Pressure Ratio:___________________________

EGT versus Fuel Flow:___________________________________________________

EGT versus Turbine Expansion Ratio:_______________________________________

Thrust versus EPR-0:_____________________________________________________

LPC Pressure Ratio versus EPR-0:__________________________________________

HPC Exit Temperature versus EPR-0:_______________________________________

Takeoff EGT Margin versus EPR-0:__________________________________________

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 Task 3-2

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 Task 3-2

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 Task 3-2

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 Task 3-2

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 Task 3-2

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 Task 3-2

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 Task 3-2

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 Task 3-2

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 Task 3-2

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 Task 4-1

JT8D-9A Life Limited Parts - Exercise (cont):

• In this exercise you will compute the maintenance cost per engine flight hour for three different
workscope plans.

• Assumptions:
• The hot section is capable of approximately 6,000 to 8,000 cycles since overhaul.
– The cost for hot section refurbishment is $300,000 USD -- the cost includes the price to replace any
LLPs that has expired.
– The cost for a shop visit to just replace the LLPs in a module is $200,000 USD.

• Compute the average engine maintenance cost per engine flight hour (MC/EFH) based on the product
of shop visit rate (SVR) and shop visit cost (SVC).

• MC/EFH ~ SVR * SVC

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TASK 4-1: ENGINE’S REMAINING DISK LIVES
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 Task 4-1
Hot Section costs $300K (includes its LLP replacement), LLP replacement costs $200K

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 Task 4-1
C4 C3 C6 T2 T4
limit C13 T3

Base cyc
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000

C4 C3 C6 T2 T4
limit C13 T3

a). XX
cyc
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000

C4 C3 C6 T2 T4
limit C13 T3

b). X XX
cyc
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000

C4 C3 C6 T2 T4
limit C13 T3

c). X X XX X
cyc
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000

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 Task 4-2

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 Task 5-1
PW4462-3 SB Business Case for Operator PWX:

Average cost per engine shop visit ..……. $ 1,200,000

Average yearly fleet utilization (hours).. 5,400
Average hour to cycle ratio …………...…… 6.5

SB % Eng. Total # SB Man-

SB # CAT Completed Status To Do of Eng. SB MMC/Eng. hour
615 5 100.00% old 0 68 $ 266,000 N/A
716 7 0.00% new 68 68 $ 313,000 N/A

Assumptions:
Ignore cost of money (IRR or hurdle rate)
Ignore labor cost (blades are replaced when engine is in the shop)

Task: Result

Determine the current shop visit rate, from chart 1.

Estimate impact of Blade Turbine 2 Stage problem on SVR in % , from chart 2.

Estimate average loss in MC/EFH due to Blade 2 Stage problem (delta MC/EFH).

Estimate the MMC per engine to implement SB 716 relative to SB 615.

Estimate the break-even point in hour per engine after 100% implementation of SB 716.

Estimate Maintenance Cost savings at year two (2) after 100% SB 716 implementation.

Estimate the increase in MTBSV (in hours) as a result of the SB implementation

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 Task 5-1

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 Task 5-1

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 Task 5-2 : PW4000-3 SB72-763 Business Case for Operator ABC
Average cost per engine shop visit ..……. $1,200,000

Average yearly fleet utilization (hours).. 4,300

Average hour to cycle ratio …………...…… 5.8

13 B747-400 aircraft plus 6 spare engines

Assumptions: Ignore cost of money (IRR or hurdle rate)

Tasks: Ignore labor cost (blades are replaced when engine is in the shop)
Results
1) Determine the current shop visit rate of Airline ABC from SVR chart 3. __________

2) Estimate impact of the T2B problem on SVR in %, from the Top Problems chart 1. __________

3) Estimate average loss in MC/EFH due to T2B problem (delta MC/EFH). __________

4) Estimate the change in MMC per engine to implement SB 763 __________

5) Estimate the break-even point in hours per engine after 100% implementation. __________

6) Estimate Maintenance Cost savings at year two (2) after 100% SB 763 implementation. __________

7) Estimate the increase in MTBSV (in hours) as a result of the SB implementation. __________

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 Task 5-2 : Top Causes of Engine Shop Visits for Airline ABC

Chart 1

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 Task 5-2 : Top Causes of Engine Shop Visits for Airline Fleet

Chart 2

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 Task 5-2 : Shop Visit Rates of ABC and of the entire Fleet

Chart 3

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 Task 6-1

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 Task 6-1

CRUISE EGT VERSUS EGTINDEX

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 Task 6-1

CRUISE N1 VERSUS EGTINDEX

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 Task 6-1

CRUISE N2 VERSUS EGTINDEX

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 Task 6-1

CRUISE TURBINE EXPANSION RATIO VERSUS EGTINDEX

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 Task 6-1

CRUISE N1-N2 VERSUS LPC PRESSURE RATIO

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 Task 6-1

CRUISE LPC EXIT TEMPERATURE VERSUS

LPC PRESSURE RATIO
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 Task 6-1

TAKEOFF EGT MARGIN VERSUS CRUISE EGT

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 Task 6-1

CRUISE EGT VERSUS FUEL FLOW

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 Task 6-1

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 Task 7-1

Estimate the cost of operating an aircraft that

uses an additional 2% fuel pad due to excessive
drag (improper rigging trimming aircraft system).

Penalty in USD = $_______________

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Task 7-2 : Single Engine Taxi Fuel Savings Exercise

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 Task 8-1

EXAMPLE OF ESTIMATED MC BENEFITS

(BASED ON 10% DERATE TAKEOFF)

a. ENGINE TYPE: ____________________

b. FLEET SIZE (NUMBER OF ENGINES): ____________________

c. AIRCRAFT UTILIZATION PER YEAR (HRS): ____________________

d. FLEET HOURS TO CYCLE RATIO: ____________________

e. TYPICAL MC/EFH AT 0% DERATE: ____________________

f. SAVINGS (%) ON 10% DERATE IN MC

FROM T.O. CURVES): ____________________

g. SAVINGS ($) IN MC/EFH [(f)(e)]: ____________ x ____________ = ____________________

h. SAVINGS ($) IN MC/YEAR/FLEET [(g)(b)(c)]: ________ x _______ x _______ = ____________________

Line ”h” above represents savings in MC at 10% derated takeoff. (Other benefits include labor, OSR, lower SVR, LLP time
and more.)

MC BENEFIT ESTIMATES FROM REDUCED TAKEOFF

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 Task 8-1

JT8D RELATIVE MC vs. FLIGHT LENGTH AND

THRUST REDUCTION
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 Task 8-1

JT9D RELATIVE MC vs. FLIGHT LENGTH AND

THRUST REDUCTION
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 Task 8-1

PW2000 RELATIVE MC vs. FLIGHT LENGTH AND

THRUST REDUCTION
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 Task 8-1

PW4000 RELATIVE MC vs. FLIGHT LENGTH AND

THRUST REDUCTION
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 YOUR ANSWERS TO THE REVIEW QUESTIONS
SECTION 1: SECTION 3: SECTION 6: SECTION 9:

1. ___ 1. ____________ 1. ___

2. ____________ 1. ___
2. ___ 2. ___ 2. ___
3. ___ 3. ___ 3. ___
4. ___ 3. ____________
4. ___ 5. ___ 4. ___ ____________
5. ___ 6. ___ 5. ___ ____________
6. ____________ 7. ___ 6. ____________ ____________
____________ 4. ___
____________ 5. ___
____________ SECTION 4: SECTION 7: 6. ___
____________
1. ___
7. ____________ 1. ___
2. ___
____________ 2. ___
3. ___
____________ 3. ___
4. ___
____________
5. ___
____________
____________ SECTION 8:
____________
SECTION 5:
____________ 1. ____________
____________ ____________
1. ___
____________ ____________
2. ___
____________
3. ___
2. ___
SECTION 2: 4. ___
3. ___
5. ___
1. ____________ 4. ___
6. ___
2. ___ 5. ___
7. ___
3. ___ 6. ___
4. ___
5. ___
6. ____________

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