Seal repair solutions

Transcription

1 Seal repair solutions Joshua Duquette May 2018

2 Agenda Product overview Repair station overview Repair capabilities Repair types The benefits of seals repairs with Eaton 3

3 Overview of products Eaton designs, manufactures & repairs multiple seal configurations EATON is able to maximize sealing solutions through product breadth, and has the most extensive dynamic seals product offerings in the industryc 4

4 Where are Eaton seals found? High pressure compressor and turbine (Gas path) Accessory gearbox Main Shaft Bearings Accessories pumps APU S turbomachines tramsmissions 2018 Eaton. All Rights Reserved.. 5

5 Dynamic seals 101 Stator / Seal assembly Primary Sealing Interface Spring Secondary seal Rotor / Mating ring Shaft Axial Radial 2018 Eaton. All Rights Reserved.. 6

6 Dynamic seals Hydrodynamic (Non-contacting) Hydrodynamic (Non-contacting) 2018 Eaton. All Rights Reserved.. 7

7 Hydrodynamic technology Highly engineered grooves in the primary sealing component provide hydrodynamic pressure Pressure creates lift and separates or reduces contact loading of the sealing components Reduces heat generation and torque loss Increases seal life During steady state operation there is virtually no contact, thus heat generation and wear is low eliminating the root cause of leakage and coking Repair upgrades can incorporate hydrodynamics to increase life and reduce leakage Radial Hydrodynamic Axial Hydrodynamic Target Platforms: Leap Mainshaft & AGB Trent XWB AGB PW2000 AGB GTCP TFE 731 CFE 738 Contacti ng Hydrodyna mic Air Flow Mating Ring Spiral Groove Lift-off Force Air Flow OI L Carbon AI R Reduced heat eliminates carburization = reduced leakage = reduced wear = longer time on wing = value 2018 Eaton. All Rights Reserved.. 8

8 Additional opportunities brush seals General Information High temperature nickel-cobalt alloy bristles Radial seals which may be used in place of traditional labyrinth seals Applications in large and small aerospace/gas turbine primary, secondary and tertiary flow gas paths Low-hysteresis damping plates allow seals to withstand large radial movements without opening Able to manage high temperature, high-speed environments with long life capabilities Weighs significantly less than machined labyrinth seals 25-30% of labyrinth leakage rates Requires less axial space Existing partnership with Waukesha for industrial power generation market. Conventional Back Plat Weld Front Plate Bristles Flex-ring Side plate Weld Side Plate Bristles The conventional brush seal design, shown above, is not an ideal repairable design since the bristle pack is welded to the high cost side plates. Flex-ring design allows for interchangeable low cost bristle packs for repairable designs. Conventional brush seals are high performance, but relatively high price 9

9 What is the commercial advantage of a Flex-ring repairable brush seal? Major cost driver are side plates of brush seal First repair will salvage one of the side plates and introduce the cavity for the Flex-ring When the repaired seal is returned the next time, both side plates will be salvaged No machining of OD required after Flex-ring weld Can build Flex-ring inventory for quick TAT Eaton can provide Flex-ring or complete repair service through licensing Back plate Front plate The repairable brush seal decreases material cost, processes and TAT while maintaining seal performance thus offering a high value solution for the end customer. Flex-ring 10

10 Eaton dynamic seal repair facilities North America Europe East Providence, RI United States Coignieres, France The East Providence facility is Eaton s Center of Excellence for carbon seal design, manufacture, and repair. 11

11 East providence repair station The seal repair business started in Providence in 1939 Total Site: 145,000 square feet of floor space Repair station covers 13,000 sq ft. and there is room within the site for expansion New manufacturing equipment and streamline layout Experienced and knowledgeable repair technicians. Full service FAA Part 145 repair station. FAA / EASA / CAAC / CASE The East Providence facility and repair station were designed for manufacturing excellence. 12

12 East providence repairs business Dedicated to the MRO Activity Dedicated Area of 13,000 sq ft. ID/OD Grinding Machines Oil soak tanks Lathes and millings machines Vertical milling machines Leak testing Lapping tables Heat treating furnaces & ovens Inspection equipment - computer measuring machines FPI, plating, welding (FAA approved supply base) Dedicated Resources Repair Station Manager Customer Service Representatives dealing 100% with our aftermarket customers Designated technicians and operators Quality Manager Shop Floor Supervisor Designated Manufacturing Manager Designated Engineering Manager for MRO Product Sales Manager Dedicated Inventory of Piece Parts Kitting process for each reference for easy access and TAT performance Ducting and Sealing Repair Video 13

13 East Providence certifications and approvals FAA #VJPR395K EASA # CAAC approval #F AS9100C and ISO 9001 certified AS9100A certified NADCAP certified (heat treat, welding, EDM) Multiple OEM Supplier Qualifications and QMS Approvals (UTC, RR, GE, HON, etc.) 14

14 East Providence aftermarket team Contact information: Dawn Degnan Repair Station Manager Judy Rezendes Sr. Customer Service Manager Josh Duquette Seal Aftermarket Engineering Manager Glen Ollman Product Sales Manager Global Aftermarket Sales Managers also available for support. 15

15 Seal repair types offered by Eaton EM / CMM repairs EM / CMM licensing engine OEM developed repair procedures Source demonstrated repairs repair procedure developed by Eaton, approved by engine OEM. DER repairs Technical data and repair procedures developed by Eaton and approved the FAA DER. Owner operator repairs Technical data and repair procedures developed by Eaton, approved by the aircraft Owner Operator and added to the Owner Operator EM or CMM. 16

16 Current carbon seal repair capabilities OEM Engine AGB Seal Repair Mainshaft Seal Repair CFM56 X GE 90 X GE Engines CF6-80 X CF6-6 X CF6-50 X CF34-8 X PW 4000 X X PW 2000 X X PW Engines V2500 X JT8D X X JT3D X X Honeywell GTCP331 X UTAS APS3200 X Eaton also offers many other FAA Authorized customized repairs for it s customers. 17

17 How do these repair capabilities benefit MROs/airlines? Customer requirements Eaton solutions Before After Availability/TAT Quick turn times (routable pools) Cost Management Repair pricing superior to new replacement spares Customized solutions Ease of doing business Eaton able to offer repair/upgrade solutions for virtually any carbon seal (Manual Repairs or DER s) Over 70 years experience in seal manufacture and repair. OEM supplier for new aftermarket spare parts. Dedicated customer support. Easy access to OEM technical staff 2017 gearbox seal repair performance 100% OTD 10 days average TAT 2,000 CFM56 seals shipped 3,300 total seals shipped 18

18 Key takeaways for seal repair Eaton can repair virtually any carbon dynamic seal Seal Experts - OEM on many applications Problem solvers Quick TAT: 8-16 week TAT for development and 10 day lead time thereafter Rotable pools can be used to further reduce TAT Aftermarket structure and dedicated resources improves overall customer experience 19

19 Questions/Comments 20

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