AZUL AIR­LINES MAK­ING BRAZIL PROUD

Pratt & Whit­ney’s large com­mer­cial en­gines power more than 25 per cent of the world’s main­line pas­sen­ger fleet

SP's Airbuz - - Table of Contents - BY R. CHAN­DRAKANTH

Azul is the fastest grow­ing air­line in Brazil and cur­rently has the largest air­line net­work in the coun­try in terms of cities served.

FRED­ER­ICK RENTSCHLER FOUNDED PRATT & Whit­ney in Hart­ford, Con­necti­cut, in 1925 and its first air­craft en­gine trans­formed the avi­a­tion in­dus­try. It was the 410-horse­power, air-¬cooled Wasp, which de­liv­ered un­prece­dented per­for­mance and re­li­a­bil­ity for the time. Since then, Pratt & Whit­ney has been lead­ing the change, de­vel­op­ing game-chang­ing tech­nolo­gies for the fu­ture, such as the PurePower PW1000G en­gine, with patented Geared Tur­bo­fan en­gine tech­nol­ogy.

The com­pany’s world­wide large com­mer­cial en­gine main­te­nance, re­pair and over­haul net­work pro­vides in­no­va­tive ser­vices that add value and de­light cus­tomers around the globe. Pratt & Whit­ney’s large com­mer­cial en­gines power more than 25 per cent of the world’s main­line pas­sen­ger fleet. The com­pany con­tin­ues to de­velop new en­gines and work with its part­ners in In­ter­na­tional Aero En­gines and the En­gine Al­liance to meet air­line cus- tomers’ fu­ture. Pratt & Whit­ney Canada has pro­duced over 80,000 en­gines, of which there are cur­rently more than 50,000 en­gines in ser­vice by more than 10,000 op­er­a­tors in 200 coun­tries.

Founded in 1928, Pratt & Whit­ney Canada is shap­ing the fu­ture of avi­a­tion with de­pend­able, high-tech­nol­ogy en­gines. It in­vests heav­ily in re­search as it un­der­stands how cut­ting-edge tech­nolo­gies are go­ing to de­ter­mine the fu­ture of avi­a­tion, not just in eco­nomic terms but also in en­vi­ron­men­tal terms.

In con­tin­u­a­tion of its com­mit­ment to re­search and de­vel­op­ment, in 2014 it an­nounced that it was in­vest­ing over $1 bil­lion in R&D over the next four to five years to de­velop the next-gen­er­a­tion of high per­for­mance air­craft en­gines. The in­vest­ments were in Longueuil (Que­bec) and Mis­sis­sauga (On­tario) fa­cil­i­ties. The in­vest­ment in­cludes a $300 mil­lion re­payable con­tri­bu­tion from the Gov­ern­ment of Canada un­der the Strate­gic Aero­space and De­fence Ini­tia­tive (SADI) pro­gramme.

DE­VEL­OP­ING CUT­TING-EDGE TECH­NOLO­GIES. Pratt & Whit­ney Canada is de­vel­op­ing the most ad­vanced propul­sion tech­nolo­gies for im­proved en­vi­ron­men­tal per­for­mance, in­clud­ing re­duced fuel con­sump­tion and weight, lower emis­sions and less noise. These tech­nolo­gies will be lever­aged across the com­pany’s prod­uct fam­i­lies for new and ex­ist­ing tur­bo­fan, tur­bo­prop and tur­boshaft en­gines in busi­ness, re­gional and gen­eral avi­a­tion and he­li­copter ap­pli­ca­tions. Pratt & Whit­ney Canada is also cur­rently in­vest­ing $275 mil­lion over five years in cut­ting-edge tech­nolo­gies and up­grades to its fa­cil­i­ties, in­clud­ing the cre­ation of a world-class cen­tre of ex­cel­lence for in­tel­li­gent man­u­fac­tur­ing in Longueuil. This cen­tre of ex­cel­lence will fea­ture three new in­tel­li­gent pro­duc­tion lines ded­i­cated to man­u­fac­tur­ing highly com­plex key com­po­nents for the new-gen­er­a­tion fam­ily of PurePower en­gines. It is ex­pected to be fully op­er­a­tional in 2015.

“Pratt & Whit­ney Canada leads the in­dus­try in de­vel­op­ing the next-gen­er­a­tion of high-per­for­mance and sus­tain­able tech­nolo­gies,” said Saabas. “Our lat­est R&D pro­grammes in­clude cut­ting-edge ma­te­ri­als such as com­pos­ites and ad­vanced al­loys to im­prove en­gine weight, a high-ef­fi­ciency com­pres­sor tech­nol­ogy to en­hance en­gine per­for­mance and re­duce fuel con­sump­tion, and fur­ther im­prove­ments to our com­bus­tion sys­tems to re­duce en­gine emis­sions. We are also im­ple­ment­ing ad­vanced tech­nolo­gies and in­tel­li­gent cell con­cepts to bol­ster our man­u­fac­tur­ing ca­pa­bil­i­ties in Canada. This in­vest­ment will en­sure that we re­main tech­nol­ogy-ready to sup­port our cus­tomers in the years ahead.”

CON­TIN­UED COM­MIT­MENT TO R&D. This R&D in­vest­ment will also strengthen Pratt & Whit­ney Canada’s long-stand­ing col­lab­o­ra­tion with ma­jor uni­ver­si­ties and sup­pli­ers across Canada. “Ev­ery year, we in­vest $10 mil­lion in projects with close to 20 Cana­dian uni­ver­si­ties to de­velop new en­gine tech­nolo­gies for the next-gen­er­a­tion of en­vi­ron­men­tally-friendly and fuel-ef­fi­cient air­craft,” said Saabas. “To date, hun­dreds of stu­dents have worked on more than 800 projects in col­lab­o­ra­tion with P&WC’s engi­neer­ing team. We are proud to con­trib­ute to the de­vel­op­ment of fu­ture en­gi­neers and tech­ni­cians.”

Pratt & Whit­ney Canada has a long-es­tab­lished com­mit­ment to in­vest­ing in R&D to spur in­no­va­tion and power sus­tain­able growth. With an av­er­age $450 mil­lion in an­nual R&D in­vest­ments over the past 10 years, it ranks among the top Cana­dian R&D in­vestors. Con­tin­u­ous R&D in­vest­ments have al­lowed the com­pany to cer­tify more than 100 en­gines over the past 25 years, a bench­mark in the aero­space in­dus­try.

The long list of in­no­va­tions in­cludes:

Next-gen­er­a­tion com­bus­tion and aero­dy­namic tech­nolo­gies to meet emerg­ing, strin­gent en­vi­ron­men­tal stan­dards

Ad­vanced en­gine aero per­for­mance tech­nolo­gies to im­prove fuel ef­fi­ciency

Physics-based mod­el­ling to re­duce de­vel­op­ment cy­cles and in­crease speed to mar­ket

High-speed/pre­ci­sion man­u­fac­tur­ing tech­nolo­gies to en­hance prod­ucts and in­crease pro­duc­tiv­ity

Lever­ag­ing of emerg­ing di­ag­nos­tic tech­nolo­gies to im­prove en­gine re­li­a­bil­ity and safety. With 20 years of re­search and de­vel­op­ment, com­po­nent rig test­ing on all ma­jor mo­d­ules, ex­ten­sive ground and flight test­ing un­der­way, two en­gines in the fam­ily cer­ti­fied and the PW1100GJM car­ry­ing pas­sen­gers on a daily ba­sis, the PurePower PW1000G en­gine with Geared Tur­bo­fan tech­nol­ogy de­liv­ers game-chang­ing re­duc­tions in fuel burn, en­vi­ron­men­tal emis­sions, en­gine noise and op­er­at­ing costs.

The PurePower PW1000G en­gine’s fan-drive gear sys­tem is just one com­po­nent of this next-gen­er­a­tion en­gine. The PurePower PW1000G en­gine also in­cor­po­rates ad­vances in aero­dy­nam­ics, light­weight ma­te­ri­als and other ma­jor tech­nol­ogy im­prove­ments in the high-pres­sure spool, low-pres­sure tur­bine, com­bus­tor, con­trols, en­gine health mon­i­tor­ing and more.

TECH­NOL­OGY OF THE FU­TURE. Pratt & Whit­ney has been ac­tively test­ing all key com­po­nents of the PurePower PW1000G en­gine fam­ily, with 16 tech­nol­ogy rigs run­ning around the world. In 2008, Pratt & Whit­ney’s full-scale demon­stra­tor en­gine com­pleted its rig­or­ous 400-hour ground and flight test pro­gramme with test re­sults that in­di­cated the en­gine de­liv­ers the per­for­mance and ef­fi­ciency tar­gets of this rev­o­lu­tion­ary tech­nol­ogy.

The PW1100G-JM en­gine for Air­bus A320­neo fam­ily of air­craft and the PW1500G en­gine for the Bom­bardier C Se­ries are cer­ti­fied. The PW1400G-JM en­gine for the Irkut MC-21 air­craft, the PW1200G en­gine for the Mit­subishi Re­gional Jet and the PW1900G for the Em­braer E190-E2 are all in test­ing. The PW1100G-JM be­gan pow­er­ing rev­enue flights in Jan­uary 2016.

FAA CER­TI­FI­CA­TION. Pratt & Whit­ney’s PurePower Geared Tur­bo­fan PW1900G en­gine re­ceived cer­ti­fi­ca­tion from the US Fed­eral Avi­a­tion Ad­min­is­tra­tion. The PW1900G en­gine pow­ers the two largest air­craft in Em­braer´s sec­ond-gen­er­a­tion of the E-Jets fam­ily of com­mer­cial air­craft. The E190-E2 took its first flight in May 2016 and the E195-E2’s first flight was on March 29, 2017.

“The FAA val­i­da­tion of the PW1900G en­gine type cer­tifi­cate is a key pro­gramme mile­stone,” said Chris Calio, Pres­i­dent, Com­mer­cial En­gines. “The en­gine pro­vides 23,000 pounds of thrust and is cur­rently pow­er­ing five flight test ve­hi­cles with more than 900 hours of flight test­ing com­pleted.” The cer­ti­fi­ca­tion test pro­gramme spanned nearly 18 months and in­cluded sea level as well as op­er­abil­ity and per­for­mance test­ing among the rig­or­ous pro­to­col the en­gine un­der­went.

The PW1900G en­gine, the fourth in the PurePower fam­ily to be cer­ti­fied, is sched­uled to en­ter into cus­tomer ser­vice on the E190-E2 in 2018, with the 195-E2 sched­uled to en­ter ser­vice in 2019. The E-Jet E2 pro­gramme is one of two pro­grammes that Pratt & Whit­ney and Em­braer are work­ing to­gether on. Pratt & Whit­ney is part of the col­lab­o­ra­tion which sup­plies the V2500-E5 en­gine for the Em­braer KC-390, which is un­der cer­ti­fi­ca­tion cam­paign. It also sup­plies the aux­il­iary power unit for the E-Jet E2 pro­gramme.

The Pratt & Whit­ney PurePower en­gine fam­ily has more than 80 cus­tomers, for both an­nounced and unan­nounced firm and op­tion or­ders, from more than 30 coun­tries. In-ser­vice per­for­mance of the PurePower en­gine fam­ily has demon­strated its abil­ity to re­duce fuel burn by 16 per cent, reg­u­lated emis­sions by 50 per cent and noise foot print by 75 per cent.

CON­TIN­U­OUS R&D IN­VEST­MENTS HAVE AL­LOWED THE COM­PANY TO CER­TIFY MORE THAN 100 EN­GINES OVER THE PAST 25 YEARS, A BENCH­MARK IN THE AERO­SPACE IN­DUS­TRY

Pratt & Whit­ney’s PW1100G-JM en­gine

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