GE Aviation and Etihad Airways have partnered to launch GE’s 360 Foam Wash to optimize the performance of Etihad’s GE90 and GEnx-1B engines on its Boeing 777 and 787 fleets. The GE’s 360 Foam Wash technique is a groundbreaking jet engine cleaning system alternative to water wash method to optimize engine performance by reducing build-up of deposits, lowering engine exhaust temperatures, and improving engine compressor efficiency which leads to low fuel consumption thereby reducing costs. MRO Business Today spoke to the engineering team behind GE’s 360 Foam Wash technology. To know more READ ON!
Q – 360 Foam wash, the name itself is self-explanatory. However can you tell us very briefly how this technique is better & more efficient than a normal water wash?
A – GE’s proprietary detergent solution has more cleaning capability than typical water wash. Also, GE’s 360 Foam Wash detergent is driven into the engine via a controlled cleaning process by the 360 Foam Wash cart. The foam fills target areas within the engine, enabling more effective removal of dust and dirt that can buildup in engines and decrease engine efficiency.
Q – As of now, the technique is used on Etihad’s fleet of 777 and 787, when will we see a wider application of the technique.
A – GE’s 360 Foam Wash is available for customers on several GE Aviation engine models. We welcome GE Aviation engine customers to reach out to request more information and to discuss a license agreement for GE’s 360 Foam Wash. Contact your GE Aviation Customer Support Manager and Customer Program Manager.
GE’s 360 Foam Wash is approved for use on multiple GE engine programs, including models of GE90, GEnx, CF34 and CF6, as well as Engine Alliance’s GP7200 engines. Customers need to obtain a technical license to use 360 Foam Wash, due to the proprietary solution and for training purposes on the process. To date, technical licenses have been awarded to multiple GE customers on GE90 and GEnx engines since 2019.
The announcement on February 4 with Etihad Airways included how Etihad is the first customer to receive a technical license to use 360 Foam Wash on GE90 engines. Etihad also has a license for its GEnx-1B engines, making Etihad Airways the first airline to receive licenses for multiple GE engine programs (GE90 and GEnx).
Meanwhile, we continue to trial the patented 360 Foam Wash system with more customers globally, to continue to learn more about the benefits of the engine cleaning system in different operating conditions and with additional engine models.
Q – What were the challenges faced while making this foam wash technique?
A – GE started the 360 Foam Wash development journey to improve engine cleaning effectiveness, particularly in the hot or harsh environments. Through the development of the technology, we’ve learned there are many variables that can impact the effectiveness of traditional cleaning methods and the 360 Foam Wash technology, including region, cleaning process and detergent formulation among other variables. GE has concluded the 360 Foam Wash process to be more effective than traditional water wash for fuel burn reduction and engine performance restoration and retention.
Q – How is the overall experience working with Etihad on the Greenliner Program & this cleaning technology?
A – Etihad Airways has been a very important partner in the development of GE’s patented 360 Foam Wash technology.
GE Research and GE Aviation have been developing an engine cleaning solution for hot and harsh environments for several years before technology testing started with customer engines. Extensive testing was performed on components and test engines before releasing the procedure for field use. The first on-wing trial of 360 Foam Wash was with an Etihad Airways’ GE90 engine in January 2017.
GE is collaborating on other initiatives under the Greenliner program with Etihad and Boeing, such as:
- GEnx engines power Etihad Airways’ Boeing 787 Dreamliner fleet participating in its Greenliner programme, including a specially-themed Greenliner aircraft.
- Implementing lean to improve engine change turnaround time.
- Testing additional technologies developed for engine maintenance and enhanced inspection.
Q – Enhancing fuel efficiently & reducing carbon emissions, is the main aim behind the 360 foam wash. What is your estimate fuel reduction & CO2 emission in the next 5 years?
A – GE’s 360 Foam Wash is found to be more effective than traditional cleaning methods. Specific fuel efficiency improvement and associated carbon emission reduction vary by engine line and region, among other variables. GE works closely with our customers to optimize 360 Foam Wash and maximize the benefit to their fleets.
Q – The entire aerospace industry is geared up for sustainable aviation by 2050. Many newer technologies are being developed every day. How soon can we expect practical application of these technologies?
A – GE’s 360 Foam Wash is available for customers on several GE Aviation engine models. We welcome GE Aviation engine customers to reach out to request more information and to discuss a license agreement for GE’s 360 Foam Wash. Contact your GE Aviation Customer Support Manager and Customer Program Manager.
GE Aviation fully supports the industry’s ambitions to reduce carbon emissions and achieve a more sustainable future. During technology trials with its GE90 and GEnx engines, the 360 Foam Wash solutions allowed Etihad to improve engine performance by reducing build-up of deposits in the engine, lowering engine exhaust temperatures, and improving engine compressor efficiency. These improvements led to reduced fuel consumption and increased engine time on wing.
Airlines worldwide are reducing carbon emissions leveraging GE Digital Aviation Software products, advanced technologies and services that help them reduce fuel consumption and improve flight path navigation, reducing time between destinations.
Q – As the world is advancing towards a sustainable & better future, there is rising demand from the operators. What according to you are operators’ expectations from engine manufacturers?
A – GE Aviation will lead in creating the next generation of engines to help this industry meet its sustainability imperative.
That includes GE Aviation’s commitment to continue to closely collaborate with customers to help meet their goals for more sustainable aviation. GE Aviation is also committed to delivering new commercial aircraft engine products with lower fuel consumption than their predecessors, and to offer technology and services to help optimize the performance of their existing engine fleets, such as GE’s 360 Foam Wash.
GE and its partners have reduced fuel consumption and carbon emissions in each new generation of narrow body and wide body commercial aircraft engines:
- CFM International’s LEAP engine has 15% lower fuel consumption than CFM56 engines introduced in the 1990s;
- The GEnx engine offers up to 15% improved fuel efficiency than the CF6; and
- The GE9X™ engine will have 10% lower fuel consumption than the GE90-115B when it enters service.
CFM International is a 50-50 joint company between GE and Safran Aircraft Engines.
Q – Covid-19 pandemic has affected the aerospace workforce market severely. What would you tell the aspiring candidates planning to pursue aeronautical engineer as a career.
A – GE Aviation is optimistic that longer term, demand for passenger air travel will come back. When it does, GE Aviation will lead in creating the next generation of engines and services to help the commercial aviation industry meet its sustainability imperatives. Meanwhile, GE has not let up in its investments in research and development for next-generation technologies to build on the company’s existing suite of composite material and additive manufacturing advancements.
