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GE Aviation Engine Testing, Research and Development Centre ACEC – Project Attribute Description February 2013

Icing Testing at the TRDC

1.0 INTRODUCTION

The U.S. Federal Aviation Administration (FAA) requires that all jet engines endure a series of rigorous

testing in order to obtain FAA certification and ensure public safety is not in jeopardy. The range of test

regimens is incredibly diverse and includes bird ingestion, blade-out, endurance, and icing testing among

others. Ice poses a serious threat to jet engines as freezing mist can propagate through the engine, coat

key engine components and significantly affect performance. A multitude of test variables are prescribed

for icing tests by the FAA and include items such as wind speed, test duration, temperature, and water

droplet size. State of the art facilities are required to conduct the icing and other tests prescribed by the

FAA.

In 2006, General Electric

Aviation (GE), a world-leading

provider of commercial and

military jet engines and

components as well as avionics,

electric power, and mechanical

systems for aircraft, constructed

an aviation engine icing test

facility at the Mirabel

International Airport in Quebec.

Icing tests were conducted at

this facility over a five year

period; however, GE was

notified that their test facility would have to be relocated due to expanded use of the Mirabel airport in July

of 2010. GE assessed potential sites for the new facility based on favorable outdoor icing temperatures in

the range of -4°C to -20°C, year round operation fo r additional types of testing, and relocation and

operational costs. Based on GE’s assessment, the James A. Richardson International Airport in Winnipeg

was selected as the location for the new GE Aviation Engine Testing, Research and Development Centre

(TRDC).

In autumn of 2010, GE formed a partnership with StandardAero, one of the largest independent

aerospace maintenance, repair, and overhaul service businesses in the world, providing comprehensive

services to commercial, military, business aviation, helicopters and industrial operators. The partnership

assigned StandardAero with the responsibility for construction of the new TRDC in Winnipeg as well as

management of the relocation of existing equipment from GE’s existing test facility in Mirabel and

operation and maintenance of the TRDC in Winnipeg through to January 1, 2021.


The design and construction of the TRDC was fast tracked for start up during the icing season beginning

in late 2011. StandardAero contracted a diversified team of consultants in spring of 2011 leaving less

than one year to complete the design and construction of the facility. Hanuschak Consultants Inc., KGS

Group, and MCW/AGE were contracted by StandardAero to provide engineering design services for the

TRDC. StandardAero not only managed the project but also provide engineering design of key elements.

This project embodies engineering achievement through exemplary project coordination and collaboration

to deliver a complex project on time and on budget. The use of innovative technology and a diverse range

of engineering expertise were paramount to the success of the project and will help ensure safety of the

aviation industry well into the future.

2.0 PROJECT TEAM

StandardAero contracted a diversified team of consultants each with a unique set of skills in order to meet

the aggressive project schedule. Hanuschak Consultants Inc., KGS Group, and MCW/AGE were retained

by StandardAero to provide engineering design services for the project with StandardAero providing

additional engineering design work on the facility.

StandardAero provided project management services for the project. This included coordination and

distribution of information on the existing systems from the Mirabel site that were being relocated to the

new TRDC. StandardAero provided design services for a number of items including the general facility

layout, wind tunnel platform, oil water separation system, adapter for engine mounting, engine hoisting

systems, and the augmentor tube and blast basket required to direct engine exhaust. In addition, they

coordinated the design of the sound attenuation system with Blast Deflectors Inc.

Hanuschak Consultants Inc. was contracted for the structural engineering design of the site foundations.

Key aspects of the foundations include the thrust pad foundation for the engine test stand, the general

site foundation surrounding the test stand, and fuel and oil spill containment.

MCW/AGE provided engineering design services for electrical and mechanical site and building services

and systems. Electrical design services included new site electrical distribution equipment, underground

and overhead cabling for facility interconnection, site grounding and lightning protection, site lighting, and

auxiliary building electrical systems design. Mechanical design services included drainage of the test

platform and site pad. In addition, MCW provided on-site support for construction and CSA re-certification

of existing electrical equipment relocated from the Mirabel site.

KGS Group was retained to coordinate and develop a 3D model of the facility in order to fast track the

design and construction of the TRDC. This coordination aspect involved development of the 3D model


Installation of the Single Post Stand

from KGS Group’s mechanical, electrical and structural groups, importing 3D components created by

StandardAero’s engineering design group, importing GE’s engine models, as well as generating 3D

models based on the 2D design drawings developed by Hanuschak Consultants Inc. and MCW/AGE. In

addition, KGS Group provided design services for a variety of mechanical, electrical, and structural

aspects of the project. Services included design of piping systems for jet fuel, compressed air, instrument

air and carbon dioxide services; cable tray and wireway systems for electrical power and instrumentation

distribution; and structural design of the test stand control housing and supports for electrical and piping

systems.

3.0 TRDC FACILITY DESCRIPTION

The new GE Aviation Engine Testing, Research and Development Centre is a leading edge, jet engine

certification test facility capable of testing engines up to 150 inches in diameter and 150,000 lb of thrust.

The TRDC is approximately 94,500 square feet and is located on the secure side of the James A.

Richardson International Airport in Winnipeg. The site location within the airport grounds was selected to

minimize noise penetration to the surrounding community and allow for optimum alignment with prevailing

winds. The key components of the facility include a single post jet engine test stand, a wind tunnel

capable of producing icing conditions at the test stand, a noise attenuation wall to limit noise pollution

generated by the facility, and the infrastructure required to control, power, fuel and support the operation.

A portion of the key components for the TRDC were transferred to Winnipeg from the existing test stand

facility in Mirabel and include the single post test stand, wind tunnel and some auxiliary support systems

required for operation of the facility. Key components

constructed new for the TRDC included the sound attenuation

wall and support infrastructure such as the site foundations,

electrical power and instrumentation distribution, and piping

systems. The knowledge gained through GE’s operation of test

facilities in Cincinnati, Ohio and Mirabel, Quebec was applied in

the design of this facility allowing for improved operation

capabilities, making it truly state of the art.

Single Post Test Stand

The TRDC includes a single post test stand which supports the

jet engine during testing. The stand is embedded in the 6 foot

thick test stand foundation and is capable of testing engines up


Sound Attenuation Walls and Augmentor Tube

to 150 inches in diameter and 150,000 lbs of thrust. The stand is 56 feet tall and is topped by an

enclosure housing mechanical piping services for support of testing operations. The enclosure is

accessible via a stair and platform structure.

The piping within the enclosure was designed as a skid assembly to allow for shop fabrication and

assembly of the system and to minimize field fabrication on top of the stand. The system was extensively

modeled with 3D design software to ensure all system components had adequate space for operation

and maintenance within the enclosure envelope. This approach allowed the complete piping assembly to

be hoisted into place and minimized the quantity of final field connections required.

Noise Attenuation

Operation of the TRDC is capable of producing sound for extended periods of time at deafening levels in

close proximity and considerable noise pollution to neighbouring communities. To reduce noise levels to

acceptable levels in the nearby communities the TRDC utilizes a state-of-the-art noise attenuation

system. The system is comprised of three main components: the blast deflection walls, augmentor tube,

and exhaust stack. The noise attenuation system was designed by Blast Deflectors Inc. and coordinated

by StandardAero.

The blast deflection walls enclose

a 120 ft long and 100 ft wide area

around the test stand and wind

tunnel on three sides. The walls

stand 51 ft high and are designed

to limit the transmission of noise

outside the test area. The

augmentor tube is located directly

behind the jet engine to capture

engine exhaust and air from the

wind tunnel and to transmit sound

through the exhaust stack

vertically upward rather than

horizontally outward towards populated areas. The tube is 16 ft in diameter and 45 ft long and includes an

axially translating 24 ft collector bell for accurate positioning behind the jet engine during testing. The

exhaust stack is 42 ft long, 34 ft wide and 52 ft high and effectively reduces sound levels generated by

the facility.


Wind Tunnel

The noise attenuation system was designed to meet the requirements of the Winnipeg Airport Authority

and ensures that noise levels experienced in neighbouring residential areas do not exceed equivalent

sound pressure levels (Leq) of 65 dB. Equivalent sound pressure level is the steady sound level that, over

a specified period of time, would produce the same energy equivalence as the fluctuating sound level

actually occurring. The project team worked directly with local, municipal, airport and provincial regulation

authorities to ensure full compliance with applicable regulations.

Wind Tunnel

The heart of the TRDC is the wind tunnel system that produces icing conditions during testing. The wind

tunnel is powered by seven 250 hp electric motors which are controlled by variable frequency drives

(VFD) capable of producing over 2,800 lbs/sec of airflow and wind speeds in excess of 100 km/hr. Icing

conditions are generated by an array of spray nozzles that deploy micron-sized droplets of water into the

frigid air stream.

The wind tunnel, relocated from the Mirabel

site, was installed on a platform to increase

the tunnel centerline to 20 ft to allow for

alignment with the jet engine supported by

the test stand. Support systems required for

operation of the tunnel are housed on the

platform and include the water tank, VFD

control trailer, and the water pump trailer.

The TRDC employs a rail system to allow

the wind tunnel platform to translate up to

800,000 lbs of equipment 100 ft axially.

This is a notable enhancement from the Mirabel facility because it allows the TRDC to operate year-round

and facilitate test regimens such as performance and endurance testing, bird ingestion, ice crystal and

mixed phase (hail and ice) testing.

Supporting Infrastructure

The supporting infrastructure of the TRDC is a key component of the overall design and includes site

foundations, electrical systems, and piping and drainage systems. These items are described in detail on

the following sections.


Site Foundations

The design of the site foundations was a critical aspect of the TRDC due to heavy loading requirements

of the system components and the need to provide a large stable platform over an area of approximately

94,500 sq. ft. The thrust pad foundation surrounding the jet engine test stand is approximately 45 ft wide x

50 ft long x 6 ft deep and required 45 caissons measuring 5 ft in diameter and 30 ft deep. This portion of

the foundation had to be designed to accommodate such unique criteria as withstanding the impact of an

engine blade released by explosive bolts from GE’s largest engines while running at full speed. The

remaining site foundation surrounding the thrust stand is 270 ft wide x 350 ft long x 1 ft deep. This

foundation includes a spill containment area built in to the foundation around the fuel and oil storage

tanks to protect the environment from oil and fuel spills. A total of 330 caissons were drilled and poured

for the foundations at the TRDC.

A major challenge with the installation location was the expansive clay subsoil which swells and shrinks

with changes in moisture content. To accommodate this issue, the design utilized a structurally supported

platform in lieu of a heavy slab on grade. A thick, poured in place, two way reinforced concrete structural

slab was chosen as the most economic solution. The foundation is supported by a grid of drilled concrete

caissons bearing on a dense glacial till located approximately 20 to 25 ft below the surface. A special

collapsible void form was used below the slab in order to isolate the foundation from the effects of subsoil

movements. A two way grid of uniformly spaced reinforcing bars was used to simplify the installation in

order to meet the aggressive project schedule. The use of a monolithic heavy concrete slab provided a

cost effective and durable platform using environmentally sustainable material. The structural solutions

employed were designed to address the fast track project schedule while still providing a cost effective

solution to the client in order to deliver the project on time and on budget.

Electrical Systems

The TRDC includes new above and below ground power distribution, cable trays, site grounding, site

lighting, and site lightning protection. Electrical power is currently supplied by diesel generators; however,

the power distribution system includes provisions for future hookup to a 25kV utility service from Manitoba

Hydro. The electrical design also included building systems designs for a storage building, oil separation

and pumping building, and temporary control building facility as well as on-site support for construction

and CSA re-certification of existing electrical equipment relocated from the Mirabel facility.

Piping and Drainage Systems

Operation of the TRDC requires services such as jet fuel, compressed air, instrument air and carbon

dioxide. These piping systems were designed for the new facility in 3D which allowed for generation of

detailed piping isometric drawings to facilitate fabrication which aided in fast tracking the construction

process. Operation of these piping systems was designed using advanced modeling software to analyze

the hydraulic performance of the systems thus mitigating potential issues associated with system


3D Model

operation during start-up and commissioning. The jet fuel system also including design of the storage and

transfer of fuel from the storage tanks to the test stand. Additional mechanical design included drainage

of the test platform and site pad which included systems for oil removal and water holding for pump out.

The oil water separation system was design to reduce oil content to 10 ppm and the drainage system

includes a drain water storage capacity of 20,000 usgal.

4.0 PROJECT COORDINATION USING A 3D DESIGN ENVIRONMENT

The project was faced with a number of challenges including:

• An aggressive project schedule

• A large and diversified project team

• A combination of new and existing equipment and infrastructure

• Construction had to occur on the secure side of an active international airport next to active

runways, therefore all of the project elements had to fit together the first time to avoid mistakes

that would be multiple times the cost than if the construction site were in a less hazardous, less

secure location.

These challenges required a

unique and focused approach

to ensure the success of the

project. The overall complexity

of the project demanded a

highly coordinated and

collaborative effort by the entire

team to deliver the project on

time and on budget.

The project team addressed the

challenges by coordinating the

project in a 3D design

environment using AutoCAD,

Tekla Structures, AutoPLANT,

Inventor, and Staad Pro software. This approach allowed the team to successfully mitigate the risk

associated with each of these challenges. The 3D model was the heart of the project, allowing designs

from all team members and all new and existing infrastructure to be coordinated in a single location.

Bringing all the pieces of the design together in a virtual environment allowed the team to assess the

interactions between all design elements, enabling immediate identification of any conflicts before


construction of the project began. This was paramount to ensuring that changes to the design during

construction were minimized thus keeping the project on schedule and on budget.

Generation of the model included development of 3D models by KGS Group’s mechanical, electrical and

structural groups, importing 3D components created by StandardAero’s engineering design group,

importing GE’s engine models, as well as generating 3D models based on the 2D design drawings

developed by Hanuschak Consultants Inc. and MCW/AGE. All piping systems were modeled in 3D which

allowed for generation of detailed piping isometric drawings to facilitate fabrication which aided in fast

tracking the construction process. Further, piping systems were modeled using Pipe-Flo software to

analyze the hydraulic operation of the systems thus mitigating potential issues associated with system

operation.

5.0 ENVIRONMENTAL IMPACT

Operation of the TRDC poses potential risks to the surrounding environment and the design of the facility

had to include features to minimize potentially damaging effects to the environment. Major consideration

had to be given to three main areas including noise pollution transmitted to nearby communities,

containment of fuel and oil spills on the site, and separation of oil from the drainage system. The project

team worked directly with local, municipal, airport and provincial regulation authorities to ensure full

compliance with applicable regulations.

Noise pollution was a critical issue due to the potential for excessive noise produced by the operating jet

engine during testing. A state-of-the art noise attenuation system was designed to maintain noise levels in

nearby communities to within acceptable limits. The system was designed to ensure noise levels

experienced in neighbouring residential areas will not exceed equivalent sound pressure levels (Leq) of

65 dB as prescribed by Manitoba Conservation.

Fuels and oils are stored on the TRDC site to support operation of the facility and systems were required

to ensure that a spill would not contaminate the surrounding environment. A 16,000 sq. ft. spill

containment area was designed into the site foundation which has a capacity of approximately 33,000

usgal. In addition, oil water separation was designed into the site foundation drainage. The system

includes a 20,000 usgal double wall storage tank and is capable of reducing oil concentration down to 10

ppm.

6.0 SOCIAL IMPACT

The TRDC was a remarkable undertaking and provides a number of benefits both locally and

internationally. Initially, the facility will include a staff of 10 employees with potential growth of up to 50


employees within the next 5 years. StandardAero and its employees are under contract to operate the

facility into 2021.

From an additional social perspective, the TRDC provides an extremely valuable benefit by safeguarding

the public and improving the overall safety of air travel. All new jet engines must pass a demanding

quantity of testing procedures in order to obtain certification for use and the purpose of the TRDC is to

allow engineers to execute these rigorous test regimens, furthering the overall advancement of

commercial and military aviation.

The partnership formed between GE and StandardAero was awarded the prestigious 2012 Canadian

American Business Council (CABC) Achievement Award for their collaboration on the TRDC. The award

is judged by an independent team of individuals from the business and academic sectors in the Canada

and U.S. and is presented to a partnership between a Canadian company and a U.S. company that

excels in job creation, environmental responsibility, sustained profitability, financial strength, and

exceptional innovation. The GE and StandardAero partnership was nominated by the Ohio Department of

Development and the Consulate General of Canada in Michigan and competed against dozens of

partnerships spread over a diverse range of sectors throughout North America. This level of recognition

advances the economic and social benefits associated with the project as it promotes StandardAero and

the capabilities of the Winnipeg aerospace industry to the world. The facility’s unique design and layout

were even considered technically interesting and aesthetically appealing enough to warrant a feature

article with color photos in Popular Science, further promoting the project on a global scale.

In addition, the noise attenuation system design ensured that from a social perspective, this project would

be a responsible “good neighbour” to the community just beyond the airport perimeter.

7.0 CONSTRUCTION HIGHLIGHTS

Construction of the TRDC began on April 26, 2011 and only took 7 months to reach substantial

completion. The most intensive portion of construction was the installation of the site foundations which

took a little over 5 months to complete with the final foundation pour occurring in early October 2011.

Mechanical and electrical contractors mobilized on site on September 6, 2011. Up to 21 electricians were

on site from September to December 2011 and at any time up to 200 contractors were working on the

site. The project is a dramatic example of how the successful use of a 3D design environment can be

used to fast-track the design and construction process and provide a project on schedule and on budget.

The project involved over 17,000 hours of engineering design and project management.


8.0 CLIENT’S NEEDS

This project was delivered on time, allowing for GE and StandardAero to fulfill their engine testing

contractual requirements making the TRDC a success in terms of project management. The project was

also delivered on budget, making it a success from an economic standpoint. All of StandardAero’s

technical requirements were met by the engineering team making the project a technical success as well.

Finally, effective quality management ensured the project was online and ready to perform when required.

9.0 SUMMARY

The GE Aviation Engine Testing, Research and Development Centre was a complex project that required

the involvement of a diversified project team to deliver the project on time and on budget. The project was

faced with a serious challenge due to the aggressive project schedule and highly restricted site logistics

which required the project team to develop an innovative strategy that would allow them to fast track the

design and construction process. A focused, collaborative, and coordinated effort was employed in a 3D

design environment to ensure seamless integration of the diverse aspects of the project thus minimizing

delays during the construction process. The project’s complexity is demonstrated by the over 17,000

hours of engineering design and project management required to complete the project.

The TRDC incorporated a directed effort to ensure a positive impact on social, economic and

environmental aspects. Additional jobs were created through the development of the TRDC and design

measures were taken to reduce the potential for harmful environmental impacts such as noise pollution

and fuel and oil spills. The TRDC has already been recognized internationally, receiving the 2012

Achievement Award from the Canadian American Business Council for excellence in job creation,

environmental responsibility, sustained profitability, financial strength, and exceptional innovation. The

use of innovative technology and a diverse range of engineering expertise were critical to ensuring the

safety of the public and advancing safety within the aviation industry.

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