Foley plant has hand in Dreamliner

Published by the Mobile Press Register

Foley plant has hand in Dreamliner
Sunday, July 08, 2007
By KAIJA WILKINSON
Business Reporter
When Boeing debuts its new 787 passenger aircraft today, a group of people in Foley will watch with more than passing interest. That's because the Foley Service Center of Goodrich Aerostructures has had a hand in production of a crucial Dreamliner component -- the nacelle, a large, high-tech structure that surrounds the engines on the plane.
"The engine couldn't function without one," said Stuart Kay, general manager of the Goodrich Service Center, which is adjacent to the Foley Municipal Airport. "Also, the new noise regulations are stricter, so without (the nacelles) you wouldn't be able to fly into most of the major airports."
Goodrich is the exclusive nacelle provider for both of the Dreamliner's engine options, one from General Electric and the other from Rolls-Royce. Thus far, Goodrich is building nacelles for six flight-test airplanes, three with each brand of engine, as well as a spare set for each, the company said.
The components of the nacelles come from Goodrich facilities worldwide. They are assembled in Chula Vista, Calif. -- Goodrich's aerostructure headquarters -- and tested in Peebles, Ohio.
The Foley facility is involved in two ways -- treating the components in a giant autoclave, a process that applies intense heat and pressure, and providing a six-member team to oversee testing of the nacelles, a process that lasts about a year.
The Foley facility is among the candidates for full-scale nacelle production for the 787, Kay said. The company is expected to make that decision in the next year or two, he said.
Though it may look like a simple engine fan, a nacelle is much more, consisting of acoustical, directional and aerodynamic components, according to Goodrich. They are:
A nose cowl, which sends air to the engine fan and includes a de-icing system.
Fan cowls, which surround the engine and allow access for service or maintenance. Comparable to an auto's hood, this system consists of two or more hinged panels that can be raised.
Thrust reversers, which surround the engine with noise reduction panels and redirect an aircraft's thrust forward to help the aircraft decelerate upon landing. Exhaust cone, which helps maintain optimum airflow by funneling exhaust out through a nozzle built of temperature-resistant material such as titanium.
Pylon, which links a nacelle and engine to the wing, and contains electrical, hydraulic and fuel lines for controlling the engines.
Goodrich is an old hand at making such complex components, Kay said.
"Pretty much every aircraft that has flown, we've been on that aircraft in one way, shape or form," he said. "If you look at the (Airbus) A320 family, for instance, we produced the nacelles for all of those aircraft. And I think they just celebrated their 3,000th production."
Goodrich can handle design, testing, production and maintenance of a nacelle, he said. Depending on the size, or damage if the work involves repairs, work on a nacelle can cost from $100,000 to $500,000, Kay said.
Goodrich has both its Alabama Service Center and an Original Equipment Center in its Foley complex. The service center performs maintenance and repair, while the equipment center oversees steps in the production of nacelles. About 750 people work there, and the company estimates its local economic impact at between $55 million to $60 million.
Workers start at $10 to $13 an hour, said Vickie Langham, manager of marketing and communications for the Foley service center. The company said it has openings for 75 new employees.
Goodrich just added 60,000 square feet of workspace to its service center.
"The (Boeing) 737 and A320 fleets are maturing and needing overhaul, and they're very big fleets," Kay said. said. "We're seeing a high demand for our services." Goodrich recently signed a 15-year agreement with Airtran Airways to service its 717 and 737 fleets, he said.
Langham said that Goodrich's win on the entire nacelle contract for the Dreamliner was "a big coup," and its effects will trickle down to Foley.
"Ultimately, we'll do the repair and overhaul, and possibly the manufacture and assembly here," Langham said. Added Kay: "So far as our future as nacelle providers, we'll be very busy for the next 10 to 15 years."