Fan turning tool fixture

Designed and manufactured by staff

A new fan turning tool fixture at LTQ Engineering in Melbourne eliminates risks during the work process and enables an ergonomic working position for the technicians. The development of the fixture was carried out in-house – with colleagues’ ideas and technical skills. Costs were minimized by the use of 70 percent recycled material.

A team of LTQ Engineering developed and manufactured a fan frame fixture: John Broadfield (standing left), Anthony Said (standing right), Stephen Donnelly (left), Manny Calleja (center) and Mark Casey(right).

Technicians and staff of LTQ Engineering identified some issues related to Ergonomics, Health & Safety (EH&S) risks within the process of fan frame module inspection and repair. The technicians had to work upon platforms at a height of about 15 feet to carry out inspections or repairs. The team was tasked to come up with a process that would minimize or even eliminate risks to staff. Ergonomics were also taken into account within the project scope. The aim was to have staff working in a position that was comfortable and at optimum height for carrying out the required work.

The team came up with an idea to use an old engine stand and manufacture a fixture that could hold the fan module and rotate it. This would allow inspections and repairs to be carried out at optimum level and eliminate the risk to staff working at height and also having to use stands to work at the side or top of the fans. The fixture would also be universal so that it could be used on all the CF6 engine family types currently overhauled at LTQ.

The team of LTQ colleagues designed, engineered, manufactured, welded and assembled this fixture. It was manufactured in-house utilizing 70 percent of recycled materials. On completion the fixture had to be load tested to make sure it could take the weight of the largest and heaviest fan frame - the CF6-80E fan with an approximate weight of 1,400 kg. The fixture was load tested well above the actual weight requirements. The time frame for completion of the project was six months