This September, a significant milestone was reached in South Asia’s aviation industry: GE Aerospace’s GEnx engine marked 2 million flight hours in the region. In just over a decade, the engine has reshaped the landscape of long-haul flights, enabling millions across South Asia to travel further and more efficiently. With the adoption of Boeing 787 Dreamliners powered by the GEnx engine, long-range air travel became more accessible, creating a ripple effect of technological and operational improvements in the region’s aviation sector.
Changing the Landscape of Aviation
When the GEnx engine was first introduced to South Asia in 2012, the aviation landscape was markedly different. India had fewer widebody aircraft, and the concept of direct flights to Europe and America was often out of reach without layovers in hubs like Dubai. Vikram Rai, CEO of GE Aerospace South Asia, notes that the arrival of the GEnx-powered 787s, especially in Air India’s fleet, played a key role in opening up these new routes. As Air India took delivery of 27 Dreamliners equipped with GEnx engines, GE Aerospace established itself as a leader in South Asia, thanks to the engine’s unprecedented reliability and efficiency.
Engineering Reliability in Challenging Conditions
Achieving 2 million flight hours is no small feat, especially in the challenging climates of South Asia. The GEnx engine boasts a 99.98% on-time departure rate, attributed to its engineering advancements over the years. Ravi Kanth, senior services manager at GE Aerospace, highlights that the engine’s reliability has continuously improved, enabling extended “time on wing” — a measure of how long an engine can operate before requiring maintenance. In 2021, GE Aerospace redesigned the stage 1 high-pressure turbine (HPT) blade and introduced new coatings for the combustor, further extending the engine’s durability in the region’s hot and dusty environments.
The introduction of 360 Foam Wash, an advanced cleaning process, has been another game-changer. This method removes dust and debris, which can deteriorate engine components over time, particularly in the harsh conditions of South Asia.
Leveraging AI for Predictive Maintenance
To further enhance reliability, GE Aerospace has integrated analytics-based maintenance (ABM), which uses flight data to anticipate and address potential issues. Continuous data from altitude, rotor speeds, and temperature readings enable predictive maintenance models, helping airlines avoid unscheduled removals and improving operational planning. AI-enabled tools like the Blade Inspection Tool allow for precise monitoring of critical engine parts, extending the GEnx engine’s time on wing fourfold compared to its competitors.
A Sustainable Future with the GEnx Engine
The GEnx engine has also been a crucial part of South Asia’s transition toward sustainable aviation. It consumes 15% less fuel and emits 15% fewer emissions compared to its predecessor, the CF6-80C2 engine. Additionally, the GEnx engine is capable of running on sustainable aviation fuel (SAF) blends, aligning with industry goals to reduce carbon footprints.
Nipun Aggarwal, Air India’s chief commercial officer, attests to the engine’s importance in supporting the airline’s expansion plans. With Air India and other regional airlines increasingly investing in GEnx-powered fleets, the engine’s impact on sustainability is set to grow.
The Road Ahead
With 90 GEnx engines currently powering flights across South Asia, the region’s demand for widebody jets continues to rise. Boeing projects a need for around 380 widebody jets in India alone, emphasizing the GEnx engine’s role in supporting this growth. As Air India plans an additional order of 20 GEnx-powered aircraft in 2025, GE Aerospace anticipates that the next million flight hours will be achieved in record time.
The journey of the GEnx engine in South Asia is far from over, with its reliability, efficiency, and sustainability continuing to drive progress. “Five million flight hours might come sooner than anyone expects,” says Rai, encapsulating the optimistic trajectory of GE Aerospace’s work in the region.
