Muftasoft TM

The cost of an A330 Auxiliary Power Unit (APU) can vary significantly based on several factors, including whether it is new or used, the specific model of the APU, and the supplier or maintenance provider.

On average, the cost for a new A330 APU can range between $1.5 million to $3 million.

Used or overhauled APU units can be significantly less expensive, typically falling within the range of $500,000 to $1 million. The cost will depend on the condition of the unit and the level of maintenance it has undergone.

In addition to the purchase price, there are also ongoing costs for maintenance and parts replacement. Regular APU maintenance is crucial for ensuring safe and reliable operation. These maintenance costs can vary depending on factors such as:

1. Usage: How frequently the APU is used (e.g., number of flight hours or cycles).
2. Airline’s Operational Needs: The airline’s specific maintenance requirements and schedules.

These maintenance costs can fluctuate based on the type of service needed, such as:

1. Routine inspections
2. Repairs or parts replacements
3. Full overhauls

By managing these costs effectively, airlines can ensure the longevity and reliability of their APU systems.

For the A330 aircraft, the Auxiliary Power Unit (APU) is typically one of the following models:

• Honeywell GTCP 331-350: This is one of the most commonly used APUs for the Airbus A330. It's known for its reliability and performance, providing electrical power and air conditioning to the aircraft when the main engines are off.

• Hamilton Sundstrand APS 5000: This model is another option for the A330. It is an advanced APU known for its fuel efficiency, low maintenance costs, and environmental performance.

• New APU (Honeywell GTCP 331-350): A brand-new unit typically costs between $1.5 million and $3 million.

• Used or Overhauled APU: The cost for a used or overhauled Honeywell GTCP 331-350 can vary widely, but generally ranges from $500,000 to $1 million, depending on factors such as:
  • Hours used
  • Condition of the unit
  • Type of overhaul (e.g., full or partial)

• Overhauled APU: An overhauled unit might cost around $750,000 to $1 million.
• Used APU: A used APU with fewer hours may be priced in the range of $500,000 to $700,000.

• Routine Maintenance: Regular maintenance intervals typically occur every 3,000 to 5,000 hours or 24 months, depending on usage. Routine checks, inspections, and minor repairs can cost between $30,000 to $50,000 per visit.

• Major Overhaul Costs: A full overhaul for the Honeywell GTCP 331-350 APU can cost between $250,000 to $500,000 depending on the service provider and scope of work. This involves replacing high-wear components such as the starter motor, bearings, and seals.

• Spare Parts and Components: Over time, parts such as fuel pumps, exhaust systems, and electrical components may need replacement. These components can cost tens of thousands of dollars, and prices may vary depending on whether they are OEM (Original Equipment Manufacturer) or aftermarket parts.

In some cases, operators may choose to replace the APU entirely rather than continue with repairs if the costs of maintaining a high-hour unit exceed the cost of a new or overhauled APU.

• Aircraft Utilization: Airlines that operate more flight hours may experience higher wear and tear on their APUs, leading to more frequent maintenance.

• APU Configuration and Model: Different models (e.g., Honeywell vs. Hamilton Sundstrand) and configurations might affect the price.

• Location and Service Provider: Costs may vary based on the location where the APU is purchased or serviced. For example, some parts of the world might offer more competitive pricing for overhauled units.

The overhaul process for an A330 APU typically involves several key steps, depending on the extent of wear and tear, operational hours, and manufacturer guidelines. Overhauls are conducted at specialized maintenance, repair, and overhaul (MRO) facilities or by the OEM (Original Equipment Manufacturer) like Honeywell or Hamilton Sundstrand. The process ensures the APU is restored to factory-like conditions and can continue to operate efficiently.

• Initial Inspection: A thorough assessment is conducted to determine the current condition of the APU. This involves reviewing flight logs, previous maintenance history, and conducting a visual inspection of key components.
• Disassembly: The APU is carefully disassembled into its core components (e.g., turbine, starter motor, exhaust system, fuel system, etc.) for detailed inspection and testing.

• Performance Tests: Key components such as the turbine, starter, and generator are tested to check for any performance degradation. Sensors, fuel pumps, and electrical systems are also tested for function and efficiency.
• Non-Destructive Testing (NDT): Techniques like ultrasound, x-ray, and magnetic particle inspection are used to assess the internal structure of key parts for cracks, corrosion, or other signs of wear without damaging the parts.

• Component Repair/Replacement: Components that are found to be beyond acceptable limits may be repaired, refurbished, or replaced entirely. For example, seals, bearings, turbine blades, or fuel nozzles may be replaced depending on their condition.
• Upgrades: During an overhaul, APUs can be upgraded with newer technology or more efficient parts (e.g., modern sensors, improved exhaust components), leading to lower maintenance costs and better performance.

• Reassembly: After the necessary repairs and replacements are made, the APU is reassembled. This step involves carefully assembling the unit back to its factory specifications.
• Functionality Tests: After reassembly, the APU undergoes a series of tests to ensure it meets manufacturer performance standards. These tests usually include a spin test to ensure that the turbine operates smoothly and efficiently.
• Operational Testing: Once the reassembly is complete, the APU is tested under simulated operational conditions to ensure that it delivers the correct power, air conditioning, and backup functions as expected.

• Documentation: After passing all tests and ensuring the APU is operational, the unit is certified and receives a return-to-service report. All repairs, part replacements, and tests are documented for regulatory and operational purposes.
• Return to Service: The APU is then ready to be installed back on the aircraft or returned to the operator as a refurbished unit.

• Honeywell GTCP 331-350 APU Overhaul: The overhaul cost for this model typically falls between $250,000 and $500,000 depending on the service provider and the level of work needed. This could include labor, parts, testing, and any upgrades performed during the overhaul.
• Hamilton Sundstrand APS 5000 APU Overhaul: The cost for an overhaul on this model might range between $300,000 and $600,000.

The cost of labor is a significant portion of the overhaul price and can vary depending on where the work is done. For example, overhauls done in North America or Europe might have higher labor rates than those in other regions.

There are multiple avenues through which you can purchase used or overhauled APU units for your A330. Here are some reputable suppliers and service providers:

• OEMs and Authorized Service Providers
  • Honeywell: As the manufacturer of the GTCP 331-350, Honeywell offers both new units and overhaul services through its global network of authorized service centers.
    • Website: [Honeywell Aerospace](https://aerospace.honeywell.com)
  • Hamilton Sundstrand (Collins Aerospace): For APS 5000 units, Hamilton Sundstrand (a part of Collins Aerospace) also offers overhauled units and servicing.
    • Website: [Collins Aerospace](https://www.collinsaerospace.com)

• Independent MRO Providers
  • AAR Corp: A global MRO provider offering APU services.
    • Website: [AAR Corp](https://www.aarcorp.com)
  • DHL Aviation: Known for providing aircraft component overhaul services.
    • Website: [DHL Aviation](https://www.dhl.com)
  • ST Aerospace: Another major MRO service provider specializing in component repair and overhaul.
    • Website: [ST Aerospace](https://www.staerospace.com)
  • Aviall: Aviall, a Boeing company, provides APU parts, repairs, and services.
    • Website: [Aviall](https://www.aviall.com)

• Online Marketplaces and Aircraft Parts Resellers
  • AerSale: A marketplace for aircraft parts and equipment, including APUs.
    • Website: [AerSale](https://www.aersale.com)
  • Global Aircraft Trading: A company that specializes in trading used aircraft components, including APUs.
    • Website: [Global Aircraft Trading](https://www.globalaircrafttrading.com)

These suppliers provide a variety of options for purchasing used, overhauled, or refurbished APUs. Be sure to inquire about the unit’s history, hours of operation, and warranty details to ensure a reliable purchase.

• Service History: Ensure that the unit has a documented maintenance and service history, including overhauls, repairs, and any operational issues.
• Warranty: Some suppliers offer warranties on overhauled units, which can provide peace of mind.
• Certification: Verify that the APU has been overhauled and certified by a reputable MRO provider.
• Operational Hours: Check the number of hours the unit has been in service. This is crucial for estimating its remaining useful life.

Below is a detailed breakdown of some suppliers and their common rates for APU (Auxiliary Power Unit) overhaul, repair, and maintenance services, including both task-based and hourly-based costs:

Honeywell is the OEM for the GTCP 331-350 APU (commonly used in the A330) and provides overhauls, repairs, and support services directly or through authorized service centers.

Honeywell APU Overhaul & Maintenance

1. Full Overhaul: Typically ranges from $250,000 to $500,000 depending on the extent of the work.
2. Partial Overhaul (limited scope): Approximately $150,000 to $250,000.
3. Hourly Labor Rates: Honeywell typically charges $150 to $250 per hour for labor during the overhaul or repair process.
4. Repair/Component Replacement: Individual components may cost an additional $10,000 to $50,000, depending on the part (e.g., turbine blades, starter motors, and fuel pumps).

Typical Tasks and Costs:

1. Routine Inspection/Check: $5,000 to $15,000 for a basic operational check (labor rates can vary).
2. Testing & Diagnostics: $3,000 to $8,000 for detailed performance testing (using test benches or flight simulators).

For further details, you can reach out to Honeywell Aerospace:

1. Website: [Honeywell Aerospace](https://aerospace.honeywell.com/)

Collins Aerospace, a subsidiary of Raytheon Technologies, manufactures the APS 5000 APU commonly used for various Airbus models.

Collins Aerospace APU Overhaul & Maintenance

1. Full Overhaul: Approximately $300,000 to $600,000.
2. Partial Overhaul: Typically ranges from $150,000 to $300,000.
3. Hourly Labor Rates: Collins typically charges around $175 to $275 per hour depending on the location and complexity of the work.
4. Component Repair/Replacement: For parts such as turbine blades, fuel pumps, etc., costs can range between $10,000 and $50,000 per component.

Typical Tasks and Costs:

1. Routine Inspections: Routine inspections like Hot Section Inspections (HSI) can cost between $10,000 and $30,000.
2. Operational Testing: Performing spin testing and diagnostics can cost approximately $5,000 to $12,000.

For direct inquiries, visit Collins Aerospace:

1. Website: [Collins Aerospace](https://www.collinsaerospace.com/)

AAR Corporation is a well-known independent provider of aviation MRO services, specializing in APUs, engine services, and component overhauls. They offer both task-based and hourly services for APUs.

AAR Corporation APU Overhaul & Maintenance

1. Full Overhaul: Generally costs between $250,000 and $500,000, depending on the specific APU model and condition.
2. Partial Overhaul: This can range from $100,000 to $200,000, with lower costs for less-intensive overhauls.
3. Hourly Labor Rates: AAR's labor rates typically fall within the range of $100 to $200 per hour for APU overhaul and repair services.
4. Component Repairs: The cost of replacing components such as the starter motor, fuel nozzles, or turbine blades can range from $5,000 to $20,000 each, depending on the part.

Typical Tasks and Costs:

1. General Overhaul: An estimated $200,000 to $500,000 for full servicing.
2. Routine Inspection: Depending on the APU’s condition, standard inspections can cost anywhere from $5,000 to $15,000.

For more information on AAR’s services:

1. Website: [AAR Corporation](https://www.aarcorp.com/)

ST Engineering Aerospace provides comprehensive MRO services, including APU repairs and overhauls, and is known for its high-quality standards and competitive pricing.

ST Engineering Aerospace APU Overhaul & Maintenance

1. Full Overhaul: The overhaul cost typically ranges from $250,000 to $450,000.
2. Partial Overhaul: Prices for partial overhauls start from around $120,000, depending on the scope of work.
3. Hourly Labor Rates: They charge $125 to $200 per hour for labor.
4. Component Repairs: Costs for specific components (e.g., turbine blades, bearings, starter motors) may vary but are usually between $5,000 to $25,000.

Typical Tasks and Costs:

1. Standard Inspections: Inspection packages typically range from $7,000 to $12,000.
2. Testing: Functional and performance testing (including spin tests) might cost anywhere between $5,000 and $15,000.

For direct inquiries, visit ST Engineering Aerospace:

1. Website: [ST Engineering Aerospace](https://www.staerospace.com/)

Aviall is a well-known parts distributor and MRO provider that works with many airlines and aircraft operators to service APUs, engines, and other components.

Aviall APU Overhaul & Maintenance

1. Full Overhaul: $250,000 to $500,000, depending on the APU model and condition.
2. Partial Overhaul: Generally costs between $150,000 to $250,000.
3. Hourly Labor Rates: Aviall's labor rates generally range from $100 to $200 per hour, similar to other MRO service providers.
4. Component Replacements: Parts such as starter motors, bearings, or sensors can cost anywhere from $5,000 to $25,000.

Typical Tasks and Costs:

1. Routine Inspections: $5,000 to $15,000.
2. Performance Testing: $3,000 to $7,000 for spin tests and diagnostic procedures.

For more details on services from Aviall:

1. Website: [Aviall](https://www.aviall.com/)

Conclusion These suppliers provide a broad range of APU services, from full overhauls to component replacements and routine inspections. Rates can vary depending on the complexity of the work, the APU model, and the geographic location of the MRO facility.

If you want specific quotes for an APU overhaul or to inquire about a specific part or service, it's always a good idea to directly contact the service provider with details about the unit’s condition and your operational requirements.