AWnewsletter AW139: UNRIVALLED PERFORMANCES IN A CHALLENGING ENVIRONMENT. Summer 2016

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1 Summer 2016 AW139: UNRIVALLED PERFORMANCES IN A CHALLENGING ENVIRONMENT In July, our best selling AW139 intermediate twin-engine helicopter arrived in Pakistan on a ferry flight, to carry out trials where it showed outstanding hot and high altitude performance and mission capabilities. The central desert area of Multan, where temperatures reached 49 C, was the location of part of the trials, which lasted a couple of weeks. Other trials were conducted in the northern areas of the Karakoram Range where the helicopter was tested to demonstrate its operational capabilities in hot and high environments. The flight programme in desert areas included demonstrations of the AW139s tactical low level flight capabilities and the ability to shut down and restart engines in just one minute. High altitude performance flights included take-offs and landings on unprepared surfaces at 16,300 feet density altitude and flights at 20,000 ft pressure altitude. The most demanding missions in terms of altitude and temperature were all performed with at least eight passengers and two pilots on board, in a fully mission equipped configuration, including a passenger transport layout with up to 12 seats, air conditioning, a comprehensive avionic package encompassing TCAS II (Traffic Collision Avoidance System), HF radio, plus rescue hoist and cargo hook provisions. The challenging trials programme was planned to cover different missions and was performed including fuel for well in excess of one hour of flight plus required reserves, even in the most demanding conditions. The aircraft demonstrated significant power index margins, highlighting its unrivalled performance and handling capabilities in an extremely challenging environment. The AW139 confirmed itself as being a preferred choice for military and commercial customers around the world. Its excellent features and capabilities have led to the signature with the Government of Pakistan for two different contracts for AW139 helicopters which are to be used for transport and EMS mission, or to perform search and rescue across the nation.

2 FIPS CERTIFICATION FOR AW189 The AW189 Full Ice Protection System (FIPS) was certified at the end of June 2016 and the first helicopters equipped with this kit are ready to be delivered to the customer. Thanks to a special effort throughout the entire programme, which included six icing campaigns in three years, during which two prototypes were used at the same time for the first time ever, the result was achieved in less than 30 months from the AW189 main certification, reaching a key milestone for the AW189 SAR programme. Leonardo Helicopters is the only company to hold 4 icing civil certifications (AW139 FIPS/ LIPS, AW189 FIPS/LIPS) obtained in the last 7 years. The system has all been developed based on the experience gained on the AW139 FIPS and LIPS and taking advantage of the certification activities carried out for the AW189 LIPS system. The applicable Instructions for Continued Airworthiness and the RFM Supplement have been published through the usual channels (IETP Issue 9, AW189 RFM Rev. 1 Issue 9). This FIPS system is designed to allow operations in full icing conditions; it provides indication of ice accretion and prevents icing formation on the windshield, main and tail rotor blades. The system is composed of the following items and subsystems: AC generation subsystem; Rotors heating subsystem; Ice detection subsystem; Windshields heating subsystem; SLD marker; Intakes protection subsystem; Cockpit controls and messages. News 2

3 News AWnewsletter AW189 - AVIONIC SW PHASES MANAGEMENT Starting from Revision 8, the AW189 QRH has been divided into two different volumes, in order to easily identify the instructions applicable to a specific Avionic SW phase: Volume I is for aircraft fitted with Avionic Software Phase 2.0 or 2.1 only (pre BT ); Volume II is for aircraft fitted with Avionic Software Phase 3.0 or later (post BT ). The two volumes were distributed to all AW189 operators, to guarantee they are aware of the applicable instructions, either before or after BT compliance. 3

4 AW139 LIFE EXTENSION AW139 Product Support Engineering is pleased to inform all the AW139 Community that new achievements have been reached with regards to the Life Extension Programme activity; which will reduce the aircraft maintenance burden and provide a positive impact on DMC reduction. REAR FUSELAGE AND TAIL ASSY LIFE EXTENSION PROGRAMME Rear Fuselage and Tail assy lives have been recently extended following the positive results of the full scale cabin fatigue tests performed in collaboration with the University of Milan. Both Rear Fuselage and Tail assy have now an extended Retirement Life which is respectively 40,000 FH and 19,600 FH/78,600 landings; this achievement has already been published in the Air vehicle Maintenance Planning information set (AMPI) in Chapter 04 Issue 4. The life extension is available for new production build helicopters without any modification, whilst for the previous configuration, a dedicated modification is required, introducing new titanium fittings and new longerons, along with a new fin assy reinforcement. The applicable modifications instruction are available for all the customers by means of BT and BT , both recently issued. BT allows all short and long nose AW139 helicopters to improve the rear fuselage, while BT is applicable to the tail structure assemblies P/N 3G5350A00132/-133/-134/-135. Engineering AW109/AW119 CORROSION PROTECTION AND CONTROL We have recently released the First Issue of the AW109/AW119 Series Corrosion Protection and Control Publication (CPCP), which is aimed at providing operators with information to implement corrosion prevention programmes for their fleets. Some of the information it contains was available in the past via other means such as Maintenance Manuals or dedicated SRM/ASRP instructions. It is now all included in this new manual, which can be referred to as a unique instructions repository for this topic. In addition to that, we have included, as a first, a very detailed Corrosion Standard Practice Section (ATA 20); which fully benefits from the experience gathered over the past years of inservice feedback (see for reference SIL A109E Series Product Improvement, dated 4th Nov., 2009). It also includes usage of the latest Corrosion Protective Compounds the market. The First Issue of the CPCP also provides customers with a suggested Corrosion Inspection Programme with the intent to integrate with the Scheduled Maintenance Programme provided for each model. The inspection tasks type and interval are indicated based on the category of the aircraft operating environment: Severe, Moderate or Mild. We trust with this manual will be of service to operators on corrosion topics. It has been demonstrated that effective corrosion control programmes implemented by customers working in harsh environments have significantly reduced the magnitude of corrosion maintenance problems. 4

5 TVA TUNING PROCEDURE The AW189 is equipped with two Tuned Vibration Absorbers (TVA) P/N 8G1860A01611 installed under the cabin floor, to reduce the 5/rev vibration level of the aircraft. The basic configuration requires the installation of these two TVAs, located behind the pilots seats, one on the right and one on the left. Further reduction of the vertical vibration can be obtained by installing two additional masses in the rear part of the cabin, which are available as an optional kit, P/N 8G1860F These are purely passive devices and their maximum effectiveness is achieved at a defined frequency. Each time a TVA is replaced or the vibrational environment is unacceptable to either the pilots or the passengers, this can now be resolved thanks to a new tuning procedure, which sets at a given 5/ Rev frequency the anti-resonance measured at the TVA attachment point. The tuning instructions are available in the IETP and require the use of a dedicated Vibrations Absorber Tuning Tool (P/N 9735-W-077). Engineering ROTOR TRACK & BALANCE The lastest Heliwise update was released online in June 2016 implementing new features for Rotor Track and Balance (RTB) correction calculation and optimization. The improved feature implements a correction calculation algorithm which, starting from the data collected during the flight by the On Board System (OBS), suggests the adjustments required for pitch links, rotor blades balance weights and trim tabs position. This allows a faster and easier rotor track and balance operation avoiding the need for dedicated fligths. The repositioning of one HUMS accelerometer in the cabin compartment, aimed at improving the reliability of the system, is a preliminary requirement for the use of the automatic correction calculation. The instructions for the repositioning is provided with Technical Bulletin BT , with a minor maintenance impact. 5

6 TRAINING FOR THE ROYAL THAI ARMY The Royal Thai Army will take delivery in Philadelphia, Pennsylvania, of six AW139 helicopters within the third quarter of As each helicopter delivery presents many exciting opportunities and unique challenges for all departments involved, this programme has proven to be an unexpected model for future training programmes for one department in particular our Training Academy in Philadelphia. The Training Academy, in close collaboration with Customer Support, has supported and is successfully delivering a comprehensive training package, including the flight training on an actual AW139 helicopter. The courses were attended by 18 pilots, who were split into 3 classes and consisted of three areas of instruction: glass cockpit familiarization (1 week), type rating and both theoretical ground and simulator sorties (4 weeks), as well as flight training on the aircraft (1 week). The use of the real helicopter during the flight training in addition to the standard AW139 type rating was what brought the pilot courses to a higher level for our Training Academy in the United States. This is clear evidence of our capability and our commitment to support and deliver extended programmes requiring training on the aircraft in addition to the approved level D AW139 Full Flight Simulator. The comprehensive training package included not only the pilot training, but also courses for 22 maintenance students (18 maintenance technicians and 4 avionics) and instructor training programme courses. The 22 maintenance students were split into 3 courses to attend theory classes (4 weeks) and work on practical elements (2 weeks). During the 6 weeks of training, students were supported by training aides and were training on a dedicated AW139 maintenance simulator. This important project required a collaborative effort also from logistic and coordination points of view, with the involvement of 6 ground instructors, 10 synthetic flight instructors and 4 flight instructors in two different locations: Whippany, New Jersey and Philadelphia, Pennsylvania. In order to assist the students during the full duration of the classes and enable them to fully understand the courses, we provided the services of mother tongue Thai interpreters. The extent of our commitment and support to the customer included the full involvement of the Training Academy administrative staff, who assisted the customer with all their non-flying requirements. The training is expected to finish at the end of October It has been a big effort, but the success in completing the project, and meeting the customer s requirements has been achieved also thanks to all the different departments involved, and the individual and collective effort to bring this plan to fruition. This has set a new precedent regarding flight and maintenance training in Philadelphia, Pennsylvania. Training 6

7 AW139 NEW MAIN ROTOR ROTATING SWASHPLATE CERTIFIED Another main target has been achieved with the certification of the new MR Rotating Swashplate. The successful fatigue testing campaign met the goal to significantly extend the component retirement life from 4,800FH of the actual configuration to 17,300 FH. In addition, the new design will have a positive impact on operative costs reduction and maintainability improvement through the removal of the Mandatory Inspection (MI-62-06), which remains applicable to the current swashplate configuration. The design modification, other than the swashplate itself, involves retaining bolts and the outer locking ring, without affecting overall dimensions and weight. News AW TRAINING APP 2.0 Leonardo Helicopters is committed to continuously support our customer teams, aircrews and ground crews, in accomplishing their helicopter missions. As anticipated in the AWNewsletter Autumn 2015, since November 2015 customers who are registered for the Leonardo Helicopters Training Academies courses, can download the AW Training mobile App. The gateway App allows students to access the Helicopter Training Course information, through their own devices (ios, Android). With respect to the first issue of AW Training, the new version 2.0 provides the following additional features: DISTANCE LEARNING MODULES All the students, enrolled in a course where Distance Learning is provided (as pre-learning), are able to perform the Distance Learning Course through the App, on and off-line. ACTIVITY COMPLETION AW Training 2.0 gives the students the possibility to track progress on their own device with the Activity Completion function. The completion of each module of the Distance Learning Course can be recorded in automatic mode and/or manually marked. EASY ACCESS COURSE CONTENT AW Training 2.0 improves the look and feel of the courses content with the capability to review the resources in off-line mode. 7

8 AW609 CERTIFICATION ACTIVITIES BACK ON TRACK AW609 flight testing activities have recently resumed and the first as well as the third AW609 prototypes have both arrived in Philadelphia. With industrialization underway, Philadelphia has taken the leading role in the programme. The flying AW609 (AC1) departed from Arlington, Texas and reached our facility in Philadelphia on Wednesday, August 10, with an overnight stop in Huntsville, AL. A total of 1,476nm (2,657km) were flown during the ferry flight. The third prototype (AC3) arrived in Philadelphia after having recently been assembled and ground tested in Italy. Furthermore we are working on assembling another AW609 there, AC4, so that, according to plans, it can enter the test fleet in Certification of the AW609 is expected in 2018, with deliveries to customers to follow. Thanks to the involvement of the Philadelphia site in the AW609 programme, we are working towards assembly and certification with the FAA as the initial certification authority. Our facilities in Italy, UK and Poland continue to play critical production roles, especially as the first AW609 prototype prepares to be relocated to Italy to continue flight testing activities. 8

9 AW169 FOR RENEWABLE ENERGY: HELISERVICE HeliService International is one of Northern Europe s leading providers of offshore helicopter services with bases in Bremerhaven, Emden, Husum and Esbjerg. After the signature of a 5-year contract with Siemens Wind Power A/S, HeliService have chosen our AW169 for their support operations. The Siemens Wind Power A/S project called GEMINI is an offshore wind farm which will supply clean energy for 1.5 million people, making a significant contribution to achieving the renewable energy targets of the Netherlands. Wind farms are becoming an increasingly important source of renewable energy and are used by many countries as part of a strategy to reduce their reliance on fossil fuels. HeliService International has more than 27 years of experience in commercial air transportation, and they have selected the Leonardo midsized twin-engine helicopter in the 4.6-ton class - the first of its kind for the challenging operational requirements of the GEMINI Offshore Wind Farm. The AW169 is specifically designed for demanding offshore applications. Its performance, technology and high safety standards fully meet or exceed the project s requirements. In August 2016, just prior to the beginning of the operations of the world s largest offshore wind energy project, HeliService International received their first AW169. The aircraft, registered D-HHTJ, is equipped with a dedicated offshore interior and has a special lightweight configuration. It meets the customers requirements for the transfer of maintenance personnel to and from the wind turbines. The low noise-level of the AW169 was one of the key factors during the selection phase. Equipped with a Goodrich hoist, the AW169 will increase the capabilities of HeliService International to a whole new level for hoist-operations onto wind turbines. HeliService is supported by Leonardo Helicopters Customer Support & Services Italy and collaborates daily with all departments to maintain the highest levels of fleet availability and to further enhance its operations. Customer Focus EMS OPERATIONS IN JORDAN Jordan is a country where specialist hospitals are restricted to a few cities and ground transportation is limited by Jordan s road network. A helicopter EMS service is therefore key to this type of environment. The Jordan Air Ambulance Centre (JAAC), located at Amman Civil Airport at Marka, began operations in August 2015 with its two new Leonardo Helicopters medically-equipped AW139s. Along with 42 personnel including six pilots and eight paramedics, who can leverage on a wide range of medical equipment for air evacuation operations, the service is now a reality. Specialist equipment includes heart monitoring and defibrillators, respirators and oxygen monitoring equipment. The centre provides an essential EMS capability in the region, having a response time of 15 minutes from time of request of service with the JAAC pilots authorised to land at all heliports in Jordan, which are scattered over more than 45 locations. They can also provide medical evacuation from neighbouring countries including the north of Saudi Arabia and Palestine. Typically the crew on board these AW139s is composed of two pilots with two paramedics, or one paramedic with a doctor. All of the crew have the correct training for this kind of mission, as the paramedics were trained in the US while the pilots, most of them former Jordanian Air Force pilots, train in Abu Dhabi where the UAE Air Force has an AW139 simulator. The demand for EMS missions is expected to rise to approximately 400 a year by 2020, so in order to meet this requirement JAAC is planning to open another base located at King Hussein International Airport in Aqaba, and possibly in other locations. This will dramatically improve the service emergency response time. 9

10 Technology AWnewsletter FLYING HIGHER WITH THE AW119KX Recently our AW119Kx multi-role single engine helicopter, built at our site in Philadelphia and part of our test and demonstration fleet with AWPC, carried out the trials campaign to extend the flight envelope from 15,000 ft (actual certification limit) to 24,000 ft. The helicopter flew 1,500 miles in two days to reach Leadville in Colorado, where all test activities took place. The test programme lasted from mid August to mid September, and the location was chosen as the surrounding area is very demanding for hot and high conditions. The flight programme was focused on performance tests such as hovering (both IGE and OGE), cruise, rate of climb and autorotation. The aircraft was fully instrumented for the flight test including an instrumentation boom. High altitude performance flights included take-offs and landings at 14,880 ft density altitude and flights at 24,000 ft pressure altitude. The AW119Kx demonstrated significant power index margins, highlighting outstanding performance and handling capabilities in an extremely challenging environment. 10

11 AW169 FULL FLIGHT SIMULATOR IN OPERATIONS The first Level D full flight simulator for the new generation AW169 light intermediate helicopter was certified by ENAC (Ente Nazionale Aviazione Civile Italian Civil Aviation Authority) and by the European Aviation Safety Administration (EASA) on June 30th Thanks to this new simulator we can now deliver advanced pilot training courses for the benefit of our AW169 customers. The full flight simulator is a CAE Series 3000 device, jointly developed to EASA Level D by Leonardo and CAE and is operated by Rotorsim, the joint venture owned equally by CAE and Leonardo. The simulator is available to all customers undertaking Type Rating conversion to enter service with new delivered AW169s, as well as for recurrent training for rated pilots. Training activities started in July immediately after certification to support safe operations and crew readiness. Pilots in training will be able to practice all required operational tasks and procedures in normal and emergency situations, both flight and mission related, including low-level flight, confined area operations, autorotation and landing on platforms at sea. The event marks a major milestone in the AW169 programme and the first ever implementation of the EASA Operational Suitability Data (OSD) process for helicopters. It meets the authority s new requirements issued in January 2014, mandating aircraft manufacturers, including those building helicopters, to submit data EASA considers important for safe operations. OSD also covers pilot training, maintenance staff and simulator qualification. The certification of the full flight simulator for the AW169 completes the comprehensive range of training solutions for the type, which also include a flight training device (FTD), full maintenance training simulator, virtual interactive procedural trainer, virtual maintenance trainer, distance learning course and traditional classroom training as well as live flight training. Since the startup of training activities, more than 90 pilots and 180 engineers have been trained on the AW169 helicopter on the different devices available. Our Training Academy in Sesto Calende now features the entire AWFamily Level D full flight simulators the AW139 and the AW189 FFS. All simulators are located in the same building, and feature the same CAE S3000 Series technology, maximizing commonality approach and easing the transition across the Family helicopters. 11

12 Leonardo - Finmeccanica - Società per azioni Registered Head Office: Piazza Monte Grappa, Rome - Italy Tel Fax Leonardo Helicopters Head Office: Via Giovanni Agusta, Cascina Costa di Samarate - Italy Copyright Leonardo S.p.a. Helicopters 2016 This document contains information that is proprietary to Leonardo - Finmeccanica - Società per azioni and is supplied on the express condition that it may not be reproduced in whole or in part, or used for manufacture, or used for any purpose other than for which it is supplied. leonardocompany.com