HAI 2015 - AW109-119

Manufacturer Technical Briefing HAI 2015, Orlando, 4th March 2015

2 AgustaWestland Proprietary Information Commercial in Confidence

Proprietary Notice

This document contains confidential data and information which

are property of AgustaWestland. AgustaWestland forbids its

circulation, reproduction or disclosure, whether in part or in its

entirety, without AgustaWestland written consent.


AgustaWestland Technical Support

Product Support Engineering Teams

Andrea Barca AW109/119 Product Support Eng. Mgr. Italy

[email protected]

Christopher Lemieux AW109/119 Product Support Eng. Mgr. Philadelphia

[email protected]


1. FLEET OVERVIEW

2. MIT & MAINTAINABILITY UPDATE

3. RELIABILITY IMPROVEMENTS UPDATE

4. PUBLICATION SERVICES

5. CUSTOMIZATION ITEMS

Content


FLEET OVERVIEW


Fleet Overview

Over 1380 total helicopters delivered to

more than 700 Customers

1162 helicopters in service

Over 60 helicopters delivered in 2014

Logged more than 3,300,000 FHs

Fleet leader exceeded 11,500 FHs

More than 75 Countries over the

5 Continents

DELIVERED HELICOPTERS


Fleet Experience


Fleet Leaders

Model S/N Total Time Operator

A109A 7153 6,995 Reach Air Medical Service (USA)

A109AII 7273 9,868 Air North West (USA)

A109C 7651 8,712 North Air Care (USA)

A109K2 10036 11,550 Viamax Fleet Management (SA)

A109E 11065 9,799 North Air Care (USA)

A109S 22153 3,891 Viamax Fleet Management (SA)

AW109SP 22243 1,870 Saddle Mountain Inc. (USA)

A119 14035 7,737 NYPD (USA)

AW119MkII 14701 5,937 ERA Helicopters (USA)

A109C S/N 7637, operated by North Air Care, retired from service mid of 2014

with more than 11,920 FHs


MIT & MAINTAINABILITY UPDATE


Background

Program launched in Sept 2011, in order to drive reduction of the AW109/AW119 maintenance

burden, with the feedback of a selected group

of Operators.

Recurrent Meetings

Maintenance Improvement Team (MIT)

Event Date Place

1st MIT Sep 2011 AWPC

2nd MIT Mar 2012 Texas (HAI)

3rd MIT Jul 2012 Ohio

4th MIT Nov 2012 Arizona

5th MIT Mar 2013 Las Vegas (HAI)

6th MIT Jun 2013 AWPC

7th MIT Nov 2013 Palm Beach

8th MIT Jun 2014 AWPC


Main Achievement Summary

109/119 action items closed (5 agreed no action) since the MIT started.

New A109E M/R Damper: Overhaul from 600 to 2400FH

Vibration Damper Life Limit from 1200 to 3200FH A109E Cold Weather STC to -35C T/R Blade bolt damage limit expansion and

alternate corrosion protection

AW119 Structural Reliability Improvements

Main In-Progress Topics

Vertical Gyro Reliability Digital Gyro Chapter 5 +/- 10 Percent Tolerance T/R Shimming Process

Maintenance Improvement Team (MIT)

CLOSED 72%

IN-PROGRESS

19%

OPEN 9%


Tail Rotor Blade Retention Bolt

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Background

Bolt damaged during installation due to interference with

bushing and retention straps.

Analysis Laboratory test in salt laden atmosphere to confirm:

Damage and cadmium layer acceptable allowances;

Effectiveness of CPCs applied to the bolt shank;

Status TMI109-419 issued, allowing grooves up to a maximum depth

of 0.02mm.

Voids/Removal of Cadmium layer is no longer a cause for bolt

replacement.

CPC application prior to bolt installation.

Ardrox AV25.

Rust Guard (MIL-PRF-16173).

CLOSED


Tail Rotor Hub Shimming Process

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Background

MMHs and possible inaccuracy of planarity with

the existing process to lap shims to the required

dimension.

Improvement Shim Kit with a discrete number of shims (kit) will

be made available with various thicknesses within

to the most commonly found range.

Status Study, to determine the list of shim thicknesses

to be provided - Complete.

Initial certification for the 109-0162-01-105 T/R

Assy expected within 1Q 2016.

Additional versions for legacy T/R Assy under

evaluation.

IN PROGRESS


AW119 Structural Reliability Improvements

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Background

Cracking found in 3 locations on the AW119 fleet

with low TIS:

Improvement Reinforcement Retromods designed for the areas:

Aft Cabin Door Post

FWD Cabin Door Post

Aft Engine Cowling

Status Retromod design complete for in-service aircraft.

Available as repair or alteration in service via 8110

approval.

Similar reinforcement design incorporated in the

basic design.

Applied in production from Acft S/N 14831.

CLOSED


Vertical Gyro VRS-3000

Background

VG failures related to damaged spinning masses and bearings.

Helicopter handling affects VG reliability, especially if performed prior to

caging.

Improvement New Laser Technology VGs, manufactured by L3,

fully intermixable with present technology.

Component Reliability not suceptable to vibration/handling.

Status AW119MKII Flight activities concluded with positive results.

Vibration Test In Progress at L3 - Within 2Q 2015.

AW119MKII certification within 2Q 2015.

A109E & A109S certification within 4Q 2015.

Spare parts availability starting from July, 2015.

Production rate can be increased based upon Customer interest.

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IN PROGRESS


Chapter 5 Tolerances - 109CAB-068

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Background

Customers requested higher flexibility in

managing inspection interval tolerances.

Improvement Revision of Chapter 5 tolerances to allow for

+/- 10 percent. As long as an inspection is

performed within 10 percent of its schedule,

the subsequent inspection schedule shall

remain unchanged.

Status MPM revision has been made available for

approval to Design Organization.

Approval on A119/AW119MKII committed

within 2Q 2016.

IN PROGRESS


Life Extension Target

New MRBs P/N 109-0104-01-119 defined.

MRBs full interchangeability.

100FH repetitive inspection for Tip Cap debonding on MRBs with more

than 8,800 FHs accumulated.

EASA certification achieved during 4Q 2014.

FAA certification expected within 2Q 2015.

Main Rotor Blade Life Extension

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P/N Cargo Hook

Penalty Factor Retirement Life

(Chapter-4 Change 7)

109-0104-01-111 2 8,800 FH

109-0104-01-119 3 12,000 FH / 30,000 Ldgs

CLOSED


Achieved Targets

EASA AMPI Chapter-4 Issue-2 Change-8 includes the results of ALS

extension campaign.

Airworthiness Limitations Extension

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Component Original ALS Extended ALS (Chapter-4 Change 8)

MRB Elastomeric Bearing 50 FHs 60 FHs

Fuselage 200 FHs 450 FHs

CLOSED


RELIABILITY IMPROVEMENT ITEMS


Solenoid Fuel Drain Valve

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CLOSED

Background

Electrically operated valve.

Occurrences of valves found stuck in the open position.

Improvement New Solenoid Valve P/N 109G2870V02-101 features:

Spring energized to the CLOSED position;

Electrically/Manually operated to the OPEN position;

Mixed configuration allowed.

Weight savings: 260gr. Vs. 400gr.

M.T.B.F. drastically increased.

Status Valve certification achieved 1Q 2015.

Optional BTs issued Feb 2015.


Hydraulic System Filter Group

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CLOSED

Background

Pop-out indication influenced by environmental conditions.

Improvement New Filter group P/N 109-0760-41-109 features:

By-pass valve in the return line;

Teflon ring at the bottom of each filter cartridge;

Enhanced pop-out indicator;

Same Form, Fit & Function of the present Filter Group,

except on AW109SP.

Status Filter Group certification achieved 1Q 2014.

Optional BT 109SP-086 applicable to AW109SP issued

1Q 2015.

IPDs updated as an alternate P/N for the remaining

models.


Cold Weather Operations (I)

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Background

Hydraulic pressure affected by environmental conditions.

Analysis Pressure increases due to fluid viscosity changes at low

temperature.

Helicopter hydraulic system already designed for continuous

operation at 1600psi (Same as A109S / AW109SP).

Improvement Hydraulic Pressure threshold extended to 1600psi

(AW119Kx only). STC Certification following TC Certification.

Garmin Software already capable of displaying the new limit.

Hydraulic Pump P/N 109-0760-42-107.

Air Inlets Cover Kit to reduce amount of cold air within the

helicopter roof compartment.

Revised Transducer Calibration Procedure

IN PROGRESS

AW119Kx


Cold Weather Operations (II)

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CLOSED

Background

Present Pumps P/N 109-0760-42-105 are set to

1520 +/- 20psi during production.

In some cases, in low operating temperatures,

cockpit pressure indications seen above the current

1550psi normal system operating limit.

Improvement New Hydraulic Pump P/N 109-0760-42-107 features:

Lower factory setting 1480 +/- 20psi.

Ideal for low-temperature operations.

Same Form, Fit & Function of the present Pump.

Status Hydraulic Pump certification achieved in 4Q 2014.

IPD will be amended according to 2015 schedule.


Cold Weather Operations (III)

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Background

Variance in Pressure Transducers output for

hydraulic pressure cockpit indication.

Tolerance of pressure transducer increases in cold

temperatures.

Improvement New calibration procedure introduced to improve

the accuracy of the cockpit indication.

Reduction in pressure indication up to 50psi.

Status New calibration procedure introduced 1Q 2015.

Specific tooling available for rental or can be

purchased independently.

CLOSED


NACA Air Intake Covers

Ram Air Intake Cover

Cold Weather Operations (IV)

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IN PROGRESS

Background

NACA and Ram Air Intake Openings increase the

cooling affect and contribute to fluid viscosity

changes during low OAT.

Improvement Air Inlets Cover Kit developed for use in low OAT

operating environments.

Easily to remove/install for seasonal application.

Status

Design and initial cold weather test flights completed

1Q 2015.

Remaining test flights and data collection for

determination of high temperature threshold for the

kit is pending EASA availability.


Electrical Step Actuator

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Background (AW109SP)

Foldable step operated by two actuators.

During operation, due to stroke misalignment,

actuators may fail and lock in position.

Background (A109E/A109S) Foldable step operated by a single actuator.

Cases of actuator failure due to a broken

pin internal to the actuator.

Improvement All present configurations replaced by single heavy

duty actuator with improved MTBF.

Status Optional BT for AW109SP issued during 1Q 2015.

Optional BT expected on A109S and A109E within 2Q 2015.

IN PROGRESS


TRDS Fairing Gasket

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Background

Cases of interference between the TRDS Fairing

and the upper skin of the Tail Boom, eventually

leading to skin cracks.

Specific Repair Drawings issued for occurrences.

Improvement Installation of a shaped Gasket A146A1906CB

eliminates the chaffing.

Status Optional BTs issued 4Q 2014.

Material is available.

Gasket A146A

CLOSED


Vertical Fin Masses

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Background

Cases of damage to anti-vibration masses.

Masses are made of Lead.

Mandatory BTs require removal of the masses.

Improvement New masses made of Tungsten for

improved strength.

Vertical Fin Retro-Mod reinforces upper

web and front spar.

Prerequisite for the new masses.

Status Tungsten masses certification expected within 3Q 2015.

Vertical Fin Retro-Mod certified.

Optional BT to be released after certification of the

masses and first validation of the instructions.

IN PROGRESS


Vertical Fin Retro-Mod

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IN PROGRESS

Background

Cases of damage to the vertical fin structure due

to vibration and wear of the lead masses.

Cracks on the Fin Fairing 109-0373-03.

Improvement Molded web replaced with a machined web.

Reinforcing doublers on front spar and ribs.

Fin Fairing skin thickness increased

Edge distance of mounting holes increased;

Status Vertical Fin retro-Mod certified.

Optional BT in preparation. Release then pending

the first validation of the instructions on a

customer aircraft.

Machined Rib

Reinforcings

Thicker Skin

Increased edge

margin


Oil Cooler Fan

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Background

Premature wear of fan pulley installation on Technofans Amdnt.B.

Confirmed reliability improvements on Amdnt.C, in service for two years.

Improvement New TEMA Fan Assy with composite construction.

Approximately 40% weight savings.

Maintenance interval improvements:

Pulley Bearing discard time: 400FHs (AW will extend to 1200FHs)

Inspection: 1200FHs (instead of present 200 FHs)

Overhaul: 4800FHs

Mixed configuration is not allowed.

Status

Certification expected within early 2Q 2015.

Optional BT will be issued within 3Q 2015.

IN PROGRESS


Ejector Insulation Blankets

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CLOSED

Background

Thermal blankets showing cracks along welding

beads.

Blanket replacement must be performed at shop level.

Improvement Split removable blankets

ejector assy developed.

Ejector can be retrofitted

at shop level.

Mixed configuration with present

tailpipes is allowed.

Status New Ejectors certified during 4Q 2014.

Optional retrofit BTs issued: 109EP-137, 109S-061 and 109SP-083.

Specific SILs issued to provide logistic support details.


Flight Control Computer -0A07

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Background

Current FCC software 109-0774-04-0A06 algorithm improved in order to

fix spurious fail indications during the Pre-Flight test.

Improvement New FCC 109-0774-04-0A07 (Software Change Only):

Quick Disconnect check-interval between channels extended from

20ms to 300ms. Risk of 1(2) AP TEST FAIL

at the end of the pre-flight test minimized.

Removed a redundant consistency check between

Linear Actuators and LVDT.

Risk of 1(2) AP P/R/Y FAIL during the pre-flight test

minimized.

Status FCC P/N 109-0774-04-0A07 certified 4Q 2014.

Mandatory BT will be issued within 1Q 2015.

CLOSED


GPS Receivers Mod.4

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CLOSED

Background

Operators reported cases of GPS1(2) FAIL Caution

message displayed on EFIS in flight and during approach.

Geographical areas where GPS Constellation coverage

is reduced are more subject to this issue.

Improvement Additional Software implemented within the GPS receiver to better manage

GPS Signal availability and mark invalid parameters exceeding thresholds.

Added Capacitors on the internal boards allowing the GPS Atlas to be

retained up to 54 Hours (currently 16 Hours) within the RAM Memory

Status GPS Receiver P/N 109G3450I01-101 certification achieved during 3Q 2014.

FAA Certified 4Q 2014.

Alternate part added to the IPD.


Background

For missions with a high rate of start/stop cycles, if the battery

has not been correctly charged, some CAS messages

temporarily appear during engine start.

Improvement 20 Cells Battery certified.

BT 109SP-064 issued to retrofit in-service helicopters.

Commitment Customers requested instructions to allow Battery upgrade in

the field.

Optional BT to be issued as soon as retrofit kit will be available.

Battery Upgrade

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19 Cells configuration 20 Cells configuration

Marathon P/N 33181-001 33181-004

CLOSED


Background

Portable fire extinguisher P/N A072A non more

available from supplier due to issue with the

procurement of the fire bottle.

Improvement

New portable fire extinguisher P/N AW003ZE02

certified.

New extinguisher contains the same quantity of

Halon1211 as the previous P/N A072A

Helicopter interface compatible with previous

extinguisher.

New portable fire extinguisher CLOSED

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TECHNICAL PUBLICATIONS


New website and Leonardo interface


IETP 2015 Revision Plan

JA

N

FE

B

MA

R

AP

R

MA

Y

JU

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JU

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AU

G

SE

P

OC

T

NO

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DE

C

A109A/AII X

A109C X

A109K2 X

A109E X X

A119/AW119MKII X X

A109S/AW109SP X X


Amerigo 4

Features

Applicability to Microsoft Windows 8.

Changes to the layout of the IETP to improve the use on PC Touch

Screen introduced by Windows 8.

New work card functionality.

PDF Printer

Link to Effectivity code DM.

Status

With A109C IETP 12th Issue, scheduled for March 2015, AW

concluded the migration process from Amerigo 3 to Amerigo 4 .


Main Rotor Blade Anti-Erosion Shield

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ISSUED

Background

Cases of MRBs Anti-Erosion shield cracks

Improvement Shield manufacturing process reviewed.

Shield Assy now manufactured as a finished

product (no trimming necessary upon

installation), thus reducing crack sources.

Shop Maintenance procedure made

available allowing erosion shield

replacement through AW Part-145 and

authorized Blade Repair Centers.

Status TMI109-310 issued.


Main Rotor Blade Grip

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ISSUED

Background

Necessity to provide clear instruction to repair

MRBs grips P/N 109-0112-03 / -05.

Status TMI109-311 issued, providing instruction to

replace the Lower Drop Stop Bracket.

TMI109-328 issued, providing instruction to

replace Plates, Washers and Shims.


Tail Gearbox 1600 FHs Inspection

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ISSUED

Background

Operators requesting detailed

procedures to perform the 1,600 FHs

Scheduled Inspection on TGB.

Status TMI109-405 issued, providing

instruction to inspect the TGB.


Hydraulic Tanks Repair

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ISSUED

Background

Operators requesting instructions to

repair the weld beads at the hydraulic

tank brackets.

Status TMI109-421 issued, providing

instruction to repair and weld as

necessary.

Welding Beads


Main Gearbox 3200 FHs Inspection

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Background

Service Centers requesting detailed

procedures to perform the 3,200 FHs

Scheduled Inspection on MGB.

Status TMI109-411 to be issued, providing

instruction to inspect MGBs installed

on A109E.

TMI109-413 to be issued, providing

instruction to inspect MGBs installed

on A109S and AW109SP.

IN PROGRESS


TRDS Support Bearings Alignment

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Background

Requirement to check the alignment

every time one of the supports is

replaced or a structure repair is

accomplished underneath the

supports.

Status

TMI109-417 issued, providing

instruction to check the alignment of

the Support at STA5027.

TMI109-418 issued, providing

instruction to check the alignment of

the Support at STA5782.

ISSUED


MGB Anti-torque Plate Fittings

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Background

Requirement of replacement of LH and RH

Support Fittings P/N 09-0330-17 when found

damaged.

Status

TMI109-415 issued, providing instructions to

replace the Support Fitting and guarantee the

proper alignment of the MGB .

To be extended to other applicable models

when necessary.

ISSUED


Overhaul Manual

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Background

Customers requesting the possibility to

improve the readability features of the

A109-A119 Series Overhaul Manual.

Improvement

Main Features:

Dynamic layout related to the

applicable IETP Model;

Paragraph/sections not applicable to

that model have been greyed out to

avoid applicability mistakes;

Status

Overhaul Manual 2nd Issue has been

released in November, 2014.

ISSUED

In-View Paragraph

Greyed Paragraph


Low-Density Sealant Naftoseal MC-780

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Background

A109 IETPs require Structural Sealing using ProSeal 890 .

ProSeal 890 - Class-B has a density of 1.65 g/cm3.

Improvement New Low Density Sealant qualified by AW: Naftoseal MC-780 .

Specific Class (A, B or C) depending on type of application:

Class-A: Overcoating of fasteners - Density 1.15 to 1.25 g/cm3.

Class-B: Edge sealing - Density 1.03 to 1.13 g/cm3.

Class-C: Fasteners wet installation and Mating surfaces sealing -

Density 1.03 to 1.13 g/cm3.

Weight savings on A109E of approximately 3Kg.

Status Product qualified by AW.

IETPs will be amended beginning with 3Q 2015 revisions.

IN PROGRESS


Electrical Standard Practice Manual

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9E

A1

09

A/A

II

A1

09

C/K

2

Background

Necessity for operators to have detailed

instruction to perform wires and connection

repairs.

Provide information and procedures that are

common to primary electrical installations. It

also provides details to relocate, repair and

replace electrical wiring, cables or

components in order to maintain the

manufacturers standards of performance

and quality

Status

Standards and source data available.

IETP will be amended beginning with 4Q

2015 revisions.

IN PROGRESS


Corrosion Protection & Control Publication

AW

10

9SP

A

10

9S

A1

19

/AW

11

9M

KII

A

10

9E

A1

09

A/A

II

A1

09

C/K

2

Background

Necessity for operators to have clear and detailed

instructions to protect helicopter structure and

systems against corrosion.

A Corrosion Control Scheduled Maintenance Plan

will be developed based upon Customers

experience and feedback.

Status

Project launched late 2014.

Collection of customer feedback and analysis is

ongoing.

Materials Standards and Protection Methods will be

available for CPCP editing within 1Q 2015.

IN PROGRESS


Product Improvement Information Letter

On February 20th, 2015 the seventh

Product Improvement Information letter

was issued to highlight all the available

improvements issued from the

previous Information Letters and

published through the dedicated

Technical Publications (IETP, BT).


CUSTOMIZATION ITEMS


Operation at -40C OAT (I)

AW

10

9SP

A

10

9S

A1

19

/AW

11

9M

KII

A

10

9E

A1

09

A/A

II

A1

09

C/K

2

Background

AW109SP currently certified for operation down to

an OAT of -25C.

Actions

AW performed cold trials operation in Alaska.

Handling Qualities, Performance, System Failures

and Load Survey have been performed

successfully

Status

Certification expected within 1Q 2015.

Optional BT to retrofit the helicopter will follow.

IN PROGRESS


Operation at -40C OAT (II)

AW

10

9SP

A

10

9S

A1

19

/AW

11

9M

KII

A

10

9E

A1

09

A/A

II

A1

09

C/K

2

Configuration Requirements

Following Kits/Components will need to be

installed to comply with the design specification:

IN PROGRESS

Remarks from Cold Trial Action / Certification

MLG bottoming at very low temperature New MLGs with overinflated chamber

Windshields misting at start-up ECS/Heating with De-misting capability

Pax Windows Evacuation Test New Sliding Door Window Seal

VNE Limitations to be extended EFIS Software 25-EFIS70F-SW-003 + VNE Placard

Load distribution on MLG Box Beam Structural Modification


Garmin G1000H - STC SR03280NY

AW

10

9SP

A

10

9S

A1

19

/AW

11

9M

KII

A

10

9E

A1

09

A/A

II

A1

09

C/K

2

Original STC

Released in 2013 and included:

Cockpit configuration

EMS configuration

NVG configuration

2014 Amendment

Released Mid 2014, included:

VIP and Utility configuration

2015 Amendment

Added TDFM9100 Radio (replaces TDFM6000 series)

In-Progress changes

Extension of operating temperature with G1000H from -25C to -35C

Foreign validations

Brazil ANAC Completed 3Q 2014

China CAAC Completed 1Q 2015

IN PROGRESS

THANK YOU FOR YOUR ATTENTION

HAI 2015 - AW109-119

Documents

Transcript of HAI 2015 - AW109-119