Eurocopter toward green helicopterEurocopter toward green helicopter

11 September 2012 – presented by Yves Favennec

What is "Green" ?

External noise reduction– Produced noise– Perceived noise

Emission & fossil fuel consumption reduction– Consuming less energy– Producing energy more efficiently– Non fossil fuels

Eurocopter transparency: a metric for green helicopters

Green manufacturing

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External Noise: main sources

Anti-torque system

Main Rotor: Impulsive noise- Blade-Vortex Interaction- High-Speed Impulsive

Engines: air intakes and exhausts

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True figures to know

Close to your bed

On the road

68 dB

77 dB

72 dB

73 dB

What you hear if you are sleeping here

In your room, loud and clear!

70 dB

5

Rules for noise certification

ICAO noise standard certification for each type of helicopter :– Maximum permissible noise level.

Helicopter noise level certified to the standard applicable at the date of the airworthiness:

– If evolution of the type : no obligation to get new certification.

Two standards applicable for noise certification : ICAO Annex 16, Chapter 8 or Chapter 11 (< 3175 kg).

− Although more restrictive, Standard Chapter 8 supported by EC: – it includes 3 flight conditions (fly over, take off and approach).– better reflects human hearing (EPNL instead of SEL).

Therefore, utmost care should be exercised when making comparisons with competitors:

− Helicopter noises can only be compared when certified under the same Standard Chapter.

Eurocopter has invested heavily in acoustic research, to become the leader in this field

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Eurocopter: the quietest range in the world

Two major innovations gave Eurocopter the leadership:

Automatic variable speed control system.– Exists on EC130, EC135, EC225

Quiet Fenestron shrouded tail rotor, belonging to the latest generation

of Eurocopter aircraft. It is designed with unequally spaced tail blades.– Exists on EC120, EC130, EC135, AS365 N3, EC155, EC 145 T2

Some results:Some results:

EC120, EC130 and EC135 were the first helicopters to comply with Grand Canyon National Park most restrictive level .

In 1996, the EC120 and the EC135 were rewarded for the

result in terms of global noise level in their category (Decibel d’Or).

Eurocopter’s modern range is still the quietest in the world.

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A 30-year experience in noise reduction design

EC130

EC135

EC120

DauphinGazelle

• Reduced rotation speed

• Non continuous angular distribution of the blades

• Higher distance between rotor and stator

The silent tail rotor (Fenestron®) 1970 1980 2000

The reduction of Fenestron® noise is a topic of continuous research and development, and Eurocopter is pursuing both passive and active

noise reduction methods.

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Main rotor noise

Blade-Vortex Interaction (BVI)

Cause : Large, impulsive loads induced on the surface of the blade by previously shed tip vortices.

Effect : Loud and annoying popping sound, efficiently radiated to the far-field.

Mitigation Methods Reducing strength/core size of vortices Reducing blade response to vortices Increasing miss-distance Optimization of the blades tip shape

9

GREEN : Bluecopter Technology

Blue Edge™ Blade (EC + Onera)− A breakthrough in main rotor blade concept.

− Double swept design.

− Passive concept.

− Reduce the typical Blade Vortex Interaction (BVI) noise.

− Increase the performances.

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GREEN : Blue Edge principle

Strong BVI occurs when blade is ‘parallel’ to a vortex.

Blue Edge™ blade concept: Avoid strong parallel interaction on the entire blade interaction still occurs, but is weaker.

Tip vortices

V

Tip vortices

V

Parallel interaction on the entire blade

Tip vortices

V

Tip vortices

V

Parallel interaction only on part of the bladeSoundExplain

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– Technology: Piezo-electrically actuated servo flaps

– Benefits:

– Exterior noise & cabin vibration reduction

– Dynamic load reduction

GREEN : External noise reduction - Blue Pulse

Active Blade Control by flaps = Impulsive Noise Reduction

World Premiere 8 Sept 2005

Flight with Active Flaps on EC145

Smart ActuationSmart Actuation

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GREEN. External noise reduction - Blue Pulse

Piezo-actuator

Flap element

Technology

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To reduce external noise – Drag– Active blade trailing edge.– Flight abatement procedures

To reduced engine consumption &

noise at same performance.

GREEN : Friendcopter

Helena code

Active trailing edge

Modified lateral intakes and gas exhausts

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GREEN: Friendcopter

HELENA code– Predict helicopter noise footprints & define new procedures for

low noise approach and take off of EC130/EC135. – Help manufacturers to predict the external noise of the new

helicopters under certification conditions.– Support of heliports authorities with respect to noise impact on

the surrounding area.

Application : to all helicopters of Eurocopter

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Greenhouse effect sources

Examples of percentages of the global annual emissions

of anthropogenic GHGs (in terms of CO2 – eq)

during the 1970 – 2004 period

Sou

rces

: IP

CC

wor

ldw

ide

data

(20

04) + = 13.5%

= 8% !

= 19.4%

= 2.8% !

In this period, civil aviation was less than 3% of the total.

General aviation (out of scheduled & non-scheduled

airliners) is only 1% of the civil aviation, less than 0.03% of

the total world GHGs emissions.

Helicopters represent around 1/10th of this total.

A very small figure indeed! So what is the contribution of

helicopters? Infinitesimal!!

… but in 2005, part of transportation has grown to 23%, of which only 2.65%

were from Aviation activities

= 25.9%

+

+

+

+

= 13.1%

+

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The turbine’s gas emissions

Average figures (% in weight)

Air

+

N2

+

O2

Kerosene

C12H23…

CO2 72%

+

H2O 27.6%+Other 0.4%

CO2 & NOX have a negative impact on the

greenhouse effect. CO2 is cumulative and permanent.

NOx is decayingin time but affects population health.

N2 75.2%

+

O2 16.3%

+

Other 8.5%

Soot 0.1% + UHC 4%+CO 11.9%

+

NOX 84%

UHC = Unburned Hydrocarbon

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CO2 emissions reduction: a huge challenge

0

100

200

300

400

2000 2010 2020 2030 2040 2050

% o

f C

O2

Em

iss

ion

s c

om

pa

red

to

ye

ar

20

00

(Courtesy )

500 Growth in passenger/km

“Sustainable” aviation emissions targets

Possible improvement in flights management

Effect of alternative fuels

Impact of best possible available technology

Aviation has the highest steady growth rate; and CO2 has become the primary threat …

… to the aviation industry growth

Aviation is an essential part of the world economy. To fill the gap, the aviation industry must develop new technologies; and share the technical benefits in order to offer cost effective “green” aircraft. Growth rate estimated in early 2008, before the world economical crisis.

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What is a “green” helicopter engine?

Compared to the today’s turbine, it is an engine with drastic reduction of pollution during all cycle life See Clean Sky / ACARE targets:

– Fuel consumption: rate reduction of pollution directly in relation with fuel reduction rate.

– CO2 reduction: directly dependant on fuel reduction but can also be achieved by some alternative fuels.

– NOx reduction: benefits from SFC reduction but can only be radically reduced by using specific combustion technologies.

– Noise reduction: achieved by emission reduction and emission attenuation.

– Application of REACH regulation: eliminates from product and processes the substances and products which are dangerous for health and environment.

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Reduction of gas emissions: already done ….

Beyond the Clean Sky targets, in 2020, the specific consumption of a 500/800

kW turbo-shaft engine will have decreased by 16% since 2000.

Arrius: CO2 emissions have been reduced by 15% over the last 10 years.

Arrius: NOx emissions have been reduced by 65% over the last 10 years.

Facts & Figures:

From the 50ties to the early 90ties the consumption has been dramatically reduced:

Artouste 2C = 144 kg/h = 3.03 kg CO2/km

Arrius 2F = 97 kg/h = 1.50 kg CO2/km

33% consumption less! 50% emissions less!!!

+ More power (safety) and higher speed (time saving)

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Alternative fuels: technical and logistic points to be cleared

Examples of points to be checked:

– To insure that bio-fuels bring CO2 reduction on full cycle and without

competition against human nutrition and not detrimental to world forest areas

– Physical-chemical properties of synthetic fuels: lubrication capability, energetic

density, compatibility with other materials, behavior at extreme T° (high and low)

…

The CO2 reduction is directly dependant on fuel reduction but can also be

achieved by some alternative fuels; but they must offer:

– Suitability: specific energy, combustion characteristics, storage stability,

compatibility, …

– Sustainability: long term potential, lower impact on the environment (GHG) during

the full “life cycle process” of the product, impact of extraction on resources, …

– Industrialization: mass production, acceptable cost, distribution, …

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Alternative fuels: on-going research program

– Selection of the most appropriate fuel brand.

– Fuel impact on engine systems.

– Tests of components.

– Demonstration incl. long endurance tests on

existing engine.

– Demonstration that alternative fuels (50% JetA1 + 50% HVO (UOP)) can be used

in an aero-engine without major modification and in H/C fuel system. Official

approbation of ASTM standard D7566-11: up to 50% bio derived jet fuel can be

added to conventional jet fuel for commercial use.

The goal of DREAM (WP5), is to demonstrate, only for technical aspects,

the ability of a turboshaft engine to operate with alternative fuel.

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Optimal: to save fuel by saving time

Rotorcraft SPECIFIC procedures:

– Specific IFR approach procedures

based on GBAS, SBAS

– Steep / Curved / Segmented IFR

approaches

– Simultaneous Non Interfering (SNI) IFR

procedures

– Enablers: GBAS, SBAS.

Optimised Procedures and Techniques for Improvement of Approach and Landing.

Air-ground co-operative project, which is aiming to define and assess:

a) Innovative procedures for the approach and landing phases of aircraft and rotorcraft.

b) New ATC tools and new airborne functions to support these new procedures.

At the same scale !

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Eurocopter: a member of the “Clean Sky” project

Joint Technology Initiative “Clean Sky” for Aeronautics & Air Transport

– Clean Sky JTI is one of the largest European research projects

– Budget: €1.6 billion, equally shared between the European Union (DG Research) and industry,

– Aim: to speed up technological breakthrough developments and shorten the time to market for new solutions tested on Full Scale Demonstrators.

– Target: To reduce noise, gas emissions and impact of aviation industry on the environment

Eurocopter : funding member of the JTI and co-leader of Eurocopter : funding member of the JTI and co-leader of the Rotorcraft ITDthe Rotorcraft ITD

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Clean Sky: A Joint Technology Initiative

6 Integrated Technology Demonstrators (ITD)Eco-design

for Airframe and Systems

Green Regional Aircraft

Green Rotorcraft

Clean Sky Technology

Evaluator

+ AgustaWestland

Smart Fixed-Wing Aircraft

Sustainable and Green Engines

Systems for Green Operations

• All market segments addressed

• Whole supply chain involved

• Integration of mature techno bricks

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GRC technical objectives

Emissions reduction

REACH REACH compliancecomplianceREACH REACH compliancecompliance

Halving noise

Green Life Cycle

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GRC technical objectives

Project Foreseen Demo Configurations

GRC1(blades)

Ground testing of a full scale active blade segmentDownscaled wind tunnel model with active and passive bladesFlight with optimised rotor (Westland, TBC)

GRC2(drag)

Downscaled wind tunnel modelFlight with modified rotor hub fairings; improved turboshaft engine installationVirtual H/C integrator

GRC3(electrical systems)

New electrical architecture for medium/heavy helicopters with corresponding equipment tested on “Copper Rig”

GRC4(Diesel engine)

Modified EC120 (2 ton class) with Diesel engine to be adapted/developped

GRC5(Flight path)

Quiet departure & landing to/from :Airport with commercial traffic (SNI Simultaneous Non Interfering)Heliport IFR & VFR fuel-saving routes

GRC6(Eco-Design

Rotorcraft Airframe)

Industrial applicability of EDA* results of full life cycle for : Typical helicopter composite components : door, cabin floor Typical helicopter metallic components : gear box housing and gear

* EDA= EcoDesign for Airframe (generic for all types of aircraft)

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GRC technical objectives

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GRC1 - Innovative Blades

Reduction of both Noise & Power Demand, by means of : – Design optimization i.e. tailoring of shape & structure

– Active control esp. active twist

Based on background from earlier / on-going projects :

− Friendcopter (WP5):

− Active flexible trailing edge

− Active twist

− GOAHEAD

− Computational Fluid Dynamics

− Wind tunnel data base

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GRC2 - Drag Reduction

Drag Reduction of airframe & non-lifting rotating components :

– Main and tail rotor pylon & hub

– Fuselage-tail junction

– Turbo-shaft engine installation

(intakes, nozzles)

– Tail unit and tail surfaces

– Shape optimization

– Active flow control

– Wind tunnel tests & flight demos

– Lower fuel consumption & CO2

Methods:

Hub Powerplant

Tail coneTail unit

Results:

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GRC3 – Electrical Systems

Goal : removal of hydraulic fluid, deletion of engine bleed air circuit.

Efficient electrical generation, conversion and distribution (generic for small aircraft).

Electromagnetic Actuators for helicopter flight control (ground testing).

Efficient power generation and control for piezoelectric actuation, esp. active blades.

Electrically driven Tail Rotor (concept studies).

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GRC5 – Environment-Friendly Flight Paths

SNI shorter routes to minimise fuel emission and gas emission

IFR & VFR approach and departure procedures (noise footprint minimization)

Low level VFR & IFR en route navigation (noise impact minimization)

Consistency of IFR low noise procedures with ATM (Simultaneous non Interfering approaches)

In IFR conditions, automatic generation of low noise flying path (implementation of predictive noise footprints and automatic low noise flight through FM – automatic pilot)

In VRF conditions, real time update of noise footprint model (through a board sensors) allows the pilot to follow the lowest noise flying path.

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GRC4 – Installation of Diesel Engine

Target : light single helicopter (EC120)

Investigation of the concept

Integration study

Engine specification => Partner to develop / adapt

Ground testing (+flight beyond Clean Sky)

Take-offCruise

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Installation of a Diesel engine on a light helicopter

Rationale and technical targets:– Small turbine engines helped the light multi-mission helicopter market

to grow fast from the fifties, thanks to significant advantages w.r.t. AVGAS piston engines :

– Automatic control of the rotor speed.– Large weight saving, despite higher fuel consumption and bigger tanks.– Better safety without carburetor and ignition problems.

– Further improvements beneficial to all sizes of helicopters came :– Free turbine engines helped to get rid of clutch problems.– Digital control units helped to optimize the engine power ratings all over the flight

envelope and to improve safety.

– Diesel car engines made tremendous progress in the fields of :– Direct high pressure fuel injection.– Digital control system.– Turbocharger.– Emissions control.

In addition to the large reliability improvements of all components specific

to reciprocating engines brought by the huge car market and competition.

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Installation of a Diesel engine on a light helicopter

Rationale and technical targets…– Today, the advantages of such modern Diesel engines for

helicopters are clear :– the engine maximum power can be down sized by approx. 20 % thanks to

the turbocharger which provides constant power up to high altitudes,

– the thermodynamic efficiency is in the range of 32-35 %, instead of 25 % for small turbine engines the sophistication of which is limited by the cost aspects

– the maximum efficiency (i.e. the minimum fuel consumption) is kept on a large power range, and not only at the Take-off power.

– the installation power losses at the level of air intakes and exhausts are potentially eliminated.

– The helicopter market has the opportunity to take advantage of synergies with the car industry in terms of :

– reduce rate of FOSSIL FUELS USE.

– engine EMISSIONS CONTROL and REDUCTION.

– further EFFICIENCY improvements.

– COSTS and SUPPORT network.

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Installation of a Diesel engine on a light helicopter

Rationale and technical targets…

– Preliminary analysis helped to define the following targets :– 45 % average fuel consumption reduction.

– 50 % NOx emission reduction.

– 500% CO (poison gas) emission reduction.

– TBD % CO2 emission reduction (no reference known on turbines, but should follow the fuel consumption reduction).

– TBD % (> 100%) particles emission reduction thanks to particle filters.

Viability of the concept is closely linked to a weight optimization of piston engines and integration into the helicopter in order to recover the empty weight penalty through fuel savings in less than 1 HOUR flight time, instead of a 2.5 hours order of magnitude with the current available data.

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How to Measure Environmental Performance

Need for environmental information

– Public acceptance of helicopter activities is under attack–Compliance: ever-demanding environmental regulations–Market demand: emerging need to understand helicopter’s environmental performance

Need for a specific indicator–Simple to understand: visual, transparent, honest–Specific to helicopters and different from other means of transportation–Could become an industry standard

Need for an additional benchmark tool–Environment is another criterion for selection in addition to performance, safety, costs, DMC, comfort, etc. –Will trigger R&D efforts in environmental areas

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3 Life Cycle Stages, 2 Predominant Criteria

Over the entire life cycle, the operation phase contributes to up to 70% of a helicopter’s total environmental impact

Noise and emissionsare dominant during operations

3 Life Cycle Stages, 2 Predominant Criteria

« Eurocopter believes that transparent environmental communications by the rotary-wing aircraft industry is essential to building a relationship of trust with the public, and it encourages industry stakeholders as well as to invest heavily in the protection of the environment » Eurocopter President & CEO Lutz Bertling said.

The following metrics (noise and emission) has been established and published by Eurocopter.

The committee’s efforts resulted in proposals for slight modifications of Eurocopter’s initial environmental performance indicators and the company now plans to integrate these recommendations in the definitions of environmental indicators.

In the frame of an AHS Int’l ad hoc committee, it has been discussed with the other manufacturers.

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Perceivable Noise

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Emissions: equivalent CO2 = f (fuel flow)

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Flight Hours Rather Than Distance

Emission as a function of distance

– Already an established standard for cars = CO2/ km.

– Airliners do not compete favorably.– Totally inappropriate for helicopters.

Emission factor should consider helicopter’s multi-role capacity– Point-to-point transportation accounts for just 30% of total missions.– Aerial work and SAR missions are performed at hover.– Time generally matters more than distance.

What is an average mission profile?– Hover: 10%– Vbe: 30%– 120 kts: 60%

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Metrics

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Appendix: Eurocopter Compared to Competitors

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Eurocopter commitment to “industrial” environment

Context– Eurocopter is working in a worldwide competition.

– Regulations are national, European or/and worldwide.

– Management of obsolescence is a legal necessity but

Eurocopter set up a preventive policy and is working in advance.

Difficulties– Actors (Customers, Suppliers) are not in the same regulatory system (Europe, Asia, Americas…).

– Legal requirements are at different levels (Europe, States, Regions), applicable rules also depend on internal policy, contract specifications, export authorizations,… .

Protection of the Environment: a global approach– ISO 14001: an Eurocopter group willingness

– REACH: an European regulation (1st June 2007)

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ISO 14001: To improve the environmental situation.

Key issues: ISO 14001 introduction for a transversal

organization allows:

– Taking into account of the environmental impacts of

Eurocopter’s activities and services at every level.

– Matching the suitable responses with socio-economic and

legal requirements.

The goal is to be in accordance with the most stringent

rules related to environmental protection for the following

activities:

– Surface treatment

– Painting materials and processes

– Management of wastes

– Control of chemicals and studies for substitution if necessary

– Reduction of atmospheric emissions and power consumptions

– Products recycling or “green” elimination processes

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French sites environmental actions plan

Improved management and use of chemicals:

– To ensure 100% traceability

– To secure 100% procurements

Control of atmospheric emissions:

– To realize 100% of mandatory measurements

– Reduction of VOC emissions: 40% Marignane,

65% La Courneuve

To improve waste’s management = reduction

of 3%, valorization 70 %

Reduced consumptions:

– Energy = - 3%

To develop sense of responsibility towards:

– 100% staff awareness of environmental issues.

– 100% of the most important internal suppliers.

ISO 14001 Certified

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Environmental technology for “green” environment

Donauwörth

– Surface treatment sector: the painting booths have been equipped with an air flow

rate system of 160,000 m3/h.

– Heating plant (40 MW): ultramodern control system and new pumps are parts of the

equipment which will reduce CO2 emissions by 25% per kWh and will decrease the

consumption by around 10%. Investment: € 240,000.

ISO 14001 Certified

In June 2008, the adhesion of ECD to the

Bavarian Environmental Pact was signed.

This is a commitment that ECD environmental

efforts will go beyond legal requirements.

Advantages of the systems:• Cost reduction• Reduction in CO2 emissions

• Reduced emissions of particles

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Environmental technology for “green” air

Among the goals:

– to reduce environmental impact,

– to use substitution goods,

– to decrease the risks for workers by design,

– to minimize the risk of fire.

ISO 14001 Certified

La Courneuve: the new Blades Finishing Workshop recently inaugurated.

− Dust particles picked up by sucking devices at the source (sanding machine),

− Painting booths only fed with clean air and equipped with filters,

− Replacement of 2 or 3 products by only one being a lower rate of Volatile Organic Compounds emission,

− Substitution of primary paints by other ones less dangerous.

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Environmental technology for “green” protection

− Innovative infrastructure with recycling system based on the

prevention principle.

− Different types of waste sorted and collected separately.

− Site’s underground sewage network designed to minimize

maintenance overheads by limiting the output of untreated waste,

reducing noise emissions, spillage and accidental release, while

cutting energy consumption.

ISO 14001 Certified

Albacete

− Internal audit, preliminary appraisal and certification audit are planned by end of in the coming weeks.

− Workshops team leaders have received training on environmental impacts of production activities.

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REACH: Registration, Evaluation and Authorization of Chemicals

Objective : EU regulation to protect human

health

and environment.

Will impact: - chemical elements (natural or obtained

by manufacturing),

- their compounds, - all

substances containing them.

New way of doing Business = Reversal of the

burden of the proof:

– Industrials to prove the safe use for each substance.

– Major legal liability (criminal, civil, administrative).

– Each use not formally authorized is forbidden.

– Information to be exchanged throughout the supply

chain, to be transmitted to customers and employees “Tool”: European Chemicals Agency – Located Helsinki

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REACH: Technologies must be into “Green Fields”

Better evaluation of the risks throughout their cycle of life and

progressive elimination of the most hazardous substances of which the

residual uses will be under authorization.

Among 30,000 substances, 3,000 declarable ones,

……. of which 300 may have to be replaced.

Carcinogenic, mutagenic, toxic to reproduction

Very toxic to aquatic organisms, may

cause long-term adverse effects in the aquatic

environment

Business risks: “No data = no market” => potential supply Business risks: “No data = no market” => potential supply chain disruptionchain disruption

Conclusion

The "greener helicopter" is not a luxury– More & more a prerequisite of the acceptance of rotorcrafts by the

 "civilian society" and thus a condition for the operators to increase the scope of their operations.

Lost of "greener" is of course a key point: it must not endanger the profitability of the sector.

"Green" is one of the 4 research axes of Eurocopter– It must be consistent with the 3 other ones:

Safety Cost reduction Extension of the fields of use

Eurocopter is investing in a consolidated matter in these directions to propose to its customers, products even more adapted to the needs of tomorrow

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