The never-ending pursuit of reduced life-cycle costs for helicopter operators is inspiring engine maker Rolls-Royce to develop new dual channel Fadec and control systems to replace hydro-mechanical equipment on some legacy turboshafts, which will not only help keep costs low but provide additional health monitoring and data recording capability. These technology upgrades are in early use on the 650- to 715-shp Series IV members of M250 family today with the Boeing AH-6i helicopter and the Northrop Grumman MQ-8C Firescout. Recently, Rolls-Royce signed an agreement with MD Helicopters to release the upgraded engine, designated the C47E model, to the MD530F.  

 “These systems will improve the reliability of engines, and we expect to be able to introduce increases in TBO [time between overhaul] for some components, resulting in lower dollar per operating hour for customers,” explained Jason Propes, Rolls-Royce’s senior vice president for helicopters and light turboprops.

Another recent upgrade for operators, is the Value Improvement Package kit that allows Series IV operators to boost hot and high performance by up to eight percent. The modification, which went into production in 2016 and is standard equipment for the M250-C47B/8 engine that powers Bell’s new 407GXP aircraft, is based on design changes to the impeller, diffusor and first-stage nozzle that improves air flow. It also delivers more power and up to a two percent reduction in fuel consumption.

“This is all part of how we are trying to offer more value,” Propes told AIN. “It starts with providing an affordable propulsion solution and then looking to reduce life-cycle costs for operators, delivering more for the same or lower cost.”

This year, the M250 turboshafts are set to pass an impressive milestone of having flown 250 million hours. The extensive engine family has powered more than 170 different types of helicopter.   

Rolls-Royce is also in talks with customers to discuss ways to further improve the process by which performance data is gathered from its engines as part of the drive to reducing operating costs. “We know that the use of data to drive smarter operational decisions is increasingly a desire for our customers,” said Propes. 

In the same vein, Rolls-Royce is developing a new engine management unit for the CTS800 turboshaft produced by its LHTEC joint venture with Honeywell. This will provide a clearer and more comprehensive data record from the engine, which powers Leonardo Super Lynx 300 and AW159 Wild Cat military helicopters.

The manufacturer also plans to expand the certified operating envelope of the CTS800 to allow greater mission versatility. The engine was recently selected to power Turkey’s new light utility helicopter.

Production continues of the RR300 engine, which provided an affordable turbine powerplant for helicopters at the upper end of the piston-powered spectrum. In March 2015, Robinson Helicopters signed a contract calling for 1,000 RR300s over 10 years. Rolls-Royce has no current plans to restart development of the more powerful RR500 turboshaft, which was suspended back in 2012.

New Service App

At this week’s Heli Expo show, Rolls-Royce is launching a new application that will give operators easy access to its service network on any smart device. Via clickable links, it will allow customers to locate and contact service locations around the world.

Meanwhile, improved customer support infrastructure is part of a $600 million investment being made over five years at Rolls-Royce’s main U.S. facility in Indianapolis. The company is conducting a complete renovation of its manufacturing plant.

“We’re very proud our performance in customer satisfaction surveys recognizing our network of third-party and factory-owned service centers globally,” concluded Propes. Its customer support center in Indianapolis operates on a 24/7 basis, supplemented by parts distribution service provided by Aviall.