Aircraft Updates

B757 Upgrade Update

‘Almost Rebuilt’

Boeing NZ7571 is in the final stages of re-assembly at Mobile Aeronautical Engineering (MAE), in Mobile, Alabama. The complexity of the modification programme has been particularly evident during this final integration and assembly phase. The main cabin is slowly being rebuilt with final wiring, relocated toilets, galleys, baggage units, internal air-stair, crew access ladder, overhead lockers and panels progressively being fitted. This has been a challenging period for everyone involved.

Fourteen RNZAF personnel deployed to Mobile in early January of this year to commence Acceptance Test and Evaluation (AT&E) support activities for the Ministry of Defence and to conduct training on the aircraft’s new and modified systems.

A significant milestone was achieved on February 3, with the successful testing of the Electronic Flight Bag (EFB). The EFB was successfully integrated for the RNZAF by the MoD Resident Project Team in Mobile, in partnership with personnel from the Directorate of Logistics Capability, the Introduction Into Service team and the Integrated Mission Support Squadron.

The palletised seating system to be used for the modified aircraft has been completed and is ‘mocked-up’ in the hangar adjacent to the aircraft, awaiting ground testing once the cargo handling system is fitted to the aircraft.

Ground testing was scheduled to commence in late February, leading through to flight testing in Mobile in late March. NZ7571 will be delivered to Boeing Integrated Defence Systems (BIDS) in Wichita, Kansas by RNZAF flight crew, following flight testing in Mobile for fitting and testing of the military communications and navigation system components. The aircraft is planned to return to NZ to commence Operational Test and Evaluation (OT&E) and graduated tasking in mid- May 2008.

The second aircraft, Boeing NZ7572, is well advanced into the structural modifications phase of the upgrade for the cargo conversion, with the Door Surround Structure currently in place and being ‘stitched in’. NZ7572 is scheduled to commence AT&E in late June.

C-130 Life Extension Project Update

A significant milestone in the progress of the C-130 Life Extension Project has been achieved at the L-3/SPAR facility in Edmonton, Canada with the arrival of two crews from 40 Squadron and commencement of formal training with the company on 22 January 2008.

Training

The training course will cover all aspects of the new systems fitted to the aircraft and prepare the crews for the Ministry of Defence led Acceptance Test and Evaluation (AT&E) of NZ7003, the prototype and first of our aircraft to be modified. The course will also help in the development of the training material required to convert current Squadron crews to the updated aircraft and, in the future, take ab-initio aircrew from flying training and convert them to C-130 operations.

Running in parallel with the training course is the comprehensive ground testing of the aircraft systems to ensure that the systems meet our requirements and will be safe to operate in the air. The complexity of the integrated system requires us to utilise the Part Task Trainer, a procedural training tool developed by CAE Canada, which is specific to the RNZAF aircraft configuration. Whilst not a full flight deck simulator, the Part Task Trainer has proved to be an extremely valuable tool in developing and practicing basic and emergency procedures and will certainly be of significant benefit to training when installed in the new facility in Whenuapai. The Part Task Trainer development is supported by W/O Kelman from the Integrated Mission Support Squadron (IMSS) who has the responsibility of supporting complex training devices in day to day use.

The RNZAF will also soon provide additional resource to the Resident Project Team to assist in preparing the aircraft for use with our Computer Maintenance Management System (CMMS) and for the management of rotable items removed from NZ7004.

Meanwhile progress on NZ7004, the first production aircraft, continues as components are progressively removed; these include the horizontal and vertical stabilisers with the centre wing due extraction in March. In addition, SAFE Air limited is working steadily with L3 SPAR in preparing for the second production aircraft (NZ7001) which will be inducted into SAFE later this year. Furthermore, the RNZAF has also recently committed a number of technical personnel to work with the NZMOD as resident team members overseeing the SAFE Air activity.

Back in New Zealand, a number of technical personnel are preparing to depart for Edmonton, to join their operational counterparts as part of the formal training program. Preparations are also well underway, in order for the RNZAF to undertake the necessary Operational Test and Evaluation (OT&E) of this new capability immediately following the return of NZ7003.

Testing

The first aircraft is progressing well through its ground testing and with the training being conducted in parallel, both the aircraft and crews will be ready to commence the flight testing programme. As well as dealing with the rigours of test flying, both the aircraft and crews will have to cope with the often extreme weather conditions in Canada, with 20° C below mornings not being uncommon. On completion of Acceptance Testing, NZ7003 will return to New Zealand, to undertake OT&E of the new systems fitted to extend the life of this sturdy workhorse of the RNZAF.

P-3K2 Update

NZ4204, the RNZAF P-3K aircraft currently undergoing an avionics and sensor upgrade in Greenville, Texas has seen significant progress during the past few months with many visible project milestones being achieved. As the project moves into the sensor and system integration and testing phase, the complexity and scope of the upgrade has required an extension to the project schedule. The delivery date for the prototype aircraft is now January 2009, some eight months later than originally programmed. The highly integrated nature of the aircraft upgrade requires extensive testing to ensure that each component and system performs to documented specifications. RNZAF staff in Texas are working with the Ministry of Defence and L-3 teams to ensure that the RNZAF receives a quality product whilst minimising delays wherever possible.

Milestones

Visible hardware related milestones recently completed include the completion of the Data Management System (DMS) installation, a completed ‘fit check’ of the new flight deck instrumentation and the installation of new upper fuselage antennas. On the sensor front, the Radar antenna and Electro Optic turret installations have been completed. From a hardware perspective, all that remains is the final installation of the flight deck equipment and lower fuselage antennas.

Software & Integration Testing

The Systems Integration and Training Lab (SITL), which is effectively the ‘P-3K2 back end simulator and test lab’, is being utilised for daily DMS software testing and subsystems integration. Weekly software builds are tested by L-3 engineers to verify the software and hardware integration processes.

The majority of the sensor sub-systems have completed their integration practice tests or ‘dry runs’ in preparation for the formal Factory Acceptance Test scheduled for April 08. The onsite NZ team has been impressed by the capability enhancements that the new equipment will offer and look forward to the day that NZ4204 lands back at home at Whenuapai.

RNZAF Preparations

Meanwhile, preparations back in New Zealand have stepped up a gear with the completion of the Integrated Mission Support Squadron (IMSS) infrastructure and the formation of a Training Design (TD) team. The TD team is tasked with developing the training packages for the P-3K2 Conversion Course and ab-initio Air Warfare Specialist (AWS) training. SQNLDR Glen Graham has been appointed the TD Team lead with W/O Mork McCorkindale (AWS) and FLTLT Jayd Hickey (EDUC OFFR) assisting him. SQNLDR Graham points out that ‘the Air Warfare Specialist trade will be faced with a diverse range of new challenges onboard the P-3K2, hence the need to completely redesign the training courses.’

Training

The 10 members of the P-3K2 avionics team have completed their prerequisite training in preparation for their three month deployment to Texas to undertake contractor provided maintenance training. The complex nature of the new aircraft systems has required the RNZAF technicians to increase their computer networking and specialist sensor knowledge prior to deployment. The leader of the avionics team, F/S JC Thompson, says that the team members are “chomping at the bit” to get their hands on the new and exciting systems onboard the upgraded aircraft. To support the introduction of the technologically advanced systems, CTRGG, ACAFPERS, DLC and LMTC staff have been busy redesigning and scheduling courses for the technical trades that will support the P-3K2. An 11-member aircrew team, drawn primarily from No. 5 Squadron, will deploy with the maintenance team to undertake P-3K2 system training followed by a period of formal acceptance testing and evaluation flights. The challenging training and testing phase will see the aircrew and maintenance teams in Texas for up to seven months. As with all RNZAF capability enhancements, there are many more personnel ‘Stepping Up’ behind the scenes to ensure that the P-3K2 introduction and ongoing operational and logistics support are planned and professionally managed. The introduction of the P-3K2 will provide an enhanced level of capability to the RNZAF, NZDF and ultimately the Government and people of New Zealand. The P-3K2 is definitely a STEP UP!

NH90 Critical Design Review

NZ Ministry of Defence and RNZAF representatives recently attended the NH90 Critical Design Review (CDR) held at NATO Helicopter Industries (NHI) headquarters in Les Milles, France. Held over the period 26-30 November, CDR was a major project milestone at which the detailed design of the helicopter was frozen prior to production commencing. The review involved a detailed examination of the proposed TNZA design (TNZA is the RNZAF’s NH90 variant designation) in order to confirm that the Crown’s requirements are satisfied. While there is still ongoing work regarding a few of the detailed issues raised during the review, the overall objectives of CDR were successfully achieved.

While NHI is the NH90 Original Equipment Manufacturer (OEM) the helicopter is actually manufactured by four Partner Companies (PCs). The PCs are Eurocopter (France), Eurocopter-Deutschland (Germany), Stork-Fokker (The Netherlands) and Agusta (Italy).

The PCs act as NHI’s subcontractors with delegated responsibilities for the design, development, production and qualification of specific aspects of the NH90. A lead PC is appointed for each customer and is responsible for the final assembly and qualification of that customer’s NH90 variant. The lead PC for the TNZA is Eurocopter with final assembly being undertaken at their facility at Marignane, France.

The first TNZA is scheduled to be delivered to the Crown in France in late 2009 and, in order to meet production schedules, the PCs have already begun manufacturing the TNZA fuselage modules. Once completed, the modules will be transported to Marignane for fuselage mating (circa April 2008) and for subsequent component and systems integration, testing and qualification prior to the delivery of the prototype aircraft.

Breakdown of NH90 Parts and their Origins

Fokker (The Netherlands)

• Tail structure – doors and sponsons
• Landing gear – intermediate gear box

Eurocopter (France)

• Power plant – rotors electrical system
• Flight control system
• Core avionic system
• Assembly line for New Zealand, France, Sweden, Finland, Greece, Oman, and Australia.

Eurocopter (Germany)

• Forward and centre fuselage fuel system
• Communication system
• Avionics control system
• Common and TTH mission systems
• Assembly line for German TTH and NFH

Agusta Westland (Italy)

• Rear fuselage – main gear box
• Hydraulic system
• Automatic flight control system
• Plant management system
• NFH mission systems and integration
• Assembly line for Italian, Dutch, Portuguese and Norwegian NH90

On 30 January 2008, SQNLDR Shaun Johnson travelled to the Eurocopter Deutschland (ECD) factory to participate in a ceremony to celebrate the completion of the first NZDF NH90 (TNZA-01) fuselage modules.

Although NH90 fuselage modules are produced at a number of locations throughout Europe, all TNZA centre and forward fuselage modules will be manufactured at the ECD facility, with the rear fuselage sections being manufactured at the Agusta factory in Southern Italy. After assembly in Germany and Italy, TNZA fuselage modules are transported to Eurocopter France (Marignane) where they are glued and riveted together before entering the NH90 Final Assembly Line. TNZA-01 is scheduled to enter the Marignane Assembly Line in April of this year and will be ready to commence test flying by Jan 09.

SQNLDR Johnson is currently seconded to NZ MoD as the Engineering Manager of the Crown’s NH90 Project Team at Eurocopter France. He has been with the TNZA project since 2004, moving to Southern France in Nov 06 with his family. When asked for his thoughts on representing the Crown at this ceremony, SQNLDR Johnson stated:

'Participating in this ceremony was both an unusual and rewarding experience.

It was unusual from an RNZAF Engineer’s perspective as, at first glance, the NH90 fuselage sections resembled parts of a large plastic model. Apart from a handful of metallic components in areas of extreme temperature, wear or loads, the NH90 is almost completely made from composites. Yet the individual composite beams, frames and panels are held together with traditional aircraft fasteners such as bolts and rivets. This mélange of traditional and modern aircraft manufacturing techniques means that as well as being incredibly light, the NH90 fuselage can be repaired using many of the maintenance techniques that our aircraft technicians are already familiar with. Exterior panels and even some primary structural components can be de-riveted and replaced or repaired if damaged.

As a member of the project team, this experience was very rewarding. Seeing and touching our first fuselage components provided me with the first tangible evidence of the many thousands of hours of work that have gone into the NZDF Medium Utility Helicopter project. I think it is important to remember that personnel from all corners of the NZDF and MoD have contributed to this project. From the first draft of the Iroquois replacement study, to TNZA NH90 Critical Design Review held in France late last year, the success of this project has relied heavily upon NZDF support.

Of particular note, the MoD Project Team in France could not function without the dedicated support of the RNZAF Directorate of Logistics Capability and Introduction into Service Team members. So I was both proud and humbled to attend this ceremony as the representative of everyone who has contributed to this project thus far.'

Image Gallery - Issue 90