Project

Explanation

Description

The $2,088 million Air 5402 project will provide the ADF with five new generation Airbus A330 Multi Role Tanker Transport aircraft (MRTT), to be known as the KC-30A in RAAF service. The MRTT will be equipped with both hose & drogue and boom refuelling systems capable of in-flight refuelling of current and future aircraft, including F/A-18 Classic and Super Hornets, F-111, Hawk Lead-In Fighter, Wedgetail Airborne Early Warning and Control, C-17 Globemaster III, and Joint Strike Fighter. The MRTT will also provide significant Air Logistics Services capability for carriage of up to 270 passengers and cargo. The acquisition also establishes the infrastructure necessary to deliver services including engineering, maintenance, spares management, technical data, software and training support for the new fleet.

Background

Government gave the equivalent of second pass approval in May 2003 for a new generation air-to-air refuelling capability.

An open Request for Tender was released in June 2003 for both the Acquisition and Through Life Support Contracts. In April 2004, Government announced that the Military Transport Aircraft Division of the European Aeronautic and Space Company Construcciones Aeronauticas S.A. (EADS CASA), teamed with Qantas Defence Services, had been selected as the preferred tenderer for the supply of five Airbus A330 MRTT aircraft and their associated support.

The Acquisition Contract was signed with Spanish company EADS CASA in December 2004. The Through Life Support Contract was signed with Qantas Airways Limited in February 2007.

In April 2009, the Military Transport Aircraft Division of EADS was amalgamated with the Airbus Military Division, and commenced trading as Airbus Military.

The A330 MRTT is based on the Airbus A330-200 medium/long-range twin aisle commercial aircraft. The first (prototype) aircraft is modified and tested by Airbus Military in Madrid, Spain. The remaining four aircraft are modified by Qantas, under subcontract to Airbus Military, at the Australian Conversion Centre, located at Brisbane Airport, Australia.

A Contract Change Proposal (CCP) was signed in March 2006 for the procurement of a Full Flight Mission Simulator, Integrated Procedures Trainer and a Simulator Training Facility.

A CCP was signed in December 2006 for changes to the cockpit layout to accommodate redesign of the refuelling operator console and associated changes to the cockpit access door and forward lavatory. Implementation of these changes on the first aircraft required the conversion and test activities to be divided into two phases:

■  Phase 1 involves the structural modification of the aircraft, including installation of boom and pods for civil certification.

■  Phase 2 involves the installation of the military systems, installation of the refuelling operator console and completion of cabin modifications for full military certification and qualification of the modified aircraft.

Uniqueness

Air 5402 is the lead customer of the A330 MRTT platform, including the lead customer for the Airbus Military developed Advanced Refuelling Boom System. Whilst Airbus Military has previously developed and delivered underwing pod equipped A310 MRTT aircraft to the German and Canadian Air Forces, the A330 MRTT is a significantly more complex developmental effort to design, build and test the first of type, highly integrated military mission and refuelling systems. In parallel, Airbus Military is required to develop the publications, training devices and training material to support introductory training of aircrew and maintenance staff and for transition to the Through Life Support Contractors for ongoing support of the new tanker capability.

Major Challenges

Airbus Military's ability to meet the contracted schedule milestones continues to be the greatest challenge due to an underestimation of the overall scope and complexity of work and system improvements introduced during the development. In addition, Airbus Military has been challenged by the under-performance of major subcontractors responsible for military system software development and major refuelling hardware components development. Delays experienced with the aircraft development have impacted the associated design, development and verification of the Support System; particularly, in the areas of training and publications.

Airbus Military has, however, met many significant challenges during the reporting period including: completion of the development of the Aerial Refuelling Boom System on the EADS A310 Boom Demonstrator aircraft, conduct of developmental testing of the aerial refuelling pod and boom systems on the A330 MRTT; completion of civil certification of military provisions; set up of complex industrial network to support aircraft conversion in Australia and substantial progress towards completion of conversion of the second aircraft at the Australian Conversion Centre.

Other challenges expected during the next reporting period include: completion of the flight test program for the first aircraft, completion of conversion of the second aircraft at the Australian Conversion Centre and its subsequent return to Madrid, Spain, to augment conduct of test, certification and customer acceptance.

Current Status

Cost Performance

The project remains within the approved Budget.

Schedule Performance

Certification and qualification test and evaluation on the first aircraft in Madrid, Spain is currently expected to commence in the third quarter of 2009, approximately 14 months behind the contract baseline schedule. Conversion of the second aircraft in Brisbane, Australia, is currently expected to be completed during the third quarter of 2009 prior to ferrying the aircraft to Spain to support test and evaluation activities in Madrid. The third aircraft has been ferried from Madrid to Brisbane and is currently being prepared for conversion.

Capability Performance

Civil certification of the performance and handling of the modified aircraft has been completed, including verification that the modified aircraft is free from aerodynamic vibration throughout the flight envelope. Operational workload assessment of the military communications and navigation suites has identified changes to improve efficiency of tanker operations. The Mission Planning System is lagging the remainder of the Mission Avionics System; however, solutions have been identified but not yet implemented.