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RUSSIA’S ON THE RI HSEEL ICOPTER INDUSTRY

For the last 20 years, the fleet of Soviet- and Russian-made helicopters has decreased several times. In 1992, Russia manufactured 337 helicopters and in 1998 – only 26, according to the Alliance of Aircraft Engine-Building Association (ASSAD). At present, experts say helicopter production has stabilized in Russia again. According to ASSAD, Russia manufactured 121 helicopters in 2008. At the same time, Oboronprom United Industrial Corporation General Director Andrei Reus says 169 helicopters were produced a year before.

Untangling Figures Interestingly, there are some differences in calculations of vehicles manufactured. According to Oboronprom General Director Andrei Reus, the Kamov Plant manufactured 55 Mi-8/17 helicopters and Rostvertol – 44 ones (20 Mi-24/35M and Mi-28N combat ones and also modernized 24 Mi-2s that were calculated as new-made), the Ulan-Ude Aircraft Plant – 59 Mi-8/17s, Kumertau Aircraft Plant – 11 Ka-27/28/32s. The total result is 169. But why does ASSAD give other figures? Russian Helicopters OJSC clarified that the figures are being constantly specified.
For example, 24 modernized Mi-2s are considered as produced in 2008. The authors say “considering the type and scope of work carried out by Rostvertol to upgrade 24 Mi-2 light helicopters to the Mi-2M version as well as significantly renewed service life of their main parts, it is reasonable to call these vehicle newmade
ones.”

Anyway, the both figures make it clear that Russia’s helicopter-building industry has gained a small momentum. This relative prosperity is chiefly achieved due to Mi-8/17 helicopters enjoying stable demand abroad – they are used in over 50 countries. 12,000 such helicopters have already been produced.

Unlike the civilian aircraft-building industry, which manufactures about 10 times less vehicles, one can say that Russia produces helicopters in series. By the way, it allows loading subcontractors supplying helicopter-building plant with parts rather steadily. With that, Russia practically did not produce new types of helicopters last year except several Mi-28N, Ansat and Ka-226 combat ones. Nevertheless, it tested and manufactured pilot models of such new vehicles as the Ka-52, Ansat-U, Mi-38, Ka-60, upgraded Mi-24, Ka-27M, Ka-28M and Ka-31 versions.

The year 2008 is called a milestone, when the nearing crisis still failed to influence the production schedule. Preliminary data proves that Russian Helicopters OJSC received over 40 billion roubles of income – 20% more than a year before. At that, the holding’s profit reduced by 240 million roubles against 2007 and totaled 1.56 billion roubles. It is hard to say how successful this year will be. Experts mention a number of significant reasons curbing the development, namely the still existing decentralization of some enterprises and the lack of the united development programme. Despite this, attempts to gather and direct helicopter builders in the right way are being constantly made.

Course is Chosen The year 2008 saw accelerating consolidation of many enterprises by Russian Helicopters as part of the Oboronprom United Industrial Corporation.

It has already worked out the Helicopter Industry Development Strategy up to 2020, which was approved by the Russian government. Russian Helicopters has already chosen helicopter types to be produced in two stages.

Ambitious Programme
The Russian Helicopter Industry Development Programme is divided into two stages up to 2015: From 2008 to 2011, it is planned to raise the production of existing types of helicopters, implement modernization projects, design new helicopters, put them into series production and form the sciencetechnical reserve. In 2011-2015, the new types are to be produced in series. Russia’s helicopter production is to triple and reach 500 vehicles a year. Thus, it will account for at least 15% of the world market and helicopter sales will increase up to 400 billion roubles. The programme contains plans for the development of helicopter engine building.

The programme provides for continuing series production of the following helicopters: Mi-34 light sport helicopter, Ka-226 and Ansat light multipurpose helicopters, Mi-8/17 medium transport and multipurpose helicopters, Mi-26 heavy transport helicopter, Mi-24/35 transport/combat helicopter, Mi-28N and Ka-52 attack helicopters, Ka-27/28/29/31/31-family deckbased and multifunctional helicopters.

At the same time, designers are to create radically new base models and upgrade the existing ones including promising unmanned helicopters based on previous developments by the Mil Moscow Helicopter Plant and Kamov Design Bureau, the Aktai light multipurpose helicopter as well as
Mi-38, Mi-54, high-speed helicopter, etc.

Infinite Plans
This year, Russia will manufacture 231 civil and military helicopters for the domestic market, Defense Ministry and foreign customers. Experts say the increase of production from 169 to 231 vehicles in 2009 is quite real. The Defense Ministry alone plans to acquire about 40 Mi-28N and Mi-8 helicopters. 2009 will see the further consolidation of industry enterprises as well as their re-equipment to raise labour efficiency, focusing financial and real assets on the most important modernization projects and creating promising models and science-technical reserve.

Now, it is still early to speak about the prospect of main helicopter plants – the Mil Moscow Helicopter Plant, Kamov Design Bureau and Kazan Helicopter Plant. The latter revealed its plans not long ago – it will manufacture Ansat and Aktai helicopters. Anyway, it is clear that all helicopter production and modernization projects can be corrected by the current crisis in Russia and the world. The main trends on these enterprises can already be seen. Mil Moscow Helicopter Plant

Mi-2
At present, Russia has about 600 Mi-2 helicopters, of which about 170 ones are actively working. A small number of Mi-2s are in service with the Russian Air Force. Last year, 22 Mi-2s were overhauled and slightly modernized. They were sent to the Syzran Military Helicopter
College.

There are two ways of upgrading the Mi-2 – the Mi-2A receives new transmission parts and the Mi-2M – old VR-2 reductors. Rostvertol is carrying out the modernization on its own initiative and at its own expense, which affects the terms badly. Informal sources prove new engines were being installed on the test helicopter in late April, but their type is still unknown.

Mi-8/17
According to some estimates, about 2,000 Mi-8 helicopters work in Russia and
the same number – abroad.

Its modernization should increase the maximum and cruise speeds and flight range without extra fuel tanks. It is planned to raise the cruise speed up to 290 km/h, but there is a chance to make it more than 300 km/h. With that, the flight range will increase from current 630 to 800 km. Telling the truth, all Mi-8/17 helicopters seem to be upgraded no sooner than in 8 years.

Mi-24/35M
This year, the plant will continue to manufacture Mi-24PN modernized (limited number) and more advanced Mi-35M export helicopters as well as to carry out R&D works on improving both Mi-24 combat (the
Mi-24M version) and Mi-35M export ones.

Mi-26
According to the Mil plant’s General Designer Alexei Samusenko, the modernization of the Mi-26 to the Mi-26T2 version slated for 2010 firstly allows for renewing avionics and reducing the crew down to 2-3 members.

The helicopter will get advanced radionavigation and flight equipment – all information will be shown on multifunctional LCD monitors, while pointer instruments will become reserve ones.

Mi-28N
In December last year, the state tests of the Mi-28N were successfully completed. This helicopter will be produced for the Russian Air Force in series since 2009 (Rostvertol has manufactured only 20 Mi- 28Ns so far). In April, the first 6 Mi-28Ns were delivered to the Budyonnovsk, Stavropol Territory-based 487th Separate Helicopter Regiment of the North Caucasus Military District. Promising Models

Mi-34 The helicopter powered by the M- 14V26V piston engine was manufactured in Arsenyev (25 vehicles have been built including 3 pilot models) but did not have sufficient demand. That is why, it was decided to improve it by raising the service life of its parts up to the world level. The demand for various Mi-34 modifications is estimated at 355-402 vehicles. The manufacturer hopes the payback period will last 6-7 years. The Mi-34 has a considerable advantage over other promising helicopters – the Ministry of Transport ordered 20 helicopters already at the development stage.

Mi-38
The R&D programme for the Mi-38 helicopter powered by two Pratt & Whitney turboshafts is, perhaps, the largest in the Russian helicopter industry. Pilot helicopter No.1 (OP-1) has already been made and is undergoing plant testing. Interestingly, real test results exceeded design calculation – its maximum speed reached 320 km/h instead of 290 km/h. The cruise speed equalled 300 km/h and dynamic ceiling – 8,200 m, thus surpassing even the best foreign light helicopters.

In the end of 2008, pilot model No.2 (OP-2) was built but does not have engines for it as Pratt & Whitney has not delivered them after South Ossetia events due to strange formal obstacles. At the same time, the OP-3 is being constructed at the Kazan Helicopter Plant.

Certification of the Mi-38 under the AP-29 standard was scheduled for 2011 and its series production – for 2012. But delays in engine deliveries by Pratt & Whitney Canada (and even their full termination) may affect certification terms and its series production badly. After this pressure, Russia is seriously considering powering the Mi-38 by the Russian TV7-117V turboshaft, which is almost similar to the Canadian engine and even more powerful. But this will require extra 1.5-2 years.

Mi-54
There are plans to create the Mi-54 helicopter with a takeoff weight of 4.5 t. Russia has almost no vehicles of such type. The helicopter will be powered by two advanced Klimov-designed VK-800 turboshafts. The preliminary design was reported to be fulfilled last spring. It will take several years to design this helicopter and another 1.5 years – to certify it.

KAMOV OJSC

Ka-27/28
The Ka-27 deck-based antisubmarine helicopter and its export version dubbed Ka-28 are being modernized and flighttested now. The fleet of Ka-27s is to be upgraded to the Ka-27M version by 2015. Kamov General Designer Sergei Mikheev thinks the Ka-27 will remain a deck-based antisubmarine and rescueand- search helicopter in the heavy-lift class in the future. Ka-28s are to be upgraded, too, particularly in India. At 2008 year-end, it was reported that India planned to upgrade 12 Ka-28 helicopters and buy another 11 vehicles worth $129 million. According to Kamov General Designer Sergei Mikheev, there are plans to make a new antisubmarine helicopter, which will be lighter than the Ka-27. Ka-31

Despites its deliveries to India, little is known about the Ka-31 deck-based helicopter. At present, works on its landbased version designed for the Land Forces are underway. A year ago, the tests were considered to be over in 2009. About 12 Ka-31 helicopters are known to have been built so far, of which 9 are in India and the rest – in Russia. With that, we can expect that their production will be resumed and at least 9 Ka-31s will be made for India.

Ka-32
For a number of years, the Kamov design bureau is developing a helicopter

with increased cargo and passenger capacity, manifold structure, a large sliding door and extended cabin dubbed Ka-32-10 (initial designation – Ka- 32AM). In fact, this version is the deeply modernized Ka-32A11VS. It is planned to raise the helicopter’s lifting capacity up to 4-5 t in the body and up to 6-7 t on the external pod.

Ka-50-52
The Arsenyev Progress plant is continuing to manufacture the pilot batch of Ka-52 helicopters for operation testing. In December last year, the first stage of Ka-52 state tests was successfully completed, which allows the aircraft plant to start the production of the initial batch. Last year, building three Ka-50s was finished (8-10 Ka-50s are now in operation), of which one was delivered to Torzhok. Another two Ka-50s were at the plant in early 2009 and this year they will be given to the Defense Ministry, too. In addition, two Ka-52 helicopters were built in 2008 (five Ka-50s and Ka-52 were manufactured in 2008). Three Ka-52s from the initial batch will be delivered to the Defense Ministry in the first half of this year and another batch of Ka-52s – after state tests in 2009-2010. Thus, 20-25 helicopters can be yearly produced by 2011-2012 for domestic and export purposes.

Ka-60/62
Russian Helicopters is carrying out R&D works on the Ka-60 designed for the Russian Air Force and intended for transporting an infantry squad and its civilian version dubbed Ka-62. Two almost identical helicopters have already been built, namely Ka-60 and Ka-60U. At present, their factory testing is underway and state tests are to begin later this year. In the end of last year, Russia’s Defense Ministry specified its requirements for the Ka-60 – it plans to buy 300-400 Ka-60 helicopters. Their commissioning is possible since 2011-2012. The Ka-60’s powerplant, however, aroused big questions, so it was decided to equip it with Russian RD-600 engines. The Ka-62 will be probably produced in small batches since 2012 and the Progress plant will be able to manufacture 30-40 vehicles a year by 2014. According to Kamov’s pessimistic estimates, Russia will need some 350 Ka-62s by 2020, the same number can be sold abroad. Thus, we receive about 700 helicopters.

Ka-226
The Ka-226 multipurpose seven-seat helicopter powered by two 460-hp Rolls- Royce 250-$-20R/2(SR) turboshafts is manufactured in small batches on two plants – the Orenburg Strela Production Enterprise and Kumertau Aircraft Industrial Enterprise. Last year, these plants manufactured two and four helicopters, respectively. Less than 20 helicopters have been made so far.

Russian Helicopters have included the Ka-226T (T means Turbomecca) version powered by two 730-hp Turbomecca Arrius 2G1 turboshafts into the model range. The Ka-226T project is known to be funded by a $100 million 8-year investment loan. Its sales to the Emergency Ministry, Federal Security Service and Gazprom are being discussed. At the same time, this model will take part in the Indian tender for about 200 light helicopters. Experts say the plant will reach a design output of 70 helicopters a year (20 Ka-226s and 50 Ka-226Ts) by the end of 2011.

Ansat
As of now, the Kazan Helicopter Plant has produced over 20 light (takeoff weight up to 3,300 kg) Ansat helicopters propelled by two 630-hp Pratt and Whitney %W-207& turboshafts, of which five were exported to South Korea. The plant is preparing the Ansat’s series production – 10-15 helicopters a year and later reach the output of 25 vehicles a year. In December last year, state tests of the Ansat-U combat trainer were successfully completed. According to the Defense Ministry’s requirement, this machine will have wheeled chassis unlike other Ansats. A contract for shipping only three Ansat- U helicopters in 2009 has been signed, though it was initially planned to order 12 aircraft.

According to various sources, the Russian Air Force needs 25-100 Ansat combat trainers. These helicopters will be delivered to helicopter flight colleges in 2009-2010.

Aktai
It is planned to equip the 1,240-kg Aktai three-seat light helicopter designed by the Kazan Helicopter Plant with one Swiss Mistral G-300-H powerplant using AI-92 fuel. Two helicopters were put into production a year ago and in 2011, their series manufacturing should begin with the aim of 60 vehicles a year. Now, ground tests of the test model are underway. The Kazan Helicopter Plant, Oboronprom and Russian Helicopters estimate the demand for Aktai helicopters at 1,600 items for 30 years given the current price of $350,000.

Reaching New Speeds
A high-speed helicopter combining high speed and STOVL capability is a conceptual project promoted by Russian Helicopters. But the first flight model will be made in about seven years. For this time it is necessary to specify the main requirements, conduct the contest of designs, choose one design (and, perhaps, two), build demonstrators and only after their tests decide whether to build the helicopter or not. Such a helicopter is already required in remote areas of Siberia and Far East as well as for operations at the Shtokmanovskoye field.

High-speed helicopters are now designed by two bureaus – Mil and Kamov. The both versions will be powered by turboshaft engines. The Mil Mi-X1 project provides for VK-2500 engines. It is considered that additional development of the pusher is needed to reach speeds of 450-500 km/h. The Ka-92 project allows for two VK-300 turboshafts. The rear pusher will be driven by both of them. The Kamov helicopter is to have a flight range of at least 1,400 km and a speed of about 450 km/h given that 15-30 passengers will be carried at a distance of 700 km and return to the initial point without refueling.

UAVs
The capacity of Russia’s market for unmanned helicopters is estimated at several thousand aircraft. According to the Unmanned Helicopters Programme, four types of UAVS are required on the military and civil markets, namely close-range (up to 20-50 km), small-range (up to 100 km), medium-range (up to 400 km) and long-range (over 400 km). Each helicopter plant will set up a design bureau for unmanned helicopters – Kamov will have 4 projects and Mil – 3 ones.

The main Kamov’s project is a helicopter drone with a weight of up to 300 kg. Also, UAVs based on the Ka-115 helicopter (its weight is 1,500 kg and the range - 500-600 km) will be created. Most probably, Ka-115-based helicopters will be made for the Navy.

At the same time, the Mil plant will develop small range helicopter drones (up to 100 km) weighing from 50 to 70-80 kg and flight endurance of up to 6 hours.

Dmitriy Kozlov