Ithambo costs up to R622.4 million

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The cost of Project Ithambo, the avionics and cockpit upgrade of 35 of the South African Air Force’s (SAAF) Pilatus PC-7 MkII fleet has crested R622.4 million with the award of a further R19.9 million work package to Pilatus of Switzerland.

That is somewhat more than the R400 million publicly attributed to the programme. Total expenditure on the aircraft stands at R1 019 547 561.83 since 2007. The first aircraft upgraded under the programme an avionics replacement programme was handed over to the SAAF at Air Force Base Langebaanweg, home of the Central Flying School in July.

The SAAF was the first customer for the PC-7 MkII trainer when an order for 60 was placed in 1993. The final aircraft was delivered in 2006. As the aircraft were fitted with a South African-developed avionics suite, they received the local name of Pilatus Astra. By 2006, more than 300 pilots had been trained on the Astra system and 100 000 flying hours flown. However, the Astra fleet had experienced considerable avionic obsolescence and reliability problems. The original South African avionic manufacturer was no longer in business, the front of the instrumentation had begun to delaminate and the SAAF was experiencing considerable problems in obtaining spare parts. As a result, the Astra was no longer certified to fly in Instrument Meteorological Conditions (IMC). This impacted on the training of pilots, briefers told the media at a ceremony to mark the first handover.

Oscar Schwenk, CE and chairman of Pilatus explained “it was also in 2006 that the requirement had been identified to improve the capability of the Astra through replacement of the avionics suite. In line with today’s stringent civil airworthiness requirements, the SAAF required a state-of-the-art avionics system enabling operation of the aircraft even during adverse weather conditions.” Ithambo was the result. A contract was signed with Pilatus Aircraft Ltd in October 2008. According to Armscor Acting General Manager Acquisition Dawie Griesel “only a proven, turn-key, off-the-shelf solution could fit within the time scale and budget constraints”. Eighteen local and international companies were approached for bids but only Pilatus was able to demonstrate that they fully met the system reliability requirement for the installed system, he added.

The Pilatus solution was to install the avionic suite as fitted to factory produced Pilatus PC-7 MkII aircraft which are in service with other air forces. This avionic system is certified by the Swiss Federal Office for Civil Aviation for operation under Instrument Flight Rules (IFR). The project also includes structural upgrades, requiring the separation of wing and fuselage and the replacement of all wiring harnesses. “(The upgraded aircraft) will in future play a vital role in narrowing the gap between initial training and the advanced flying platforms that were procured under the Strategic Defence Package programme.
“This aircraft now had a full glass cockpit that will allow pilots to be trained in all weather conditions,” Griesel said. As a result, pilots graduating on the upgraded aircraft will be fully instrument rated when they receive their wings. It was also announced that as the modifications to the aircraft have resulted in the aircraft being returned to the standard configuration used worldwide. Therefore, the upgraded Astra in SAAF service has been renamed the Pilatus PC-7 MkII.

The new avionic installation was flight tested in Switzerland on a SAAF aircraft there for corrosion tests in September last year and factory approved in November. During this period, three instructors, a test pilot and a test engineer spent time at Pilatus training on and testing the new system. A further five technical instructors received their training at seaside Langebaanweg.

The contract with Pilatus includes industrial participation projects to include South African industry. The installation and upgrade is being performed by Aerosud, under the supervision of Pilatus, at Langebaanweg. All the looms for the aircraft are manufactured by Electro Thread.

The speed at which the project continued is described by Chief of the Air Force, Lieutenant General Carlo Gagiano: “On the day that factory approval was achieved, Aerosud started the installation of the new avionics suite on two Astras at Langebaanweg and from August 2010, one upgraded aircraft will be delivered every month until March 2013.”

The first locally upgraded Astra (tail number 2010) has already been completed and the two upgraded aircraft are being used to train more instructors on the PC-7 MkII. The Operational Test and Evaluation Phase (OT&E) has already commenced and a further four aircraft are in the process of being upgraded.

According to Captain Roy Sproul who test flew the aircraft in Switzerland, the new avionics take some getting used to. “It’s incredible what it can do and it’s really a step forward. We have so much more capability, especially when it comes to instrument flying and bad weather. It’s also a lot more reliable, with more redundancy.”The advent of the PC-7 MkII has also meant that the five existing Astra simulators are being replaced by just two new flight simulators and an additional instructor station. As a result of the upgrade, the maintenance requirement of the avionic system is reduced greatly, which should relieve some of the pressure on the air force maintenance budget.

Although the SAAF purchased 60 Astras, not all the aircraft were in use due to fewer pupils undergoing pilot training. Half the fleet had been placed in storage, with the active and stored fleet exchanged at regular intervals to balance out the flying hours per airframe. Four aircraft have been written-off since delivery, while at least two others have been damaged. Thus, the decision to only upgrade 35 Astras to PC-7 MkII standard.

While no decision has yet been taken on what will happen with the surplus airframes, it is possible that they will be offered for sale. If that is the case, any prospective purchaser will have to upgrade the aircraft in a similar manner to Ithambo, as the original avionic system will not be supported.

Replacement of a Pilatus Astra avionic suite – extension of ETEL/2006/614
– TEL/S2010/4028 25 Nov 2010 R19 919 587,50 Pilatus Aircraft Ltd

Pilatus Astra avionic suite replacement
– ETEL/2006/614 23 Oct 2008 R602 490 102,50 Pilatus Aircraft Ltd

Pilatus Astra PC-7 Mk 2 system product support services
– ELGS/2007/516 30 Oct 2008 R375 000 000,00 Pilatus Aircraft Ltd

Product maintenance support for the Pilatus Astra Aircraft systems
– LGS/S2008/3777 4 Sep 2008 R5 000 000,00 Pilatus Aircraft Ltd



Product maintenance support for the Pilatus Astra Aircraft System – extension of ELGS/99/856
– LGS/S2007/3574 25 Jan 2008 R9 780 000,00 Pilatus Aircraft Ltd
– LGS/S2007/3430 31 May 2007 R7 357 871,83 Pilatus Aircraft Ltd c/o Intertechnic