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The management of Kazan Helicopters has decided to start development of light helicopter in late 90s – early 2000s. This was dictated by the desire to decrease risks, caused by manufacturing only one helicopter type – Mi-17, and expand the product line. It goes without saying that the best practices in the area of helicopter industry were studied. One of the most advanced technologies of that time was usage of fly-by-wire (integrated control system – KSU-A), It had no counterparts in the world helicopter industry back then.
The design bureau of Kazan Helicopters has chosen this way and the system was successfully implemented on Ansat helicopter. However, the success of Kazan Helicoters’ designers and their unique development have become the unexpected obstacle on the path to certification of Ansat. It turned out that neither Russia nor Europe or USA has developed certification requirements for such systems. Since the specialists of Kazan Helicopters were pioneers in this area, they had to travel a very long way along with Interstate Aviation Committee (IAC). As a result the type certificate was acquired. However, since the complete set of requirements for such systems has not been developed yet (neither in Russia nor in any other country), the certificate is limited – operators cannot transport passengers using these helicopters.
The enterprise believes that this control system is very reliable. The fact that Ansat-U helicopter has passed all the state tests in accordance with military requirements and the helicopter was put into operation by the Russian armed forces as the basic helicopter for initial training supports their position. Another batch of Ansat-U helicopters was delivered to Syzran branch of Military training scientific center of the air forces in 2011 (in accordance with the operating contract).
«Ansat» is the light multi-role helicopter with maximum takeoff weight of 3,5 tons. Since Ansat GMSU have not gone aloft yet, the enterprise’s test pilots have performed special demonstration flights on Ansat (KSU) and Mi-17-V5 helicopters. The employees of Kazan Helicopters noted that they have never seen such an impressive pilotage on these helicopters before. And I agree with them - you won’t see such a show performed by our helicopter pilots even at the world’s largest airshows.
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Market research confirms that this helicopter is in demand at the global market and has good prospects. That is why, for fear of wasting time, the decision to develop modification of the helicopter with traditional hydro-mechanical flight control system has been taken. Two prototypes were manufactured in the network of this program – one for the ground testing and the other – for the flight testing. The flight tests will be started in the nearest future and certification will be completed in 2012. Kazan Helicopters has already sent an application to Aviation Registry of Interstate Aviation Committee (AR IAC) for acquisition of supplement to the to the type certificate allowing installation of hydro-mechanical flight control system (GMSU). Certification of Ansat with GMSU will help certify the helicopter for passenger transportation. The enterprise plans to deliver 20 Ansat helicopters per year.
Russian Helicopters Holding Company is carrying out marketing and precontractual work on civil version of Ansat with hydro-mechanical flight control system. Potential customers from Russia and foreign countries are already taking interest in Ansat equipped with the new control system. According to experts, the modernized Ansat has some significant competitive edges as compared to its rivals. The holding intends to promote the vehicle at traditional markets of our helicopter industry: CIS Region, South-East Asia, Africa, Central and South America.
The demonstration of the latest simulator for Mi-8MTV helicopter manufactured by Transas and installed inside the territory of Kazan Helicopters has become another surprise. The unique development – vibroacoustic field simulates the real flight experience.
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Even though Ansat is relatively new vehicle, Kazan Helicopters is already developing the helicopter’s modifications. Among other things, the further modernization of the basic model is being carried out in order to improve its performance, economics and operating characteristics. At present Ansat helicopters are equipped with Pratt Whitney PW-27K engines, but there is a possibility of installing Russian advanced VK-800 engines on the helicopters in future, so some modernization will be required. There is also a project for more comprehensive modernization of the helicopter – Ansat-M with the maximum takeoff weight of 4.5 tons. Such modification may be created in case of successful development of VK-800.
In addition, the vast modernization of Мi-17-V5 and Мi-171-А2 is being carried out. However the schemes of modernization are slightly different.Мi-171-А2 is the civil modification, thus all the work on its modernization will be completed right away and then the helicopter will be certified. Since Мi-17-V5 may be sold in the network of military-technical cooperation, the phase-by-phase modernization will be performed in accordance with the customers’ requirements.
Medium multi-role Mi-17 helicopter is derived from Mi-8MTV. Its flexibility and high performance made it one of the most wide-spread helicopters in the world. At present Kazan Helicopters is manufacturing three main modifications:
- Мi-172 – intended for passenger transportation. There is also a special VIP-version;
- Мi-8МТV-5 (Мi-17-V5) – transport helicopter intended for transportation of cargo inside the cabin and suspended load. Maybeusedfortransportationofre
- Мi-8МТV-1 (Мi-17-1V) – multi-role modification; serves as the basis for models with different purposes, including the flying hospital.
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We have seen different modifications, which are ready for delivery to the customers, at the helipad.
The vehicles made by Kazan Helicopters are operated in 80 countries of the world. The enterprise is forming part of Russian Helicopters (subsidiary of Oboronprom Corporation, forming part of Russian Technologies State Corporation). RussianHelicoptersHoldingCompa
The revenues of Russian Helicopters in 2011 were 103.9 million rubles (+27.8%) according to IFRS, the scope of deliveries was 262 helicopters. More than 8000 helicopters made by Russia/USSR are operated in 110 countries today.
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The holding’s strategic goals are aimed at increasing the share of Russian helicopters at the global market. Kazan Helicopters is one of the leading enterprises of the holding and it plays significant part in implementation of these goals. The enterprise’s backlog provides workload until 2014. That is why Russian Helicopters and Rosoboronexport are forming backlog for 2014-2016 now.
Kazan Helicopters has delivered over 90 helicopters to the customers. The turnover of Kazan Helicopters’ end products has exceeded 30 billion rubles (over $1 billion). The sales of Kazan Helicopters’ vehicles have increased 2.7 times during last four years. The output sold per employee was $160 thousand. Theoutputsoldperworkingmanwas$
The design bureau of Kazan Helicopters is developing helicopters for general aviation. Besides Ansat, another lighter Aktai helicopter was offered for development but the work was suspended. The main reason for this decision – lack of suitable engine. At first it was planned to equip the helicopter with VAZ-4265 rotary engines made by AVTOVAZ. But the design bureau developing this engine has slipped out of existence. And they have not found another engine yet. And any new engine will require making changes in the design of the helicopter. Thus the decision to suspend the helicopter’s development was taken.
Kazan Helicopters is also participating in development of new multi-role Mi-38 helicopter. The enterprise is completing the assembly of its third prototype. The helicopter is equipped with advanced IBKV-38 avionics made by Transas (the “glass cockpit” concept is implemented in this system). However, there are some delays due to late delivery of engines by Klimov (TV7-117V) and Pratt Whitney. Nevertheless the program of manufacturing the prototype is being implemented according to its schedule. Kazan Helicopters is responsible for production of Mi-38 prototypes and the helicopter’s serial production. Since all the problems connected with engines have been solved, no more delays are expected. The certification of Mi-38 will be carried out by Moscow Helicopter Plant and it should be completed by 2015.
The enterprise hopes that besides increasing the output, the product line will also be expanded. Besides its main products (different modifications of Mi-17), Ansat and Ansat-U helicopters have been added to the product line and the serial production of Mi-38 will be launched in the next few years.
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The enterprise’s technical re-equipping is being carried out in the network of a general program of Russian Helicopters Holding Company. The problem of mechanical processing equipment renewal was solved on a first-priority basis. The engineering teams not only renewed the equipment and machining stations but also modernized the whole mechanical assembly production. And now the level of equipment and qualification of the enterprise’s personnel meet requirements of the highest international standards. The next step is modernization of such areas as welding, electroplating, painting, etc. One of the most important tasks is decreasing the share of manual work in production of aggregates, automation of riveting operations. But you cannot abandon the manual work completely. But there are two main areas of enterprise’s activities:
1. Implementation of composites in order to reduce the number of assembly operations. This is necessary because of changes in the design of helicopters. The plant is working in close cooperation with Mil design bureau (Mi-8/17 helicopters) and Kazan Helicopters design bureau (Ansat).
2. Automation of operations. And the first steps have already been taken. However, as against the aircraft industry, helicopters have a lot of modifications with different fuselage contours. That is why the complete automation of riveting work is impossible.
Kazan Helicopters has already invested $53 million in modernization of its production.
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«The technical re-equipping program was started in 2008. According to the program, the technical re-equipping and reconstruction of the enterprise should be completed by 2015, - said CEO of Kazan Helicopters, Vadim Aleksandrovich Ligay, - The program assumes: acquisition of the equipment, reconstruction of mechanical processing, block forging and painting production, fabrication of composite blades, modernization of storage facilities, etc. The program is financed using the enterprise’s own funds and funds provided in the network of Federal target program. We are participating in two Federal target programs: About serial production of Ansat-U and The program for development of civil aviation – with Mi-38 helicopter. We are acquiring funds intended for manufacturing prototypes of Mi-38 and launching its serial production through Moscow Helicopter Plant. And there is one more Federal target program – Development of Military-Industrial Sector (until 2020). Kazan Helicopters participates in the program as part of Oboronprom Corporation and some areas of modernization and technical re-equipping are included in the program. The cost of plant’s modernization program is assessed at 8-9 billion rubles.
Another important factor is our personnel policy. There are a lot of working dynasties at the enterprise. The average salary of Kazan Helicopters’ employee is 26600 rubles. The salary indexation is carried out every year. The employees may increase their salary: we have significant uplifts for mentoring, years of employment, victory in a labor competition. If someone needs a large sum of money he does not have to go to the bank and take a credit. There is a mutual aid fund and material assistance fund at Kazan Helicopters. Administration issues purpose-oriented loans for its employees, for example, intended for repair of their houses or for getting education. The plant is taking part in implementation of the law “On state support of house building in Tatarstan”. In the network of the law’s implementation Kazan Helicopters is taking part in the target program for provision of houses using social mortgage since 2006. 107 families of the plant’s employees have already improved their housing conditions. More than 1000 of the plant’s employees are undergoing retraining every year».
Reference:
Kazan Helicopters is performing development and production of helicopters, carrying out post-sales support, MRO activities and personnel training. The production is certified in accordance with ISO 9001 standards. The number of enterprise’s employees is about 7000 ones.
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The plant was founded on September 4th 1940. Every 10th Po-2 aircraft was assembled by this plant during the Second World War. Kazan helicopter plant launched production of Mi-1 helicopters in 1951; it was the first serial production of helicopters in USSR. The plant has produced the first national exported helicopter – Mi-4, and the most popular helicopter – Mi-8. The total flight time of Russian helicopters made by Kazan Helicopters exceeds 50 million hours. Kazan Helicopters has delivered over 12 000 Мi-4, Мi-8, Мi-14, Мi-17, «Ansat» helicopters (and their modifications) to 100 countries of the world.
