Boeing will take more losses to deal with new KC-46 problems as USAF seeks buffer

KC-46 Pegasus and F-16D Fighting Falcon. Photo: Boeing.

More bad news for Boeing emerged this week: the US Air Force identified two more problems in the new KC-46A Pegasus tanker, produced by the Seattle manufacturer. The two are considered Category 1, the most serious, where it can prevent the operation of the aircraft. 

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The USAF has found that drain tubes in the refueling receptacle, used to remove water from the aircraft, can crack when the tanker operates in low temperatures, the organization said in response to inquiries from the portal. Defense News. According to the USAF, this problem has occurred about three times, when the water in the pipes froze and expanded, forming cracks in the system. 

The other problem is a software bug in the Flight Management System (FMS) which, according to Boeing, triggered "navigation anomalies", adding that the problem did not make the aircraft any less safe and that each KC-46 has already been cleared for to fly.

Boeing KC-46 refuels an F/A-18C Hornet. Photo: Boeing

The USAF, which has already taken delivery of 46 units of the troubled plane, says this problem was limited to "isolated incidents", most recently during a March 03 flight over the Pacific Ocean. The crew used “other methods of navigation and did not declare an emergency during the flight” before landing safely in Honolulu, the Air Force said.

"Boeing will address both issues at its own expense", Air Force spokesman Captain Josh Benedetti said in a statement. “There are no operational restrictions for the KC-46s in service due to any of these deficiencies,” he said. “The [program office] and Boeing have established operational processes and maintenance procedures to mitigate impacts and ensure issues do not add extra risk to personnel, aircraft or operations.”

As a short-term strategy to address the cracked air refueling receptacle tube issue, Boeing has issued inspection guidance to the Air Force to mitigate known risk factors. The USAF also explains that to permanently fix the problem, however, it will be necessary to redesign the drain line tubes and retrofit existing KC-46s with the modification.

Meanwhile, General Electric, Boeing's subcontractor for the FMS, is already testing a software fix aimed at resolving stability issues. Updated pre-flight guidelines and procedures were also delivered to crew . 

The two new Category 1 problems other old problems that “haunt” the aircraft, with emphasis on the failures of the Remote Vision System (RVS), which has problems with the cameras and the set of sensors that transmit images to the operators of the booms that conduct in-flight refueling (REVO).

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KC-46 REVO Boom Operators Station. Photo: USAF.
In the US, the most commonly used refueling system is Boom and Receiver, where a tanker has a boom at the rear with a rigid pipe that transfers fuel to the receiving aircraft, which must hold in position while the boom is moved. to the receptacle. 
 
The boom is controlled by a military called “Boom Operator”. On the KC-135 Stratotanker and KC-10 Extender, the operator sits in a compartment at the rear of the aircraft and sees the boom with his own eyes, while on the KC-46, images of the boom are transmitted to a special station inside the cabin, through the set of cameras and sensors designated VRS. 
 
Currently, the system has shown image quality failures, causing difficulties for operators. To give a better perception of depth, they use 3D glasses, but the problems persist, getting to the point that they often cannot see the tip of the spear, guiding themselves through shadows and using their own experience, explains the portal. The War Zone.
 
Operator's view of the REVO boom of a KC-135. Photo: John E. Lasky/USAF.
Other than that, the aircraft has problems with boom stiffness and fuel leaks. Another situation was the leakage of contents from palletized washbasins. The USAF acquired 179 Pegasus and the model has already brought a loss of more than $5 billion to BoeingThe aircraft was also acquired by Japan Air Self Defense Force and must be purchased by Israeli Air Force Also. 
 
On June 16, during a House Armed Services Committee Air Force budget hearing, Republican Representative Rob Wittman expressed outrage at the problems of the KC 46: “We are paying $226 million apiece for a lemon”, he said. “Every month we hear about another Category 1 disability… I am frustrated.”
 
On the same day, the USAF Life Cycle Management Center issued a statement explaining that it is seeking a “buffer tanker plane”, through the Bridge Tanker Program, where refueling aircraft derived from commercial aircraft would be acquired to complement the KC fleet. -46 at the end of deliveries. 
 
“The new aircraft will fill the gap for the next recapitalization phase of the Advanced Air Refueling Tanker, formerly known as “KC-Z”. The existing KC-46A fixed-price contract is limited to 13 production lots, with the last procurement planned in 2027 and delivered in 2029.”, says the USAF, stating that the program's requirements are still being defined and that “required resources will be incorporated into the final Request for Proposal”, which should be issued by the end of 2022. 
 
A KC-135 in the foreground, while a KC-10 Extender refuels a KC-46 prototype. Photo: Christopher Okula/USAF.

The Bridge Tanker could be a chance for the Airbus A330 MRTT, which mainly competes with Boeing's tanker because it is the only one with a boom, that is, apart from the KC-46, it is the only one that can meet the requirements of the US Air Force. 

In the first competition for new tanker planes, the European plane, at the time called KC-45A for the acquisition, was even announced as the winner, but Boeing ended up going to court. In 2011, the American manufacturer was chosen. 

A330 MRTT and F-16D of the Royal Singapore Air Force. Photo: Airbus/Disclosure.

Today, there are more than 60 A330 MRTTs in service in countries such as Australia, England, South Korea, Singapore, and others. The REVO aircraft will also be used as a tanker tly operated by member countries of NATO, the US-led military alliance. 

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Gabriel Centeno

Author Gabriel Centeno

Journalism student at UFRGS, spotter and military aviation enthusiast.

Categories: Military, News

Tags: Boeing, KC 46, in-flight refueling, usaexport, USAF

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