Embraer KC-390 Millennium. This is the “first and last name” of the largest military aircraft designed, developed and manufactured in the South American continent. An aircraft that carries in its DNA the history of perseverance and vision of Ozires Silva with the EMB-110 Bandeirante of the 1960s, as well as the state-of-the-art technology that puts it in the hall of the most capable transport aircraft in the world.
In August, the Portal Aeroflap team got to know the KC-390 up close to produce a series of videos, as well as this report. There are currently four aircraft in service with the 1st Troop Transport Group (1st GTT), the Zeus Squadron, a unit that since 2018 has its headquarters at Wing 2, Anápolis Air Force Base.
But before talking about the present, let's go back to the year 2005.
C-390 and KC-X: a project and a need
16 years ago, Embraer began the first designs of what is now the KC-390. The aircraft was born from a study by the Brazilian manufacturer's intelligence sector, which ended up meeting a long-term market need. Several nations would, in the coming years, replace older military transport aircraft, especially the Lockheed C-130. The C-130J Super Hércules and the Airbus A400M Atlas were already a reality, however, an expensive one.
From these studies, the manufacturer began the project, with the design being initially called CXX and later designated as C-390. The design was basically a modified E190 E-Jet with a large cargo bay, high wings and horizontal stabilizers mounted on the fuselage rather than on top of the drift as we have today.
At the same time, the Brazilian Air Force was already studying the future of its own fleet of C-130 Hercules. The Hercules is one of the most celebrated military aircraft of all time. An aircraft recognized worldwide for its robustness, easy maintenance, versatility and other nouns. In production since 1954, the C-130 serves in military and government institutions around the world, but its history in Brazil begins in 1964 with the arrival of the C-130E 2450. In all, 29 examples of the 130E and 130H variants were acquired between 1963 and 2001, with extensive modernization beginning in 2003. In 1974, the FAB ordered two KC-130Hs, which were also updated. Today they are designated KC-130M and C-130M.
The years of operations in the most diverse corners of Brazil and even Antarctica took their toll, with the FAB announcing this year that the Hércules will be retired in 2024. In 2007, the Air Force launched the KC-X project to seek a replacement for the C/KC-130. Embraer, which already has a historic partnership with the FAB, presented its project already modified in accordance with the preliminary requirements of the Air Force.
The two organizations then merged, with the FAB starting to work actively on the design of the C-390. Fast forward a few years and the project was re-designated KC-390, the name we know it by today. The letter K indicates that the aircraft is a tanker plane (KC-130, KC-135, KC-46, for example), making clear the main missions of the Brazilian plane: transport and in-flight refueling (REVO).
In 2009, FAB and Embraer signed the contract for the development of the KC-390, as well as the production of two prototypes, in the amount of R$ 3.028.104.951, published in the Official Gazette of the Union on April 23 of that year, marking the first official commitment of the Federal Government with the Embraer aircraft. Five years later, on 20/05/2014, the FAB signed contract Nº 9/2014 – UASG 120006 in the amount of R$ 7.255.896.086, g the acquisition of 28 KC-390 aircraft, with the expected delivery of the first unit for 2016.
Five months and one day after the publication of the acquisition contract, the roll out ceremony of the first prototype of the KC-390, the PT-ZNF, was held in Gavião Peixoto (SP). The largest aircraft developed by Embraer, and the largest aircraft designed and produced in South America, was officially presented to the public. On February 03 of the following year, the PT-ZNF made its first flight, manned by two test pilots and two Embraer engineers. The second prototype, PT-ZNJ, was ready in March 2016 and made its first flight on April 28 of the same year.
However, still in 2014 the global economic crisis began to have heavier effects in Brazil. In the following years, the project suffered some delays due to delays in transfers. Still, ZNF and ZNJ flew on to certify the model. In 2017, a serious incident left the PT-ZNF damaged: during icing and pre-stall tests (flight condition that precedes the stall, which is the loss of lift), the crew ended up losing control of prototype 001 after the release of a load. In less than 30 seconds the jet lost almost 2500 meters of altitude; in the recovery, the G Force ended up damaging the plane.
After that, the ZNF was repaired and returned to testing, but ended up getting involved in another accident on May 05, 2018. During ground tests, the plane crossed the runway at Gavião Peixoto, again suffering serious damage. Fortunately, none of the crew was injured. It is important to note that the plane was still in the development phase, so incidents are “expected” during this period.
Despite the scares, the big day arrived. Ten years after g the first contract, the Brazilian Air Force officially received its first KC-390, the FAB 2853. The ceremony held at Anápolis Air Base (Wing 2), in Goiás, was presided over by the President of the Republic, Jair Messias Bolsonaro, who baptized the new aircraft together with the then Commander of the Air Force, Lieutenant-Brigadier of the Air Antonio Carlos Moretti Bermudez, and the then Minister of Defense, Fernando Azevedo e Silva.
At the ceremony, the KC-390 was officially incorporated into the FAB fleet, starting to be operated by the soldiers of the Zeus Squadron, the 1st Troop Transport Group.
GTT – From Rio to Anapolis
The 1st GTT is not from Goiás, but from Rio. The unit was created on January 22, 1958 by Decree Nº 43.089, at Afonsos Air Base, Rio de Janeiro. Throughout his life, he operated the C-82 Packet, the legendary C-115 Buffalo and the great C-130 Hércules in missions to transport and launch troops and paratroopers for the Brazilian Army, as well as tactical, logistical and supply transport flights. in areas hit by disasters and natural calamities.
Today the squadron is called Zeus, the god of gods in Greek mythology, but before that it was known by two other names. On February 07, 1958, the 1st Squadron of the 1st Troop Transport Group (1st/1st GTT), the Coral Squadron, was activated. The Cascavel Squadron (2nd/1st GTT) was activated on November 1, 1961, by Ordinance S-67/GM3 of the Air Force itself.
In 1975, Cascavel received the C-130H, more powerful and resistant than the C-130E already operated by the FAB; the following year, the unit received two KC-130H, the first tanker aircraft of the Brazilian Air Force, which were later transferred to the Gordo Squadron (1st/1st GT). Over the years, Coral and Cascavel have always operated together, with a high level of cooperation between the units.
In 2013, after 55 years operating from Campo dos Afonsos, the GTT and its aircraft were transferred to Galeão Air Force Base, which already hosted the Esquadrão Gordo. The Group was transferred due to budgetary issues: with the C-130 units being concentrated in just one location, there is a reduction in maintenance costs, consequently increasing the availability of the aircraft. Thus, Gordo, Coral and Cascavel operated together.
However, the future reserved another challenge for the GTT. In June 2018, the FAB transferred the GTT again, this time leaving Galeão for the Midwest. The new home of the 1st GTT, now called Zeus Squadron, was Anápolis Air Force Base (Ala 2). About 150km away from Brasilia, the Air Base began to be built in 1972 to receive the brand new Mirage III EBR/DBR, the first supersonic fighters in Brazil. On the other hand, Zeus received the mission to deploy the KC-390. The Hercules were ed on to the Fat Squadron.
The first KC-390 was delivered to the squadron on 04/09/2019. The second, the 2854, arrived for the unit on 13/12/2019; the third (2855) was delivered on 27/06/2020 and the fourth plane (2856) on 19/12/2020.
Anápolis Air Base will also be the first to receive the Saab F-39E/F Gripen, a new FAB fighter that will be operated by the 1st Air Defense Group, the Jaguar Squadron. To receive these two new models, Anápolis ended up becoming a construction site. The Air Base is undergoing a series of extensive renovations in its infrastructure, with the construction of new buildings and hangars, renovation of the runway, updating of the electrical network and the lighting system, as well as other services. For this reason, GTT soldiers are allocated in a building next to the Guardião (2nd/6th GAv, which operates the R-99/E-99) and Carcará (1st/6th GAv, which employs the R-35) squadrons. The 1st GDA was transferred to the former BAAN enger room.
Procurements
Over the years, Embraer entered into international partnerships with Portugal, Argentina and the Czech Republic for the production of parts for the plane. The partnership with these nations was represented on the aircraft itself, with their flags painted next to the door. These countries, together with Chile, also expressed a strong interest in acquiring the military freighter, but of these, only Portugal has bought the plane so far. Empresa Brasileira de Correios also showed interest in the KC-390 to operate in its overnight postal network.
In July 2019, the Portuguese Ministry of Defense confirmed the purchase of five KC-390s (with an option for a sixth aircraft), a flight simulator and crew training for €827 million. On September 21, 2021, the first KC-390 of the Portuguese Air Force was energized on the Embraer production line. On the same day, the FAP disclosed that four of its military personnel, two pilots and two mechanics, have been in Anápolis since 14/09, where they are receiving training in the 1st GTT. As in Brazil, the KC-390 will replace the Portuguese C-130 Hércules. Portugal is also expected to use the planes to fight the forest fires that devastate the country every year.
In June 2020, Embraer and the Hungarian Government announced the g of a contract for the supply of two aircraft. The aircraft from Hungary were purchased with in-flight refueling capabilities and a special configuration that converts their interior into an air ICU. The contract also covers pilot and specialist training. In this way, Hungary became the second European country and the second member of NATO to buy the aircraft from Embraer.
As previously explained, the global economic crisis ended up affecting the KC-390 in 2014. Such problems have been occurring until today. On May 26 of this year, the Brazilian Air Force confirmed that it would renegotiate the contract for 28 aircraft with Embraer. The biggest reason is the impact of the New Coronavirus pandemic, which has further worsened the economic situation in Brazil and the rest of the world. The FAB stated that the purpose of the contract review is “reduce the total number of aircraft delivered, based on the current contract, and seek a production rate of 02 aircraft per year, factors considered adequate considering the operational, logistical and financial aspects.”
In an interview with Valor Econômico, the Commander of the Brazilian Air Force, Lieutenant Brigadier Carlos de Almeida Baptista Jr., confirmed that the manufacturer accepted the renegotiation, stating that between 13 and 16 aircraft should be acquired, since budgetary restrictions imposed by the fight against pandemic do not allow the financing of the 28 aircraft originally planned.
What is expected is that the remaining aircraft will be acquired in the future in a second contract.
In detail, the KC-390
The KC-390 is a twin-engine multi-mission tactical transport aircraft. The word “tactical” translates into the operational application of the plane: transporting troops, weapons, ammunition, vehicles, armored vehicles and launching parachute infantry at points closer to the front line of combat. In addition, the other mission performed by the KC-390 is in-flight refueling, which will be explained in detail later on.
Aside from transport and REVO, the aircraft is designed to perform search and rescue (SAR), aeromedical evacuation (EVAM), firefighting and reconnaissance operations. Such capabilities are being developed by Embraer and the FAB. The plane is still in its in-service deployment phase.
In November 2019, in the midst of t venture negotiations with Boeing, Embraer announced the new name and designation for the aircraft: C-390 Millennium. At FAB, the jet continues to be called KC, as the C prefix is aimed at aircraft that will be acquired without the option of in-flight refueling. A kind of “basic version” of the plane, as journalist Cláudio Lucchesi of Asas Magazine categorized it.
During the project, Embraer studied several engines for the KC-390, including the CFM International CFM56, the General Electric CF34 (already used in the E190/195), Pratt & Whitney PW6000 and the Rolls-Royce BR700/F130, but the Millennium received the International Aero Engines IAE turbofans V2500-E5. The high position of the engines decreases the intake of debris. The V2500 is a very popular engine in the market, used in the commercial jets of the Airbus A320ceo family (except the A138 'baby bus'). The V2500-E5 is based on the 2500-A5 used on the A321, but modified according to Embraer's requirements for the KC-390. Each engine generates around 31.330 pounds of maximum thrust.
The dimensions of the aircraft are these:
- Length: 35,20 meters
- Wingspan: 35,5 meters
- Height: 11,84 meters
- Cargo compartment length: 18,50 meters
- Maximum cargo compartment height: 3,20 meters
- Minimum cargo compartment height: 2,95 meters
- Cargo compartment width: 3,45 meters
- Volume: 169m³.
As it is primarily a plane dedicated to transport missions, the main feature of the KC-390 is precisely its cargo compartment. In it, the plane can transport a vehicle weighing up to 26 tons, such as the batteries for the ASTROS II/2020 rocket launch system and the Iveco Guarani troop transport vehicle.
According to Embraer, the following can also be transported:
- 2x M113 track armor
- 2x Oshkosh M-ATV
- 1x APC Patria AMV 8×8
- 1x Russian BMP-3
- 1x APC Stryker with additional armor
- 1x UH-60 Black Hawk helicopter
- 2x 20ft containers.
23 tons distributed in seven pallets of 463 liters can also be transported. The KC-390 can carry 80 fully equipped soldiers, 74 patients on stretchers with eight medical attendants in medevac configuration, or 64 paratroopers. Benches and stretchers can be quickly assembled with two loasters. With a maximum load of 26 tons concentrated, the KC-390 has a range of 2000 kilometers, with this autonomy increasing to 2722 kilometers when carrying 23 tons. The transfer range with three internal tanks is 8463 kilometers.
One of the highlights of the KC-390 is the CHS (Cargo Handling System), the Cargo Management System. To monitor and control what happens in the cargo hold of the aircraft, the responsible crew member, called the loaster, has a specific station. It has two screens that can be controlled using a mouse, similar to what happens in the cockpit. The pallet locks can be controlled automatically through simple touches, speeding up and making the work of the crew even safer.
The floor is quickly configurable. With the press of a button and a quick movement of the arm, it can be easily changed between a flat or roller configuration for easy loading of palletized loads. The aircraft is already compatible with all military employment pallets in use worldwide.
Right behind the main landing gear are two hydraulic stabilizers called struts, an important resource for the safety of loading and unloading cargo, especially the heaviest ones. The system is powered from the loaster station. The plane's own landing gear is also designed for a more “brough” operation, as the aircraft can operate from unprepared runways.
To drop loads accurately, the KC-390 uses the Continuously Computed Drop Point (CCDP), where the aircraft's computers calculate the ideal point for dropping material, using altitude data. , speed and wind. With the Low Altitude Parachute Extraction (LAPES) system, the aircraft can deliver loads of up to 10 tons, or 22 sliding plates with the CDS (Container Delivery System).
In the cargo compartment, the crew still has a bathroom at their disposal; before going up to the cockpit, there is a galley with a refrigerator, oven and waste bins. The KC-390's flight deck is dominated by the flight mechanic station (AMC), just behind the copilot's seat. It is from there that the auxiliary crew member performs the REVO operations, monitoring the fueled aircraft through cameras positioned on the aircraft. Just behind are two bunks for crew rest on long-distance missions, with the bottom bunk able to be used as a jump seat.
The main consists of five color LCD screens. These are the “main course” of the Rockwell Collins Pro Line Fusion Suite, the avionics suite employed on the aircraft, also found on the Legacy 500 executive jets and E2 Family commercial jets. The screens are intuitively controlled by the two pilots using mice mounted on the center console.
Another feature is the HUDs (Head Up Display) developed by AEL Sistemas from Porto Alegre (RS). The KC-390's HUDs provide not only flight data, but also tactical information. The equipment is also widely used on flights with bad weather, where the EVS (Enhanced Vision System) comes into play. AEL, which already has a well-known partnership with the FAB and Embraer through the modernization of the F-5M, A-1M and C-95M/P-95M, also supplies the KC-390 with mission computers and self-protection systems. .
To operate in hostile and contested environments, Embraer equipped the KC-390 with radar warning (RWR, Radar Warning Receiver), laser warning (LWS), missile approach warning (MAWS) and DIRCM (Directional Infrared Counter Measures). These systems work together in the jet's self-protection suite. The aircraft also has Chaff and Flare launchers, countermeasures used for radar guided missile defense and infrared signature. In addition, the KC-390 also has armor capable of withstanding 7,62x51mm rounds and .50 BMG.
REVO is one of the key missions to be performed by the KC-390 and for that it receives a pair of Cobham 912E pods, mounted on the wingtips. Each pod contains a 27 meter long hose, capable of transferring up to 1818 liters of fuel per minute. In refueling missions, the aircraft will be equipped with three auxiliary fuel tanks, installed in the cargo compartment, increasing the amount of fuel carried by the aircraft to 35 tons. The KC-390 can refuel fighter planes, transports and helicopters, flying between 120 and 300 knots. In addition to refueling other planes, the KC-390 can also be refueled through a REVO probe installed at the top of the cabin.
In the future, Millennium will be able to perform other missions besides REVO and transport. Embraer is working on the development and integration of a modular firefighting system. In computer graphics images, the aircraft can be seen with a system similar to the MAFFS II (Modular Airborne FireFighting System) used on the C-130 Hercules.
Unlike the MAFFS I, already used on the FAB C-130M, where two large nozzles project out of the loading ramp, on the MAFFS II, a single nozzle is projected through an adapted side door, releasing water and/or fire retardant chemicals.
In addition to firefighting, the aircraft can also be used in search and rescue (SAR) operations. The KC-390 can be equipped with SAR operations modules, where lifeboats and survival materials can be dropped on the victim with precision. An important piece of equipment that will be integrated is the Rafael LITENING II pod. Typically used on fighter aircraft to identify and attack targets with bombs, Litening can be used on the KC-390 in Search and Rescue, Surveillance and Maritime Patrol missions.
The equipment has cameras and sensors to generate TV or infrared (FLIR) images, which in SAR missions can be used to identify the location of an air accident, a shipwreck or other situations. Litening's laser can be used to acquire coordinates, mark and designate targets. The data obtained would be ed on to rescue helicopters, speeding up the rescue of a victim. A dedicated SAR version was also offered to Canada in 2015 but was not purchased.
Litening, allied to Leonardo's Gabiano T-20 tactical radar, also allows the KC-390 to carry out reconnaissance missions, working together with other aircraft of this aviation, such as the R-99, R-35 and the RQ-450 UAVs and RQ-900. They also allow the KC-390 to carry out some maritime patrol missions, also flying with the P-3AM Orion and the P-95M Bandeirulha.
All of these missions, including REVO, can be performed day or night. Embraer has already prepared the aircraft for the use of Night Vision Goggles (NVG). The systems also have a data link that increases the situational awareness of the missions and reduces the workload of the pilots.
The KC-390's Fly-By-Wire also features Quick Change features, which can be quickly changed according to the characteristics of each flight. In a tactical navigation, for example, the Fly-By-Wire can be more “relaxed”, allowing the aircraft to perform sharper turns. The aircraft itself can be quickly reconfigured between any mission in just three hours. However, the number of crew required varies according to the characteristics of the mission. On a firefighting flight, for example, only two pilots and two cargo masters would be needed.
The aircraft can be completely reconfigured in just three hours. The KC-390 has the term “Multimission” tattooed on its skin. It is a transport aircraft capable of performing numerous services in the most diverse climatic environments, whether in the cold at the poles, in the humid Amazon or in the hottest deserts.
Get to work
After its official incorporation, it didn't take long for the KC-390 to fly real missions. At the end of 2019, the first cases of Covid-19 began to appear and in February 2020 the disease was already in Brazil. One of the darkest periods in history had begun.
The collapse of health systems in dozens of cities across the country has prompted the Ministry of Defense to activate Operation Covid-19. The FAB opened an air corridor, transporting field hospitals, medicines, hospital supplies and PPE. But among all the materials that the FAB transported, oxygen stood out, especially in the second wave of the pandemic, where the Amazon was heavily affected.
The lack of cylinders meant that C-105 Amazonas, C-130 Hércules and the KC-390 itself were loaded with hundreds of cylinders of gaseous O2, but it was not being enough. The FAB started transporting large cylinders of liquid O2 in the C-130, as the KC-390 was not prepared to carry this equipment. Quickly, the Air Force, Embraer and White Martins arrived at a solution, adapting pressure relief valves on the KC-390. On 16/01, the 2853 transported the first five tanks of liquid O2 from Guarulhos to Manaus. The aircraft also carried a 17-tonne isocontainer with a volume of 6.047m³ of liquid oxygen.
It was also in the midst of the pandemic, which unfortunately still continues, that the KC-390 carried out its first international mission. On August 04, 2020, a fire caused the explosion of a load of 2750 tons of ammonium nitrate that were in a warehouse in the port of Beirut, Lebanon. The images shocked the world; 218 people died and more than XNUMX were injured.
In response, the Federal Government launched the Brazilian Multidisciplinary Mission for Humanitarian Assistance to the Lebanese Republic, where a KC-390 and a VC-2 from the Special Transport Group were sent to the country. While the presidential plane transported volunteer doctors, authorities and representatives of the Lebanese community in Brazil, including former president Michel Temer, the KC-390 carried about six tons of medicine, food and equipment for the care of the victims of the tragedy. The aircraft left Brazil on 12/08, arriving in the Lebanese capital the following day.
In mid-August of this year, Haiti was hit by a series of tremors and a tropical cyclone, leaving thousands dead, injured and homeless. On 22/08, the KC-390 FAB 2856 took off from Brasilia bound for the Haitian capital of Port-au-Prince, transporting a team of 32 military firefighters from the Federal District, Minas Gerais and the National Public Security Force, about seven tons of emergency materials and equipment and another 3,5 tons of medicines and strategic supplies. However, the 2856 had a breakdown when performing an already scheduled landing at the Cachimbo Air Force Base, located in southern Pará. In this way, the KC-390 FAB 2854 was transferred to BAPV to replace the 2856, with the mission continuing afterwards.
On 11/09, the 2854 and the 1st GTT returned to Haiti with another five tons of food, medicine, solar s and water purifiers. The aircraft also brought back to the country firefighters from the Federal District, Minas Gerais and the National Force who were helping with the searches and care for the victims.
In January 2021, the 1st GTT was in the United States participating in the Culminating Operational Exercise, with the KC-390 2855. The aircraft took off at dawn on 12/01 with 21 soldiers from the Zeus Squadron and three others from the Brazilian Army. In the training, held at Fort Polk, in Lousiana, of the FAB, EB, Army and US Air Force carried out t airborne assault operations, marking the first participation of the KC-390 and of Zeus in an international exercise. Culminating ended on February 05th.
More recently, the 1st GTT took the 2855 to participate in the International Exercise Cooperación VII, held in Colombia. Dozens of countries in the Americas gathered to train t actions in humanitarian aid missions and response to natural disasters, with the KC-390 carrying out the launch of Colombian paratroopers. The Brazilian aircraft also stood out for presenting 100% availability throughout the financial year, which took place between 30/08 and 10/09.
Today, the FAB is still working on deploying the aircraft. Since entering service, the KC-390 has shown good availability and can be quickly deployed to different locations. There may be some hiccups going into service of a brand new aircraft, but it is part of the process.
As the aircraft matures, more capabilities are being implemented and the aircraft itself becomes easier to operate, both in flight and in of sustainability. There is still a long way to go until the Final Operation Capability (FOC) is obtained, but until then, the KC-390 will continue to carry out periodic missions in favor of Brazil and other countries.
