Rotortech has just delivered its first G-checked AS332 Super Puma, after receiving its JAR 145 approval on this series aircraft back in July. MD Simon Peck said: “The major overhaul consumed over 9,500 man-hours over an 8-week period and involved several major repairs, although that is quite normal for an aircraft of this size. These aircraft are approximately 20 years old and they often fly up to ten hours every day, and several total over 1,200 flying hours a year. The G check on this aircraft is then done at 7,500-hour intervals.”

This particular aircraft is now being used to evaluate the possibility of extending the cycle in a scheme which could see the time between G checks lengthened. “These Super Puma’s are currently on a 7,500-hour cycle and there’s now talk of increasing this to 8,150 hours. A lot of the data from this aircraft produced during the check is being used to assess whether Eurocopter can extend the interval” said Peck.

Rotortech claims to be one of only a handful of JAR 145 companies worldwide with the AS332 approval. “In order to gain a new type approval, you first need to demonstrate your requirement to have it. So when the work was identified and discussed with the customer we had to put considerable effort into getting everything we needed in place to qualify for the approval, in order to make our application to the CAA. We basically had to demonstrate the capability to carry out the work, both in terms of personnel, planning equipment, tooling etc”.

“Rotortech is lucky because compared with other companies with this approval, we’re a small company, so our overheads are much lower. As a result, we can charge considerably less for this work compared with many other organisations. ”

Peck explained the process of the G check: “Basically, we completely strip the aircraft down to its bare bones – it’s a major overhaul, the biggest check the aircraft has. Everything is inspected, we replace what needs replacing, repair what can be repaired, then we put it back together again before it goes back into service in an airworthiness condition for another six to eight years.”

Gaining approval for this type of maintenance is often difficult, but Rotortech was fortunate enough to have a customer who was willing to trust the company. “We had carried out a series of nose to tail G checks and major structural modifications on several AS365 and S76 aircraft previously, where we were given very tight delivery times. We had to maximise our labour resources and work a 24-hour shift pattern and hit

it for eight weeks solid. Yet we were able to deliver aircraft to our customers in the time-frame they asked for. Because we delivered on time, we asked the customer with the Super Puma to give us a go and show that we could do it. Few people get this opportunity, mainly because unless you’re the operator or OEM sponsored, you are unlikely to be given the chance.

“It’s now been three weeks since the aircraft was delivered and we’re in the middle of a campaign to bring ourselves to the world’s attention. I think once we’ve started making potential customers aware of us and the benefits we can offer, that’s when the work will take off.”