One of the RNZAF's new NH90 helicopters at Wellington Airport.
New Zealand's new $771 million air force helicopter fleet may not last as long as expected.
Labour ordered eight NH90 helicopters in 2006 to replace the Vietnam War-era Iroquois choppers.
But the Defence Force has confirmed they are "prone to damage" from debris drawn into engines, and that without screens to lower that risk cannot operate in snowy conditions, and that they are also unsuitable for being transported on the C-130 Hercules.
Now a Defence Force paper obtained by the Sunday Star-Times this past week has raised questions over the longevity of the French-manufactured helicopters' airframe.
The paper says there is a "medium" risk the "fatigue life modelling utilised by NHIndustries may not be accurate, and may not take the Defence Force's statement of operating intent into consideration".
It warned Defence might have to reduce either the annual available flying hours, or the desired 30-year lifespan.
The paper also revealed a "high" risk that some core equipment, including fuel tanks, chaff and flare dispensers, ballistic protection, liferafts, rope rappelling devices and machine-gun mounts, would not be ready before the choppers were handed over. Those delays would "prolong the time" it took for the NH90s to reach their "directed level of capability".
Defence said it was working with NHIndustries to ensure equipment arrived as soon as possible, including investigating "alternate sources of supply".
The paper also said there was a "major risk" the helicopters' introduction into service would be delivered in three phases – "interim, final and final plus".
"This adds complexity and overheads, while reducing aircraft availability as they are taken off line, updated to the latest standard, then acceptance tested," it said.
"Operational test and evaluation effort is also increased."
The paper added the Ministry of Defence and Defence Force were "working closely together to mitigate this risk as far as possible".
The Star-Times revealed last weekend that Defence officials spent more than $1.5m on overseas travel while scoping the choppers.
Documents show the project team's travel costs were $172,035 in 2007-08, $295,290 in 2009-10 and another $106,591 in 2010. Further payments of $546,756 were made in 2010-11 and $426,768 in 2011-12 for travel related to the project, including costs for sending support teams overseas.
Earlier it had been revealed the initial purchase estimate had blown out from $400m-$550m to $771m.
Green Party defence spokesman Kennedy Graham called for a select committee to investigate the project. "Now we find out there are difficulties with the helicopters themselves, and on top of the bill, we spent hundreds of thousands on overseas travel," he said. "The Ministry of Defence needs to explain that."
Secretary of Defence (Acquisition) Des Ashton said it was "incorrect" to say there had been a budget blowout, saying the $550m figure was an early "budgetary estimate" before the evolution of the NH90.
"The question as to whether someone holds an inquiry is not mine to answer," he said. "I am more than comfortable with how the project was handled."
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