In 2017, NPO Saturn PJSC completed the implementation of three projects within the framework of federal target programs, this is the construction and commissioning of foundry building No. 140 and the assembly and testing complex of marine gas turbine units (GTU),
as well as technical re-equipment of production for the program of marine gas turbine engines (GTE).
The commissioning of a new foundry building is a significant event for the enterprise. The plant has not built such large-scale production facilities since the 80s of the last century. The creation of foundry building No. 140 will contribute to reaching serial supply of parts for the Leap family engine under a contract with Safran.
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At the first stage we are talking about machining blades, then - about the manufacture of blades. At the end of this year, the first experimental castings of these blades should be received. These two parallel projects - the creation of a powerful production foundry building, which has no analogues in Russia, and the production of parts for the most massive engine on the world market - in the long term can give NPO Saturn a significant utilization of production capacity and, accordingly, revenue.
If the technological process is properly organized and commercial interactions with potential customers are properly structured, including on the global market (in addition to the Leap project), this will give the plant the opportunity to produce products of this range in addition to the existing order portfolio worth about $100–150 million per year . And it will allow loading not only the 140th building, but also adjacent workshops. Production capacity of the new division will allow us to produce a million blades a year!
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Building No. 140 and workshop No. 34 will form a technologically closed complex full cycle manufacturing, from ore to finished part. The casting was made in one workshop, in another, located across the road, it was processed, and the part was sent for assembly. The arrangement of equipment by type of processing, according to route technological processes, reduces inter-shop and intra-shop cargo flows, ensures the shortest paths for parts to pass through all stages of the production cycle, allows to increase the equipment load factor, and eliminate the laying of parts. These principles of Lean philosophy were originally laid down in the creation of the production of turbine blades. All foundry equipment is unique, it is made for a specific customer, for a specific part.
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The planned investment volume for 2017 is 1.5 billion rubles. for equipment, and the total volume of equipment supplies is estimated at 3 billion rubles. After minimal modernization, some of the equipment will be transferred to the new building from workshop No. 41. The commissioning of the production capacity of building No. 140 is divided into two stages. In 2017, the building will begin its work on the basis of the zero stage - this year all technological stages will be created, the entire technological chain, from pouring to the release of the first usable blade. In 2019, the building should reach contract volumes of serial production.
Two other investment projects concern development Russian base offshore gas turbine construction under the import substitution program. There are plans to put into operation an assembly and testing complex for marine gas turbine engines in 2017.(SIC KSTA), created by UEC under contracts with the Ministry of Industry and Trade of the Russian Federation and the Rostec State Corporation on the basis of the Rybinsk NPO Saturn, is intended to conduct all types of preliminary, bearer, acceptance, interdepartmental and periodic tests of ship gas turbine engines, gas turbine and diesel gas turbine units.
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SIC KSTA includes: two test benches for gas turbine engines with power – 1st up to 15 MW, 2nd – up to 40 MW; areas of incoming control, storage, assembly and preparation for testing; stock diesel fuel with underground tanks for supplying summer and winter fuels separately for diesel and gas turbine engines; administrative and amenity complex to accommodate engineering and technical personnel. The total area of the complex building is 1 hectares, the area land plot with access roads of almost 2 hectares.
Stand No. 1 is designed for testing gas turbine engines M70FRU, M70FRU-2, M70FRU-R and units based on them with a capacity of up to 15 MW. It will consist of a monolithic reinforced concrete test box, a foundation slab for the location of gas turbine engines and unit components, such as a diesel engine and a ship's gearbox, bench oil circulation systems, flushing of the engine flow path and their preservation. The loading device will make it possible to test engines and units with different directions of rotation of the power take-off flange, including reverse operation during operation. The location and number of air supply openings in the walls of the stand will allow for the most complete use of the space inside the test box for all types of gas turbine units and engines with a power of up to 15 MW, including those with power take-off, both on the hot side of the engine and on the cold side.
Stand No. 2 design for testing a gas turbine engine with a power of up to 40 MW is also universal and will ensure testing of a unit consisting of two simultaneously operating gas turbine engines of the M90FR type and one diesel engine with power output through a reducer-adder.
By May 2017, civil works will be completed, bench exhaust, suction, noise reduction systems will be installed, lifting mechanisms, measuring and computing complex, system automatic control technological equipment. They will complete the improvement of the adjacent territory, supply and commissioning of the main technological systems and equipment. The installation of a recycling water supply system for hydraulic loading devices will be completed.
Primary certification of test benches (together with the Federal State Unitary Enterprise "CIAM named after Baranov") and metrological verification of measuring systems of the SIC and its introduction into industrial operation scheduled for December 2017
Also in 2017, it is necessary to complete technical re-equipment, which includes the acquisition of equipment for organizing serial production of marine gas turbine engines. The first engines of the installation batch have already been made using existing equipment.
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In 2016, as part of the import substitution program, the company launched three types of marine engines*. Behind this in a short phrase It costs a lot of work of people - designers, technologists, production workers. The development of new products was intense, but the factory workers adhered to the schedule for technological preparation of production for each part of these engines. The work was completed within the tight deadlines that were allocated.
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An aircraft engine today is a concentration of the most modern and high-tech parts, design and technological solutions, and the most widespread and complex parts in it are blades - compressor and turbine - these are the main competencies that are developed at Saturn. The topic “Turbine blades” has already been touched upon when talking about the 140th building, The “Compressor Blades” direction is also actively developing.. The goal of NPO Saturn is to enter the world market with these products at a competitive cost. There is a whole range of measures to achieve the same goals that the factory workers achieved with turbine blades. This is an increase in the material utilization rate, this is a reduction in production cycles. To achieve the set goals, the 2nd stage of the electrochemical machine section in building No. 119 was put into operation, and the technology of non-allowance stamping in building No. 2 is being actively developed.
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Will there be new projects in soon? Of course they will. This is also PD-12V ( helicopter engine instead of D-136) - layout work on the project is already underway. The next PD-35 project is still at the level of research and critical technologies - a composite fan and fan casing are to be designed, a large amount of work is planned on the low-pressure turbine.
This year the production rate of D-30KP engines will increase - this is the breadwinner of the plant, which continues its life cycle. Rhythmic production of SaM146 engines will also be ensured, with 8 sets per month at the end of the year.
2017 should be a key year in terms of decision-making on launch serial production modernized gas turbine high power GTD-110M** and the full transfer of this program into a new direction - based on the results of testing the machine, the main stage of which is completed this year. Based on market needs, project participants are considering several scenarios with maximum number production of engines up to 10 units per year. This is a national-scale project, the implementation of which depends on support from federal authorities.
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NPO Saturn has mastered the production of gas turbine engine parts from cobalt alloy using additive technologies (AT). The introduction of additive technologies into production will make it possible to create competitive global market products in as soon as possible and at minimal cost.
The superalloy is adapted for the manufacture of parts by selective laser melting of a metal powder composition. It is characterized by increased heat resistance, resistance to temperature and salt corrosion, and high operating temperature. Research into the properties and development of optimal technological parameters for layer-by-layer synthesis of cobalt superalloy have been carried out at NPO Saturn for more than 2 years, and work is currently underway to certify it.
Among other advanced technical solutions It is possible to highlight the production of gas turbine engine parts from composite materials on polymer and ceramic bases.
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Today, on the basis of NPO Saturn, there is an Additive Technologies Center (ATC), which has no analogues in Russia. It presents all the promising and most in-demand areas of AT in the industry. The center specializes in the production of parts, models and assemblies of gas turbine engines for aviation and ground use using layer-by-layer synthesis methods. Related technologies are also presented here: heat treatment, laser welding and perforation, metallurgical laboratory, computed tomography, electron microscopy, non-contact optical digitization laboratory and reverse engineering. TsAT solves key scientific, technical and technological problems: increasing the stability of the characteristics of gas turbine engine elements; the possibility of obtaining structures with a unique topology; reduction of the cycle and cost of manufacturing gas turbine engine parts; the use in construction of materials whose shaping traditional technologies either impossible or extremely expensive.
NPO Saturn has developed a technological chain for manufacturing parts using selective fusion, from the development of a 3D model to a functional part. Innovative design principles are being introduced taking into account new technological capabilities, including intelligent optimization of the topology of parts, providing the required strength taking into account the direction of the acting loads and significant weight reduction - the so-called bionic design. The center is actively involved in the development and production of domestic metal powder compositions. In 2015-2016 more than 1000 various parts gas turbine engines manufactured by selective alloying of cobalt, titanium alloys, and stainless steel have successfully passed bench tests as part of the engines.
* Development work carried out by NPO Saturn are carried out in accordance with the ongoing import substitution program in order to develop and master the production of domestic ship units, as well as to replace previously installed Ukrainian gas turbine engines in operation on Russian ships.
- OKR code "M90FR" – one of three R&D projects on marine gas turbine engines currently being implemented by PJSC UEC-Saturn. It involves the development of serial production of the M90FR gas turbine engine with a capacity of 27,500 hp. to ensure the complete set of diesel-gas turbine unit M55R. The R&D work is being carried out within the framework of the state contract between the Ministry of Industry and Trade of Russia and PJSC UEC-Saturn dated 2014, completion date is December 2017.
As of today, UEC-Saturn PJSC has carried out technological preparation of production, manufactured engines that are subject to testing as part of putting the product into production, and in parallel with the work on putting it into production, delivery M90FR gas turbine engines are being manufactured.
Work on the M90FR design and development work is carried out in accordance with the approved schedules. Based on its results, a qualification test certificate will be approved, confirming the readiness of PJSC UEC-Saturn to serial production GTD M90FR, which is currently the most in demand in the Navy of the Russian Defense Ministry.
- OKR code “DKVP Unit”– development work on the development of the M70FRU-2 gas turbine engine and ship-based gas turbine engines M35R-1, M35R-2 and M70R with a power of 10 thousand hp. It is being carried out within the framework of the state contract dated 2014 between the Ministry of Industry and Trade of the Russian Federation and NPO Saturn, completion date is December 2017.
To date, design documentation for the gas turbine engine and units M35R-1, M35R-2 and M70R has been developed, work on technological preparation of production has been completed, and prototypes have been manufactured. gas turbine engines. During the remaining period of the development work, it is planned to conduct special factory, acceptance and interdepartmental tests of the M70FRU engine, gas turbine units M35R-1, M35R-2 and M70R.
- OKR code “M70FRU-Reverse”– development work on the development of the M70FRU-R engine with a reversible power turbine for engine replacement foreign production, which are in operation on Russian ships. The R&D work is being carried out within the framework of a government contract dated 2014 between the Ministry of Industry and Trade of the Russian Federation and NPO Saturn, completion date is December 2017.
Russian ship gas turbine engines (GTE) will be able to replace products that Ukraine refused to supply as part of anti-Russian sanctions. Analysts note that the production of gas turbine engines is an extremely promising area of the defense industry. According to experts, these engines can be installed on almost all types of warships. The fact that Russia is developing a fifth-generation marine gas turbine engine for the needs of the Navy was previously announced by the director of NPO Saturn, Viktor Polyakov. The preliminary design of the unit has already been completed. What effect should you expect from the appearance the latest engines, RT understood.
Frigate "Admiral of the Fleet" Soviet Union Gorshkov" RIA Novosti
Managing Director of the Saturn Research and Production Association Viktor Polyakov announced the completion of the preliminary design of a fifth-generation marine gas turbine engine. According to him, experts have developed technical task and corresponding proposals for the federal target program.
“Together with industry institutes, we have completed a number of research and development work to shape the appearance of fifth-generation marine gas turbine engines. Based on the results of this work, we carried out preliminary design as part of research work,” Polyakov said in an interview with RIA Novosti.
Earlier, he reported that the portfolio of orders for gas turbine engines for the coming years was fully formed. In particular, patrol ships of the far sea zone of Project 22350, which are being built at Severnaya Verf, will be equipped with Russian gas turbine engines.
In 2018, the Navy should receive two frigates - Admiral of the Fleet of the Soviet Union Gorshkov and Admiral of the Fleet Kasatonov. Two more ships are in the process of construction - “Admiral Golovko” and “Admiral of the Fleet of the Soviet Union Isakov”.
“Today at our stands we are testing engines across all operational parameters, including simulation of the load on the shaft. We will deliver the first two units this year, the timing was determined by the customer - the fourth quarter of 2018,” said Polyakov.
According to the director of Saturn, the potential for modernization is built into the marine power plants that the company is developing. One of the main tasks of designers is to reduce fuel consumption while increasing efficiency.
- Marine dual-fuel gas turbine engine E70/8RD
- www.npo-saturn.ru
Sanctions factor
Information about plans to develop a fifth-generation gas turbine engine first appeared on April 25, 2017.
The press service of the United Engine Corporation announced its intention to carry out a number of research projects, including “determining the appearance of a fifth-generation marine engine.” The newest power unit should be more powerful than its predecessors and have more high efficiency.
Traditionally, NPO Saturn specialized in the development and production of aviation gas turbine engines. Since 1993, the company began to master the production of ship gas turbines. power plants. In 2000, Russian President Vladimir Putin appointed Saturn (then Rybinsk Motors OJSC) as the lead enterprise for the development, serial production and repair of all marine gas turbine engines.
The measures taken to diversify Saturn's products made it possible to mitigate the consequences of the rupture of military-technical cooperation with Ukraine in 2014, when Kiev banned the Zaporozhye JSC Motor Sich from supplying ship and aircraft engines, including gas turbine units, to Russia.
Ukrainian sanctions have delayed the delivery of several warships to the Navy. In particular, we are talking about project 11356 to create multi-purpose patrol ships for the far sea zone, which is being implemented Kaliningrad plant"Amber". In 2015, shipbuilders were forced to suspend the construction of frigates.
The situation was resolved thanks to the completion of tests of the Russian gas turbine engine M-70FRU-2 with a capacity of 14 thousand hp. With. On April 25, 2017, Vladimir Putin, during a visit to Saturn, launched the production of shipborne gas turbine engines.
- Russian President Vladimir Putin inspects the Saturn workshop, April 2017
“Then (in 2014. - RT) we made a decision: we will not do something so average, but we will develop our own new products, our new solutions, our new cars, and we even went so far as to shift the rearmament program of the Russian fleet to the right, waiting for your car.” , said the head of state.
On December 27, the ceremony of raising the St. Andrew's flag took place on the Project 11356 frigate Admiral Makarov. The patrol ship was included in the formation of surface ships of the Black Sea Fleet stationed in Sevastopol Bay.
In the coming years, the Navy will receive three ships of Project 11356 - Admiral Butakov, Admiral Istomin and Admiral Kornilov. In addition to the Admiral Makarov, the Admiral Grigorovich and Admiral Essen are now in service, having already undergone baptism of fire off the coast of Syria.
Import substitution course
The production of gas turbine engines is extremely promising direction Russian defense industry. This was reported to RT by the chairman of the Union of Geopoliticians, retired captain 1st rank Konstantin Sivkov.
He emphasized that such power plants are more efficient than conventional steam turbine units.
“Gas turbine engines can be installed on almost all types of warships, with the exception of strategic submarines and boats of various classes. They are more economical, powerful and easy to use. The production of gas turbine engines is, without a doubt, in great demand in the current conditions,” Sivkov noted.
According to the expert, Russia is striving to gain independence from Zaporozhye Motor Sich. Investments in the development of the fifth-generation engine are being carried out as part of the policy of import substitution announced by the Russian President.
“Russia is capable of creating both analogues and new propulsion gas turbine units. Despite the fact that Moscow has been purchasing these engines from Ukraine since the 1990s, our country has a powerful design school and a corresponding scientific and technological foundation,” explained Sivkov.
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on the completion of three more frigates of the Admiral Grigorovich type for the Black Sea. However, this requires resolving the issue of gas turbine units, which Ukraine refused to supply to Russia.The new warship bears the name of the last naval minister Russian Empire, Ivan Konstantinovich Grigorovich, who became famous for his brilliant speech in State Duma, the text of which was written by the famous shipbuilder and future academician Alexey Krylov. The speech had such an effect on the deputies that they almost unanimously voted to allocate 500 million rubles for the “reconstruction of the fleet” that perished at Tsushima. The warships built under the leadership of Grigorovich made up 100% of the battleships, 40% of the cruisers and 30% of the destroyers in the fleet that met the Great Patriotic War in 1941.
Project 11356R/M frigates are a direct continuation of Project 11356 patrol ships, which were built for India.
Project 11356R/M frigates are radically different from their predecessors in the composition of their equipment, weapons and architecture, which incorporates elements of low-visibility technologies. Their total displacement is 4035 tons, length - 124.8 m, width - 15.2 m. Twin-shaft gas turbine unit (according to the COGAG scheme) with a total power of 56,000 hp. allows you to develop a 30-knot full speed. Cruising range at 14 knots is 4850 miles. The crew consists of 180 people. The ships can additionally take on board up to 20 marines.
For the first time in the practice of domestic shipbuilding, Project 11356R/M patrol ships carry 36 9M317M Uragan-Tornado air defense missiles (in the export version - Shtil-1) in bow vertical launchers of the 3S90M cellular type. This reduces reaction time to emerging air threats and increases fire performance. The rate of fire increases six times compared to the old-style Uragan (Calm) air defense system (every 2 seconds instead of 12). In addition, all-round protection of the ship is provided (firing sector - 360°). These air defense systems can simultaneously fire from two to twelve air targets at ranges from 2.5 to 70 km and altitudes from 15 m to 35 km.
No less impressive are the strike weapons. The 3S-14 bow launcher houses eight missiles of the multi-purpose Caliber-NK complex, designed to destroy surface or ground-based stationary and limited-moving objects. Instead of them or parts of them, the same vertical launchers may contain supersonic highly maneuverable Onyx anti-ship missiles or 91R anti-submarine ballistic missiles.
Artillery weapons are represented by the latest 100-mm universal automatic cannon A-190 with a range of destruction of sea, air and coastal targets of up to 20 km. Two six-barreled 30-mm AK-630M assault rifles are designed for defense against cruise missiles enemy at close range and destruction of other small sea and air targets.
In addition to the 91R missiles of the Caliber-NK complex, anti-submarine weapons are represented by two twin-tube anti-submarine 533-mm torpedo tubes DTA-53-956, RBU-6000 and a Ka-27PL helicopter, for which there is a runway and hangar in the stern. The electronic equipment of Project 11356R/M frigates also meets modern requirements. There is a combat information and control system, radars for various purposes, sonar, and electronic warfare equipment.
Earlier it was reported that the second three frigates of Project 11356R/M may be sold to India due to the non-supply of Ukrainian propulsion systems for them. After the government of Ukraine announced an embargo on the transfer of military and military products to Russia dual use Nikolaev enterprise "Zorya" - "Mashproekt" stopped supplies to the Russian Baltic shipyard "Yantar" gas turbine units M7N1 for frigates of project 11356R/M, although money was paid for them. Thus, gas turbine units are available only on the first three ships of the “admiral” series.
It was precisely because of the uncertainty regarding the supply of Ukrainian engines that the commissioning of the Admiral Grigorovich fleet was delayed. And only now the Ministry of Defense has decided to establish serial production of engines for Russian warships at NPO Saturn.
NPO Saturn promises to launch production of domestic gas turbine units for warships in two years. Even if the deadlines are met, installation on production ships will require serious testing of power plants, which will take more than one month.
Isn’t it better to purchase analogues of Ukrainian engines in China for the second three frigates of Project 11356R/M? The Chinese Navy initially purchased engines for its ships produced by the Ukrainian enterprise "Zorya" - "Mashproekt", and then established own production, apparently simply copying them. It is unlikely that their production is licensed, but the trademark on the gas turbine is Chinese.
The Black Sea Fleet today is in dire need of strengthening with modern patrol ships, and it is hardly worth waiting two or three years until the appearance of domestic engines for Russian patrol ships. With Chinese gas turbines, the admiral's series of frigates will be able to appear on the roadstead of Sevastopol in the shortest possible time.
On Tuesday, April 25, Russian President Vladimir Putin said that the efficiency and service life of new Russian marine gas turbine engines will exceed foreign ones by 10-15%. He made this statement at the ceremony of the new complex of NPO Saturn for the production of marine gas turbine engines. Most of these engines from the Rybinsk Saturn have greater efficiency than their counterparts from Nikolaev - 36% versus 32%. However, when compared with Ukrainian products, not everyone has the advantage that the president voiced. domestic units. FlotProm compared the characteristics of gas turbine engines.
The launch of serial production of marine gas turbine engines at the Rybinsk NPO Saturn in 2018 will make the Russian Navy independent of imported gas turbine units. And since Saturn’s developments are more modern than the products of Nikolaev’s Zorya-Mashproekt (Ukraine), they have slightly higher efficiency. According to Vladimir Putin, the efficiency of domestic engines will increase by 10-15%, because this is “more modern technology compared to what we took before." FlotProm analyzed the efficiency of power plants.
As part of import substitution, NPO Saturn has been carrying out three development works on the M90FR, Aggregat-DKVP and M70FRU-R engines since 2014, the United Engine Corporation (UEC) told FlotProm. New engines Russian production will equip project frigates and small landing ship on air cushion"Zubr", as well as other ships and vessels of the Russian Navy.
On April 25, two ship gas turbine engines, M70FRU and M70FRU-2, were demonstrated in Rybinsk. FlotProm provides a table with the characteristics of these gas turbine engines in comparison with Ukrainian analogues and the M90FR engine.
| Manufacturer | "Zorya-Mashproekt" | NPO "Saturn" | "Zorya-Mashproekt" | NPO "Saturn" | NPO "Saturn" |
|---|---|---|---|---|---|
| Power point | M35 | M27 | M27/M7N1 | M55R | |
| Engine | DP71/DM71 (UGT6000) |
M70FRU-2 | D090 (UGT15000R) |
M70FRU | M90FR |
| Efficiency, % | 32 | 32,4 | 32 | 36 | ~36 |
| Power, MW | 7,35 | 7,35 | 14,7 | 14 | 20,2 |
| Power turbine rotation speed, rpm |
7000 | 7200 | 4400 | 6500 | 3450 |
| Temperature at the exit from power turbine, °C |
440 | 506 | 430 | 523 | - |
The efficiency of the Russian gas turbine engine for the Zubr DCVP is only 0.4% higher than the Ukrainian one
The M70FRU-2 engine produced by NPO Saturn will become the basis for the power plant of the Zubr small landing hovercraft (project 12322). The main power plant of the Zubr was initially a gas turbine unit of the M35 type. It includes three traction gas turbine units (GTA) M35-1 and two injection GTA M35-2. Each of the units includes a gas turbine engine Soviet design DP71 (in the Ukrainian classification – UGT6000) developed and produced by Zorya-Mashproekt. DP71 engines have been produced in Nikolaev since 1978.To replace the Ukrainian gas turbine engines "Saturn" in 2014, work began on the development work "DKVP Unit". The goal of the development work is to create the M70FRU-2 gas turbine engine and ship-based gas turbine engines M35R-1, M35R-2 and M70R with a power of 10,000 hp. The characteristics of the M70FRU-2 engine, presented on April 25 by NPO Saturn, indicate an efficiency of 32.4%. This is only 0.4% better than the Ukrainian gas turbine engine.
Perhaps the characteristics of the Rybinsk gas turbine engines (especially the M70FRU-2) will improve in the future, since the completion of all three R&D projects is scheduled for December 2017, and not all tests have been completed yet. The UEC stated on April 25 that " further development marine gas turbine engines can take the path of increasing power, as well as increasing efficiency engines." In addition, "Saturn" alloys are made of cobalt.
According to FlotProm's source in Nikolaev-based Zorya-Mashproekt, the use of new cobalt alloys using additive technologies can “slightly improve the characteristics of a gas turbine engine, including helping to increase its efficiency.” The Ukrainian enterprise called the use of cobalt alloys and additive technologies its “know-how”, work on which has been underway for several years.
Russian gas turbine engines for frigates of project 11356 and SKR project 11540 have overtaken Ukrainian ones in terms of efficiency
Rybinsk engines M70FRU and M90FR were created to replace Ukrainian-made gas turbine engines DS71 and D090, respectively. FlotProm was informed about this by a source familiar with the situation. In the main power plant M27, used on the Yaroslav the Mudry TFR of Project 11540 Yastreb, the “nineties” engines are afterburners, and the “seventies” are sustainer engines. At the same time, Russian engines have an efficiency of 36% versus 32% for Ukrainian-made gas turbine engines.The main power plant of Project 11356 frigates is the M7N1 installation, in which the same DS71 engines are the main engines (in the Ukrainian classification - UGT6000), and the afterburners are the DT59 (UGT16000). The efficiency of the latter is only 30%.
Manufacturers and designers of gas turbine engines: the efficiency of such installations is limited to 38-40%
According to the chief designer of the Kolomensky Plant, Valery Ryzhov, which he expressed in FlotProm in 2015, the efficiency of a gas turbine engine “is within 36%, no more. To increase this indicator, it is necessary to increase the combustion temperature in the chamber. This in turn leads to the fact that the limit of long-term strength of the material of the working blades occurs when high temperature. IN diesel engine The maximum combustion temperature reaches 1700 degrees, such a temperature cannot be created in a gas turbine engine - the turbine blades will burn out."According to the United Engine Corporation, the efficiency of most of their new engines is 36%. FlotProm's source at the Zorya-Mashproekt enterprise stated that the efficiency of gas turbine engines can be increased to a maximum of 38-40%.The latest Ukrainian developments - for example, the UGT 25000 engine, have an efficiency declared by the manufacturer from 36 to 37% (in different modifications). At the same time, the British Rolls-Royce company in 2016 stated that the efficiency of its MT-30 engine is over 40%.
The effectiveness of gas turbine engines depends on the quality of materials and spare parts
As FlotProm was told in the Dieselzipservice group of companies, which also deals with the repair of gas turbine engines, the efficiency declared by Rolls-Royce looks doubtful, it is more likely marketing ploy. The company representative added that the efficiency of gas turbine power plants strongly depends on the operating characteristics of the engine, as well as on the quality of materials and spare parts. “So, after modernizing the fuel supply system of the DZh59 engine and installing new blades made of modern alloys on it, the efficiency of the gas turbine engine increased, and fuel consumption decreased,” said a representative of the Dieselzipservice Group of Companies.He also noted that innovations such as cobalt alloys and additive technologies could further improve this figure. “For example, the DV71L (UGT6000+) engine was “tired” before the overhaul; its efficiency decreased by half from 30%. Repair at Kingiseppsky machine-building plant“Using new materials made it possible to restore this value almost to the performance of a new engine. But the factory quality of the gas turbine engine is fundamentally important,” summarized Dieselzipservice.
As an ignorant and idle talker, I give you information - when the program to create the GTA and its financing began.
Read carefully and don’t write any more nonsense... The program has been launched in 2014!
Priority programs.
GTE for marine applications.
JSC NPO Saturn is a leading Russian developer and manufacturer of marine gas turbine engines and units based on them for a wide range of ships and civil vessels, as well as for use in offshore and coastal industrial and oil and gas facilities. The main areas of activity have been identified:
- R&D “Development of technology for creating a marine unified power module based on the previously created Russian marine gas turbine engine of the 4th generation with a capacity of 10 MW for promising high-speed ships” Code “Gturbine engine module”, cost 120,523,000.0 rubles.
- R&D code “M90FR”, the goal is to master the production of the M90FR gas turbine engine to ensure the complete set of the M55R diesel gas turbine unit - the main power plant frigate of project 22350, being built at the Severnaya Verf Shipyard.
The cost of the project is 1,712 million rubles.
- R&D code “DKVP Unit”, the goal is to create, on the basis of the Russian marine gas turbine engine M70FRU and Russian components, gas turbine units for air-cushion landing ships of projects 12322 “Zubr” and 12061 “Moray”.
The cost of the project is 6,790 million rubles.
- R&D code “M70FRU reverse”, the goal is to create a reversible gas turbine engine based on the Russian marine gas turbine engine M70FRU to replace Ukrainian-made engines with expired service life on operating ships of the Russian Navy.
The cost of the project is 700 million rubles.
World market for marine (ship/ship) gas turbine engines
In addition, the implementation of marine gas turbine engines programs is underway: M75RU, E70/8RD (including the gas turbine electric generator SGTG-8 based on E70/8RD) for equipping ships and vessels. Construction of an assembly and testing complex for marine gas turbine engines and gas turbine engines is underway. The forecast for deliveries of new engines is estimated at 148 units.
Results of activities in 2014
Marine gas turbine engines programs.
1. In April 2014, a contract was concluded with the Russian Ministry of Industry and Trade to carry out research and development work "Development of technology for creating a marine unified power module based on the previously created Russian marine gas turbine engine of the 4th generation with a capacity of 10 MW for promising high-speed vessels" Code "Gturbine engine module". The 1st stage of the development work was completed and the results obtained:
- Working design documentation for a prototype of a unified ship power module has been developed;
- The material part of the gearbox and self-propelled guns was manufactured (stage 1);
- A test program has been developed.
2. In December 2014, in accordance with the subprogram “Accelerated development of the military-industrial complex” of the State program Russian Federation“Development of industry and increasing its competitiveness” and by Decree of the Government of the Russian Federation dated September 18, 2014 No. 958-26 “On amendments to the State program “Development of industry and increasing its competitiveness”, OJSC NPO Saturn entered into government contracts for the implementation OCD.
3. In December 2014 In accordance with the Decree of the Government of the Russian Federation of September 1, 2014 No. 884-25, a tripartite agreement was signed with the Ministry of Industry and Trade of Russia and the Federal Property Management Agency on cooperation on the project “Technical re-equipment of the enterprise to ensure the production of the M90FR gas turbine engine.”
Technical re-equipment of the enterprise to ensure the production of the M90FR gas turbine engine is carried out with the aim of import substitution of these products within the framework of the state defense order, including:
- extensions functionality existing equipment to implement new requirements for the M90FR gas turbine engine;
- improvement and development of new technologies for the manufacture and assembly of the M90FR gas turbine engine;
- acquisition of new equipment to ensure automation of technological processes, increase the accuracy parameters and repeatability of DSE.
The cost of the project is 1,686.67 million rubles.
4. In November 2014, in order to continue work on the creation of an assembly and testing complex for ship-based gas turbine engines, an agreement was concluded between NPO Saturn OJSC and the Rostec State Corporation to receive budget funding for the event “Organization of production and testing of ship-based gas turbine engines.” Created within the framework of Federal Target Program No. 1 under the State Defense Order under contracts with the Ministry of Industry and Trade of Russia and the Rostec State Corporation, the unique assembly and testing complex is a key element of the program to complete the creation of a completely import-independent Russian production of ship gas turbine power plants for both military shipbuilding and civil shipbuilding.
The cost of the project is 4,519.3 million rubles.
Everything is going according to the approved schedule and all work should be completed by the end of 2017.
