August 10, 2011 Rybinsk — OAO NPO Saturn (Rybinsk, Yaroslav region) is taking part in the 10th anniversary International Aviation and Space Salon MAKS-2011, which will be held August
Evaluating the distance the company has come in the time between MAKS-2009 and MAKS-2011, Saturn managing director Ilya Fedorov noted, “In this period we had a change of team, a staff turnover. We changed our values. We became, in practice, a state company, both fulfilling government orders and taking care of people. For people are our company’s greatest asset. It is thanks to them — our young, creative professionals — that we have been able to save our company for our region, our industry, and our country.
The state support measures and the actions taken by Saturn and Oboronprom allowed us to significantly cut the company’s loan portfolio by the end of 2010, and to increase our 2011 output by more than 25%. The increase in NPO Saturn equity capital significantly improved the structural balance. This gave us the opportunity to plan our development over the next two to three years and, consequently, to plan the financing of key projects. The results of a series of negotiations conducted in the first half of 2011 allow us to forecast an increase in the long-term portfolio of orders, and significant growth in earnings from 2012.
The company has successfully negotiated the ‘trough’ of the crisis, gained a selection of specialists, and continues, as ever, to modernize production, train personnel, implement line technologies, and realize production programs.”
At MAKS-2011, as part of Oboronprom and UEC exhibition, NPO Saturn is presenting five developments. In the civil department: twin turbo-fan SaM146 engine, created for use in next-generation regional long-haul aircraft. In the military department: high-powered twin turbo-prop engine ‘117C’, for the new multi-purpose Russian jet Su-35; twin turbo-prop engine the AL-55, for the global market in training and light fighter aircraft; M70FRU marine gas turbine engine with a capacity of 14,000 hp; twin turbo-prop engine ‘36MT’ for winged rockets.
The salon’s summer program includes the planned first-ever presentation of the new fifth-generation multi-purpose Su-35 fighter jet (an advanced frontline aircraft system — AFAS), which already demonstrated its potential at MAKS-2009, and includes engines developed by NPO Saturn. And making its second flight at MAKS will be the Sukhoi Superjet 100 airliner with SaM146 engines, which are now in mass production.
“The fact that in the two years between MAKSs we have got the T-50 airborne and advanced through testing the 117C/Su-35 is an undeniable achievement for the AKH Sukhoi and NPO Saturn teams. It’s an achievement for the whole country,” says Yevgeny Marchukov, chief designer of the Lyulki Research and Development Center — director of the Lyulki Research and Development Center branch. “Su-35 is already in joint state testing. Work on 117C engine is in the preliminary prototype testing stage. In accordance with the plans for hardware production, debugging, and testing, it will enter state bench testing in the second quarter of next year. Once it passes testing it will mean the product is ready for mass production.”
In the words of NPO Saturn chief designer Yuri Shmotin, the creation of two new engines for the two best Russian airplanes — Sukhoi Superjet 100 and PAK FA — is fundamentally the work of Saturn. “In 2010 SaM146 engine created by NPO Saturn and Snecma was awarded EASA certificate. And today two companies — Artavia and Aeroflot Russian Airlines — are making regular passenger flights with Sukhoi Superjet 100. This speaks to the fact that Saturn has entered a distinctly new level — mass production and support for the SaM146 in use.
Also in 2010, the advanced frontline aircraft system with engines developed by Saturn made its first flight. At the present time, comprehensive bench and flight tests are ongoing. We are simultaneously working on the engines for the second phase of the AFAS, for which a serious volume of design, and then production, work has been awarded to Saturn.”
The biggest event in this program was undoubtedly the awarding of the certificate for SaM146 engine, which took place on July 23, 2010 in Cologne (Germany) at the headquarters of the European Aviation Safety Agency (EASA). This was the first time that a European certificate had been awarded to a Russian engine manufacturer, and also the first time that an engine received the certificate before the aircraft did. On August 13, 2010 SaM146 engine was awarded a certificate by the International Aviation Authority. The certification of the engine by European and Russian standards of airworthiness allows the use of SaM146 engine in Russia, the European Union, and the CIS.
At present, post-certification testing of the engine in ongoing, due to the need to extend its operational life and some changes in the technical specifications of several details. Work also continues to minimize the size of the propulsion unit, and improve produceablity and in-use characteristics of the engine. In connection with the expansion of SSJ100 line of aircraft, work is being conducted to create modifications for SaM146 engine to increase thrust by 5%. The possibility of alternative applications for SaM146 on other types of aircraft is also under investigation.
For more than 30 years, Saturn has been mass producing and conducting aftersales service and modernization of D-30/KU/KP/KU-154 aviation engines for civil and dual purpose applications on long-haul passenger and freight aircraft (Tu-154M, Il-76, Il-62M). From 2009 to 2011, the company successfully fulfilled its contract with state company Rosoboronexport to deliver 55 D-30KP-2 aviation engines to China. Contracts have been signed with Rosorbonexport to carry out in 2011 overhaul repair on D-30KP-2 engines for foreign customers, as well as state contracts to overhaul D-30KP-2 / D-20KU-154 engines for the Russian Ministry of Defense and other Russian armed forces.
Saturn is the first Russian enterprise to get an order for full-scale development of an aviation engine to meet the needs of a foreign country. In February 2010, the airworthiness certification on AL-55I aviation engine was completed for two HJT-36 airplanes, made by HAL company in India. The corresponding report of the conclusion of airworthiness certification has been signed. In the time elapsed since the airplane’s first flight in May 2009, HJT-36 has made more than 70 flights, and with the inclusion of flights on MuG-AT airplane, more than 100 flights have been made. Within the framework of HAL contract, developmental work continues to improve the engine’s lifespan to 300 hours, as well as production of another batch of 10 engines, the first two of which will be dispatched to India in the near future.
Small size gas turbine engine programs
Programs for small and
Saturn is continuing its program of industrial gas turbines of small and medium capacities for electrical and gas transport stations: DO 49R (2.85 mW), GTE-6/8RM (6.5/8.6 mW), GTE-4/6, 3/10RM (from 4 to 10 mW). In 2009, Saturn developed a new modification for GTE-6, 3RM/8 8mW gas turbines. From
Programs for large capacity electrical GTEs
Within the program of production of large-capacity industrial gas turbines, in
-warranty and post-warranty work on Block ¹ 1 of the Ivanovsky Gas Turbine Plant (a subsidiary of INTER RAO UES); the block was launched in the second quarter of 2008, and has a capacity of 325 mW based on two GTE-110s by Saturn
-delivery to the client OGK-6 and launch of extension of Gas Turbine Plant-420 Ryazansky ES based on one GTE-110
-work on launch preparations for Block ¹ 2 of the Ivanovsky Gas Turbine Plant capacity 325 mW, the first of two GTE-110s by Saturn was delivered to the customer, by the end of 2011 the second GTE-110 will be delivered, to complete ¹ 2.
The company is realizing its plan aimed at improving the functional characteristics and exploitational reliability of the GTE-110, and improving its systems of aftersales servicing.
Marine GTE programs
Saturn is the leading Russian developer and producer of marine gas turbine engines, and has created two types which have successfully undergone state testing — M75RU with a maximum capacity of 7,000 hp, and M70FRU with a capacity of 14,000 hp.
As part of the programs in
OAO research and production association Saturn is an engine-building company specializing in the development, production, and aftersales servicing of gas turbine engines for military and civil aviation, electrical generating and gas transport facilities, and military and civil marine vessels. Saturn is part of the United Engine Corporation, itself a subsidiary of OBORONPROM, specializing in managing engine-building assets.
OAO United Industrial Corporation OBORONPROM is a multi-faceted machine-building group founded in 2002. It is part of the Russian Technologies group of companies. Its primary areas of business are helicopters (Russian Helicopters), engine-building (UEC), and other assets. In 2010 the corporation’s turnover exceeded 170 billion rubles.
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