NPO Saturn: From MAKS to MAKS

    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 16-21, 2011 in the Moscow region town of Zhukovsky, known for its aviation science, at the Gromov Flight Research Institute airfield, the countrys central testing base.

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 companys 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 companys 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.

-35   117At 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 salons 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.

 117The 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. Its 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.

SaM146 program

SaM-146   SSJ100  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.

D-30KU/KP/KU-154 program

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.

AL-55I program

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 airplanes 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 engines 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

From 2009-2011, Saturn has fulfilled several contracts to deliver small size GTEs to power winged rockets for aviation and marine deployment, manufactured by Raduga, Novator, and SmAZ. Engines are also being delivered to foreign clients, as well as to the Russian Ministry of Defense. At present, the company is continuing pre-contract work to secure delivery of small size GTEs made by Saturn for 2011-2015; expanded applications for the engines are being explored.

Programs for small and mid-sized industrial GTEs

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 2009-2011 the company delivered to Gazprom the first nine engines of this type for use at the Yamburgskaya compressor station (Yugorsk) and the Medvezhevo boost compressor station (Nadym).

Programs for large capacity electrical GTEs

Within the program of production of large-capacity industrial gas turbines, in 2009-2011 Saturn completed:

-warranty and post-warranty work on Block  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  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  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 2009-2011, the company began work to create an assembly and testing center for marine GTEs and units based on them (as part of the targeted federal program Development of the military-industrial complex from 2011-2020, with support from the Russian Ministry of Industry and Trade). In June 2011, Saturn won a competition to create a marine gas turbine electrical generator for civil applications with a capacity of 8 mW (as part of the targeted federal program Development of civil marine technology from 2009-2016).

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 corporations turnover exceeded 170 billion rubles.

You can find up-to-date information about Saturn in the company newsletter and in the pamphlet Young Leaders, located on the Saturn website www.npo-saturn.ru.

Saturn Press Service
Tel: (4855) 296-898, mobile (495)-760-94-62
e-mail: press@npo-saturn.ru.