JSC "Kronstadt Marine Plant" (since April 2016, part of JSC "United Shipbuilding Corporation") in its press release said that on April 10, 2016, the enterprise, as part of the state order, shipped the repaired ship to the Northern Fleet gas turbine engine DT59.
The ship's gas turbine engine DT59 entered the plant in the spring of 2015 for a mid-term overhaul. During the repair process, the engine is completely moved. The compressor and turbine blades dismantled from the rotors are subjected to non-destructive inspection methods, they are processed and polished, and operations are carried out to increase strength. The rotors are balanced, the alignment of the engine components is checked and other operations are carried out. In March 2016 again assembled engine successfully passed factory tests.
Past average repair at JSC "Kronstadt Marine Plant"afterburner gas turbine engine DT59 of a large anti-submarine ship of the Northern Fleet"Admiral Chabanenko" project 11551 (c) JSC "Kronstadt Marine Plant"
This is the second of marine engines repaired by the Kronstadt plant this year. The first was intended for the Far Eastern ship repairers. For testing in soon the third and fourth engines are being prepared. Currently, five more gas turbine engines are being repaired at the Marine Plant as part of the state order.
Recall that the specialized gas turbine production of the Kronstadt Marine Plant performs a full cycle of medium repair of gas turbine engines, including testing on a "hot" stand, and also performs installation supervision, and, if necessary, maintenance gas turbine plants on ships since 1967, and during this time it has repaired more than 350 engines and installations of various modifications for the needs of the navy.
The program for the repair of gas turbine engines for the Navy has been approved for a period up to 2024. The Marine Plant is responsible for the repair of engines DE59, DT59, DK59, DO63, as well as gas turbine engines of subsequent generations, and engines of domestic production.
bmpd's comment. The repaired afterburning gas turbine engine DT59 belongs to a large anti-submarine ship of the Northern Fleet "Admiral Chabanenko" project 11551, which has been under repair since April 2014 at the shipyard Branch "35 SRZ" JSC "CS" Zvezdochka "in Murmansk.
Details of the organization of repair of ship gas turbines in Kronstadt onJSC "Kronstadt Marine Plant" were presented in an interesting interviewdirector of gas turbine production (GTP) - deputy CEO JSC "Kronstadt Marine Plant" by Oleg Rekunenko and his deputy for production Natalia Rachina, published by a web resourcewww.korabel.ruin February 2016:
Few people know that in the city of Kronstadt, at the Kronstadt Marine Plant, the unique production, whose capabilities and experience in the past two years, due to changes in the international situation, have become in great demand by the domestic navy. We are talking about gas turbine production, which has been repairing marine gas turbine engines for almost half a century.
About what's in this moment Kronstadt turbinists are busy and what are their plans, we are talking with the director of gas turbine production (GTP) - deputy general director of JSC "Kronstadt Marine Plant" Oleg Borisovich Rekunenko and his deputy for production Natalia Ivanovna Rachina.
Who and when instructed the GTP of the Kronstadt Marine Plant to carry out repairs ship engines for the Russian Navy?
In 2014, due to the change in the geopolitical situation in the world and the need to repair gas turbine engines for ships of the Navy in Russia, the Ministry of Defense of the Russian Federation decided to entrust the Marine Plant with the repair of ship engines DT59 and DO63 of the M-9 unit.
In 2015, we received the first three engines (DO63 and DT 59) for repair under a government contract, and before that, we received two more DT-59 engines for repair by order of the Dalzavod Ship Repair Center and one DT59 engine from the Admiral Chabanenko" by order of the branch "35 SRZ" TS "Zvezdochka".
- Do you carry out a full cycle of repairs or is it a service?
We carry out a full cycle of medium repair of gas turbine engines, including testing on a "hot" stand, and also perform installation supervision, that is, we are engaged in installing engines at the facility, adjusting them and handing them over to the customer for sea and mooring trials. If necessary, our specialists can also perform service maintenance of gas turbine units at naval facilities.
For example, several years ago, when we were repairing DE59 engines for the Navy of a foreign customer (the ship was being repaired at Severnaya Shipyard), our specialists were engaged in adjusting and handing over the repaired equipment to the customer, went to sea, and participated in mooring and sea trials of the ship.
Why was the Gas Turbine Production of the Kronstadt Marine Plant chosen for the repair of gas turbine engines for the fleet?
The fact is that our production was founded in 1967. With the participation of specialists from NPP "Mashproekt" and PA "Zorya" (Nikolaev), the only developer and manufacturer of marine-type gas turbine engines in the USSR, workshop No. 38 was created at KMOLZ, in fact, a branch of PA "Zorya", for the repair of ship gas turbine engines ships of the Northern and Baltic fleets.
Since then, the specialized gas turbine production has been repairing marine gas turbine engines for 49 years. For the needs of the Russian Navy, we have repaired more than 350 engines of various modifications - both non-reversible and gas-reversing engines.
It should be noted that even in those years when the Marine Plant experienced economic difficulties and went through bankruptcy proceedings, work at the GTP did not stop for a single day.
When in the 1990s there were difficulties with the orders of the Navy, the leaders of Lentransgaz LLC turned to the management of the Marine Plant with a proposal to repair the converted marine engine DR59L, created by NPP Mashproekt and PO Zorya for gas pumping stations. Structurally, this engine almost did not differ from marine engines, traditionally repaired at the plant, which allowed us to master its repair in a short time. The engine was successfully overhauled and handed over to the customer in 1996. Since that time PJSC "Gazprom" has become our main customer for many years.
Left alone a big problem. The engines were sent to gas pumping stations after repair without testing, because the fuel for the DR59L engine is natural gas, and our test station was designed for naval engines operating on diesel fuel. But we have coped with this task. In 2009, we completed the re-equipment of the test station and tested the DR59L engine, for the first time applying the original development of its launch and testing on diesel fuel. Since then, GTP has repaired more than 150 DR59L engines and more than 60 GPA-10 units for compressor stations of Gazprom PJSC.
But if for the last 20 years GTP has been dealing with engines for the needs of Gazprom, how did you manage not to lose the skills of repairing ship engines?
All these years we have continued, albeit on a much smaller scale, to repair marine engines. During this time, six DO63 reversible engines were repaired, and three DE59 engines were also repaired for the needs of foreign fleets.
What capabilities (technical, personnel) does the TCO have for fulfilling the tasks set by the fleet? What is the advantage of GTP, what is its uniqueness?
The uniqueness of GTP lies in the fact that it is the only enterprise in Russia that has a set of repair documentation, tooling, stands and other equipment developed by the manufacturer of the Zorya-Mashproekt SE NPKG for the repair of gas turbine engines of the DE59, DT59, DK59, DO63 types, etc.
We have a test stand that allows us to test these engines and transfer to the customer turbines ready for installation on ships of the Navy. We have experience in repairing all these types of engines, and most importantly, qualified personnel to perform the assigned tasks.
Thus, at the time of the need for the repair of gas turbine engines in the domestic fleet, we had both documentation, well-established production, and personnel for repairing second-generation engines.
Therefore, we quite confidently started work on the order of the fleet.
- What is the scope of work capable of performing GTP?
At the moment, we have nine engines under repair - five DT 59 and four DO 63. All in varying degrees readiness. Repair times are tight, so you have to work hard. To meet the planned deadlines, it happens to work on holidays and weekends.
At the same time, we continue to fulfill orders for civil repairs. The repair plan for 2016 includes five GPU-10 units and one DR59L engine.
What is the progress of work so far? Are there any results? What difficulties arise? How do they deal with problems? In particular, documentation, spare parts, production equipment?
At the moment, the assembly of two DT59 engines for OAO TsS Dalzavod has been completed, and we have begun testing them. The repair of engines for the Russian Navy under the state contract is in full swing. The DT59 engine is in the process of being assembled, the repair of two DO63 engines is nearing completion.
Two more DO63 engines have been dismantled and are undergoing fault detection.
The DT59 engine with the BOD "Admiral Chabanenko" is at the stage of assembly.
Problems arise, as in any industry. For example, difficulties with the supply of spare parts. Many materials, components and purchased equipment have already been discontinued, we have to look for analogues, study and coordinate their replacement. Increases repair time and the need to purchase all services and purchased equipment through trading floors in accordance with the requirements of Law N 223-FZ. If earlier we could quickly resolve these issues, now it sometimes takes months to make purchases.
Is the participation of the TSU only intended to work with specified engines or will the gas turbine unit be included in the repair of ship gas turbine engines on an ongoing basis?
The program for the repair of gas turbine engines for the Navy has been approved for a period up to 2024. In addition to DE59, DT59, DK59, DO63 engines, we are assigned to repair engines of subsequent generations, for example, DR / DS76 and DR / DS77, and we are faced with the task of mastering it. We are sure that we will cope with this task.
- Thus, you are currently the leader in the repair of ship gas turbine engines?
In the repair of naval engines of the second generation such as DE59, DT59, DK59, DO63, we are indeed leaders.
Now there are other enterprises that want to master the repair of naval turbines. But they still have to master the documentation, create the necessary production base, gain experience. There are positive results. For example, one of the enterprises is mastering the repair of gas turbine engines by replacing finished units and parts.
Will GTP be able to repair next-generation engines? Will it continue to repair engines produced by domestic enterprises?
If we talk about the organization of the repair of engines of the 3rd and 4th generations in general, then this will require serious retrofitting of our production. New stands, a test station should be created, appropriate technological equipment should be made. Large capital investments are required.
The issue of creating a center for the repair of gas turbine engines of the 3rd and 4th generations, as well as Russian-made gas turbine engines at the Kronstadt Marine Plant JSC, is currently being worked out at the government level.
Repair of ship gas turbine engines for the Russian Navy at JSC "Kronstadt Marine Plant". Kronstadt, February 2016 (c) Ekaterina Leonova / www.korabel.ru
The State Enterprise Research and Production Complex for Gas Turbine Engineering (GP NPKG) Zorya - Mashproekt is the CIS leading designer and manufacturer of gas turbine engines of various modifications for gas transmission lines, energy, monopoly - for cydovyh propulsion. Almost all warships in Russia are equipped with marine gas turbine engines manufactured in Nikolaev. In addition, Ukrainian-made turbines are actively used in the energy and industry of the Russian Federation.
By the standards of the engine-building industry, the amount of proceeds of the SE NPKG "Zorya" - "Mashproekt" is very small and fluctuates at the level of 250-300 million dollars. The results of 2013 remain the highest - $397.2 million. The enterprise accounts for about 30 percent of the output of the State Corporation "Ukroboronprom". The share of exports in revenue is 90-95 percent.
The main income of the company comes from the supply of gas pumping equipment. The main customers in this segment are Russia, Uzbekistan, Kazakhstan and Turkmenistan. These products are also used in the Czech Republic, Bulgaria, Belarus and actually on the territory of Ukraine. The work is carried out in cooperation with the Sumy NPO named after Frunze.
“The biggest challenge for a gas turbine manufacturer is shrinking traditional markets in India and China”
About 2/3 of the total volume of manufactured products are 25 MW engines - the most difficult to manufacture. The construction of the Nord Stream gas pipeline turned out to be an extremely profitable project for the enterprise.
In 2008, Zorya-Mashproekt signed the largest contract in its history for the supply of one hundred 25 MW gas turbines for the gas and energy industries of Iran. In general, Russia and Central Asia remain uncontested customers, as they are the largest suppliers gas.
Contracts concluded in 2012 allow planning the production program more than five years ahead. The share of marine products will significantly increase in the structure of the company's exports.
The production of marine gas turbine plants takes total volumes about 14 percent. Historically, the main and constant customer is the Russian Navy, which includes the largest number of ships equipped with the plant's installations. GTUs are also actively supplied to India, China and Vietnam.
Since 2011, the company's revenue has consistently exceeded 300 million US dollars annually. The increase in cash receipts made it possible to start implementing the modernization investment program production capacity. In addition, the certainty that came after another change in management and the inclusion of the enterprise in the Ukroboronprom concern opened up access to financial resources. In September 2011, "Zorya" - "Mashproekt" received a revolving credit line with a limit of 20 million euros and an overdraft (unsecured loan) for 55 million hryvnias from a bank that is part of the Raiffeisen-Aval group. Obviously, these and other borrowed funds will be used for further modernization of production facilities, which started at the enterprise in 2012.
Successful example of cooperation
The work of "Dawns" - "Mashproekt" on Russian market demonstrates perhaps the most successful mechanism for cooperation in the defense sphere between Ukrainian and Russian enterprises in the entire post-Soviet history. The maintenance of broad cooperation in marine engine building, developed under the USSR, is equally a merit of the leadership on both sides. Not in last turn links were maintained through the establishment in 1993 of joint venture- CJSC "Turborus" headquartered in Rybinsk. Forty percent went to Zora - Mashproekt, and the Russian stake was distributed in equal shares between the current NPO Saturn and NPO Avrora.
At the initial stage, the main task of CJSC was to provide maintenance of gas turbine units of Nikolaev production as part of the Russian Navy and the border service of the FSB. Currently CJSC "Turborus" serves a number of gas turbines of surface ships of the Russian Navy and the border service (coast guard): MZN, M5E, M8, M10, M15A, M15-B, M15-V, M35, M7K, M7N, M9, M21A, MT70, DT4. The following types of engines are in operation: DT59, DK59, DN59, DE59, D063, DR77, DS77, DN77, DD50, DO75, DM71, DR71, DS71, DR76, DM76, DA90, DO90, DA91.
On the one hand, cooperation is maintained due to the monopoly position of the SE NPKG "Zorya" - "Mashproekt" in the field of ship gas turbine engines. In addition, not only the main design facilities of military shipbuilding (Northern Design Bureau, Almaz Central Design Bureau, Zelenodolsk Design Bureau) remained on the territory of Russia, but also all enterprises related to the automation of ships. This applies primarily to NPO Avrora, where one of the main areas of work remains the development and production complex systems management technical means surface and submarine ships. The company also actively participated in many export programs of Russian shipbuilding, especially in the Indian direction (for example, on Project 11356 frigates of the Talwar type).
An equally important task of CJSC "Turborus" is the implementation of joint work on the creation of advanced gas turbine technology. In fact, the enterprise still remains the main instrument scientific cooperation Ukrainian and Russian engine builders working for the fleet. The main program for him was the creation of the gas turbine engine M90FR with a capacity of 27,500 Horse power for promising warships and the M55R diesel-gas turbine unit for project 22350 frigates. The M55R unit includes one M90FR afterburner turbine and one 10D49 sustainer diesel engine of Kolomna production with a capacity of 5200 horsepower, the project 22350 frigate power plant - two M55R units.
Factory tests of the M90FR engine at the enterprise were completed in November 2005. State interdepartmental tests of the ship gas turbine engine M90FR - in 2006. They fully confirmed compliance specifications engine to the customer's requirements for fourth-generation shipboard gas turbine engines.
In July 2008 CJSC "Turborus" completed the installation of a new M55R diesel-gas turbine unit on a test bench. On the Russian side, JSC NPO Saturn (responsibility area - power turbine), NPO Avrora Concern (control systems for gas turbine engines, diesel and unit), JSC Kolomensky Zavod (diesel engine 10D49) , from Ukraine - SE NPKG "Zorya" - "Mashproekt" (turbocharger and gearbox). The tests were carried out on a stand in Nikolaev, since at that time there were no such stands in Russia. State tests of the M55R diesel-gas turbine unit were successfully completed at the end of 2008.
By state order and for export
The main type of installation produced for frigates is GGTU M7N.1E ( further development GGTU M7 patrol ships of the project 1135 series), including two afterburner gas turbine engines DT59.1 with a capacity of 19.5 thousand horsepower and two marching gas turbine engines DS71 with a capacity of 9 thousand horsepower. For the Indian Navy, the first three Project 11356 frigates (of the Talwar type) were built in Russia with delivery in 2003-2004, three modified ships for India are being completed, and negotiations are underway to order three more frigates. At the same time, six modified frigates of a similar type to project 11356R (11357, Admiral Grigorovich type) were ordered in 2010 for the Russian Navy, their delivery is expected by 2016.
For the main type of promising frigates of the Russian Navy, project 22350, the DGTU M55R manufactured by CJSC Turborus is used. Two M55R installations were installed on the head frigate of this project "Admiral Soviet Union Gorshkov, launched in 2010, two more ships have been laid down to date. In total, by 2020, it is planned to build six to eight units of this type.
Project 11661K patrol ships (of the Gepard type) are equipped with a twin-shaft DGTU M44 with a total capacity of 33,000 horsepower, built according to the CODOG scheme. The unit includes two main GTE DO90, one diesel engine, two gearboxes RA28 and one R044. Two ships of the project ("Tatarstan" and "Dagestan") were completed for the Caspian Flotilla of the Navy with delivery in 2003 and 2012, respectively. In addition, in 2011 Russia completed a contract for the supply of two export-version patrol ships (of the Gepard 3.9 type) for Vietnam. It is known that Hanoi ordered two more ships of this project.
For the Russian Navy SE NPKG "Zorya" - "Mashproekt" continues to supply gas turbine engines various types to maintain in service Soviet-built ships: Project 1164 missile cruisers (GTU M21 as part of the M70 and M8KF gas turbine engines), Project 1155 large anti-submarine ships (M9 gas turbine engines as part of the M62 and M8KF gas turbine engines), Project 1124M small anti-submarine ships (GTE M8M), missile ships of project 1239 (GTE M10).
In India, according to project 15, developed by the Soviet Northern Design Bureau, with active technical assistance USSR and Russia were built three destroyer destroyers Delhi type delivered in 1997–2001. The ships were equipped with a diesel-gas turbine unit of two M36N units, consisting of two DT50 gas turbine engines maximum power 27 (long-term - 23.1) thousand horsepower each and two KVM-18 diesel engines. For the next three Indian destroyers of the 15A project (Kolkata type), which are currently under construction, the M36E twin-shaft gas turbine plant has been developed. It consists of two turbo-gear units with two DT59 gas turbine engines (in each unit) operating on two shafts through RG-54 reversible gearboxes. DT-59 is a modification of UGT 16000 for ship propellers.
DGTU CODAG of the Chinese destroyer project 052 (Qingdao, joined the fleet in 1996) was built according to the CODAG scheme and consists of two gas turbine engines UGT 25000 with a capacity of 48.6 thousand horsepower each and two diesel engines 12V 1163TV83 with a capacity of 8.84 thousand horsepower MTU. The first destroyer of this project (Harbin) was equipped with a DGTU based on the American GE LM2500 turbine with a capacity of 55,000 horsepower. A similar Qingdao DGTU CODAG of Ukrainian design is also installed on Chinese destroyers of projects 052B (two ships commissioned in 2004) and 052C (two ships commissioned in 2004-2005). These installations include various modifications(DA80/DN8) GTD UGT 25000. Now in the PRC, seven more project 052C destroyers are in various stages of construction, the commissioning of the first of which was expected in the summer of 2012. It is not clear whether these ships are equipped with gas turbine engines purchased in Ukraine, or gas turbine engines of their own Chinese production.
According to some reports, back in the late 90s, Ukraine transferred a license for the production of UGT 25000 gas turbine engines to China, where they were cloned at the Xian Aero Engine enterprise under the designations QC280 and QD280, although their serialization remains in question: it is alleged that the QC280 prototypes were tested on the second destroyer project 052B. 1163TV83 diesels are also produced under license from MTU Friedrichshafen under the name Shanxi.
In the segment of ships on air cushion the most famous is the M35 installation for a small landing hovercraft (MDK VP) of project 12322 (of the Zubr type) with a capacity of 50 thousand horsepower. Zubrs were exported to Greece under two contracts from 2000-2004. For Greece, two ships were built by the Almaz shipbuilding association, and another one was completed by FGC More. The Ukrainian part of the contract provided for the construction of two ships, but the delivery of the second was suspended due to its unsatisfactory technical condition. In 2009, Ukrspetsexport signed a somewhat controversial (due to the transfer of technical documentation for these ships) contract for two more similar landing hovercraft (DKVP) for the Chinese Navy. Two Project 958 Bizon ships, built at FGC More, were handed over to the customer in 2012-2013, two more are planned to be built in China with the participation of Ukrainian specialists.
At the end of December 2012, Zorya NPKG - Mashproekt shipped to India a set of marine equipment for Project 15 ships (Delhi type), which is supplied under the program Maintenance. Previously, the enterprise provided Indian ships of project 15A (Kolkata type) with power plants. In February 2013, Zorya-Mashproekt delivered a set of equipment to the same customer. It is intended for ships of the frigate class.
In 2013-2017, the company will increase the output of marine products, a number of contracts for the supply of marine power plants, including long-term agreements with Indian shipbuilders, have been signed. In August 2013, the gearboxes of the unit for a frigate-class ship were prepared for shipment to the customer. The structure of the unit includes two afterburners, two sustainer gearboxes and an inter-gear attachment. The total production cycle for the entire group of gearboxes was 18 months. In the next five years, a program is to be implemented for the production of heavy marine units, within which the enterprise must produce four types that differ in design and manufacturing complexity. At the moment, the first gearbox of the next unit is prepared for testing.
In April 2013, State Enterprise Zorya - Mashproekt signed a contract with an Indian customer for the supply of gas turbine power plants for ships to be built at a shipyard in Mumbai. The contract was concluded following the results of the tender in 2012. Under the terms of the contract, in total, in the period from 2016 to 2019, the enterprise will equip four new ships of project 15B. Equipped with the third series. In 1993–1995, installations were delivered to India for three Project 15 ships (Delhi class), in 2005–2006, also for three Project 15A ships (Kolkata class). For the 15V project, the enterprise will produce a modernized gas turbine power plant with a microprocessor control system.
Company outlook
State Enterprise "Zorya" - "Mashproekt" is one of the most successful enterprises of the defense industry of Ukraine and engine-building enterprises of the CIS. However, the company's position in the segment of gas turbines for warships is quite controversial. Despite the monopoly in the CIS for the production of ship propulsion systems, the export of products is extremely difficult without Russian enterprises. In fact, only three single contracts can be named that were implemented without cooperation with Russian exporters and enterprises: the construction of four Project 958 Bizon DKVPs for the PRC, the Singapore ACV-1 project hovercraft program and the supply of new turbines for the American container ship LCpl Roy M. Wheat , which did not receive a continuation.
Due to the extremely limited capabilities of Ukraine in the design and automation of warships, the domestic market of Zorya - Mashproekt is negligible. And taking into account the saturation of the traditional markets of Russian shipbuilding (China, India), multiplied by their desire for self-sufficiency, including in the production of gas turbines, we should expect a decrease in purchases of both Russian and Ukrainian ships, and with them Nikolaev engines.
The second challenge is the intensification of competition with Western engine builders, in particular with the company General Electric. Licensed production of the LM2500 gas turbine engine is organized at the facilities of the Indian corporation HAL. And for the Shivalik-type frigate program, at the insistence of the Indian side, two LM2500 gas turbine engines were selected as afterburner turbines for the ship's power plant. The same gas turbine engines are supposed to be used on seven Project 17A frigates planned for construction in India.
Since 2009, the story continues with the program of the promising destroyer of project 15B. It is planned to build four destroyers for the Indian Navy, which are the development of the 15A project. The list of participants in the 15B program remained the same, but the set of key components for the ship has not been completed. The main dispute arose because of the power plant, whole line Indian designers were offered to use the same LM2500 gas turbine engine. For the Russian side, such a development of events is also undesirable, as it will lead to the loss of a number of allied enterprises from the market.
In the Russian naval market, the position of Zorya - Mashproekt is theoretically threatened by periodically initiated projects for organizing the production of ship gas turbines at Russian enterprises. However, as in the case of organizing the production of helicopter engines in Russia, little progress has been made here.
Since 1992, work on ship gas turbines has been carried out at the Rybinsk NPO Saturn, and in 2000 the latter was even recognized by the Russian Navy as the basic enterprise for offshore gas turbine construction. In reality, after 2000, Saturn was able to work out on the stands two types of marine engines, which are actually modified clones of the corresponding Nikolaev developments Soviet period: M70FRU with a capacity of 14 thousand horsepower and M75RU with a capacity of seven thousand horsepower. Both were developed by order of the Russian Navy, but so far not a single sample of these gas turbine engines has been purchased and has not hit the ships. Saturn also takes part in the M90FR gas turbine engine program (for project 22350 frigates) in cooperation with Zorya - Mashproekt. But the share of the Rybinsk enterprise in the volume joint production is only 20 percent, and the assembly of M90FR turbines is carried out in Nikolaev.
In view of this situation, in 2011 the conversation about the prospects for the purchase of SE NPKG "Zorya" - "Mashproekt" and a number of shipbuilding enterprises of Ukraine by Russian state investors resumed. However, the decision on the company's investment program in new equipment indicates that there are no intentions to privatize or transfer the enterprise to anyone. So everything points to saving current situation for the coming years.
It seems that so far no one is interested in the result. On the one hand, the Ukrainian participants in the discussion refuse to take into account the role of Russian design facilities and automation enterprises in the export of products of the SE NPKG Zorya - Mashproekt. On the other hand, the Russian proposal voiced at that time to integrate Zorya - Mashproekt into the USC caused some bewilderment. Firstly, why such a form of integration, if CJSC "Turborus" has been successfully operating for more than 20 years? Secondly, the issue of Ukraine's benefit was not brought up for discussion, although during this period the country fully corresponded to the status of a strategic partner.
In general, the form and content of such an integration proposal made dialogue impossible. Such real problems of the industry as the aging and shortage of personnel in the design bureau, the decline in scientific and technical potential, and cooperation have not been brought up for discussion. Promising for both Ukraine and Russia is the organization of assembly plants through CJSC Turborus with the subsequent transfer of licenses for old engines to the capacities of customers (India, Vietnam) and further joint development and production of new gas turbine engines for the Russian fleet following the example of the M90FR.
It turns out that import substitution in relation to Zora - Mashproekt, as in the case of Motor Sich ( more details - in "VPK", No. 18, 2014) is mostly declarative. A CJSC with a predominant share of Russian capital has been operating for more than 20 years and during all this time it has never got into conflict or disputable situations, unlike the delivery of the same Zubrov. The absence of revealing materials in the media regarding the work of Turborus confirms good choice models of cooperation not only in the financial, but also in the production aspect. A more serious challenge compared to the import substitution policy today is the expected narrowing of the company's traditional export markets in India and China.
Kronstadt Marine Plant (part of the United Shipbuilding Corporation) has prepared a repaired gas turbine engine for shipment to the customer JSC Ship Repair Center Dalzavod. The ship's gas turbine engine DT-59 entered the plant in June 2015 for a medium repair, in January-February 2016 it was tested on a special stand. Parameter matching finished engine characteristics included in terms of reference, successfully validated.
This is the first of two ship gas turbine engines designed for the Far Eastern ship repairers, and of nine currently under repair at the Marine Plant under the state order.
At the same time, the fulfillment of orders for the repair of converted marine engines for the needs of gas pumping stations continues. The repair plan for 2016 includes five GPU-10 units and one DR59L engine.
The specialized gas turbine production of the Kronstadt Marine Plant has been repairing marine engines since 1967. During this time, more than 350 engines and installations of various modifications have been repaired for the needs of the navy.
Having a set of repair documentation, tooling, equipment developed by the manufacturer, gas turbine production performs a full cycle of medium repair of gas turbine engines, including testing on a "hot" stand, and also performs installation supervision, and, if necessary, service maintenance of gas turbine units on ships.
The program for the repair of gas turbine engines for the Navy has been approved for a period up to 2024. The Marine Plant is responsible for the repair of engines DE59, DT59, DK59, DO63, as well as gas turbine engines of subsequent generations, and engines of domestic production.
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 such a statement at the opening ceremony of a new complex of NPO Saturn for the production of marine gas turbine engines. Most of these engines of the Rybinsk "Saturn" have a higher efficiency than their counterparts from Nikolaev - 36% versus 32%. However, when compared with Ukrainian products, the advantage that the president announced is not yet available for all domestic units. FlotProm compared the characteristics of gas turbine engines.
Launch at the Rybinsk NPO Saturn since 2018 serial production marine gas turbine engines will make the Russian Navy independent of imported gas turbine units. And since the developments of "Saturn" are more modern than the products of the Nikolaev "Zorya-Mashproekt" (Ukraine), their efficiency is somewhat higher. According to Vladimir Putin, the efficiency domestic engines will grow by 10-15%, because it is "more than modern technology compared to the one we took before." FlotProm analyzed the efficiency of power plants.
Line of marine gas turbine engines manufactured by NPO Saturn
As part of import substitution, since 2014 NPO Saturn has been conducting three development work on the M90FR, Agregat-DKVP and M70FRU-R engines, FlotProm was told in the United Engine Corporation (UEC). The new Russian-made engines will equip the frigates of projects 22350 and 11356, the Zubr small landing hovercraft, as well as other ships and vessels of the Russian Navy.
On April 25, two ship gas turbine engines, the M70FRU and M70FRU-2, were demonstrated in Rybinsk. FlotProm provides a table with the characteristics of these gas turbine engines in comparison with Ukrainian counterparts and the M90FR engine.
The efficiency of the Russian gas turbine engine for the Zubr DKVP is higher than the Ukrainian one by only 0.4%
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 "Zubr" was originally a gas turbine type M35. It includes three traction gas turbine units (GTA) M35-1 and two injection GTA M35-2. Each of the units includes gas turbine engines of the Soviet design DP71 (in the Ukrainian classification - UGT6000) developed and manufactured by Zorya-Mashproekt. DP71 engines have been produced in Nikolaev since 1978.
In order to replace the Ukrainian GTE Saturn, in 2014, work began on the R&D Unit DKVP. The purpose of the development work is the creation of the M70FRU-2 gas turbine engine and shipboard GTAs M35R-1, M35R-2 and M70R with a capacity 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 GTE.
GTE M70FRU2 for DKVP type "Zubr"
It is possible that 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 yet been completed. On April 25, the UEC stated that "further development of marine gas turbine engines can take the path of increasing power, as well as increasing the efficiency of engines." In addition, Saturn is mastering cobalt alloys.
According to a FlotProm source in the Nikolaev "Zorya-Mashproekt", the use of new cobalt alloys, using additive technologies, can "slightly improve the characteristics of a gas turbine engine, including increasing its efficiency." The Ukrainian company called the use of cobalt alloys and additive technologies with its "know-how", which has been under development for several years.
Russian gas turbine engines for frigates of project 11356 and TFR of project 11540 overtook Ukrainian ones in terms of efficiency
The Rybinsk M70FRU and M90FR engines were designed to replace Ukrainian-made gas turbine engines DS71 and D090, respectively. This was reported to FlotProm by a source familiar with the situation. In the main power plant M27, used at the Yaroslav the Wise TFR of project 11540 Hawk, the "nineties" engines are afterburners, and the "seventies" are marching ones. Wherein Russian engines have an efficiency of 36% versus 32% for gas turbine engines of Ukrainian production.
The power plant of the frigates of project 11356 is the M7N1 installation, in which the same DS71 engines (in the Ukrainian classification - UGT6000) are marching, and DT59 (UGT16000) are afterburners. The efficiency of the latter is only 30%.
GTD M70FRU
Manufacturers and designers of gas turbine engines: the efficiency of such installations is limited to 38-40%
According to Valery Ryzhov, chief designer of Kolomensky Zavod, which he expressed in an interview with 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 rotor blades occurs at high temperature. IN diesel engine the maximum combustion temperature reaches 1700 degrees, in a gas turbine engine such a temperature cannot be created - the turbine blades will burn out.
According to the United Engine Corporation, the efficiency of most of their new engines is 36%. A FlotProm 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, has an efficiency declared by the manufacturer from 36 to 37% (in different modifications). At the same time, the British Rolls-Royce company in 2016 claimed that its MT-30 engine was over 40% efficient.
The efficiency 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 rather marketing ploy. The representative of the company added that the efficiency of gas turbine power plants is highly dependent on the characteristics of the operation of the engine, as well as on the quality of materials and spare parts. “Thus, after the modernization of the fuel supply system of the DZh59 engine and the installation of new blades made of modern alloys, the efficiency of the gas turbine engine increased, and the fuel consumption decreased,” said a representative of the Dieselzipservice Group of Companies.
He also noted that innovations such as cobalt alloys and additive technologies can further improve this figure. “For example, the DV71L (UGT6000+) engine was “tired” before the overhaul, its efficiency decreased by half from 30%. machine-building plant"With the use of new materials, it made it possible to restore this value almost to the performance of a new engine. But the factory quality of manufacturing a gas turbine engine is fundamentally important," summed up in Dieselzipservice.
