Gas turbine engine dt 59. Kronstadt Marine Plant overhauled a gas turbine engine for Dalzavod Ship Repair Center OJSC (photo)

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 manufacturer gas turbine plants– 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 investment program for the modernization of production facilities. 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 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 advanced warships and the M55R diesel-gas turbine unit for project 22350 frigates. The M55R unit includes one M90FR afterburner turbine and one sustainer diesel engine 10D49 of Kolomna production with a capacity of 5200 horsepower, the power plant of the frigate project 22350 - 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 P044. 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 from the USSR and Russia, 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. On this moment the first gearbox of the next unit was 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 position of the company in the segment gas turbines for warships is quite contradictory. 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 General Electric. Licensed production of the LM2500 gas turbine engine is organized at the facilities of the Indian corporation HAL. And for the program of the frigate 17 of the Shivalik type, at the insistence of the Indian side for power plant ship, two LM2500 gas turbine engines were selected as afterburner turbines. 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 execution of orders for the repair of converted marine engines for the needs of gas pumping stations. 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.

Possessing 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 gas turbine installations 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.

Kronstadt Marine Plant has prepared a repaired gas turbine engine (GTE) for shipment to the customer JSC Ship Repair Center Dalzavod (Vladivostok). The ship's gas turbine engine DT-59 entered the plant in June 2015 to undergo a medium repair, in January-February 2016 it was tested on a special stand. Compliance of the parameters of the finished engine with the characteristics laid down in the terms of reference was confirmed. This was reported by the press service of the plant.

This is the first of two ship-based gas turbine engines intended for Dalzavod, 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 repair program for gas turbine engines for the Russian 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.

Kronstadt Marine Plant is the largest ship repair enterprise in the North-West region of Russia. Founded in 1858. (1858-1922 - Steamship Plant, 1922-1929 - Kronstadt Shipyard). The Kronstadt Marine Plant has been named since 1929. The enterprise is located in Kronstadt on the island of Kotlin in the Gulf of Finland, 30 km west of St. Petersburg. Production area The marine plant is over 63 hectares.

The total length of the berthing front of the embankments is 500 m, the slipway foundations are 750 m, which allows for dock repair of ships and vessels up to 230 m long and with a displacement of up to 40 thousand tons.

The plant performs complex repair ships, including dock repairs in the underwater part of the hulls with cleaning and painting, repair of bottom and side fittings, propeller, stern tube, steering, retractable and lifting and lowering devices; repair of diesel engines, gas and steam turbines, steam and hot water boilers, electrical products; manufactures metal structures, metalworking products, produces bending steel pipes, rewind electric motors and others. The Kronstadt Marine Plant is one of the oldest ship repair enterprises in Russia and the largest in the North-West region. Founded in 1858. Currently, the plant undergoes repairs of more than 100 ships and vessels annually. Since 2015, it has been part of the United Shipbuilding Corporation.

The Far Eastern Shipbuilding and Ship Repair Center (DTSSS) includes the main ship repair and shipbuilding production capacity Far East federal district, such as the Dalzavod Ship Repair Center (Vladivostok), the Zvezda Far East Shipyard (Bolshoy Kamen), the Northeast Repair Center (Vilyuchinsk). On behalf of Russian President Vladimir Putin, a consortium of Rosneft Oil Company OJSC and Gazprombank OJSC represented by a joint venture of CJSC Modern technologies Shipbuilding" is creating an industrial and shipbuilding cluster in the Far East of Russia on the basis of OJSC "DTSSS", the core of which will be the new shipbuilding complex "Zvezda" in the city of Bolshoi Kamen.