State enterprise scientific and production complex of gas turbine construction (GP NPKG) "Zorya" - "Mashproekt" is a leading designer and manufacturer of gas turbine engines in the CIS various modifications for gas transmission lines, energy, monopoly - for ship propulsion. Almost all military ships in Russia are equipped with marine gas turbine engines produced in Nikolaev. In addition, Ukrainian-made turbines are actively used in the energy and industrial sectors of the Russian Federation.
By the standards of the engine-building industry, the revenue of the State Enterprise NPKG Zorya - Mashproekt is very small and fluctuates at the level of 250-300 million dollars. The results for 2013 remain the highest – $397.2 million. The enterprise's share accounts for about 30 percent of the production volumes of the Ukroboronprom State Concern. The share of exports in revenue is 90–95 percent.
The company's main income 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 in Ukraine itself. The work is carried out in cooperation with the Sumy NPO named after Frunze.
“The most serious challenge for the gas turbine manufacturer is the shrinking traditional markets in India and China”
About 2/3 of the total volume of products produced 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 company.
In 2008, Zorya - Mashproekt signed the largest contract in its history for the supply of one hundred gas turbine units with a capacity of 25 MW for the gas and energy industries of Iran. In general, Russia and Central Asia remain uncontested customers, since they are largest suppliers gas.
The contracts concluded in 2012 allow us to plan the production program more than five years in advance. The share of marine products in the company's export structure will increase significantly.
The production of marine gas turbine units occupies total volumes about 14 percent. Historically, the main and regular customer remains the Russian Navy, which has the largest number of ships equipped with the enterprise’s installations. Gas turbines are also actively supplied to India, China and Vietnam.
Since 2011, the company's revenue has consistently exceeded $300 million annually. The increase in cash receipts made it possible to begin implementing an investment program to modernize 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 from a bank part of the Raiffeisen-Aval group a revolving credit line with a limit of 20 million euros and an overdraft (unsecured loan) of 55 million hryvnia. 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 Zori - Mashproekt on the Russian market demonstrates perhaps the most successful mechanism of cooperation in the defense sector between Ukrainian and Russian enterprises in the entire post-Soviet history. The preservation of broad cooperation in marine engine building, developed under the USSR, is equally the merit of the leadership on both sides. Last but not least, ties were maintained thanks to the creation in 1993 of a joint venture, CJSC Turborus, headquartered in Rybinsk. Forty percent went to Zora - Mashproekt, and the Russian package was distributed in equal shares between the current NPO Saturn and NPO Aurora.
At the initial stage, the main task of the company was to provide maintenance for gas turbine units manufactured in Nikolaev as part of the Russian Navy and the FSB border service. Currently, JSC "Turborus" services a number of gas turbine units of surface ships of the Russian Navy and border service (coast guard): MZN, M5E, M8, M10, M15A, M15-B, M15-B, 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 State Enterprise NPKG Zorya - Mashproekt in the field of ship gas turbine engines. In addition, not only the main design capacities of military shipbuilding (Severnoye Design Bureau, TsMKB Almaz, Zelenodolsk Design Bureau), but also all enterprises related to ship automation remained on the territory of Russia. This applies primarily to NPO Aurora, where one of the main areas of work remains the development and production of integrated control systems technical means surface and submarine ships. The company actively participated in many export programs of Russian shipbuilding, especially in the Indian direction (for example, for Project 11356 Talwar-class frigates).
No less important task CJSC "Turborus" is and performs joint work on the creation of promising gas turbine technology. In fact, the enterprise still remains the main instrument scientific cooperation Ukrainian and Russian engine builders working for the fleet. His main program was the creation of the M90FR gas turbine engine 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 afterburning turbine and one 10D49 sustainer diesel engine produced in Kolomna with a capacity of 5,200 horsepower, the power plant of the Project 22350 frigate includes two M55R units.
Factory tests of the M90FR engine at the enterprise were completed in November 2005. State interdepartmental tests of the ship's gas turbine engine M90FR - in 2006. They fully confirmed compliance technical characteristics engine to customer requirements for fourth-generation ship gas turbine engines.
In July 2008, CJSC Turborus completed the installation of a new diesel-gas turbine unit M55R on a test bench. On the Russian side, NPO Saturn OJSC (area of responsibility - power turbine), NPO Aurora concern (control systems for gas turbine engines, diesel engines and the unit), Kolomna Plant OJSC (diesel engine 10D49) are taking part in the cooperation to create the unit. , from the Ukrainian side - SE NPKG "Zorya" - "Mashproekt" (turbocompressor and gearbox). The tests were carried out at 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.
For government orders and for export
The main type of installation produced for frigates is the GGTU M7N.1E (a further development of the GGTU M7 patrol ships of the Project 1135 series), including two afterburning gas turbine engines DT59.1 with a power of 19.5 thousand horsepower each and two sustainer gas turbine engines DS71 with a power of 9 thousand horsepower each. For the Indian Navy, the first three frigates of Project 11356 (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 of Project 22350, the DGTU M55R manufactured by JSC Turborus is used. Two M55R installations were installed on the lead 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 (Gepard type) are equipped with a two-shaft M44 diesel turbine unit with a total capacity of 33 thousand horsepower, built according to the CODOG scheme. The installation includes two main DO90 gas turbine engines, one diesel engine, two PA28 gearboxes and one P044. Two ships of the project (“Tatarstan” and “Dagestan”) were completed for the Caspian Navy Flotilla with delivery in 2003 and 2012, respectively. In addition, in 2011, Russia completed a contract for the supply of two export-version patrol ships (Gepard 3.9 type) for Vietnam. It is known that Hanoi has ordered two more ships of this project.
For the Russian Navy, the State Research and Production Complex “Zorya” - “Mashproekt” continues to supply gas turbine engines various types to maintain in service Soviet-built ships: missile cruisers of Project 1164 (GTU M21 as part of GTD M70 and M8KF), large anti-submarine ships of Project 1155 (GTU M9 as part of GTD M62 and M8KF), small anti-submarine ships of Project 1124M (GTD 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 The USSR and Russia built three destroyer type Delhi, commissioned in 1997–2001. The ships were equipped with a diesel gas turbine unit consisting of two M36N units, consisting of two DT50 gas turbine engines with a maximum power of 27 (long-term - 23.1) thousand horsepower each and two KVM-18 diesel engines. For the next three Indian destroyers of Project 15A (Kolkata type), currently under construction, the M36E twin-shaft gas turbine unit 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 propulsion.
The CODAG gas turbine unit of the Chinese destroyer Project 052 (Qingdao, entered the fleet in 1996) was built according to the CODAG scheme and consists of two UGT 25000 gas turbine engines with a power of 48.6 thousand horsepower each and two 12V 1163TV83 diesel engines with a power of 8.84 thousand horsepower produced MTU. The first destroyer of this project (Harbin) was equipped with a diesel gas turbine unit based on the American GE LM2500 turbine with a capacity of 55 thousand horsepower. A similar Ukrainian-designed Qingdao DSTU CODAG 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) of the UGT 25000 gas turbine engine. Currently, seven more Project 052C destroyers are in various stages of construction in China, the first of which was expected to be commissioned in the summer of 2012. It is unclear whether these ships are equipped with gas turbine engines purchased from Ukraine, or gas turbine engines of China’s own 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 QC280 prototypes were tested at the second destroyer of project 052B. 1163TB83 diesels are also produced under license from MTU Friedrichshafen under the name Shanxi.
In the ship segment air cushion The most famous is the M35 installation for a small landing hovercraft (MDK VP) of Project 12322 (Zubr type) with a power of 50 thousand horsepower. “Bison” were exported to Greece under two contracts from 2000–2004. Two ships were built for Greece by the Almaz shipbuilding association, and another one was completed by FSK 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 performance. technical condition. In 2009, Ukrspetsexport concluded a somewhat controversial (due to the transfer technical documentation for these ships) a contract for two more similar air-cushion landing craft (HHC) for the Chinese Navy. Two Project 958 Bizon ships, built at FSK More, were delivered to the customer in 2012–2013, and two more are planned to be built in China with the participation of Ukrainian specialists.
At the end of December 2012, the State Enterprise "NPKG "Zorya" - "Mashproekt" shipped to India a set of marine equipment for Project 15 ships (Delhi type), which is supplied under the program Maintenance. Previously, the company provided power plants to Indian ships of Project 15A (Kolkata type). In February 2013, Zorya - Mashproekt supplied the same customer with a set of equipment. It is intended for frigate class ships.
In 2013–2017, the enterprise will increase the production of marine products; a number of contracts have been concluded for the supply of marine power plants, including long-term agreements with Indian shipbuilders. In August 2013, the gearboxes of the unit for a frigate-class ship were prepared for delivery to the customer. The unit includes two afterburners, two main gearboxes and an inter-gearbox attachment. The total manufacturing cycle for the entire group of gearboxes was 18 months. In the next five years, a program for the production of heavy marine units will be implemented, within the framework of which the company must produce four types, differing in design and manufacturing complexity. On this moment The first gearbox of the next unit is ready for testing.
In April 2013, the Zorya State Enterprise - 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 a tender in 2012. According to the terms of the contract, in the period from 2016 to 2019, the company will equip four new Project 15B ships. The third series has already been equipped. In 1993–1995, installations for three Project 15 ships (Delhi type) were delivered to India, and in 2005–2006, also for three Project 15A ships (Kolkata type). For the 15B project, the company will produce a modernized power gas turbine unit with microprocessor system management.
Company prospects
SE "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 gas turbines for warships is quite contradictory. Despite the monopoly in the CIS on the production of ship propulsion systems, exporting products is extremely difficult without Russian enterprises. In fact, only three single contracts can be named, implemented without cooperation with Russian exporters and enterprises: the construction of four Project 958 Bizon hovercraft for the People's Republic of China, the Singapore hovercraft project ACV-1 program and the supply of new turbines for the American container ship LCpl Roy M. Wheat , which were not continued.
Due to extreme disabilities Ukraine in the design and automation of warships domestic market"Zori" - "Mashproekt" is negligible. And taking into account the saturation of the traditional markets of Russian shipbuilding (China, India), coupled with their desire for self-sufficiency, including in the production of gas turbine units, we should expect a decrease in purchases of both Russian and Ukrainian ships, and with them Nikolaev engines.
The second challenge is increased competition with Western engine manufacturers, 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 17 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 expected to be used on seven Project 17A frigates planned for construction in India.
Since 2009, the story of the program of the promising destroyer Project 15B has continued. It is planned to build four destroyers for the Indian Navy, which are a development of Project 15A. The list of participants in the 15B program remains the same, but the set of key components for the ship has not been completed. The main dispute arose over the power plant; a number of designers from the Indian side proposed using the same LM2500 gas turbine engine. For the Russian side, such a development of events is also undesirable, since it will lead to a number of related enterprises falling out of the market.
In the Russian naval market, the position of Zori - Mashproekt is theoretically threatened by periodically initiated projects to organize the production of ship gas turbines at Russian enterprises. However, as in the case of organizing the production of helicopter engines in Russia, not much progress has been achieved 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 marine gas turbine construction. In fact, after 2000, Saturn was able to test on test benches two types of marine engines, which are actually modified clones of the corresponding Nikolaev developments of the 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 to date not a single sample of these gas turbine engines has been purchased or put on ships. Saturn also takes part in the M90FR gas turbine engine program (for Project 22350 frigates) in collaboration with Zorya - Mashproekt. But the share of the Rybinsk enterprise in volume co-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 resumed about the prospects for the purchase of the state enterprise NPKG Zorya - Mashproekt and a number of shipbuilding enterprises in Ukraine by Russian state investors. However, the decision on the company's investment program in new equipment indicates no intention to privatize or transfer the enterprise to anyone. So everything points to conservation current situation for the coming years.
It seems that no one is interested in the result yet. On the one hand, the Ukrainian participants in the discussion refuse to take into account the role of Russian design capacities and automation enterprises in the export of products from the state enterprise NPKG Zorya - Mashproekt. On the other hand, the Russian proposal announced at that time to integrate Zori - Mashproekt into the USC structure caused some bewilderment. Firstly, why this form of integration if CJSC Turborus has been successfully operating for more than 20 years? Secondly, the issue of Ukraine’s benefits was not brought up for discussion, although during this period the country fully complied with the status of a strategic partner.
In general, the form and content of such an integration proposal made dialogue impossible. These are not up for discussion. real problems industries, such as aging and shortage of personnel in the design bureau, decline in scientific and technical potential, cooperation. The organization of assembly production through CJSC Turborus with the subsequent transfer of licenses for old engines at the capacity of customers (India, Vietnam) and further joint development and the 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 mainly declarative in nature. The closed joint-stock company with a predominant share of Russian capital has been operating for more than 20 years and during all this time it has never been involved in conflicts or conflicts. controversial situations in contrast to the delivery of the same “Zubrov”. The absence of revealing materials in the media regarding the work of Turborus confirms the successful choice of the cooperation model not only in the financial, but also in the production aspect. A more serious challenge compared to today's import substitution policy is the expected contraction of the company's traditional export markets in India and China.
The Kronstadt Marine Plant has prepared a repaired gas turbine engine(GTD) for shipment to the customer JSC Ship Repair Center Dalzavod (Vladivostok). The ship's gas turbine engine DT-59 arrived at the plant in June 2015 to undergo mid-term repairs; in January-February 2016 it was tested on a special stand. Compliance of the parameters of the finished engine with the characteristics included in terms of reference, confirmed. The press service of the plant reports this.
This is the first of two ship-based gas turbine engines intended for Dalzavod, and of nine currently being repaired at the Marine Plant as part of a state order. At the same time, orders for the repair of converted ship engines for the needs of gas pumping stations continue to be fulfilled. The 2016 repair plan includes five GPA-10 units and one DR59L engine.
The specialized gas turbine production of the Kronstadt Marine Plant has been repairing ship engines since 1967. During this time, more than 350 engines and installations of various modifications were repaired for the needs of the navy.
Having a set of repair documentation, equipment, equipment developed by the manufacturer, gas turbine production carries out full cycle medium repair of gas turbine engines, including testing on a “hot” bench, and also carries out installation supervision work, and if necessary service maintenance gas turbine units on ships.
The repair program for gas turbine engines for the Russian Navy has been approved for a period until 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 domestically produced engines.
The Kronstadt Marine Plant is the largest ship repair enterprise in the North-Western region of Russia. Founded in 1858. (1858-1922 - Steamship Plant, 1922-1929 - Kronstadt Shipyard). The Kronstadt Marine Plant has had its name since 1929. The company is located in Kronstadt on Kotlin Island in the Gulf of Finland, 30 km west of St. Petersburg. Production area The marine plant covers more than 63 hectares.
The total length of the berth front of the embankments is 500 m, the slipways are 750 m, which allows for dock repairs of ships and vessels up to 230 m long and with a displacement of up to 40 thousand tons.
The plant carries out comprehensive repairs of ships, including dock repairs in the underwater part of the hulls with cleaning and painting, repairs of bottom-side fittings, propellers, stern tubes, steering, retractable and lifting-lowering devices; repair of diesel engines, gas and steam turbines, steam and hot water boilers, electrical products; manufactures metal structures, metalworking products, bends steel pipes, rewinds electric motors and others. The Kronstadt Marine Plant is one of the oldest ship repair enterprises in Russia and the largest in the North-Western region. Founded in 1858. Currently, the plant repairs more than 100 ships and vessels annually. Since 2015, it has been part of the United Shipbuilding Corporation.
The Far Eastern Center for Shipbuilding and Ship Repair (DSSS) includes the main ship repair and shipbuilding production facilities of the Far Eastern Federal District, such as the Dalzavod Ship Repair Center (Vladivostok), the Far Eastern Zvezda Plant (Bolshoi Kamen), the North-Eastern Repair Center center (Vilyuchinsk). On behalf of Russian President Vladimir Putin, a consortium of companies OJSC NK Rosneft and OJSC Gazprombank, represented by the joint venture CJSC Modern Shipbuilding Technologies, is creating an industrial and shipbuilding cluster in the Far East of Russia on the basis of OJSC DCSS, the core of which will be a new shipbuilding complex "Zvezda" in Bolshoi Kamen.
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 opening ceremony of the new NPO Saturn complex 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 all domestic units yet have the advantage that the president voiced. FlotProm compared the characteristics of gas turbine engines.
Launch at Rybinsk NPO Saturn since 2018 serial production marine gas turbine engines 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 coefficient useful action domestic engines will grow by 10-15%, because this is “more modern technology compared to what we took before." FlotProm analyzed the efficiency of power plants.
Line of marine gas turbine engines produced by NPO Saturn
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 frigates of projects 22350 and 11356, the small landing hovercraft "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.
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 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.
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.
GTD M70FRU2 for DKVP type "Bison"
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. UEC stated on April 25 that “further development of marine gas turbine engines may follow the path of increasing power, as well as increasing engine efficiency.” In addition, Saturn is developing cobalt alloys.
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. Wherein 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%.
GTD M70FRU
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 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 to the fact that the limit of long-term strength of the material of the working blades occurs at high temperature. In a diesel engine, the maximum combustion temperature reaches 1700 degrees, but 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%. 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). Wherein British company Rolls-Royce said in 2016 that its MT-30 engine is more than 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 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 engine (UGT6000+) before the overhaul was “tired”, its efficiency decreased by half from 30%. Repairs at the Kingisepp 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.
Kronstadt Marine Plant JSC (since April 2016, part of United Shipbuilding Corporation JSC) announced in its press release that on April 10, 2016, the company shipped a refurbished DT59 gas turbine engine to the Northern Fleet as part of a state order.
The DT59 ship gas turbine engine arrived at the plant in the spring of 2015 to undergo mid-term repairs. During the repair process, the engine is completely rebuilt. Compressor and turbine blades removed from the rotors are subjected to defect detection using non-destructive testing methods, they are processed and polished, and operations are carried out to increase strength. The rotors are balanced, the alignment of engine components and other operations are checked. In March 2016 again assembled engine successfully passed factory tests.
Past average renovation at JSC "Kronstadt Marine Plant"afterburning 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 the marine engines repaired by the Kronstadt plant this year. The first was intended for 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 a state order.
Let us remind you that the specialized gas turbine production of the Kronstadt Marine Plant has been performing a full cycle of medium repairs of gas turbine engines, including testing on a “hot” bench, and also carries out installation supervision and, if necessary, servicing of gas turbine units on ships since 1967, and during this time repaired more than 350 engines and installations of various modifications for the needs of the navy.
The program for repairing gas turbine engines for the Navy has been approved for a period until 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 domestically produced engines.
Comment bmpd. The repaired afterburning gas turbine engine DT59 belongs to a large anti-submarine ship of the Northern Fleet "Admiral Chabanenko" project 11551, since April 2014, under repair at the ship repair plant Branch "35 Shipyard" of JSC "CS "Zvezdochka" in Murmansk.
Details of organizing the repair of ship gas turbines in Kronstadt onJSC "Kronstadt Marine Plant" were outlined in an interesting interviewdirector of gas turbine production (GTP) - deputy general director of Kronstadt Marine Plant JSC 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, a unique production facility operates very successfully and without unnecessary fuss, the capabilities and experience of which in the last two years, due to changes in the international situation, have become in urgent 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.
We talk about what the Kronstadt turbine workers are currently doing and what their plans are with the director of gas turbine production (GTP) - deputy general director of Kronstadt Marine Plant JSC Oleg Borisovich Rekunenko and his deputy for production Natalia Ivanovna Rachina.
Who and when instructed the GTD of the Kronstadt Marine Plant to carry out repairs ship engines for the Russian Navy?
In 2014, due to changes in the geopolitical situation in the world and the need to repair gas turbine engines for Navy ships 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 installation.
In 2015, we received the first three engines (DO63 and DT 59) for repair under a government contract, and before that we received for repair two more DT-59 engines by order of JSC Dalzavod Ship Repair Center and one DT59 engine with the Admiral BOD Chabanenko" by order of the branch "35 SRZ" of the CS "Zvezdochka".
- Do you carry out a full repair cycle or are we talking about after-sales service?
We carry out a full cycle of medium repairs of gas turbine engines, including testing on a “hot” bench, and also carry out installation supervision work, that is, we are engaged in installing engines on site, setting them up and handing them over to the customer for sea and mooring tests. 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 undergoing repairs at the Northern Shipyard), our specialists were engaged in setting up 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 to repair gas turbine engines for the fleet?
The fact is that our production was founded back in 1967. With the participation of specialists from NPP Mashproekt and PA Zorya (Nikolaev), the only developer and manufacturer of gas turbine engines in the USSR ship type- Workshop No. 38 was created at KMOLZ, essentially a branch of the Zorya Production Association, for the repair of ship gas turbine engines of 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 engines with gas reverse.
It should be noted that even in those years when the Marine Plant was testing economic difficulties and went through bankruptcy proceedings, work on the GTP did not stop for a single day.
When difficulties arose with orders from the Navy in the 1990s, the managers of Lentransgaz LLC turned to the management of the Marine Plant with a proposal to repair the converted DR59L marine engine, created by NPP Mashproekt and Zorya Production Association for gas pumping stations. Structurally, this engine was almost no different from marine engines traditionally repaired at the plant, which allowed us to short time master its repair. The engine was successfully repaired and delivered to the customer in 1996. Since that time, PJSC Gazprom has become our main customer for many years.
There was one big problem left. The engines were sent to gas pumping stations after repairs without testing, because the fuel for the DR59L engine is natural gas, and our test station was designed for naval diesel engines. But we coped with this task too. In 2009, we completed the re-equipment of the test station and tested the DR59L engine, using the original development of its starting and testing on diesel fuel for the first time. Since then, the 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 the GTP has been working on engines for the needs of Gazprom, how did you manage not to lose your skills in repairing ship engines?
All these years we have continued, albeit in a much smaller volume, to repair ship engines. During this time, six DO63 reversible engines were repaired, and three DE59 type engines were also repaired for the needs of foreign fleets.
What capabilities (technical, personnel) does the GTR have to carry out the tasks assigned by the fleet? What is the advantage of GTR, what is its uniqueness?
The uniqueness of the GTP is that it is the only enterprise in Russia that has a set of repair documentation, equipment, stands and other equipment developed by the manufacturer SE NPKG Zorya-Mashproekt for the repair of gas turbine engines of the DE59, DT59, DK59, DO63 types, etc.
We have a test bench that allows us to test these engines and deliver turbines ready for installation on Navy ships to the customer. We have experience in repairing all these types of engines, and most importantly, we have qualified personnel to perform the assigned tasks.
Thus, at the time the domestic fleet needed to repair gas turbine engines, we had documentation, well-established production, and personnel for repairing second-generation engines.
Therefore, we confidently began work on the order of the fleet.
- What volume of work can the GTD perform?
At the moment we have nine engines under repair - five DT 59 and four DO 63. All are in varying degrees of readiness. Repair deadlines are tight, so we have to work hard. To meet the planned dates, it happens to work on holidays and weekends.
At the same time, we continue to fulfill orders for civil repairs. The 2016 repair plan includes five GPA-10 units and one DR59L engine.
What is the progress of work at the moment? Are there any results? What difficulties arise? How do you deal with problems? In particular, documentation, spare parts, production equipment?
At the moment, the assembly of two DT59 engines for OJSC "CS Dalzavod" has been completed, and we have begun testing them. Full swing Engines are being repaired for the Russian Navy under a government contract. The DT59 engine is in the process of being assembled, and the repair of two DO63 engines is being completed.
Two more DO63 engines have been disassembled and are undergoing fault detection.
The DT59 engine with the Admiral Chabanenko BOD is at the stage of unit assembly.
Problems arise, as in any production. 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, work out and agree on their replacement. Increases repair time and the need to purchase all services and purchased equipment through trading platforms in accordance with the requirements of Law N 223-FZ. If previously we could quickly resolve these issues, now it sometimes takes months to complete procurements.
Is the participation of the GTD expected only for work with the specified engines or will the GTD be included in the repair of ship gas turbine engines on an ongoing basis?
The program for repairing gas turbine engines for the Navy has been approved for a period until 2024. In addition to the 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 confident that we will cope with this task.
- So, you are currently the leader in the repair of ship gas turbine engines?
In the repair of second generation naval engines such as DE59, DT59, DK59, DO63, we are truly leaders.
Now other enterprises are emerging that want to master the repair of naval turbines. But they still have to master the documentation, create the necessary production base, and gain experience. There are positive results. For example, at one of the enterprises they are mastering the repair of gas turbine engines by replacing ready-made components and parts.
Will the GTP be able to repair engines of subsequent generations? Will it continue to repair engines produced by domestic enterprises?
If we talk about organizing the repair of engines of the 3rd and 4th generations in general, then this will require serious retrofitting of our production. New stands and a testing station must be created, and the corresponding technological equipment must be manufactured. 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 considered 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 Kronstadt Marine Plant (part of the United Shipbuilding Corporation) has prepared a repaired gas turbine engine for shipment to the customer JSC Dalzavod Ship Repair Center. The ship's gas turbine engine DT-59 arrived at the plant in June 2015 to undergo mid-term repairs, and was tested on a special stand in January-February 2016. The compliance of the parameters of the finished engine with the characteristics laid down in the technical specifications was successfully confirmed.
This is the first of two ship gas turbine engines intended for Far Eastern ship repairers, and of nine currently being repaired at the Marine Plant as part of a government order.
At the same time, orders for the repair of converted ship engines for the needs of gas pumping stations continue to be fulfilled. The 2016 repair plan includes five GPA-10 units and one DR59L engine.
The specialized gas turbine production of the Kronstadt Marine Plant has been repairing ship engines since 1967. During this time, more than 350 engines and installations of various modifications were repaired for the needs of the navy.
Possessing a set of repair documentation, tooling, and equipment developed by the manufacturer, gas turbine production carries out a full cycle of medium repairs of gas turbine engines, including testing on a “hot” bench, and also carries out installation supervision work and, if necessary, servicing of gas turbine units on ships.
The program for repairing gas turbine engines for the Navy has been approved for a period until 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 domestically produced engines.
