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The heart of the warships.
The heart of the warships. What are the prospects for the development of marine engine building in Russia
On the eve of the International Maritime Defense Show (IMDS-2021) in St. Petersburg, specialists from the United Engine Corporation (UEC, part of the Rostec state corporation) told TASS about the creation of power plants for the latest Russian ships
The construction of engines for warships in the ocean and sea zone is one of the key technologies - any modern navy (Navy) is unthinkable without reliable, powerful and efficient propulsion systems. Serial production of engines for corvettes and frigates largely determines the future prospects and directions of modernization of the Navy.
During the Cold War, the Soviet Union focused on the development of marine propulsion engineering - the country produced its own power plants for all types of warships. Particular attention is paid to this field of mechanical engineering in Russia - after the collapse of the USSR, it was decided to create a Russian naval base for gas turbine construction. Already in 2006 and 2008, by order of the Ministry of Defense of the Russian Federation, experimental design work (R&D) was successfully completed to create domestic marine gas turbine engines: in particular, two marine gas turbine engines were developed - M75RU with a capacity of 7000 hp. and M70FRU with a capacity of 14,000 hp.
In 2014, the second stage of the program was launched to develop and master the manufacture of marine gas turbine engines (GTE) and gas turbine units. In particular, at the end of 2017, three R&D
projects were carried out at the UEC: • to develop a technology for serial production of an engine with a capacity of 27,500 hp. for use as part of gas turbine units (GTU) of displacement ships;
• on the development of a GTA based on the M70FRU-2 engine for hovercraft;
• on the development of a reversible GTE M70FRU-R for displacement ships.
"Within the framework of the existing scientific and technical groundwork and the results of the development work on the basic M70FRU gas turbine engine, new modifications of engines and units have been created in three years, which make it possible to completely replace the Ukrainian power plants for air-cushion ships and reversible engines in operation," TASS said Deputy General Director - General Designer of UEC Yuri Shmotin. "The development of a 27,500 hp gas turbine engine in serial production allows for the completion of the customer's main power plants and makes it possible to create units for promising ships," he added.
In three years, not only three most complex works were completed, but also technical re-equipment of the enterprise, technological preparation of production, construction of a bench base for testing marine engines and units. At the end of 2017, design work and construction of the assembly and test complex were successfully completed.
"As of today, UEC has created a line of marine gas turbine engines with a capacity of 7,000 to 27,500 hp, which in the short and medium term covers the fleet's needs for gas turbine engines for all under construction and prospective ships of various classes," said UEC Deputy General Director Viktor Polyakov. Thus, UEC has competencies in design (development), serial production, warranty, after-sales service and repair of marine-grade GTEs and units based on them.
Today, UEC has created a line of marine gas turbine engines with a capacity of 7,000 to 27,500 hp, which, in the short and medium term, covers the fleet's needs for gas turbine engines for all under construction and prospective ships of various classes.
Victor Polyakov
Deputy General Director of UEC
At present, UEC has mastered the production of marine engines for all surface ships of the Russian Navy with gas turbine power plants. "In particular, the corporation is ready to provide the Navy with engines for use in air-cushion landing ships of projects 12061 and 12322, corvettes of project 20386, frigates of projects 22350 / 22350M and 11356, as well as ships in operation during their modernization," UEC.
Engines for frigates
For the latest frigates of Project 22350, the corporation has mastered the production of the M90FR gas turbine engine, which is used as part of the M55R diesel-gas turbine unit. "In 2020, UEC delivered the first two M55R units for the frigate Admiral Golovko to Severnaya Verf. To date, the third unit for the frigate Admiral Isakov has been successfully tested and the fourth unit is being tested to complete this ship," UEC, noting that the fourth diesel-gas turbine unit is planned for delivery after the completion of bench tests in July-August 2021. Project 22350 frigates "Admiral Golovko" and "Admiral Isakov" are the third and fourth ships of the series.
It is assumed that the M90FR will become the basis for advanced marine engines. In particular, the UEC is considering options for creating a 25 MW engine based on the M90FR. Shmotin said that the results will also be a scientific and technical groundwork for the development of engines in the power range of 25-35 MW.
The corporation stressed that the corporation can fully supply the state customer with GTE and GTA in the required volumes. "For today, the planned volume of supplies is about 20 M90FR gas turbine engines," the UEC reported.
It is worth noting that ships with foreign-made engines can also be equipped with M90FR during re-engining. “However, taking into account the“ age ”of the ships and the need to attract serious funds for the modernization of the main power plants and control systems of the ship, such a decision was not made, - the corporation says.
The corporation also prepared for the after-sales service of M90FR engines - for this purpose, a separate subsidiary was created. According to experts, the M90FR engine is not inferior to foreign analogues and corresponds to the world trends in the development of 4th generation marine GTEs.
Work is underway to create the latest power plants. In particular, a project is underway to develop a gas turbine unit for a promising frigate. The main engine will be the M70FRU, and the afterburner - the M90FR, developed by the UEC.
New corvettes - new engines
For use in the power plant of promising corvettes of project 20386, UEC developed a modification of the M90FR engine. "Two engines have been manufactured, successfully tested and ready to be handed over to the customer," the press service added.
In addition, the corporation has created a number of unified M70FRU engines with a capacity of 8000–10000 MW* for ships of various purposes - corvettes, small rocket ships, small artillery ships, as well as ships with dynamic support (amphibious assault ships on an air cushion).
The basic modification M70FRU was developed in 2008 (according to the results of the MVI, the product documentation was assigned the letter "O1"). Initially, this engine was intended for project 20380 corvettes, however, these ships were then equipped with diesel power plants (including those of foreign production), so no orders were received for the supply of serial M70FRU engines.
Within the framework of the state import substitution program, in the period from 2014 to 2017, UEC created two modifications of this engine - the M70FRU-R GTE with a reversible power turbine (for surface ships) and the M70FRU-2 GTE with a forward power outlet (for air-cushion landing craft). As part of this work, new, more modern engine systems were introduced on the engine - a local automated control system, a vibration diagnostics system, fuel system units, etc. During the development of the M70FRU and its modifications, technologies were applied that correspond to current global trends - according to experts, this power plant belongs to the fourth generation and is at the level of foreign analogues.
Based on the results of the work performed, the readiness of serial production of new modifications of the M70FRU GTE was confirmed, and several M70FRU-2 experimental delivery engines have already been manufactured for subsequent use as part of the 12061 Murena and 12322 Zubr air-cushion landing craft. In addition, the basic modification of the M70FRU GTE, taking into account the above modernization, is planned for use as part of the main gas turbine unit of a promising frigate.
Marine engines and production diversification
At the moment, UEC has created a dual-fuel modification of the M90FR engine, which may be in demand in the gas industry, for example, as part of drilling platforms.
On the basis of the M70FRU, a civil marine engine - E70 / 8RD - was also developed. "On the basis of E70 / 8RD, the SGTG-8 gas-turbine electric generator has been created," Shmotin said. Both E70 / 8RD and SGTG-8 have passed all the necessary tests and are ready for serial production.
UEC is ready to supply all of the aforementioned civilian engines, the corporation added.
Rostec is consistently implementing programs for the development of modern engines of all types. The creation of offshore gas turbine power plants and units is a science-intensive high-tech process. Only a few manufacturers in the world have such competencies. We are ready to meet the demand of Russian shipbuilders for new power plants
Vladimir Artyakov
First Deputy General Director of Rostec State Corporation
Development prospects
UEC is already forming a scientific and technical groundwork for the creation of a 5th generation marine engine. "As a groundwork, we mean the results of the implementation of a preliminary project for the development of a 25 MW marine engine with a low-emission combustion chamber of marine design and the development of new high-temperature corrosion-resistant alloys," Shmotin informed, adding that the corporation is also creating a marine power plant of increased power - in particular, within the framework of an agreement with the Ministry of Industry and Trade of the Russian Federation, a preliminary project is being implemented to develop an engine with a capacity of 34,000 hp. (25 MW). As priority directions for further development of ship engines, UEC singles out the creation of engines with a capacity of 25–35 and 13 MW.
Along with the creation of new marine engines, the modernization of their development and production processes is being carried out. Since December 2020, within the framework of an agreement with the Ministry of Industry and Trade of the Russian Federation, research work has been carried out to create a digital twin of a marine gas turbine engine and a gearbox. "The deadline for the completion of work is October 2023. In the process of implementing this project, UEC must obtain an operating technology / platform for creating digital twins, which will be used in all subsequent developments of new products," Shmotin said.
Additive technologies are increasingly used in the design of engines - the first positive experience of their application in the field of marine engines was obtained during the creation of the M70FRU-R engine.
Currently, UEC is already using domestic materials created using additive technologies and not inferior in their characteristics to foreign counterparts.
UEC
In addition, the development and application of new materials is being carried out to create thermal barrier coatings for the blades of the hot part of the engine, which make it possible to increase the gas temperature in front of the turbine and thereby increase the power of the power plant. "Within the framework of the agreement with the Ministry of Industry and Trade of the Russian Federation, research work is being carried out aimed at developing new high-temperature corrosion-resistant alloys," Shmotin summed up.
https://tass.ru/armiya-i-opk/11715059
* this value must be wrong
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