ODK-Saturn PAO, formerly NPO Saturn PAO, is a Russia-based company involved in the design, manufacture and after-sales support of gas-turbine equipment. It specializes in the production and repair of military engines, civil aviation engines and such power generation equipment as gas-turbine engines for industrial application, gas-pumping units, among others. The Company distributes its products on the domestic market, as well as exports them to Belarus, Uzbekistan, Tajikistan, China, India, Algeria, Iran, United Arab Emirates and others. NPO Saturn PAO is a member of the International Association of Union aviation structure of engines (ASSAD).
The need and inevitability of restructuring the Russian aircraft engine industry has been talked and written about for a long time, but real success in industry overhaul has been scarce. The Saturn scientific and production association, better known by its Russian name NPO Saturn, has been one of the first companies to take on this complex and painful task both in word and in deed. The company has integrated within a single viable entity two leading national developers - the Rybinsk-based KBM design bureau and Lyulka-Saturn design bureau in Moscow, both having large experimental and production facilities (an experimental factory in Rybinsk and the Lytkarinsky machinebuilding plant in the Moscow Region) as well as two large industrial facilities in Rybinsk.
Saturn NPO OAO (JSC NPO Saturn) is a Russia-based company involved in the designing, manufacturing and providing services of gas turbine technology. The Company specializes in the production and repairing of military motors, civil aviation engines and energy products. The Company sells its products mainly in the high-technologies market. It sells its products in the domestic market, as well as exports them to Belarus, Uzbekistan, Ukraine, Tajikistan, China, India, Algeria, Cuba, Iran, Bulgaria, Korea, United Arab Emirates and others. The Company is a member of the International Association of Union aviation structure of engines (ASSAD). The Company is a stakeholder in 28 companies. It has three branches and 15 subsidiaries.
Saturn NPO JSC was established on July 5, 2001 through the merger of Rybinsk Motors JSC and A. Lyulka-Saturn, a leading Russian aircraft engine design bureau. The Rybinsk Motors serial engine plant had merged with the Rybinsk Engine-Building Design Bureau in 1997 and acquired the production facilities of the Volga Engineering Plant - a major facility of the Atomic Energy Ministry - in 1999. As of 2004 NPO Saturn employed over 4,000 skilled designers, with the company being the industry's leader in terms of using information technologies for designing engines. The corporation employed about 18,000 personnel, with its production facilities totalling an area of roughly 1,000,000 sq.m.
The design bureaus and serial plants have always formed a single production chain; therefore it was natural to vertically integrate designers and end product manufacturers. Before the appearance of Saturn NPO, Rybinsk Motors successfully aligned with the Rybinsk Engine-Building Design Bureau and acquired the production capacities of a major machine-building plant of the Atomic Energy Ministry. This allowed the company to significantly enhance its scientific and industrial potential, expand the range of output. But still, it was not enough for carrying out strategic tasks of the industry, the most important of them being the development of a fighter of the fifth generation. The merger of Rybinsk Motors serial plant with the leading designer of military and civilian gas turbine equipment A. Lyulka-Saturn became a logical step. Saturn NPO appeared despite the resistance of minority shareholders. The shareholder meetings of Lyulka-Saturn and Rybinsk Motors approved the merger agreement and the transfer deed. The Saturn Board of Directors was elected, the company charter was approved and registered.
NPO Saturn engines power the world famous Sukhoi Su-27/30 family of fighters. The AL-31FP engine powers the Su-30MKI multirole fighter. The new 117S engine is intended for powering Sukhoi Su-35 advanced multirole fighter and other up-to-date versions of the Su-27/30 aircraft. NPO Saturn activities in military aviation also include 36/37 engines for tactical and cruise missiles, as well as AL-55 family of engines for trainer and light combat aircraft.
NPO Saturn civil engines D-30KU/KP power commercial aircraft, which are the most prevailing in Russia and the CIS countries: TU-154, IL-62 and IL-76. More than 4,000 D-30KU/KP commercial engines are operated in Russia, CIS, Middle East and Asia-pacific regions, and have logged over 45 million flight-hours, a unique track record among Russian engine manufacturers.
The PowerJet joint venture was established in 2004 by NPO Saturn (Russia) and Snecma (France) within the scope of the program of the SaM146 advanced engine development for new-generation regional jets. PowerJet is a 50/50 joint company owned by Snecma and NPO Saturn. It is in charge of the SaM146 program management tasks, including: design, production, marketing, sales and customer support, with equal finance and risk sharing in each of the above-listed directions. Snecma and NPO Saturn decided to team up on a new regional jet engine in 2002. This move reflected both confidence in the market (estimated at a potential of 5,000 aircraft in the 70-100 seat category over the next 20 years), and long-standing mutual trust between the two partners. In April 2003, the SaM146 was selected by Sukhoi Civil Aircraft Company (SCAC) for the Superjet 100 regional aircraft, which will be the first application for the SaM146. For the previous 10 years NPO Saturn had collaborated with Snecma as a subcontractor for production of CFM56 engine parts.
As of 2001 the NP Saturn board of directors featured representatives of the Gazprom oil and gas giant, International Congress of Industrialists and Entrepreneurs, Ministry of Property Relations, Russian Armed Forces, Russian Aviation and Space Agency, Raduga machine-building design bureau, Tekhnokom company, Sistema corporation and Yaroslavl region administration. Also on the board were Rybinskie Motory Director General Yuri Lastochkin and Lyulka Saturn Constructor General Igor Seleznyov.
In December, 2002, Saturn NPO JSC revaluated its fixed assets, and its charter capital is now appraised at 4 billion rubles (about $125 mln). The management is probably the controlling shareholder, while the government retains a 37% stake. According to the Saturn NPO JSC web-site, the Board of Directors includes Deputy State Property Minister N.A. Gusev, Deputy Chief of Armaments of the Russian Armed Forces V.G. Mikheev and Deputy General Director of the Russian Aerospace Agency S.Yu. Rynkevich.
Much of the company's income comes from repairs and production of D-30KP engines (for Il-76T/TD/MD, Il-78, A-50 and A-40 aircraft), D-30KU (for Il-62M) and D-30KU-154 (for Tu-154M). According to General Director Yuri Lastochkin, Saturn annually repairs 400-500 engines (up from 200-300 in Soviet times) and builds 30-50 new ones (down from 600-700 in Soviet times).
Large capacity gas turbines have been in use around the world for years but their construction is tricky to perfect. Because they operate at extremely high speeds and high temperatures, they need to be engineered to very precise standards and they use sophisticated electronic control systems to make sure that they operate efficiently. For many years Russia made no major investment in developing the technology because it was able to import the turbines or the know-how to produce them. A scheme started in the 1990s to develop a large-capacity turbine produced prototypes but they did not go into production.
After Western sanctions were imposed on Russia over the conflict with Ukraine in 2014, Russian President Vladimir Putin urged officials to replace imported technology with home-grown substitutes in energy, software, aerospace and medicine. A new 110 Megawatt turbine was developed by a consortium of ODK, a unit of state-owned conglomerate Rostec that owns the Saturn factory where the testing was being conducted, Russian state technology firm RUSNANO, and state energy firm InterRAO.
The mishap with the turbine, with a capacity large enough to power a sizeable town, underlines the technical challenges. Testing was underway on a prototype 110 MW turbine at the Saturn engineering plant in Rybinsk, central Russia, in December 2017. The turbine fell apart. They tried to repair it in time for March, but they did not manage it. March was the target date for completion of tests on the turbine. Putin, in power since 1999, won a second consecutive term in an election on 18 March 2018.
Without any home-grown equivalents, Russia should in most cases still be able to buy turbines from Western suppliers, but U.S. and European Union sanctions have made it harder to import Western power technology under certain circumstances. Setbacks to the domestic turbine program could hamper the modernization of power generation if growing tensions with Western states result in tighter sanctions since Russia's modernisation plan focused on using gas turbines.
Marine Gas-Turbine Engines (GTE)
Traditionally, NPO Saturn specialized in the development and production of aviation gas turbine engines. Since 1993, the company began to develop the production of ship gas turbine power plants. In 2000, Russian President Vladimir Putin appointed Saturn (then - Rybinsk Motors OJSC) as the lead company for the development, serial production and repair of all marine gas turbine engines. The measures taken to diversify Saturn's products made it possible to mitigate the consequences of the breakdown in military-technical cooperation with Ukraine in 2014, when Kiev prohibited Zaporizhzhya Motor Sich JSC from supplying ship and aircraft engines, including gas turbine units, to Russia.
After 2014, deliveries of Ukrainian marine gas-turbine engines (GTE) to Russia ceased. This raised the question of the development and production of domestic engines and units based on them for mass production. The Saturn gas turbine engine, supposedly completely ready for serial production, was demonstrated at the 2011 International Naval Salon. Later, the readiness for serial production of domestic marine gas turbine engines was reported in 2014, but it was not possible to establish it.
On the basis of state contracts concluded between the Ministry of Industry and Trade of Russia and PJSC “ODK-Saturn” in the framework of the state program “Development of industry and increasing its competitiveness”, as well as in the framework of import substitution, the company developed shipboard gas turbine engines M70FRU-2, M70FRU-R, mastered production one engine, and also completed the development of gas turbine units (GTA) based on them. In 2014, in order to replace the Ukrainian gas turbine engines, Saturn began work on the design and development work of the M90FR [20.2 MW], Aggregat-DKVP and M70FRU-R [14 MW] engines,. The purpose of the development work is the creation of the M70FRU-2 gas turbine engine and the ship’s GTA M35R-1, M35R-2 and M70R with a capacity of 10,000 hp.
In December 2017, the Rybinsk NPO Saturn successfully completed three development work on the M90FR, Aggregat-DKVP and M70FRU-R engines, which the company has been conducting since 2014. New Russian-made engines will be equipped with frigates of projects 22350 and 11356 , a small Zubr hovercraft , as well as other ships and vessels of the Russian Navy.
Rybinsk ODK-Saturn PJSC (part of the United Engine Corporation of the State Corporation Rostec ) was recognized as the laureate of the Aircraft Builder of the Year 2017 competition in the nomination For Success in Developing Production Diversification. The company was awarded for the successful implementation of the program to create a domestic base of marine naval gas turbine engines M70FRU-2, M70FRU-R and units based on them.
Of key importance in the implementation of the project of the Russian marine gas turbine building base was the creation at the ODK-Saturn of an assembly and test complex of shipboard GTA and diesel-gas turbine units with unique test benches for the country up to 15 MW and up to 40 MW. Here you can experience ship engines and units based on them in more than 20 different configurations. This complex is a cluster that not only fully provides for the current stage of import substitution of Russia's current needs in terms of marine powertrains, but also allows you to experience promising engines. In April 2017, in the presence of Vladimir Putin, the assembly and test complex at the ODK-Saturn was put into trial operation. Currently, the facility is operating in industrial operation mode.
“As a result of the implementation of the “sea” program, the possibility of replacing a number of foreign analogues used in power plants of Russia with domestic engines was ensured,” said Deputy General Director and Managing Director of ODK-Saturn PJSC Victor Polyakov. "It allows to satisfy the need of the fleet for ship engines for existing ship projects. In addition, the obtained scientific and technical reserve is the basis for the development of engines of ships of promising projects. The project allowed PJSC “ODK-Saturn” to seriously develop and improve its core competencies - design, technological, manufacturing, testing. ”
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