One of the priority projects of the Russian state program "Development of the aviation industry in the years 2013-2025" is the project of "Engines for aircraft MS-21", which is the lead developer of "Aircraft Engine". About how to implement the task of creating competitive production aircraft engine we are talking with the deputy chief designer, chief designer of the engine family PD Perm Design Bureau Igor Maximov.
— Igor, what results in 2012 do you consider most important?
— Significant milestone, not only last year, but the project "Engines for MS-21" on the whole I would call an engine-technology demonstrator (DDT).
DDT collected in May 2012, and in June it was done the first run on a closed test bench "Aviadvigatel." After the first phase of testing, during which a detailed study engine performance parameters of its components and systems, the engine was mounted on an open stand for acoustic tests using protivoturbulentnyh input device. Then the engine was disassembled. The specialists of "Aircraft Engine", JSC "NPO" Saturn "and JSC" NPP "Motor" studied in detail the state of its parts and components, after which the engine is assembled to continue the tests. There is an ongoing trial next stage of DDT. In 2012, tests of prototypes of the engine nacelle components PS90A.
One of the significant achievements of the past year — is approved by the Director of the "OPK" Oboronprom "and the director of the Department of Industry and Trade of Russian aircraft industry specification for propulsion engine with PD-14 to MS-21.
Also in 2012, the technical project baseline PD-14 engine, has received the endorsement of the CIAM, Institute of Civil Aviation, Aviation Materials, NIIT.
— In 2012, the next step is made from preliminary design to the technical project. Made any changes to the engine?
— One of the key changes to the engine design was to change the location of the box drive units instead of the engine compartment under the hood gas generator nacelle. This way, we significantly reduced the technical risks to ensure the necessary temperature state of the most important units of ACS, oil systems and aircraft units. In addition, we have expanded the possibilities of creating modifications of PD-14 engine for other types of aircraft. It is clear that changing the design of the gearbox, add or change the units of a specific type of aircraft is much easier when there is more space. However, this modification resulted in a change in the other engine components, fan, separating housing units nacelle.
Furthermore, all the parts of the engine are designed and implemented measures ensuring increased efficiency, life and weight.
To reduce the weight of the engine we are working with experts "Motor" completely revised the design of the low pressure turbine (LPT). New LPT became smaller in size and lighter, and use the most modern advances in aerodynamics turbines increasing its efficiency. Now the enterprise cooperation, "Motor", "Aircraft Engine", and PMZ UMPO started manufacturing the new turbine. The first set of LPT we will put to the test in CIAM stand for TS-2, the second will be testing at a demonstration in the engine.
— And how are things progressing with the combustion chamber?
— We conducted a series of tests of full combustion in the gas generator, DDT "aircraft engines", a high altitude and vysokoparametricheskom stands in the CIAM. Key findings: the combustion chamber confirmed the design characteristics. However, to reduce the risk, we are working with GP "Ivchenko-Progress" (Ukraine) for the design of alternative combustion chamber. At the beginning of 2013 it is planned to test "aircraft engines", first on a special stand, then in the gas generator demonstrator. With positive results, we plan to continue to test the COP along with our Ukrainian colleagues in CIAM. If you find that its performance is better, it is possible that the main supplier of the combustion chamber will be the engine manufacturers in Ukraine.
— You mentioned the demo engine. It is something different from the engine-technology demonstrator?
— Motor technology demonstrator designed to test the adopted design and technological solutions. Who is making the demo engine, which will be as close in design to the production engine of PD-14. In this work, busy almost all enterprises Engine Corporation. The main objective — to demonstrate the parameters of the future of PD-14. The start of his trial, we planned for the third quarter of this year.
— In the framework of the "Engines for aircraft MS-21" for the first time in the history of the creation of the domestic engine-nacelle engine specialists involved, not the developers aircraft. What was the scheme is working and what has been done?
— Indeed, the Corporation "Irkut" ordered us a power plant completely, so today as part of the project we are working in two directions: the engine and nacelle. On both fronts decorated relevant decisions on cooperation in the design, certification and manufacture.
It must be emphasized that at the stage of development and manufacturing of an experimental batch as engines and nacelles of "Aircraft Engine" is the parent company. In the future — at the stage of mass production — our CB will carry author’s support products and manufacturing engine and nacelle production plant will be.
To date, constructive look nacelle components defined. We have decided that our nacelle to be sliding type, not swing open. This allows for a more rigid, lightweight and reliable structure.
To work on the creation and preparation of production nacelle for PD-14 attracted the leading national trade institutes: Aviation Materials, CIAM, TsAGI, the Central Research Institute of Special Engineering, Ural Scientific Research Institute of Composite Materials, Kirov "Power", etc.
In the framework of cooperation of the main modules of the nacelle — air intake cowlings, thrust reverser — will be made on three main businesses: Voronezh Aircraft Company, Obninsk Research and Production Enterprise "Technology" and Permian plant "Mashinostroitel." The cooperation of the 2nd and 3rd level is well developed and includes Russian and foreign suppliers. In this case, a lot of attention paid to the maximum use in the design of the nacelle of standardized, proven solutions.
The key technologies designed to ensure the competitiveness of the product on the technical and economic parameters, are the technology of composite materials. Weight of composite parts design motogonoly exceeds 60%. Among them is made even such a complex and demanding part, as a lattice reversing device.
Tests of the first nacelle as a demonstration engine is scheduled for early 2014.
— In the current economic climate it is important to demonstrate not only goods, but also the market demand for it …
— Business goal of the project — conquering the world market of aircraft engines in the class thrust from 9 to 18 tons. For today signed an agreement to supply engines PD-14 between the management company "United Engine Corporation" and the Corporation "Irkut". Signed an agreement of intent to purchase our new engine for the aircraft such as the MC-21 with the Institute of Civil Aviation of the Republic of Cuba, the Azerbaijani company Silk Way
, received the provisional application of the Indian customers. Interest in MS-21 and MTA (multi-purpose transport aircraft) engines with PD-14 show the Ministry of Defense and Emergencies of Russia, negotiations with the representatives of the domestic passenger and cargo airlines. Thus, today, we can safely say about the need for more than 1,000 engines PD-14.
I want to emphasize that the selected options provide the ability to create a gas generator on the basis of its competitive aircraft engines in a wide range of rods — from 7 to 18 ton, gas turbine engines from 6 to 16 MW ground application. This reduces the risk of possible delays and failures on certain narrow market segments and determines the economic viability and effectiveness of the project.
Already on the results of the first tests of the engine-technology demonstrator has shown its efficiency in the whole range of conditions, up to the take-off, as demonstrated by the motor parameters in thermodynamics, acoustics and emissions better than today’s counterparts.
Conducted in 2011 by specialists Corporation "Irkut" CIAM and comprehensive assessment of the economic efficiency of PD-14 engine in the MS-21, taking into account the specific fuel consumption, maintenance and repair costs and cost control has shown that the direct operating costs of the MS-21 engine with PD 1.1-2.5 at 14% less than the engine PW1400G.