Air Transport

Increased thrust and reduced emissions will let D-30K-powered Tu-154Ms continue operating into Western Europe

Russian engine builder NPO Saturn is developing a major upgrade for the Aviadvigatel D-30K series engine to provide improved performance and greater thrust to enable the Soviet-era aircraft it powers to continue to operate internationally. The engine equips IlyushinIl-62 and Tupolev Tu-154M airliners and Il-76 freighters.

NPO Saturn, which builds theD-30K, has launched a two-stage programme that will be applicable to both in-service and new-build engines. The first stage is focused on the Tu-154M's D-30KU-154 engine to enable the airliner to continue operating into Western Europe through to the middle of the next decade, when new environmental regulations take effect.

The Tu-154M equipped with the Series 2 engine meets International Civil Aviation Organisation Chapter 3 noise levels by a small margin (around 1.6dB), but does not meet the latest ICAO emission requirements.

The newly-introduced Series 2M engine has additional noise-absorbing panels, reworked combustor, strengthened shafts and an add-on closed-type fuel drain system. The changes increase its compliance margin against Chapter 3 to 5.9dB and allow the Tu-154M to meet new emissions requirements. It also extends engine life from 18,000h to 21,000-24,000h. Saturn has built three Series 2M engines and completed long-duration tests for a 21,000h lifetime. Tests continue for 24,000h certification in 2005.

Saturn holds commitments from 18 airlines for 180 engines and re-confirmable orders from two undisclosed carriers for 15 units. The first engine will be installed on a customer aircraft in the third quarter, during major overhaul.

A more advanced derivative, the Series 3 - dubbed Burlak - is under development and incorporates the Series 2M changes along with a new larger, highly swept fan which increases airflow by 40%. This increases take-off thrust by 2,200lb (9.8kN) to 24,000lb without changes to the gas generator.

The new engine requires an investment of $55 million and will cost $1.2 million. A demonstrator engine has been completed and will be flight-tested on an Il-76 testbed. Certification is due in late 2006.

The refanned engine will be offered for retrofit on theIl-76MD/TD, providing Chapter 4 compliance with a comfortable margin at take-off weights of 190t. NPO Saturn expects to secure at least 100 orders for Il-76 Burlak upgrades, priced at $6 million per shipset. Break-even for the project is put at 80 aircraft.

The engine can also be retrofitted to the Tu-154M, but only in the two outboard positions as the larger fan would require a new centre engine air intake if installed into the number two position. A 30,800lb-thrust version, featuring a second low-pressure compressor stage, is being considered to replace the Kuznetsov NK-86s powering the Il-86 widebody airliner. An Il-62 retrofit has also been proposed, but attracted little interest.

VLADIMIR KARNOZOV / MOSCOW