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Fomin A, Feb-2013. Ilyushin 476 Undergoing Tests, Take-Off Magazine

Fomin A, Feb-2013. Ilyushin 476 Undergoing Tests, Take-Off Magazine

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Published by: Foro Militar General on Apr 24, 2013
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06/19/2013

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The governmental resolution on the devel-opment and productionising of the upgradedIl-76 in the city of Ulyanovsk was issued on 20December 2006. Since 1972, the Il-76’s pro-duction had been produced in Uzbekistan by the Tashkent Aircraft Production Corp. namedafter Valery Chkalov (TAPC) that had built atotal of almost 900 aircraft of the type over four decades. The transfer of the Il-76’s productionto Russia was caused by the snags hit by theimplementation of the September 2005 con-tract for 38 Il-76MDs, including several tanker planes, for China, with the contract having been awarded to TAPC by Rosoboronexport. Itturned out that the financial standing of TAPCand the financial conditions proposed wouldnot allow the deal to pan out. In addition, it became obvious that in addition to future com-mercial orders, there would be high demandfor the Il-76 on the part of Russian users as well, the Defence Ministry in the first place.To avoid dependence on the manufacturer sitting in a foreign, albeit friendly, country, theRussians weighed the pros and cons and optedfor having the Il-76 productionised in Russia,at the Aviastar plant in Ulyanovsk.The aircraft developed almost 40 years ago was to be upgraded heavily and its designdocumentation was to be digitized, essen-tially worked out anew in the form of 3Ddigital models. The Il-76’s basic upgradesincluded the replacement of its engines withmore powerful and more efficient PS-90A-76turbofans made in Perm (by then, the enginehad been tested on Il-76MF and Il-76MD-90prototypes) and a heavy update of its avionicssuite, including the introduction of the ‘glasscockpit’. At the same time, several considerabledesign and technological improvements have been introduced too. For instance, the wing, which retained its airfoil section and outline,has been given a new structural layout – the wing panel became a one-piece job usinglong-measuring panels with riveted stringers,and the number of the wing spars droppedfrom three to two. This allowed a sizeablereduction in structural weight and an increasein terms of manufacturability.Owing to the new wing and reinforcedundercarriage, the airlifter’s maximum take-off weight has grown from 190 t of theTAPC-built production-standard Il-76MDto 210 t, while its maximum payload hasincreased from 47 t to 60 t. Owing to the 12%fuel efficiency increase of its PS-90A-76,the aircraft have seen an increase in itsrange from 4,000 km to 5,000 km with the52-t payload. The greater thrust allowedan improvement in its takeoff and landingperformance, with the length of the run
UNDERGOING TESTS
NDERGOING TESTS
Last autumn saw the start of the flight tests of the upgraded Il-76MD-90A(‘476’) transport aircraft prototype made by the Aviastar-SP close corporationin Ulyanovsk – the first aircraft of the Ilyushin Il-76 family, built in Russia (untilrecently, the previous Il-76 versions were made in Uzbekistan). The new airlifter’sfirst flight took place in Ulyanovsk on 22 September 2012. Two weeks later, on4 October, the aircraft was shown in flight to the authoritative governmental del-egation led by Russian President Vladimir Putin. The demonstration flight wasfollowed by the signing of the contract for 39 production-standard Il-76MD-90As tobe built in Ulyanovsk for the Russian Defence Ministry, with the total value of thedeal being almost 140 billion rubles (around $4.5 billion). According to participantsin the event, this has been the most lucrative deal on aircraft acquisition for theRussian Air Force over the post-Soviet years. The contract has become the launchorder for the Il-76MD-90A and is expected to be followed by more orders, sinceRussian ministries and other governmental agencies alone will have needed atleast hundred aircraft of the type until the end of the decade.
ILYUSHIN
LYUSHIN
476
76
Andrey FOMINPhotos provided by UAC
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diminishing from 1,750 m to 1,600 m. TheTA-6A auxiliary powerplant was replaced with the more advanced TA-12A to enhancethe operating characteristics.The Kupol-II analogue flight naviga-tion system has been ousted by the digitalKupol-III-76M(A), and the SAU-1T-2Banalogue automatic flight control system has been replaced with the digital SAU-76 allow-ing ICAO Category II landing approaches andRNP and RVSM navigation. The traditional‘steam-gauge’ instruments in the cockpit havegiven way to the KSEIS integrated electronicdisplay and warning system comprising eightcolour multifunction liquid-crystal displays(MFD). The advanced BPSN-2 satnav sys-tem has made its way onboard the airlifter too.The upgraded aircraft has been designatedas Il-76MD-90A and given the index 476(for this reason, it is called Il-476 sometimes,though the designation is unofficial). In addi-tion to the prime developer, the Ilyushin Aviation Complex JSC, a wide range of con-tractors has taken part in the upgrade, e.g.the Perm Engine Company, Kotlin-Novator close corporation, Tekhpribor JSC, MIEA JSC, Gidroagregat JSC, Aviaagregat JSC,Electroprivod JSC, etc.The Russian Ministry of Industry andTrade ordered the construction of the firsttwo prototypes, and UAC – Transport Aircraft JSC acted as prime contractor. Theorder for the construction of the first exam-ple, c/n 01-01 designed for endurance tests, was placed with the Aviastar-SP close cor-poration on 15 March 2007 and the one for the manufacture of the first flying prototype(c/n 01-02) on 30 September 2009. To makethem, Aviastar set up a separate shop on theplant’s premises of the aggregate assembly facility. The first two aircraft were beingassembled in Ulyanovsk as portions of thedigitised design documentation arrived fromIlyushin. Aviastar kicked off the assembly of the first components and compartmentsunder the 476 programme in 2009. To speedup the construction of the first flying proto-type, the empennage, wing high-lift devicesand wingtips set was ordered from TAPC thathad a virtually completed backlog. The com-ponents ordered were brought to Ulyanovsk in April 2011. The flying prototype’s assem- bly had been complete by year-end 2011, andthe roll-out ceremony for the Il-76MD-90A (c/n 01-02) took place on 15 December 2011. Two and a half months before that,on 1 October 2011, the F2 fuselage sec-tion, wing centre box and wing panels – astructural component set for the enduranceprototype (c/n 01-01) – was delivered fromUlyanovsk to Zhukovsky, Moscow Region,for static tests in TsAGI.Following the rollout in December last year, the flying prototype of Aircraft 476returned to the assembly shop to complete thesystems assembly and shop tests. The plane’shandover to the plant’s flight test facility took place early in July of this year, and the firstIl-76MD-90A registered as RA-78650 wasunveiled late in August during the MATF2012 International Air Transport Forum atUlyanovsk-Vostochny airport.The first engine run took place on13 September, and a week later, the air-craft was prepared for its flight tests after the ground debugging of its new avionics.Finally, on Saturday, 22 September 2012, atabout 15.30 an Ilyushin test pilot crew led by Honoured Test Pilot, Hero of Russia NikolaiKuimov took the Il-76MD-90A for its maidenflight. The crew consisted of Honoured TestPilot Vladimir Irinarkhov (co-pilot), Valery Grechko (navigator), Alexei Zhuravlyov(flight engineer) and Sergei Orlov (flight radiooperator) as well as Vladimir Lysyagin (flighttest engineer), Alexander Tsvetkov (electricsystems operator) and Alexei Mitin (cargocompartment operator).The new aircraft’s second flight was onthe morning of 28 September, and 4 October saw the Il-76MD-90A’s presentation toRussian President Vladimir Putin on a visit toUlyanovsk for a meeting on the governmentalacquisition of Russian-made aircraft. The
 
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Il-76MD-90A just landed after its maiden flight. Ulyanovsk, 22 September 2012 
 
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President was pleased with what he had seen:Nikolai Kuimov’s crew flew the new aircrafton a short but spectacular sortie. “I haveevery reason to thank and congratulate theDesigner General and plant Director, andthe whole of the team who have worked hardto achieve this stage of the development of anew Russian transport aircraft. Today, we haveactually witnessed the final stage of its devel-opment”, Vladimir Putin said. “The event wehave witnessed today is not a mere flight of therevitalised Il-76 aircraft. Essentially, this is adrastically new aircraft upgraded by 70%. Wehave got an advanced aircraft featuring cut-ting-edge characteristics in terms of reliabil-ity, range, efficiency and lifting capacity. I amcertain that the aircraft will be in demand both in this country and with our possiblepartners abroad”, the President concluded.Then there was the ceremony of signingthe launch contract for 39 Il-76MD-90A aircraft for the Russian Defence Ministry,attended by Vladimir Putin. After the event was over, the President’s chief of staff SergeiIvanov said: “This is the largest contractthe Russian aircraft industry has ever seen”.The deliveries under the contract will havetaken place from 2014 to 2020. The con-tract’s value stands at 140 billion rubles (about$4.5 billion), i.e. more than 3.5 billion rubles(around $115 million) per aircraft. The con-tract will not be the only one signed by theDefence Ministry. As was reported in thepress, the Il-76MD-90A shall serve the basisfor an advanced tanker plane intended tosucceed the in-service Il-78M and for severalspecialised aircraft, which development has been assigned to Beriev company. Accordingto Vice-Premier Dmitry Rogozin, the 2020State Armament Acquisition Programme pro- vides for procurement of “more than 100”Il-76MD-90As in several versions.In addition, other governmental cus-tomers are expected to place orders for theIl-76MD-90A in the coming years. “Now, weneed to consolidate other customers, becausethe aircraft features a widest range of applica-tions”, Sergei Ivanov told the media in the wake of the meeting in Ulyanovsk. “It canoperate in the fire-fighting, medevac, air- borne assault and freighter roles. Therefore,the Emergencies Ministry, Ministry of theInterior, Federal Security Service, Office of the President, Transport Ministry and severalother governmental agencies should form apool of customers within a month and work out a line of credit stipulating a proactive useof leasing arrangements”.Ilyushin JSC Director General/Designer General Victor Livanov said: “The congratu-lation by President Vladimir Putin imposeson us a high responsibility. We have passedan important stage, but a lot has to be donefurther down the line: we are to test andproductionise the aircraft – both the baselinemodel and a whole range of its derivatives. Weare certain that the Il-76MD-90A aircraft isfacing new vistas”. At present, Aviastar plant is manufac-turing the first three production-standardIl-76MD-90A airlifters. Their constructioncommenced as far back as 2010 under thecontract with UAC – Transport Aircraft. According to Aviastar-SP Director GeneralSergei Dementyev, two of them are to be com-pleted as soon as this year, with the deliveriesto begin in 2014. The company’s productionplan provides for a gradual increase in theannual Il-76MD-90A output all the way to 18aircraft per annum in 2018.Meanwhile, the first flying prototype of theIl-76MD-90A was painted late in December last year. Once it has completed a series of groundtests and fixes, it is to fly to Ilyushin’s flight testfacility in Zhukovsky, Moscow Region, whereits flight tests will continue. The move wasplanned for late January or early February 2013. According to Ilyushin Designer General VictoLivanov, the first stage of the Il-76MD-90A’s offi-cial tests, which includes 50 test sorties, is to becompleted in the third quarter of 2012. One pro-totype will be enough for this purpose, becausethe official trials of the upgraded Il-76MD-90(RA-78854) aircraft, which were conducted withsuccess in 2011, will be taken in consideration.This test aircraft made in 2005 on the basis of the Il-76MD (c/n 81-05) built in 1991 was usedfor testing the advanced powerplant consisting of four PS-90A-76 turbofan engines as well as newavionics now used in the Il-76MD-90As madein Ulyanovsk.
Ilyushin 476 first flying prototype being painted at Spektr-Avia JSC, 22 December 2012 
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Il-76MD-90A prototype in its second flight, 28 September 2012.Registration has been already changed from RA-78650 to 78650

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