AUTOMATIC

CONTROL
SYSTEMS
FOR ADVANCED
RUSSIAN
GAS TURBINE
ENGINES

140A, Kuibyshev St., Perm, 614990, Russia

Tel.: +7 (342) 249-19-84 Fax: +7 (342) 269-26-46
Tel.: +7 (342) 249-32-07 Fax: +7 (342) 281-21-79
E-mail: star@ao-star.ru
www.ao-star.ru
 Company’s
status
STAR JSC is a scientific and production association specialising in development
and production of automatic control systems for gas turbine engines. The
company’s products are electronic and hydromechanical control units equipping
the gas turbine engines of aircraft and the powerplants of gas turbine electric
power plants and gas-compressor units.

In 2010, the STAR design bureau and Inkar assembly association (a production
plant) became subsidiaries of the United Engine Corporation UEC). The historical
prerequisites, latest tendencies and common strategic goals of STAR JSC and
Inkar JSC caused the merger of the two companies. UEC supported the proposal
of their merger into a single entity, and the merger, which started in the same year,
was complete in April 2011. The newly-established company retained the name
the design bureau had borne prior to the merger – STAR.

The purpose of the merger was to beef up the personnel and technological capabilities of the two companies and
enhance the effectiveness of the technologically related manufacturing facilities. Being a single entity also allows a
ABOUT THE COMPANY

reduction in development and productionising time. Thus, the establishment of a united company will result, within
the framework of UEC’s production strategy implementation, in a Perm-based centre of competence focused on
development and production of sophisticated aircraft and industrial engines.

The STAR joint stock company

was established as part
of the United Engine
Corporation in 2011
 Company’s
profile
STAR JSC is a developer and a supplier of integrated automatic engine control
systems containing digital electronic controllers, including FADEC ones, and
such hydromechanical assemblies as fuel pumps, fuel-flow governors, metering
devices, automatic distributors, valves, actuators and centrifugal governors.

Concurrently with improving and producing time-proven products, the company

develops cutting-edge technologies too. It has been developing electronic digital
circuits based on advanced structural principles and large-scale and superlarge-
scale integrated circuits since 2002. The first system like that has been developed
for the upgraded PS-90A2 engine intended to power the advanced Tu-204SM
airliner.

It is significant that the company does not rest on its laurels. Rather, it is active in using latest technologies, materials
and scientific achievements in development of advanced hardware. The company is taking part in two most important
Russian engine-making programmes – the development and production of the fifth-generation engine to power the
ABOUT THE COMPANY

future tactical fighter, the T-50, and the development and production of a family of 9–18-tonne-thrust engine family
based on a common core engine to power future passenger planes and transports. STAR JSC takes part actively in
developing the automatic control system to fit the first engine of the family – the PD-14.

Since the early ‘90s, STAR JSC has been developing automatic control systems to equip ground-based gas turbine
plants used in gas-compressor units and mobile and modular electric power plants. The company has already
developed the software and microprocessor control systems for not only the gas turbine powerplant, but the power-
generating unit as a whole as well, using industrial automation equipment from major foreign manufacturers.

Along with integrated control systems, the company develops and makes individual assemblies, e.g. gas regulators,
hydraulic and pneumatic gas turbine engine mechanisation control units, control panels, engineering consoles and
digital engine control and protection units.

We have been developing

and making reliable
engine control systems
for over 70 years
 Design and production
capabilities
The new configuration of the united company ensures the cycle of development
of automatic engine control systems and individual assemblies as a closed-loop
system anew – from development to production of complete products and their
subsequent maintenance throughout their life cycle.

The production philosophies of both companies were similar in terms of the

emphasis on latest technologies, introduction of advanced equipment and transition
to computer-aided design and manufacturing systems, but each has features of its
own due to the different tasks that used to be facing them. The difference will be
dwindling as the post-merger integration increases.

The philosophy of a common information environment, 3D computer-aided design

and computerised mathematical analysis underlies the Teamcenter Engineering engineer data management and
Altium Designer and SolidEdge design software systems being introduced to the design divisions. Full-rate production
based on CAD/CAM/CAE of the Unigraphics NX system develops manufacturing processes and numerically-
ABOUT THE COMPANY

controlled machine software and designs machine retaining devices and tools.

The company enjoys a wealth of manufacturing capabilities, including foundry, punching, rubber article, electroplating,
electrochemical and thermal process facilities and the whole range of cutting equipment as well.

STAR’s research and test facilities numbers in excess of 50 benches and installations operated in support of the
automatic control systems of gas turbine plants under conditions as close to the operating ones as possible.

The corporate aircraft design, production and repair quality management system has been certificated for compliance
with ISO 9001-2001 international standard.

STAR JSC evolves as

a complete cycle company
 Automatic control systems
and assemblies for combat aircraft
The Helicopter Engine Automatic Control System Department is developing the advanced SAU-2000V control system
to fit the TV3-117 designed to equip Army helicopters. The sophisticated automatic control system will ensure a
twofold increase in the service life of assemblies compared with that of the traditional SAU-78, adapt the fuel system
to foreign fuel with low-lubricating properties, simplify the automatic control system’s hydromechanical segment,
diagnostics and protection of the engine, and switch the engine over to on-condition operation.

Assembly index Engine Aircraft type Operators

RED-3048, NR-3048MA, TD-3048,
RS-3048MA, RR-3048M, NS-3048M, D-30F6 MiG-31 Russia, Kazakhstan
RPPO-3048, 4081S-1
Russian, other CIS
NR-53D, RSF-53B, FN-53 AL-21F-3 Su-24 countries, North African
and Middle East countries
Product Russia and over 10 other
NR-54F(F2)/NR-54(P) MiG-21/Su-25
95F(25)/195 countries
Su-27/Su-30 aircraft Russia and over 10 other
RSF-31B/V/VT-1 AL-31F/FN/FP
family countries
RSF-31VT-2 Product 117S Su-35 Russia
Mi-8MT/17/171,
ERD-3, NR-3, IM-3A, Russia and several dozen
TV3-117/VK-2500 Mi-28N, Mi-24/35,
RPR-3, DTsN-70A foreign countries
Ka-50/52, Ka-27
OUR PRODUCTS

Our systems fit in-service

and in-development aircraft

NR-3048M BKI-117 RS-3048

 Automatic control systems and
assemblies for commercial aircraft
The company is developing an automatic control system for the in-development PD-14 engine designed to power
the MC-21 short/medium-haul plane. The automatic control system will be a distributed control, monitoring and
diagnostic system fitting the engine. Compared with the centralised-type system, this automatic control system
features a higher structural reliability and fail-safety and offers an operating costs reduction throughout the engine’s
life cycle.

Assembly index Engine Aircraft type Operators

RED-90A2, NR-90A2,

Our control systems TD-90M, ART-90A2,

AIK-90-A2
PS-90A2 Tu-204SM Russia

RED-90M, ERD-3VM, Il-96-300, Tu-204, Russian, India, Cuba,

equip new-generation engines NR-90, ART-90R, TD-90
NR-30KP, NR-30KU,
PS-90A/A-76
Tu-214, Il-76MF PDRK, Jordan

TsR-1-30K, DPO-30K/KP, Russia and dozens of

D-30KU/KU-4/KP Il-62M, Tu-154M, Il-76
RNA-30R, TsNA-30K, other countries
TD-30K, IMT-3, RPPO-30KP
NR-30AR, TsR-1VR,
D-30 Series III Tu-134A Russia
TsR2-VR
RED-2000, NR-2000,
TV3-117VMA-SBM1 An-140 Russia, Ukraine
RT-2000
ERD-3, NR-3, IM-3A, Russia and dozens of
TV3-117/VK-2500 Mi-8/17, Ka-32
OUR PRODUCTS

RPR-3, DTsN-70A other countries

RED-90A2 NR-90A2 TD-90

 Automatic control systems
of ground-based gas turbine engines
In the electric power generation and gas-main pipeline spheres, the company works along the following lines:
- design, development and production of industrial powerplant and gas-compressor unit automatic control systems,
fuel metering equipment and engine actuators;
- introduction of industrial powerplant and gas-compressor unit automatic control systems;
- installation, installation supervision and commissioning work;
- maintenance and repair.

The Ground-Based Automatic Control System Design Department has been running the development of a marinised
version of automatic control systems of gas turbine engines to power cargo ships. The ship-based gas turbine
engine’s twin-fuel local control system allows burning diesel fuel and gas.

Lately, STAR JSC has productionised a wide range of oil pumps and accessory gearboxes designed to transfer toque
from the powerplant’s compressor shaft to actuators.

There are the following ground-based application assemblies as part of the automatic control system – DGE-2,5,
DG-009, DG-90 and DG-30 gas regulators, KA-30 control units, AIK-16 and AUK-25 servo-valve assemblies,
BUSh-96 gas regulator electronic control units, BUD engine control units, KS-90 check valves, control panels,
engineering consoles and engine protection engines.
OUR PRODUCTS

STAR JSC is proactively refines

automatic control systems
to fit industrial gas turbine
powerplants KA-30GE-VI DG-009-VI RED90E
 Aftersales servicing

Fuel metering systems from STAR JSC are used as part of the engines exported to
more than 30 countries. The variety of the aircraft types operating the hardware
made in Perm, numerous countries operating it and different climatic conditions
have established for both the product quality and timely and quality aftersales
maintenance.

The company performs warranty and post-warranty maintenance and has set
up a special backup stock to quickly replace malfunctioning units or units, whose
service life expired. A separate aftersales support programme has been launched
for the users of fuel metering systems as part of ground-based gas turbine plants.

Under the aftersales support programme, STAR JSC manufactures maintenance

kits for users of various aircraft.

Assembly index Engine Aircraft type

30KU/KU-4/KP maintenance kit D-30KU/KU-4/KP Il-62M/Tu-154M/Il-76
NR-54 maintenance kit Product 95F(25)/195 MiG-21/Su-25
System 3048 maintenance kit D-30F-6 MiG-31
OUR SERVICES

System 40 maintenance kit TV2-117 Mi-8

NR-3A, VM and VMA Mi-8/17, Mi-24/35, Mi-28,
TV3-117/VK-2500
maintenance kits Ka-50/52, Ka-27/28/32

Our key objective

is uninterrupted operation
of automatic control systems