Russian Airlines Face Growing Spare Parts Shortage, Struggling to Maintain Fleets

Russian airlines are confronted with an increasingly critical shortage of Western-made aircraft spare parts, which is impeding their ability to maintain operational fleets. More than a year has passed since Western sanctions were imposed, banning the delivery of commercial aircraft and maintenance services to Russia following the country’s invasion of Ukraine in 2022. Despite local mandates to keep fleets in operation, the scarcity of spare parts has become a mounting concern.

According to Aviation Week, the Federal Air Transport Agency (Rosaviatsiya), the industry’s local regulator, has prohibited the cleaning of fuel filters for SaM146 turbofan engines until the Russian manufacturer, UEC Saturn, obtains formal certification for the procedure. SaM146 engines are utilized in Russian-made Sukhoi Superjet 100 regional aircraft, with over 130 of these aircraft currently in service by Russian carriers for both domestic and international routes. The suspension of spare part supplies, including the filters, by SaM146 manufacturer PowerJet (a joint venture between UEC Saturn and Safran of France) has intensified the crisis.

While UEC Saturn expects certification for the cleaning process from Rosaviatsiya soon, the company has also been working on a Russian-made replacement for the fuel filters. However, progress updates on the development and certification of the indigenous filters have not been disclosed.

In addition to the fuel filter shortage, Russian carriers operating the Sukhoi Superjet 100 have raised concerns about the lack of igniter plugs for the SaM146 engines. The igniters and exciters were previously supplied by Unison Industries, a subsidiary of GE Aerospace based in Jacksonville, Florida. If a domestic substitute for these components is not found promptly, affected carriers may need to reduce their operations using the SSJ100 aircraft.

To address the scarcity of spare parts, efforts are underway to develop local manufacturing capabilities. S7 Technics, a subsidiary of S7 Group, recently acquired a majority stake in Berdsk Electromechanical Plant (BEMZ), a Russian manufacturer of aircraft components. However, manufacturing spare parts for Western-made jets without OEM approval remains a challenge.

Seattle-based aviation consultant Boris Rybak highlights the difficulties faced by Russian MRO providers, emphasizing that maintenance work on Western aircraft within Russia is now deemed illegal due to the absence of recognized approvals from OEMs or international authorities. Currently, the majority of maintenance work on Russian-operated Western narrowbody aircraft is outsourced.

The spare parts shortage not only impacts Russian-built aircraft but also affects the more than 600 Western-made commercial aircraft in Russia, most of which were seized from international lessors following the Ukraine invasion. The local registry, facilitated by Rosaviatsiya, tasked local MRO providers with maintaining this fleet. However, obtaining larger components such as engines and landing gears has proven to be exceptionally challenging.

As Russian carriers grapple with the spare parts crisis, maintaining the airworthiness of their fleets has become increasingly difficult. The industry continues to explore alternative solutions and strategies to overcome these obstacles and ensure the operational efficiency and safety of their aircraft.