8  85^th anniversary of the Ural Turbine Plant.

All these 85 years the plant has lived and changed together with its country, having experienced everything: ups and downs, devastation and periods of rapid construction. But at all times Ural turbine builders have created reliable equipment for the energy industry of Russia and other countries. It was here that bold technical solutions were born, it was here that people set ambitious goals and achieved them. For 85 years of selfless work, Ural turbine plant has passed the path of great achievements. The energy industry of Russia and many partner countries is impossible today without reliable operation of Ural turbines.

14 Steam turbine PT-150/160-12,8 for reconstruction of power units with K-160-130.

Key words: turbine, reconstruction, low pressure cylinder, heating

Abstract

The article describes the design of the PT-150/160-12,8 turbine, developed to replace the existing K-160-130 turbines produced by the Kharkiv Turbine Generator Plant. When designing a new turbine, the possibility of preserving the existing foundation was taken into account, as well as the possibility of organizing thermal steam extraction (including three-stage heating of mains water) and steam extraction for their own needs. In addition, during the development of the PT-150, there is a potential possibility of increasing the electric power to 180 MW, as well as creating condensation turbines based on it in the power range of 140...195 MW with both the presence and absence of intermediate steam overheating.

On the basis of the created design of the PT-150 turbine, specific samples are already being designed – a K-140-12,8 type condensing turbine and a Kt-186/196-12,8 type turbine for delivery during the construction of new power plants. The turbine is a two-cylinder unit consisting of a combined high- and medium-pressure cylinder and a two-flow low-pressure cylinder. In the nominal operation mode of the turbine, 150 MW of electric power is provided, 115 Gcal/h – thermal, as well as steam consumption in the production selection of 30 t/h to the station collector.

 

20  Modern heat exchange and auxiliary equipment developed and manufactured by Ural turbine works JSC.

Key words: heat exchanger, low pressure heater, oil cooler, steam jet ejector

Abstract

The article presents an overview of heat exchange and auxiliary equipment developed and manufactured by JSC Ural turbine works (UTZ). The enterprise constantly improves serial production and develops new equipment. From the latest equipment mastered in the production, a line of low-pressure heaters and a newly developed new remote oil cooler are presented with a description of technical solutions. It also provides an overview of serial steam jet ejectors, including new modifications of the main ejectors of the EP type and seal ejectors of the EU and EPU type, their characteristics and technical description are presented.

The authors present measures to improve the reliability and efficiency of the heat exchange main and auxiliary equipment of the UTZ. The measures have been developed taking into account many years of experience in the development and operation of such equipment.

 

26  Updating the principles of steam turbine creating.

Key words: unification, functional and cost analysis, modular principle of technical systems integration, efficiency

Abstract

The article presents the concept of «unification», discusses the features of functional and cost analysis and the technology of modular development of a modern steam turbine, allowing to reduce the material consumption of the product and the complexity of equipment manufacturing, as a rule, without reducing its efficiency.

It is shown that the use of functional cost analysis and the modular principle of steam turbines creating make it possible to fully take into account the individual requirements of equipment customers, reduce costs at all stages of the life cycle of steam turbine equipment. The article indicates that the development of domestic mechanical engineering, especially in recent years, has shown that it is possible to ensure the current and prospective level of competitiveness through the transition from unification to modular technology.

The use of a new ideology of design and techno-logical preparation of production and maintenance of the life cycle of equipment is also relevant for steam turbines. The introduction of modular approaches to their development and production should be associated with the digital transformation of the turbine enterprise, which will allow it to achieve digital maturity and ensure automation of maintenance of all stages of the life cycle of turbine equipment.

 

32  Mathematical modeling and field tests of cogeneration steam turbine with electrical load drop.

Key words: cogeneration steam turbine, control and protection system, load drop, disconnecting the generator from the grid, shaft line rotation speed overshoot, steam volumes

Abstract

The main provisions of the method of mathematical modeling of the rotation speed overshoot of steam turbine shaft line with electrical load drop are considered. The presented model takes into account the energy losses caused by the operation of the turbine at idle, and is a system of two first-order differential equations describing the process of changing the rotational speed of steam turbine shaft line when the electrical load is discharged. As a result, a dynamic characteristic of the change in the speed of rotation of the shaft line during the discharge of the electrical load for the PT-65/75-130/13 steam turbine produced by UTZ was obtained.

It is shown that speed overshoot of the steam turbine shaft line does not exceed the setpoint of overspeed trip mechanism. The main activities of the test program for the regulation and protection of steam turbines in accordance with the Rules of technical operation of power plants and grids of the Russian Federation are also considered. The results of operational tests of the PT-65/75-130/13 control system after a comprehensive 72-hour testing are presented; a comparative analysis of modeling and testing. The main design factors of steam turbines affecting the value of the shaft speed overshoot are listed.

 

38  Single-cylinder Kp-77-6,8 steam turbine with axial exhaust pipe.

Key words: steam turbine, axial exhaust pipe, dynamic compliance of supports, cylinder deflection, centering technology, total loss coefficient, gas dynamic testing

Abstract

UTZ JSC has designed a single-cylinder steam turbine with an axial exhaust pipe Kp-77-6,8, the base for the line with the possibility of using both in the steam power cycle in the absence of a water source for the organization of water cooling of the condenser, and in combined cycle. As part of the project, a significant amount of calculations was carried out to determine the appearance of the turbine, meet all requirements in terms of static and dynamic strength, as well as ensure maximum efficiency. The turbine cylinder can be structurally made of two (steam outlet, exhaust) or three (steam outlet, middle, exhaust) parts, depending on the initial pressure and the length of the flow part. The axial exhaust pipe has been worked out from the point of view of dynamics, taking into account the mutual influence on the turbine rotor, has high gas-dynamic efficiency indicators exceeding those of exhaust pipes with radial exhaust. In the turbine, it is possible to organize the necessary selections both for the station's own needs and for heating.

The maximum electric power of the developed turbine in the condensation mode is 77 MW with the parameters of fresh steam adopted during development, with a potential increase of up to 90-100 MW.

 

44  Modern steam turbine condensers designed and manufactured by Ural turbine plant JSC.

Key words: condenser group, condenser, condensate collector, structural materials

Abstract

The article presents an overview of the designs and a comparison of the technical characteristics of modern condensers that are part of steam turbine installations for thermal and electric power plants developed by engineers of the special design bureau of UTZ JSC. The condenser groups KG2-6300 and KG2-7300, each of which consists of two separate condensers, are considered, their advantages are noted and design features are shown. The article also describes a large-sized single capacitor K-9500, the main feature of which is an unconventional block connection scheme, the condenser is designed to work with serial turbines such as T-100 and PT-150. A line of K-1900 and K-3100 condensers for steam turbine installations that have the ability to operate in «degraded vacuum» modes designed for increased pressure of cooling (mains) water is presented. The design features of the condenser K-1900-Im, K-3650-III and K-2950-II, designed to work on sea cooling water, with the data of the applied structural materials of the main units of the water chambers of the condensers, are noted.

 

50  Gas-dynamic modeling of exhaust hoods of heat-generating steam turbines in low-flow operating modes.

Key words: steam turbine, exhaust hood, gas dynamic testing, low-flow modes, cooling system

Abstract

When working out and designing exhaust pipes of steam turbines using numerical modeling methods, only nominal operating modes are traditionally taken into account. The article draws attention to the fact that when performing such optimization, it is important to take into account the variable operating modes of the turbine, since due to an irrational design, reducing the flow rate into the exhaust pipe can lead to increased losses in it, uneven distribution of steam and unilateral heating of the exhaust pipe. A method for modeling the operation of the exhaust pipe in low-flow mode is proposed.

The proposed method is based on the applied method of gas-dynamic calculation of exhaust pipes, while it is indicated that in order to obtain a reliable picture of the steam flow, it is necessary to simulate the turbine stage and the expanded steam volume, including the condenser transition pipe. Using the proposed method, the issue of steam flow in the exhaust pipe with the barrier cooling system turned on and the effect of its operation on the formation of the flow pattern is investigated. The steam flow was evaluated for different designs of barrage steam cooling systems.

 

58  CNPC Jichai gas engine power plants will be assembled in Russia.

On September 22, 2023, during the III Kurgan Industrial Festival, Intertechelectro and CNPC Jichai signed an agreement on joint activities to locaize the equipment of a Chinese company in Russia.

The agreement provides for a three-stage transition from large-scale assembly of power plants to their partial and then full production, including spare parts, at the facilities of the Kurgan Plant of Integrated Technologies (KPIT, part of the Intertechelectro group).

 

64  DELTA dual-fuel system for diesel generator sets.

The technological scheme implemented by Hatraсo LLC allows to preserve all the advantages of diesel engines while significantly saving diesel fuel by replacing most of it (up to 70%) with natural gas. DELTA dual–fuel system of the company Hatraсo is a set of equipment for supplying natural gas to the cylinders of a diesel engine under various operating modes, for monitoring the parameters of the engine and the system itself. It ensures the operation of the diesel engine in dual-fuel mode (simultaneous consumption of diesel fuel and natural gas) while maintaining all operating parameters within the specified limits, as well as a smooth return of the engine to 100% diesel fuel consumption mode (both at the operator's command and automatically).

The DELTA dual-fuel system is supplied with an electronic control panel that monitors and displays the key parameters of the engine and the system itself. Analyzing the signals of various sensors and the set parameters, the panel activates or deactivates the dual-fuel mode.

 

68  Gas engine plants production: whether to use engines of the Asia-Pacific countries?

Given the huge, undiscovered potential of Chinese equipment, Russian power plants manufacturers have begun to massively master Asian technologies. However, accustomed to western quality standards, they immediately faced a number of problems. Among the problems are low levelof technical support, great number of equipment manufacturers, terms of delivery, warranty, etc.

 

70  The ignition system of a gas turbine on natural gas with glow plug.

Key words: glow plug, premixing, low NOx combustion chamber, gas fuel, gas turbine engine, ignition, ignition delay time

Abstract

The results of an experimental and computational study of the gas turbine engine ignition system on natural gas are presented. The ignition of a gas-air mixture by glow plug requires a higher temperature of the heated body than the ignition of other fuels.

The studies were carried out in a non-stationary formulation for the flow of reacting flow of a mixture of compressible gases. They showed that in addition to the required heating temperature of the fuel-air mixture in the range of 1450...1500 K, it is also necessary to ensure the residence time of the mixture at a given temperature of about a few milliseconds, which is possible due to the limitation of mass transfer by the external shell of the glow plug.

The studies were carried out for the conditions of the combustion chamber of DG-90 engine used for gas transportation in Gazprom PJSC. The developed ignition system has passed pilot tests as part of a low-emission PST combustion chamber developed by NPF Thermophysics.

 

78  Perm Motors research and production complex to small power industry of Russia.

Perm Motors has devoted three decades to the development and serial production of gas turbines for the fuel and energy complex of Russia. During this time, dozens of types of gas turbine units have been developed in the power range from 2.5 to 25 MW. 1203 GTU were delivered to customers, with total operation time of more than 41 million hours. Of these, 447 GTPP and 344 power plants are currently in operation, the total operating time of which exceeds 19 million hours. Power equipment of the company operates at the facilities of Gazprom PJSC, LUKOIL PJSC, NK Rosneft PJSC, Irkutsk Oil Company LLC and many others.

 

84  Digitalization of production processes in complex mechanical engineering.

Currently, many enterprises in Russia are engaged in the implementation of digital technologies. But by itself, the performance of work on the creation of complex machine-building products with the help of modern computers and even perfect software will not give a tangible effect if you do not radically change and optimize the processes at the enterprise.

In this article, based on the successful introduction of digital technologies in various branches of mechanical engineering, the key principles of building processes in complex mechanical engineering with their use are presented. Modern technologies of design and preparation of production are a unique tool for increasing the competitiveness and investment attractiveness of the enterprise. The effectiveness of their application is due to the deep design and technological study of both the design and the technology of its manufacture on a full electronic model of the product. 

 

90  Low-voltage complete devices manufactured by INGK-PROMTECH LLC.

INGK-Promtech LLC is a developer and manufacturer of low-volage complete devices with many years of experience. The devices produced by the company can be used in all areas of energy consumption, where it is necessary to ensure the input and distri-bution of electricity.

To date, INGK-Promtech has manufactured, delivered and successfully operated many low-voltage complete devices at the Yurubcheno-Tokhomskoye and Evo-Yakhinskoye fields in the Russian Federation, at the Chinarevskoye oil field in Kazakhstan, at the Yuzhnaya Tandyrcha gas condensate field in Uzbekistan.

EPLAN Electrical P8 advanced automatic design system is used in the development of design documentation. The use of CAD significantly speeds up the design process and eliminates technical errors.

 

92  Development of two-rotor blowers for barrier air of gas pumping units.

The Russian industrial market is currently facing a number of problems due to the departure of foreign manufacturers. Russian companies that use blowers in their production need both maintenance and a complete upgrade of equipment. The article describes the R&D carried out by Veltex company in order to develop and manufacture its own line of twin-rotor blowers.

Two-rotor blowers are widely used in various fields of economic activity: pneumatic transport of bulk materials, water aeration plants, wastewater treatment plants, air supply to gas burners of furnaces, etc. Blowers are also used in gas pumping units as auxiliary equipment in the barrier air supply system – for receiving and pumping barrier air.

The compressor barrier air supply system prevents the appearance of an explosive gas concentration after dry gas dynamic seals, and also provides blowing of the magnetic bearings.