6 The development of Russian mechanical engineering in the hands of young scientists

In this issue of the magazine we present to your attention several articles about companies and their key products. In the issue you will be able to read the article MGTT Enterprise: the modern look and goals of the updated company. The MGTT company not only fulfills its contractual obligations for the service of gas turbines, but also expands. The program for the development of production, repair and maintenance of equipment for combined-cycle power units is being implemented, which includes expanding the range of services provided to Russian generating companies. In accordance with the traditions of the publication, we present an interview with Nikolai Dmitrievich Rogalev, Doctor of Technical Sciences, professor, rector of the NRU MEI, Chairman of the Scientific and Technical Council of the EEC.

 

8 The National Research University MPEI is the leader in training of the personnel for advanced sectors of the economy

Qualified specialists are one of the most important components of the successful functioning and development of such complex high-tech knowledge-intensive industries as power and mechanical engineering. For many years the National Research University MPEI has been a leading university for the training of engineering and scientific personnel for energy and mechanical engineering: designers of power equipment, designers of thermal and nuclear power plants, autonomous power facilities, heat and power supply systems, as well as operating personnel of energy facilities. Providing high-tech sectors of the economy with highly qualified engineering and scientific personnel is the topic of the conversation with Nikolai Dmitrievich Rogalev, the rector of the National Research University MPEI.

 

12 The method of studying the fan blade of aviation gas turbine engine for impact strength when a foreign object strikes

Key words:turbofan engine, turbojet engine, protection from foreign objects, bird strike

Abstract

Aircraft gas turbine is prone to the damage caused by the debris strike the most of all the elements of an airplane. During its operation, the foreign object debris (FOD) strike may cause local or complete destruction.

In the research the classification by reason of the damage, by the sources of the damage, by the passage of the damage and safety precautions are listed. As a result of the study the phenomenon, its reasons and consequences of the foreign object debris strike with the aircraft engine of civilaviation were analyzed.

Different protection systems were observed. During the study, two fan blade sections of the same height, same chord of the root section (old generation blade and new generation blade), used in the civil aviation of the aircraft engine were compared as a reason to elaborate the methodology of analysis the influence of the collision between an object and blade section.

The material and the shape of the object were chosen according to its features which simulates, with a good authenticity, possible influence on an engine while colliding with FOD.

In represented study the collision of the object and both blades was simulated. The stress-strain behavior of the blade after the collision on different heights was received. The conclusion about the advantages of using irregular outline of the blade according to the results of the modelling was conducted.

 

18 MGTT enterprise: the modern look and goals of the updated company

Modern Gas Turbines Technologies, the Russian high-tech enterprise, is constantly expanding the range of products - elements of heavy duty gas turbine plants, as well as increasing the volume of repair and maintenance of energy equipment - gas and steam turbines, electric generators. The company provides reliable service of an increasing number of combined-cycle gas power plants, which are the basic ones in the energy system of the Russian Federation.

 

22 Investigation of interchangeability of parts made by 3D printing from polymeric materials in the process of operational repair

Key words: operational repair, additive technologies, 3D-printing, mobile repair complexes, reverse engineering, gas turbine engines, strength, harmonic vibrations, thermal state

Abstract

In the modern world one of the priorities of technological progress is the development of advanced production technologies, one of such technologies is additive manufacturing, which can be realized in autonomous mobile complexes for operational repair. The essence of such complexes is in emergency recovery of the working state of the object, in cases of distance from repair centers. Such complexes are actively used in many countries, which allowed them to increase the service life and resource of operating objects.

This article studies the feasibility of using parts made of polymeric materials with the help of additive technologies for operational repair on the example of a part installed on a gas turbine engine (GTE).

The study is carried out by numerical modeling of real working conditions for two geometrically identical parts made of different materials (silumin and polyamide-12), with the following estimation of thermal state, static and dynamic strength.

The authors have modeled close to reality operating conditions of the case, evaluated the results obtained and concluded about the possibility and feasibility of using parts made of polymer material for operational repair.

 

30 Evolution of filtration systems and use of highly effective HEPA filters

Key words: gas turbine plant, inlet air filtration system, preparation of the GTP working fluid, air pollution, GTP power degradation

Abstract

The paper considers one of the main problems of gas turbines – the quality of preparation of the working fluid of gas turbine plant and protection of the engine from ingress of foreign particles. Atmospheric air contains a huge amount of impurities, so incoming air filtration systems are necessary for any gas turbine. From simple coarse particulate removal systems, they have evolved into sophisticated filtration systems that remove both solid and liquid particles. This is due to the fact that gas turbines are becoming increasingly sensitive to foreign particles entering it, which in turn is associated with an increase in operating temperatures and an increase in air consumption during operation of modern gas turbine engines. The poor quality of the incoming air can significantly affect the operation, performance and service life of the gas turbine engine.

The consequences of poor-quality air treatment are pollution, erosion and corrosion – these processes lead to degradation of gas turbine power. To minimize this effect, high-performance HEPA filters are installed in the inlet air filter unit of GTP as the final stage of purification. But due to the wide range of particle sizes contained in atmospheric air pre-cleaning filters are necessary.

 

36 The first experience of GTU-25P application for LNG production

Since 2021, the Yamal LNG project (NOVATEK PJSC) has been operating gas pumping unit for the production of liquefied natural gas (LNG). The drive of the LNG compressor unit is a GTU-25P gas turbine unit with a PS-90GP-25 engine developed and manufactured by UEC-Aviadvigatel and UEC-Perm Motors (part of the United Engine Corporation Rostec). The production and sale of liquefied natural gas is one of the most rapidly developing segments of the global energy sector. Today, LNG production in Russia is based on licensed technologies implemented by foreign contractors using imported gas turbine, compressor and heat exchange equipment. Therefore, LNG production in the Russian Federation is critically dependent on imported technologies. Their use is directly associated with significant risks of both a price nature (due to changes in exchange rates) and sanctions pressure.

 

40 Increasing the maintenance interval for SGT5-2000E and SGT5-4000F gas turbines

Since 2002, MGTT LLC has been engaged in its own department of service engineers for automation systems of power units. During this time, they have carried out a complex of works at more than 30 power plants. Currently, the company's specialists carry out design-oriented development and modernization of the hardware and software of gas turbine plants automatic-control system according to customer requirements, preparation and conducting acceptance tests of the GTP control equipment using their own software and hardware simulator.

 

42 Ural Vibration Laboratory NPP: a systematic approach to building a life cycle management system for power equipment

The knowledge intensity and complexity of the tasks that need to be solved within the framework of building a life cycle management system for turbine equipment dictates the need for comprehensive research on an industry scale. They should be aimed at improving existing and developing fundamentally new approaches and methods for monitoring, diagnostics, commissioning, as well as organizing repair and maintenance services. The modern concept of life cycle management should meet current realities and be based on the principles of a personalized approach to assessing the technical condition of turbine plants.

 

48 Localization of remote digital services of power plants

The remote monitoring center of MGTT LLC allows not only to improve the preparation of maintenance of power plants, but also to detect malfunctions in their operation before critical situations arise, to give customers recommendations on defects in advance, as well as to save significant resources related to repair and replacement of equipment. Thanks to the competencies of the service department of MGTT LLC and the collected database on the operation of power plants, specialists manage to prevent potential emergencies, effectively identify and eliminate malfunctions in the operation of power plants, which in turn ensures the continuity of operation of power facilities, with minimal delays. The Remote monitoring Center of the MGTT company has all the necessary competencies for monitoring, diagnostics and engineering analysis of causes of deviations in the operation parameters of equipment.

 

52 Research of axial compressor blades erosive wear influence on their strength characteristics

Key words: gas turbine plant, axial compressor, erosive wear, digital simulation, static strength, modal analysis

Abstract

The paper presents the results of a study of the influence of erosive wear on the strength characteristics of the working blades of an axial compressor. The problem of erosion and its impact on various operating characteristics of both an axial compressor and the entire gas turbine plant is discussed. The purpose of the work is formulated as an assessment of the influence of erosive wear on strength and vibration reliability. The working blade of the model transonic stage of the NASA Stage 37 axial compressor was chosen as the object of study in the work. The main method of conducting the research was numerical modeling of the stress-strain state of the working blade of anaxial compressor using the finite element method to evaluate and determine the influence of geometric deviations on its strength and vibration characteristics. The paper presents an analysis of the results of calculations of static and dynamic strength: the position of the stress concentrators on the blade blade was determined and the model was verified based on the values of the maximum stresses arising in this area, the dependence of the change in stress on the change in the mass of the blade caused by erosive wear was formed, a Campbell diagram was constructed and the first six frequencies of natural oscillations, their types and their changes were determined.

 

58 Piston and screw compressor plants designed and manufactured by INGC LLC

During the period from 2011 to 2024 the INGС production and engineering company implemented a significant number of projects for the manufacture and supply of complete modular compressor plants. The company's assets include more than 20 regions where compressor plants are supplied, including the Russian Federation, countries of the near and far abroad –Uzbekistan, Kazakhstan, Congo, Cameroon, etc. Moreover, the geography of supplies of manufactured compressor equipment is constantly expanding: with the participation of specialists from INGC LLC.

 

64 Software complex for calculating the impeller of a centrifugal compressor

Key words: design, preliminary calculation, input parameters, geometry, critical section, losses, centrifugal compressor, impeller, methodology, software package, application

Abstract

The design methodology of the impeller of the centrifugal stage of the compressor includes seven main stages: preliminary calculation, calculation of input section parameters, calculation of geometric characteristics, calculation of critical section parameters, calculation of output section without loss, recalculation of output characteristics taking into account the influence of losses and profiling of the impeller.

At the first stage the main parameters of the compressor are determined. The calculation of the input parameters allows you to set the initial flow conditions at the entrance to the wheel. During the geometry calculation, the dimensions and shape of the wheel blades are designed, which is important for its aerodynamic efficiency. The calculation of the critical section parameters takes into account the conditions in the most loaded zone of the wheel, ensuring an even distribution of pressure and temperature. The evaluation of the parameters of the output section without taking into account losses determines the basic characteristics of the compressor performance.

The next stage includes the calculation of losses, which allows you to more accurately simulate the actual operating conditions of the compressor and adjust the output characteristics taking into account the impact of losses. The final stage is the profiling of the impeller, which optimizes the shape and location of the blades to ensure the most efficient operation of the compressor.

The methodology also provides for the creation of a software package for Windows OS, which facilitates the design process and allows the user to model and evaluate several potential compressor configurations [1].

 

72 Reverse engineering in aircraft engine building solution of the inverse problem in compressor design

Key words: reverse engineering, axial compressor, compressor manufacturing, aviation engine building, RD-33, high-pressure compressor, multistage compressor, given parameters, mathematical modeling, flow part

Abstract

Modern aircraft engines require increasingly high thrust and efficiency to ensure their optimal performance. The key components influencing these indicators include axial compressors.

To modernize their design, it is important to constantly master and implement new calculation methods, design and manufacturing technologies. One of these methods is reverse engineering, which allows you to optimize the design process and significantly reduces the cost of implementing new design and technological solutions.

Reverse engineering in the design of an aircraft compressor is an analysis of existing components in order to further improve its gas dynamic characteristics, which includes a detailed study of the geometry, materials and operating parameters of compressors. The use of reverse engineering in the aviation industry has become especially relevant due to the need to modernize existing early-generation engine models and develop new ones that are more efficient in terms of technical and economic indicators. Thus, the use of reverse engineering in the design of aircraft compressors is a promising way to improve the efficiency and reliability of aircraft engines.

In this study, the application of the reverse engineering method in the design of an aircraft compressor is considered, namely, the solution of the direct and inverse problem in the calculation of a high-pressure compressor (KVD) of an RD-33 engine.

 

80 Investigation of the effect of jet pump ejection

Key words: HPP, PSPP, regulation, jet pump, ejection, Pelton turbine

Abstract

This paper examines the potential use of a jet pump (JP) as a component of the guide apparatus of a Pelton hydroturbine to improve the quality parameters of Pelton hydroturbines. The objective of the research is to determine the impact of the JP on the operating mode of the hydroturbine and its efficiency under various installation options. The article presents a description of the JP's operating principle within the hydraulic system of the HPP's water conduit and details a field experiment. The experiment was conducted to establish the nature of the free jet at the outlet of the jet pump, which in turn determines the feasibility of installing the jet pump in place of the nozzle of the guide apparatus of the Pelton hydroturbine. The experiment involved changing the outlet cross-sectional area of the JP to simulate different positions of the guide apparatus nozzle needle.

A visual assessment of the jet from the jet pump outlet into the atmosphere and its comparison with a jet from a cylindrical nozzle suggests the potential use of the JP as a regulating element for active hydroturbines, as it does not significantly affect the appearance and length of the jet. Thus, this paper represents one stage in the investigation of the feasibility of using the JP as a regulating element for Pelton hydroturbines and opens up prospects for further research in this area.

 

84 Improving the life cycle of steam turbine equipment

Key words: steam turbine, steam turbine plant, product life cycle, life cycle stages, digital transformation life cycle efficiency improving

Abstract

The improvement of tools, tools and techniques to optimize the life cycle of the main and auxiliary steam turbine equipment is an extremely important task.

It is necessary to form a systematic and integrated approach to solving numerous problems that arise at all stages of the equipment life cycle, mainly at the first stages of design and technological preparation of production, which is the most efficient and less costly. Additionally, it is necessary to analyze the possibilities and enhance the recoverable technical and economic effect from the introduction and improvement of equipment design and at the next stages of the life cycle, starting from production and operation to maintenance and repair. This makes it possible to achieve a greater effect than the implementation of measures such as improving operating modes, maintenance programs, repair technologies, etc. at these stages.

The article shows that the solution of equipment automation problems can be solved at different levels and with a different degree of autonomy (unit, system, equipment, complex and steam turbine plant) when it is considered taking into account the influence on its parameters and operating modes of adjacent equipment, for example, boiler, generator or other complexes of main and auxiliary equipment the power unit under study, repair technologies, etc [1-5].

 

90 I Conference on the problems of service life extension and improving the reliability of gas turbine plants

The conference, held at the beginning of June at the site of NPO CCTI, was devoted to improving the efficiency of air treatment at the inlet of gas turbine engine and gas turbines lubricating fluids, reducing operating costs, improving the reliability of gas turbines systems and the power plants as a whole. The organizers were NPO CKTI, EMW Filtertechnik rus LLC. Filtration Technical Company LLC, S-Technics LLC. The General Director of the NPO CKTI V.E. Mikhailov addressed the participants with a welcoming speech. He noted the importance of the event, which received a positive response from specialists and became an annual event.