6 Engineers from all over Russia - unite!

A year has passed since the beginning of publication of Turbines and Diesels magazine as a scientific one. We actively present the successes of Russian enterprises, emphasizing that our main task is to unite the Russian engineering community, to present their best developments and experience on the pages of the magazine!

In the issue you will read an interview with the CEO of Rotec Components and Materials LLC, A. M. Ivashchenko, who spoke about the company's achievements and plans. Specialists of Power Machines JSC have prepared a number of publications on the development, production and maintenance of equipment in operation.

On the pages of the issue you will find articles about new developments and best practices of domestic companies. Thus, the article about the completion of a large inspection of a gas turbine at Kirovskaya CHP-3 was prepared by the specialists of Turboservice Rus LLC.

 

8 Today ROTEC KM enterprise has advanced technological capabilities

The development of turbine equipment repair technologies is one of the priorities for maintaining the technological sovereignty of the country.

The ROTEС KM enterprise makes a significant contribution to the development of gas turbine fleet repair technologies, participates in the development and production of Russian gas turbine engines.

Alexander Mikhailovich Ivashchenko, General Director of the company, told us about the achievements and plans of ROTEC Components and Materials LLC.

The company started its activity in 2018 as a division of ROTEC JSC with the launch of the Components and Coatings project.

In 2024, the project became a separate legal entity – ROTEС KM LLC. The main task at the same time was and remains to provide manufacturers of stationary turbine equipment and aircraft engineswith high-tech components.

Today, ROTEC KM has a powerful production base and modern equipment.

 

12 Estimation of thermal state of gas turbine plant in transient operating modes

The paper describes an approach to assessing the thermal state of a gas turbine plant (GTP) in transient operating modes by combining a 1D hydraulic model of the secondary air flow system and a 2D thermomechanical model of the entire engine. The hydraulic calculation is performed in software developed at GTP design bureau of Power Machines JSC. Axisymmetric joint thermal and structural models are formed in Ansys Workbench. To combine these models into a single computational model, a Python programming language code has been developed in which, by successive approximations, the thermal state, mechanical deformations and parameters of secondary air flows are interconnected. The model is designed to assess the thermal state of the gas turbine engine according to the operating cycle, the formation of boundary conditions of the third kind, taking into account the heating of air in the channels of the cooling system. The results obtained can be used to calculate the values of radial and axial gaps between the elements of the rotor and stator and to refine the thermodynamic model of the GTP by taking into account the values of air intake in transient operating modes.

The paper compares the results obtained with a method in which convective boundary conditions are obtained by scaling based on the calculation results of the thermodynamic model of GTP in transient modes. The influence of air heating in the channels of the secondary GTP system on the change in the magnitude of the temperature gradient in the turbine discs during their heating and cooling is considered. Conclusions are made about the applicability of the approaches given in this work to the assessment of the thermal state of the gas turbine engine.

 

18 Investigation of the structure and properties of X12CrMoWVNbN10-1-1 chrome-plated martensitic steel for GTE-65.1 gas turbine disk

In modern power engineering, there is a tendency to increase the operating parameters (temperature, pressure, speed), which requires the use of high-strength alloys, in particular increased heat resistance, which again makes the issue of using martensitic chromium steels relevant [1].

These steels fill the temperature gap between low-alloy steels of the pearlite class and high-alloy steels of the austenitic class. The use of 12% chromium steels is designed for a temperature range of 560...620 оС, while the main advantage compared to low- and medium-alloy steels of the pearlite class is increased resistance to gas corrosion [1], and the main disadvantage is reduced viscoplastic characteristics.

By the order of the Power Machines company, blanks made of steel X12CrMoWVNbN1011 for the GTE-65 project were manufactured at the facilities of AEM-Spetstal LLC (a branch of AEM-Technologies JSC) and using the technology of this enterprise. The properties of the blanks were regulated by the technical requirements (TR) for delivery.

The paper investigates the uniformity of properties and structure over the cross section of the disk after a full manufacturing cycle and the correlation of the properties of the transfer samples with the properties in the volume of the disk. Directions for correcting the technology are proposed, and the results of testing workpieces after adjustments are presented.

 

22 Localization, innovations, new opportunities of MGTT LLC in the maintenance and repair of gas turbines

The Modern Gas Turbine Technologies Company (MGTT LLC) organized and held in October 2024 a regular conference of gas turbine users at its own production site in the Leningrad Region. The event was attended by more than 100 representatives of generating companies from different regions of the Russian Federation and the Republic of Belarus. The participants of the conference, specialists operating SGT5–2000E/GTE-160 and SGT5-4000F gas turbines, received first-hand up-to-date information about the capabilities and competencies of MGTT to provide high-power GT service. Customers trust MGTT to solve various issues arising during the operation of complex equipment, based on the fact that since 2011 MGTT has performed more than 300 inspections of gas turbines, including more than 50 major inspections.

 

26 Analysis of the temperature state of the cooled turbine blade of high power during the transition from air to steam cooling

Recently, our country has been actively creating a line of its own gas turbines. Along with the development and commissioning of mass production of domestic high-power GTP, the relevance of researching possible options for upgrading such turbines is increasing, one of which is cooling the hot path of the turbine unit, which reduces thermal loads of the body, thereby increasing the resource and efficiency of operation. A promising method is steam cooling, which is able to absorb more heat by changing the aggregate state.

The article presents the results of a study of the effect of the cooler type on the temperature state of the blades of stationary high-power turbines using the example of the guide blade of the 1st stage SGT5-2000E (GTE-160). The difference in the efficiency of air and steam cooling is shown, and the advantages of using steam as a cooler for high-temperature stationary gas turbine units are substantiated. The introduction of steam cooling reduces the temperature of the blade on the entire surface of the pen, thereby significantly increasing its service life.

 

32 Perm Engines Research and Production Complex 90 years in aviation and industrial turbine building

Since 1994, Perm Motors has produced and delivered to customers 1,280 GTP for mechanical and power drive with a capacity from 2.5 to 25 MW, their total operating time as of 07.01.2024 exceeded 44.4 million hours.

Of these: GTP for mechanical drive – 822 units with a total operating time of 24.3 million hours; GTP for gas turbine power units (GTEA) – 458 units with a total operating time of 20.1 million hours.

UEC-Aviadvigatel used two fundamentally different technical approaches in the development of industrial GTP based on aviation prototypes. Low-power GTP in the 2.5...6.0 MW class based on a third-generation D-30-3 turbofan engine with relatively moderate cycle parameters were developed while maintaining the power circuit, the main structural components (gas generator, low-pressure turbine, outer circuit housing, etc.), technologies and materials of the basic aircraft engine.

 

40 New generation AL-41ST-25 gas turbine engine at Arskaya compressor station

In order to develop the program of expanding the use of AL series industrial engines in the unified gas transportation system of Russia, in 2019, Gazprom PJSC and UEC JSC signed an agreement of intent providing for the creation of a promising new generation AL-41ST-25 gas turbine drive engine. The AL-41ST-25 engine was created as a highly efficient gas turbine drive and is the first product in the model range of AL engines with a nominal capacity of 25...42 MW. The engine developer is the A. Lyulka Design Bureau (a branch of UEC-UMPO PJSC), the manufacturer (assembly and bench tests) is UEC-UMPO PJSC.

It was planned that UEC JSC would develop and manufacture the first prototype engine, and Gazprom PJSC would provide a site for its pilot operation as part of a gas pumping unit at one of the compressor stations.

 

42 Numerical study of GTE centrifugal nozzle characteristics

The paper studies geometric and hydraulic characteristics of a tangential-type centrifugal nozzle with a nozzle diameter of 1.35 mm, a swirl chamber diameter of 2 mm and a swirl arm of 0.7 mm. A comparative analysis of the technique based on the use of semi-empirical dependences with the technique of numerical CFD-calculation of multiphase flow in three-dimensional formulation was also performed. The CFD calculation was based on the RANS model of turbulence (k-ω SST) and the Volume-of-fluid (VOF) method. The calculated data obtained from these techniques were compared with the values obtained from the conducted experiment over the investigated nozzle. The final values indicate a good agreement between the experimental data and the results of both computational techniques.

Also, the article shows and explains the advantages of using numerical methods of calculating centrifugal nozzles in the design and finalization of atomizing devices of gas turbine engines. The CFD calculation method helps to determine with greater accuracy the characteristics of centrifugal nozzles at the early stages of design and to identify their dependence on the changes made to the nozzle geometry.

 

48 INGC manufactures power plants with a capacity of 2 MW based on its own design gas turbine engine

The new development of INGC LLC – GTD AA-2000 is a radial type engine made according to a simple cycle scheme, with a low-emission combustion chamber and having a high degree of reliability and performance (in comparison with a conventional axial GTE). In addition, it has significantly smaller dimensions and weight than gas engine plants of similar capacity. The main components of the engine are an input device and compressor, ignition system and combustion chamber with a fuel collector, turbine, rotor bearing assembly, a set of sensors for monitoring the parameters of gas turbine engine and a turbine/gearbox coupling.

 

50 Computational and experimental analysis of analytical models for estimating energy losses in the grids of turbomachines

One of the key tasks in the design of power plants is to calculate the aerodynamic efficiency of the flow parts of steam and gas turbines. Aerodynamic effectiveness affects efficiency and performance characteristics, which depend on energy losses in the nozzle and working grids. There are a large number of computational methods for estimating losses in the grids of turbomachines. Each of the considered techniques has been developed with certain assumptions, as well as taking into account the geometry of the lattice profile and operating parameters. The results of the numerical estimation of losses may differ and give a result with a greater or lesser error, for example, some techniques may be more accurate for certain ranges of flow velocities or for gratings of a certain geometry, while others may be less accurate or not applicable at all for the conditions under consideration.

The paper analyzes a number of the most commonly used computational models and algorithms for estimating energy losses. To do this, loss calculations were performed using various methods and compared with experimental values of profile losses in the operating speed range in the stages of steam and gas turbines, which were obtained in the laboratory of the Department of Steam and Gas Turbines named after A.V. Shcheglyaev.

 

56 Development of a highly efficient flow part of a 300 MW high-pressure ST cylinder using multi-criteria optimization

The Power Machines JSC company has developed a design methodology for the blade apparatus using an optimization algorithm that allows creating highly efficient flow parts of steam turbines. The creation of highly efficient flow parts of steam turbines is a prerequisite for competitiveness in the global market.

Using the example of a steam turbine with a capacity of 300 MW, approaches to optimizing the blade apparatus of the flow part of a high-pressure cylinder (HPC) in order to obtain optimal geometry and increase efficiency are considered.

A series of comparative gas-dynamic calculations in a three-dimensional formulation of the problem was performed, which confirmed the assessment of the increase in efficiency of the new blades in various operating modes of the steam turbine. The optimal safety margin of the new working blades is confirmed by strength calculations using the finite element method.

The design documentation of the HPC-blade unit has been developed, designed for use in projects of new and modernized K, KT type steam turbines (for thermal power plants) with a capacity from 300 to 350 MW.

 

62 Introduction and implementation of modular steam turbine designs

Special issues of life cycle maintenance (LC) of steam turbines and steam turbine plants are considered, the solution of which is aimed at reduction of the cost of design and technological preparation of production and manufacturing itself, meeting the requirements of the project and the interests of the customer who will operate such equipment in specific conditions of the facility.

To achieve these goals, tasks are being solved to increase the level of unification by introducing modular design, reducing the range of modules used for equipment layout, as well as reducing the range of turbine equipment that meets all market demands. The improvement of instruments and tools for the development, production, operation and life cycle management of main and auxiliary equipment makes it possible to optimize the processes of life cycle maintenance at all stages – from development to operation and maintenance of equipment.

This, in turn, leads to the elimination of duplication of work, structures and technologies, builds a common line of development of enterprises participating in the equipment life cycle maintenance in favor of a systematic approach while increasing the level of unification of equipment and processes, and therefore to increase the efficiency of life cycle maintenance of the equipment in question.

 

68 The drive unit for gas pumping and power plants manufactured by INGC LLC

Since 2015, the INGC production and engineering company has been developing and manufacturing gas pumping and power plants of the Irtysh series with a gas turbine drive. During the period from 2015 to 2024, the company implemented projects for the supply of complete gas pumping units (GPU) with a gas turbine drive in the power range of 6...16 MW, which include drive units of its own design. In addition to the GPU, the drive unit is also used as part of gas turbine power plants in the power range of 6...12 MW.

Depending on the customer's requirements, INGC LLC produces units in hangar, block-modular, block-container shelters or without shelters – for installation in existing or newly built customer workshops.

 

72 The development of sports cars – is a step in the development of students - future Russian engineers

Motorsport is a platform for innovation and technological progress. Many of the technologies developed for racing cars are subsequently used in production cars, improving their safety, efficiency and environmental friendliness. In addition, motorsport contributes to economic development by attracting investments in the automotive and related industries.

The article presents a number of systems that are among the key ones for racing cars, using the example of the Formula Student Polytech North Capital Motorsport team car. The algorithms and schemes of the electronic car control system are presented, the error of measuring the suspension stroke ± 2.5 mm is estimated. The gearshift device described in the work reduces the gear change time to 0.2 c. The exhaust system, made using additive technologies, allows you to achieve a noise level of up to 109 dB without increasing the back pressure.

The article includes a description of the stages of development of the aerodynamic package. The application of OptimumLap software to determine the target characteristics of an aerodynamic package is considered. The above prototypes of the deformable element assume the use of programmable deformation technology.

 

80 Turboservice Rus LLC has completed a major inspection of the gas turbine at Kirovskaya CHP-3

The GTE-160 gas turbine engine manufactured by Power Machines JSC with a capacity of 160 MW has been operated at the CHP as part of the combined cycle gas plant PGU-220 since August 2014. During this time, the plant has worked more than 72,000 equivalent hours.

 

84 Adsorption and application of compressed cellulose for filtration of sludge, varnish and minimization of varnish deposits (part 2)

There are two main types of adsorption – physical and chemical (physiosorption and chemosorption, respectively). Physical absorption depends on the weak physical attraction of the solid phase (adsorption filter material) to the components in the liquid phase (varnish molecules).

Although some aspects of lubricant filtration imply that the absorption of varnish particles may include chemisorption, it is more likely that their absorption is controlled by physical adsorption. The forces of physical adsorption are divided into two main categories: Van der Waals forces (or dispersion forces) and electrostatic forces.

The oil filtration equipment manufactured by FTC is a combination of deep filters, ion exchange elements, filters with dry sorbent or vacuum dehydrators, which can be used separately, simultaneously or sequentially.

 

88 Nevsky Energy Prospect 2024. The future of the Russian energy complex

Nevsky Energy Perspective-2024 scientific and technical conference was held n September 11-13. It was organized by NPO CKTI JSC and dedicated to the problems of the power engineering complex of the Russian Federation. The event brought together leading experts, scientists, major representatives of the energy industry and relevant organizations.The conference opened a series of events on the eve of the 100th anniversary of the NPO CKTI and became a platform for the exchange of experience and knowledge of leading experts in the energy industry.The conference was attended by representatives of the Ministry of Industry and Trade of the Russian Federation, the Committee on Industrial Policy, Innovation and Trade of St. Petersburg, specialists from Gazprom Energoholding, Inter RAO, MPEI national research institute, Power Machines JSC and other enterprises working in the field of energy.

 

92 LXXI Scientific and technical session of the Russian Academy of Sciences on problems of gas turbines

The session has been held at various sites in Russia for 71 years now, and employees of research institutes and specialized universities, representatives of design organizations and leading engine-building enterprises specializing in the development, production and operation of gas turbineequipment actively participate in it.

The main topic of this session was the scientific and technical problems of complete localization, design, production and maintenance of stationary gas turbine plants in Russian Federation.

The session is timed to coincide with the anniversaries of the Perm engine building enterprises: the 85th anniversary of UEC-Aviadvigatel design bureau and the 90th anniversary of UEC-Perm Enginesserial plant. Over the past 32 years, Perm engine builders have developed and mass-produced two families of GTP for gas pumping units and power plants rated at 2.5…25 MW.

  

94 Russian Motors JSC has been in motion for 150 years

The creation of engines that ensure the operation of a variety of technically complex equipment and structures is a strategically important task today. It is solved by enterprises with a decent history, rich experience and a high level of competence. One of the flagships can be called a company, the origin of which was in the XIX century. Today, RUMO JSC celebrates its 150th anniversary: for a century and a half it has been in the leading positions of marine engine building, energy and oil and gas engineering.

By the one and a half century anniversary, RUMO JSC came up as a large-scale enterprise operating on an area of 9 hectares, with workshops for mechanical processing, welding and procurement, assembly and storage.

  

96 Analyzing the effect of power loss factor on the cost of seawater desalination using nuclear power plant

In the past decade, studies on the economic efficiency of nuclear energy for water desalination have increased, showcasing its successful use in some countries. The study suggests that highlighting the economic benefits and efficiency of cogeneration systems could help gain government backing.

The main objective of the work is to assess the power loss ratio (PLR) in multi-effect desalination systems in conjunction with nuclear power plants. The research connects technical and economic factors, indicating that while increased water production raises costs, better production rates can lower overall energy and operational expenses.

In particular, PLR and efficiency of a cogeneration plant, which showed a PLR of 7.6% alongside increased total heat costs, creating an optimal scenario for minimizing heat expenses. Additionally, it allows for a tenfold increase in daily water output at low costs while maintaining high operational efficiency.

  

104 Assessment of system reliability indicators of compressor stations and cross-country gas pipelines

The article presents new methodological approaches in the process of assessing the system reliability of modern main gas pipelines (MG).

Considering MG as a complex technical system, these approaches include a combination of three basic components: loss of productivity (throughput) during shutdown of gas pumping units, considered as a parametric failure of MG; reliability indicators of GPU (traditional indicators of availability and technical use); dimension of GPU and, as a result. As a result their number at the compressor station and in cross-country gas pipeline.

Methods of analysis: modification of hydraulic calculations, probabilistic estimation of maintenance and repair time and forced downtime, elements of probabilistic combinatorics.

It is proposed to perform GPU redundancy according to the scheme: the number of installed units for the MG design throughput mode is assumed to be equal to the number of working + repair GPU necessary to ensure all types of maintenance and repair, i.e. without backup GPU, one (or more) backup unit should always be provided for the design performance mode.

A universal formula for estimating the MG reliability coefficient and recommendations for its application at the pre-design stage, when specific characteristics of gas compressor equipment have not yet been selected, are proposed.

 

112 Evaluation of interfaces of diagnostic and monitoring systems of power equipment according to the method of preliminary usability analysis

The article shows, using selected examples, the possibility of using the preliminary usability analysis technique to evaluate the interfaces of technical diagnostics systems (TDS). The quality of user interaction with the TDS is largely determined by the degree of usability. There are a large number of criteria for evaluating this kind of convenience: both general principles that cannot be accurately measured, and quite specific metrics that are mathematically calculated based on the results of testing a software product on users. However, STD users are a narrow circle of highly qualified specialists with limited time, which significantly narrows the possibilities for conducting full–scale testing. Therefore, the authors propose to introduce the stage of preliminary evaluation of the system (PES) into the design process of the TDS, which will significantly reduce the time spent at the usability testing stage. The PES includes an expert assessment of the interface according to a number of parameters proposed specifically for the preliminary analysis of the convenience of the TDS, as well as an assessment of the interface by users according to the UMUX-Lite indicator.

The article focuses on the practical application of the «preliminary» convenience analysis for the evaluation of TDS. Examples of using the proposed methodology on real systems demonstrate its effectiveness and expediency of use in the energy industry.