6 The engine is the heart of any machine!

 

The applications of internal combustion engines, gas and steam engines, and hydraulic turbines are very diverse. In the new publications we will tell more about research, new developments and operating experience of engines for various purposes.

We start the new 2025 year with a new General Partner, TurboService Rus LLC, which, without exaggeration, has become a driving force in the Russian power industry and power engineering industry for the development of gas turbine unit service. It is known that the engine is the «heart» of a car, so it will be interesting to read an interview with E. V. Nikolaev, a multiple winner of the Dakar and Silk Way races, the head of the KAMAZ-Master sports team, Honored Master of Sports of Russia.

In this issue, we're bringing you several articles about new companies. One of them is about our partner, RENN Group, which has many years of successful experience in implementing projects in various industrial fields.

 

 

8 We are driven by the will to win and unwavering confidence in our vehicles!

 

While our successes in ballet and gymnastics are recognized worldwide, we must also highlight another source of national pride–the KAMAZ-Master team, the undisputed world leader in off-road truck racing.

Each victory is the result of immense effort and dedication from a diverse team of specialists–pilots, engine builders, electronic engineers, designers, navigators, mechanics and many others.

 

 

12 RENN Group: bringing together the best

 

RENN Group has many years of successful experience in executing projects across various industries. The company’s specialists provide a wide range of services in the construction of power engineering, petrochemical, and oil refining facilities.

The history of the RENN Group dates back to 2009 when the idea emerged to leverage extensive experience gained at leading heavy engineering enterprises to establish an independent business.

Over the past 15 years, the company has developed into a diversified and expansive business, continuously growing and evolving.

Today, the group includes LLC RENN Management Company (St. Petersburg), LLC RENN-K (Kazan), and LLC ARTEK (Kazan). Its core activities encompass the supply of complex process equipment for power engineering, petrochemical, and oil refining enterprises, as well as construction, installation, commissioning, service, and repair of steam and gas turbines.

 

 

18 Rotec KM tested promising Russian alloys for gas turbine engines

 

The article offers solutions related to the problem of shortage of modern heat-resistant alloys in the engineering industry in general and in the production of gas turbine engines in particular. Modern alloys of foreign production have better physical and mechanical properties in comparison with the Russian analogs developed in the 1970s, which allows to obtain higher performance characteristics of manufactured parts, and as a consequence increases the efficiency of the turbine. There is also a lag in the development of the technology of cold rolling of 0.05...0.3 mm thick foil, as a result of which the obtained raw material in the state of delivery requires additional vacuum heat treatment.

 

ROTEС KM and one of the largest domestic metallurgical companies are developing and testing promising alloys for their further application in the production and repair of parts and assemblies of gas turbine engines. The results of studies of chemical and mechanical properties of samples of alloys CHN78T and NN718 (analog Inconel 718) in the state of delivery and after vacuum heat treatment are given. Samples of manufactured parts and assemblies of gas turbine flow path seals are shown. Recommendations on direction of researches for improvement of mechanical properties are given. Further plans for research and mastering of production of promising grades of Hastelloy X and Haynes-214 alloys are outlined.

 

 

20 Development of a hybrid gas-thermomechanical model of complete gas turbine engine

 

This paper presents a thermomechanical model for a full gas turbine engine, incorporating coupling between hydraulic and thermo-structural solvers. The dynamics of secondary air flow are calculated using 1D-methods within the Simcenter Flomaster package, which provides gas temperatures and heat transfer coefficients to the thermo-structural solver. Solid temperature and deformation are computed using the finite element method within the Simcenter 3D-package, where solid temperatures and labyrinth seal gap values are then transferred back to the hydraulic solver. Data exchange between the two solvers is facilitated by a custom-developed program code. The thermo-structural model incorporates a combination of 2D-axisymmetric elements, plane-stress elements, and 3D-periodic sectors, the latter used for modeling disk locks and blades. This paper presents the results of coupled static and transient flight cycle simulations, considering axisymmetric loads such as centrifugal and aerodynamic forces, as well as thermal expansion of components. Key findings include the evolution of gaps in labyrinth seals and blade tip clearances throughout a flight cycle, along with temperature distributions at critical engine points.

 

 

28 Small-Capacity gas  turbines in the context of energy policy

 

Small-scale distributed generation plays a crucial role in a country’s overall energy system–not because of the volume of energy supplied, but due to its strategic importance. The primary value of small-scale power generation lies in its ability to bridge energy gaps where there is no access to centralized infrastructure, as well as in the mobility and rapid deployment of its solutions. A prime example is the GT-009GT gas turbines from GT Energo, which demonstrate how small-scale power generation is adapting to the evolving energy policy landscape in Russia.

 

 

32 Domestic gas turbine power unit GTE-110M operates as part of Udarnaya TPP

 

The use of Russian-made high-power gas turbine engines allows not only to improve the state of the energy sector of the Russian Federation. As a result of wide cooperation between enterprises, scientific institutes, and design bureaus, many industries in the country are actively developing.

As part of the Import Substitution Program in the field of gas turbine power equipment, ODK-TBM is actively developing cooperative relations with Russian machine-building enterprises.

 

 

38 Testing of air filters and data evaluation

 

Air filtration technologies are widely used across various industries, including residential, industrial, medical, and power generation applications. However, each sector imposes different requirements on air filters, such as particle capture efficiency, particle slip, and dust-holding capacity.

In recent years, numerous standards have been introduced to classify air filters, each tailored to a specific application. Some standards establish minimum efficiency levels for general-purpose filters, while others define integral and localized efficiencies for high-efficiency filters.

A relatively new concept, minimum fractional efficiency (ePM), has also emerged, with distinct methodologies for its determination.

Choosing the right air filter requires an understanding of these classifications. Selection should be based not only on technical specifications but also on the specific conditions of use. A clear understanding of current standards and regulatory requirements ensures optimal air filtration for various applications.

This article provides an overview of current classification and testing standards in Russia to help guide informed decision-making.

 

 

46 Comparison of mathematical modeling of processes in the GTU T32 coflowing swirl apparatus with a numerical experiment

 

As part of the modernization program for the T32 gas turbine plant, efforts are underway to increase the gas temperature before the high-pressure turbine while extending the lifespan of blade units to meet modern standards. Achieving these objectives relies heavily on the efficiency and cost-effectiveness of turbine cooling, particularly in the cooling of vane devices within the working rings. These components are cooled using air drawn from the stator elements of the compressor into the turbine rotor of the gas generator.

This article demonstrates how mathematical modeling enables reliable multivariate calculations of cooling air outflow from the swirling apparatus. As part of the T32 gas generator modernization at NZL [13, 14], the TANPG (Twisting Aerodynamic Nozzle Profile Grille) software was developed and is being used to calculate exhaust gas behavior from the swirling apparatus into the turbine rotor.

To ensure the accuracy and reliability of the mathematical model embedded in the software, verification studies were conducted. Using TANPG, the mathematical model’s adequacy was assessed by comparing its results with reference calculations.

This paper presents the key results of the verification calculations, including the one-dimensional calculation method and a simplified flowchart of the program, demonstrating the effectiveness of the applied modeling approach.

 

 

52 Application of the features of giant shark mouth structure for the supply lines of axial hydro turbines

 

This paper explores the feasibility of using a Giant Shark Mouth-Shaped Input Device (GSMSID) as an intake system for an axial hydraulic turbine to enhance the performance of hydraulic units. The study aims to evaluate the impact of the geometric characteristics of the input device on the turbine’s operational parameters and efficiency across different configurations.

To identify the most energy-efficient intake geometry, CFD simulations were conducted. Additionally, a full-scale experiment was performed to validate the hydrodynamic calculations of both the hydraulic unit as a whole and the GSMSID in particular.

Experimental results demonstrated the feasibility of integrating GSMSID at the inlet of an axial hydraulic turbine as an alternative to conventional intake designs. Tests compared the GSMSID-equipped turbine with a toroidal inlet of similar shape and dimensions, revealing an increase in power output.

This study serves as a preliminary investigation into the potential of GSMSID as a more effective intake solution for axial hydraulic turbines, laying the foundation for further research and development in this field.

 

 

58 Development and experimental studies of a model prototype prototype feed electric pump PEN-290-115

 

This article presents the results of numerical and experimental studies on a model prototype of the PEN-290-115 feed pump, developed by the Hydromechanical Engineering Laboratory of Peter the Great St. Petersburg Polytechnic University for JSC Power Machines. The research was conducted as part of the project «Development of RCDs for High-Efficiency Pump Units of Large Capacity for Thermal Power Plants and Organization of Their Production», supported by the Ministry of Education and Science of Russia under Agreement No. 075-11-2021-044, dated June 25, 2021.

The PEN-290-115 pump is designed to operate as part of the APE-290-115 unit, supplying feed water to heat recovery steam generators (HRSGs) in CCPP-230 and CCPP-460 thermal power plants.

The research focuses on a model prototype of the PEN-290-115 feed pump, consisting of three stages identical to the full-scale pump and tested at reduced rotor speeds. The article provides a detailed description of the hydrodynamic problem formulation, where the boundary conditions match those of the experiment, ensuring accurate validation of the numerical model.

 

 

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.

 

63 Modernized DGS on Paramushir Island, Kurilly Islands

 

VladModul company completed overhauls of 4 Caterpillar 3516V diesel generator sets with capacity of 1600 kW each, voltage 6,300 V, installed at the power plant of Severo-Kurilsk.

All repairs were performed within the planned timeframe. In addition, overhauls of high-voltage generators were performed, as well as repairs of exhaust gas heat recovery system equipment and Terberg control system equipment.

The specialists of Vlad-Modul Ltd. carried out full functional diagnostics, examined electronic modules and replaced controllers.

 

 

64 Tatenergo JSC and Turboservice Rus LLC: successful partnership in the field of gas turbine maintenance at CHPP-1 and CHPP-2 in Kazan

 

Turboservice, one of the largest gas turbinemaintenance and repair companies in Russia, signed a long-term contract with Tatenergo JSC for maintenance of four gas turbine units at Kazan CHPP-1 and CHPP-2. The term of the contract is 10 years. Within the framework of the agreement, the company will perform a full range of works, including works directly at the plant, repair of components, supply of necessary spare parts and technical support. One of the key stages of the partnership will be the main inspections and repair work on gas turbines of Kazan CHPPs.

 

 

66 Modular repair of GTE-25PA under operating conditions significantly reduces unit downtime

 

Modular repair of Perm aircraft engines under operating conditions has also become widespread in the power industry. Specialists of ODK-Aviaadvigatel JSC developed a technology for replacement of free turbine modules, high and low pressure turbines, as well as a set of flame tubes of PS-90GP-25A engine under operating conditions.

 

 

68 Designing the future: energy waste utilization plant in the Republic of Tatarstan

 

Caring for future generations means being mindful of natural resources and the ecology of our land. One of the key tasks in this regard is the safe and efficient utilization of industrial and household waste, a challenge being addressed by Rotec's Design Solutions Center.

An incineration plant is currently under construction in the Zelenodolsk municipal district of the Republic of Tatarstan, with a capacity to process 550,000 tons of solid waste per year. This thermal neutralization plant is not only a solution to the region’s environmental challenges but also represents an important step towards enhancing the area’s infrastructure. As a result of this project, the quality of life for the local population will improve, and the environmental conditions in the republic will see significant benefits. The Rotec Design Solutions Center continues to work diligently on developing the design documentation for the facility, with the most critical construction stages ahead.

 

 

70 Principles of unification of GPU of the Irtysh series with gas turbine drives

 

Currently, the fleet of gas compressor units (GPU) supplied by various enterprises is characterized by a wide variety of main equipment–including drives, compressors, automatic control systems, and supporting systems–as well as numerous unit configurations, such as hangar, block-modular, and block-container designs. These units are deployed in diverse climatic zones, and this variety is driven by the specific requirements of customers, as well as political and economic factors.

The production of unified units is crucial for meeting deadlines for design documentation and material delivery, as well as for implementing proven technical solutions that ensure the required level of unit quality. For consumers, this unification leads to reduced capital expenditures and shorter commissioning times for gas transportation facilities.

This article outlines the fundamental principles of unifying the Gas Compressor Units (GPU) of the Irtysh series, developed and manufactured by INGC LLC. The approach follows a two-level separation method, categorized by power range of drives and systems, and their corresponding components. The main design solutions are demonstrated through examples of units with an 8 MW capacity. Additionally, the development results of the unified UGPA-16(25), created based on the technical requirements of Gazprom PJSC, are discussed.

 

 

78 Experimental study of Azipod electric motor complex when the ship is operating in ice

 

This paper presents the initial results of an experimental study on the dynamics of the propulsion system of gas carriers equipped with electric propeller columns (ECPs) and gas-piston generator drive engines when operating in ice.

Offshore gas carriers designed for operation in the Arctic often utilize electric propulsion to enhance maneuverability. These vessels typically use part of the transported gas for propulsion, and gas-piston engines drive the generators. However, the operation of such vessels in Arctic conditions has revealed significant challenges related to the dynamics of the propulsion system.

The article discusses the initial results of the experimental study of the dynamics of the propulsion system aboard the gas carrier «Christophe de Margerie» (operated by Sovcomflot) during a three-month Arctic operation. These vessels are Arc7 Arctic class and are equipped with three Azipod type VDCs (each with 15 MW capacity), as well as a system for measuring and recording propulsion system parameters. This setup enabled the collection of unique experimental data across all operating modes of the vessel.

The use of this data facilitates the development of a mathematical model of the propulsion complex, which can be used to study its dynamics in greater depth. The results of this study are also relevant for newly built gas carriers, such as the «Alexey Kosygin» type, currently under construction at the «Zvezda» Shipbuilding Complex.

 

 

84 Joint productions of Intertehelektro and CNPC Jichai companies will provide the market with modern HPPPs

 

Joint production of power equipment will ensure not only the assembly of power units in Russia, but also their quality maintenance, scheduled and unscheduled repairs, and timely delivery of spare parts.

 

 

88 Some development opportunities gas turbines

 

Increasing the efficiency and power of Gas Turbine Units (GTUs) can be achieved by raising the temperature of the working fluid. This is not done by simply increasing the initial temperature, which would significantly raise the cost of the GTU, but instead by enhancing the average temperature during the expansion process in the turbine. This concept is illustrated through several patents for inventions. In practice, this increase in efficiency is achieved by complicating the cycle. One method is to use a second combustion chamber (CC) between the turbine expansion stages, which necessitates the lengthening of the GTD shaft. In the international patent classification (IPC), this is categorized under the F02C subclass and further refined in subgroup F02C3/14, which is characterized by the arrangement of the combustion chamber. One patented idea involves fuel injection through numerous microchannels into the flowing cavity of the turbine (subgroup F02C3/16). The fuel undergoes spontaneous combustion due to the high temperature of the working fluid. However, to achieve the optimal balance between power and efficiency, it is necessary to increase pressure. This can be done by employing the injection effect (subgroup F02C3/32), which results from a local increase in the volume of the working fluid in the space between the turbine nozzle blades with a carefully designed aerodynamic profile.

In this system, additional guide vanes with nozzles are placed between the nozzle vanes of the second expansion stage. These nozzles are equipped with channels to supply additional fuel and cooling air. The outlet is positioned at the narrowest cross-section between adjacent nozzle vanes and acts as a flow turbulator, similar to the angle combustion stabilizers used in conventional micro-flare burners. This ensures combustion stability, similar to how an afterburner chamber operates in aircraft gas turbine engines (GTEs).

 

 

95 Golden Lightning, the main award in the field of distributed power generation, was presented in Moscow

 

Last December, the X International Award «Distributed Power Generation – Great Achievements» was presented at the headquarters of Business Russia.

The prestigious award for the best projects in the field of small-scale energy was establishedby the Distributed Power Generation Association with the support of Business Russia and aroused great interest among specialized energy enterprises, business and authorities. Representatives of more than 100 companies came to the Russian capital for the award ceremony.