6 Russian gas turbine power industry. We produce small and large turbines

Significant interest in gas turbine equipment in the country from oil and gas and energy companies has allowed us to step up work at Russian enterprises to create new engines and power plants based on them. This issue is dedicated to our magazine's partner, INGK LLC, which is celebrating its 15th anniversary this year. Oleg Vitalievich Bychkov spoke about the results of the company's approach to this date in an interview. From it, you will learn about the company's successes and achievements in the development and production of high-tech energy equipment. Oleg Vitalievich told the editorial board of the magazine about the actual and potential development of production facilities and the range of products. He also highlighted the company's unique projects implemented in various regions of the country and the world.

 

8 We are confident in our capabilities, expanding our production and competencies

INGC LLC is a modern industrial-engineering company with its own production of complete compressor and power equipment of GPU of full cycle. Oleg Vitalievich Bychkov, General Director of INGC LLC, told about the expansion of production, development of new products and several other important matters.

 

12 We run high voltage

Due to its production and engineering potential, experience of design, construction and adjustment works the enterprise AES-Komplekt occupies a strong position in the market of high-voltage electrical equipment in the Republic of Belarus. AES-Komplekt has been working in the energy sector for more than 20 years. Together with Belenergo, the company has brought to the market a model range of the latest equipment for voltages 10-35-110 kV. The reliability of the presented equipment is confirmed by 5-year manufacturer's warranty and positive experience of its operation.

 

16 Russia has mastered the production of components of the hot part of the combustion chamber of the AE64.3A turbine

Russian high-tech enterprises, design bureaus and specialized scientific institutes are working intensively to master repair technologies and produce on an industrial scale high-temperature elements of the hot part of foreign-made gas turbine units.

 

20 Power units manufactured by INGC LLC

INGC Production and Engineering Company is one of the few full-cycle enterprises in the country. The company's engineers create GPU of any capacity. Gas turbine power plants and gas turbine units created at the company operate in the harshest climatic conditions, at extreme temperatures, dustiness and on offshore platforms. Experience in engine aggregation of the world's leading manufacturers allows to realize the most complex project tasks. Since 2015, INGC has been developing and manufacturing gas compressor and power units of Irtysh series with gas turbine drive. Over the past period, projects for the delivery of complete gas turbine power units (GTPU) with a capacity of 6 and 12 MW have been implemented.

 

24 Alternative fuels for aviation gas turbine engines: emission level

Under the depletion of traditional energy resources and the global trend toward reducing pollutant and greenhouse gas emissions, the aviation industry faces the necessity of transitioning to alternative energy sources. This paper provides an overview of harmful emissions from aviation gas turbine engines in Russia’s aircraft fleet. The article analyzes various alternative fuels that can be used in aviation engines.

Fuels derived from fossil and renewable resources, such as liquefied natural gas (LNG), liquid hydrogen, Fischer-Tropsch synthetic fuel, and bio-derived fuels, particularly bioethanol and biodiesel.

The study examines the potential environmental benefits of these fuels and their impact on aircraft performance. Special attention is given to safety issues and technological compatibility with existing aviation systems. Based on the analysis, conclusions are drawn regarding the feasibility of implementing alternative fuels. The conducted review of alternative energy sources for aviation gas turbine engines (AGTEs) provides a comprehensive understanding of the current state and future prospects of this industry.The article may be of scientific interest to aviation industry specialists, environmentalists, and developers of new energy solutions.

 

32 Modern service of power equipment

The article describes modern approaches, solutions, technologies and tools that are part of the profile of modern power equipment service. Today the modern format of support of the life cycle of power equipment, and the service stage in particular, is the technology of restoration of high-temperature resource components, the introduction of repair of products with removal and restoration of thermal barrier coatings, the use of polymeric, composite materials and high-temperature plastics, expertise of operation of main and auxiliary equipment using digital monitoring and diagnostic tools, phased introduction and use of the modular concept in modernizations and equipment renovations, application of additive methods in component remanufacturing and spare parts manufacturing. Special attention is paid to the concept of long-term equipment service (LES) as a key direction in the transformation of the service model. Of particular importance is the introduction of polymer materials in the design of bearing arrangements. Their use ensures stable operation under conditions of aggressive media, variable loads and limited lubrication. The technical advantages of such solutions confirm their prospectivity in modern gas turbine plants.

 

38 ODK-Aviadvigatel gas turbine drives for technical re-equipment of gas compressor stations

Perm Design Bureau ODK-Aviadvigatel is the leading enterprise of the Russian aircraft engine industry in the development, production and maintenance of aircraft derivatives of gas turbine engines for ground application in the power range of 2.5...25 MW.Perm enterprise has been working in the field of GTU development for ground application for more than 30 years. Since 1994 up to 01.06.2025 1302 gas turbine engines for mechanical and power drive with the capacity of 2.5...25 MW have been manufactured and delivered to customers. The total operating time of the units amounted to more than 47 million hours. For mechanical drive, 841 GTEs were manufactured with a total operating time of more than 25.8 million hours, for gas turbine power units – 461 engines with a total operating time of more than 21.3 million hours.

 

44 Backup solutions for GPUs and DGUs based on energy storage systems

Energy storage technologies are becoming an integral element of modern energy infrastructure. With increasing demands for sustainability, lower operating costs and environmental friendliness, energy storage systems (ESS) are demonstrating high efficiency in both isolated and hybrid energy solutions.

 

46 Production of steam and gas turbine components: modern approaches and materials

The article presents modern approaches to power machine building. The authors point out that the rapid development of Russian power engineering can be ensured only by radically increasing the degree of unification of manufactured equipment, which predetermines the introduction of modular equipment designs. This vector of equipment development and improvement of its life cycle support is confirmed by the development trends of the global power engineering industry.

With regard to turbine equipment in terms of the possibility of recombination of modules and their improvement by all participants of the life cycle allows us to talk about the potential for modernization of equipment and improvement of technical, economic and operational performance of the equipment and the object as a whole.

The article reveals one of the key innovation-technological tools for quick and effective solution of problems on optimization of modules, including the improvement of their interface units, is the production of parts and whole units using additive technologies. Moreover, the development of various areas of additive manufacturing allows to reliably and economically feasible change the methods and materials of production, creating parts, assemblies, modules and equipment with new qualities that are fundamentally unavailable in other ways of production of these parts and assemblies.

 

54 Russian-made fast-built GTPPs

The modern energy market requires flexible solutions in conditions of capacity shortage, the risk of emergency situations or the need for rapid commissioning of generating capacities. ODK Engineering (part of Rostec's United Engine Corporation) develops and implements fast-erecting GTPPs that combine high power, mobility and reliability. In many regions of the country, due to rapidly growing demand for electricity, power systems are operating with increased load. It is often not possible to eliminate power shortages by building traditional power plants of large capacity due to the long lead times for their construction and commissioning. One of the real ways to solve this problem is the use of fast-built GTPPs for distributed power generation and their operation as part of power systems.

The equipment is delivered to customers in a state of maximum factory readiness, while the commissioning time is shortened.

 

56 Potential of TPP reconstruction with CCGTs in the Russian Federation

Increasing the efficiency of power plants today is possible both through the development of new turbine units and modernization of outdated facilities for power generation. The use of CCGT to improve energy efficiency is an economically feasible solution.

In their time (1960-70s) scientists of the Department of Turbine Engineering of the Leningrad Polytechnic Institute, in particular, Professor L.V. Arseniev, Associate Professors E.A. Khodak and G.A. Romakhova, were engaged in the development of the basics of the theory of combined cycle plants. Unfortunately, due to the low cost of hydrocarbon fuel in the USSR, the results of the work were not put into practice.

In the world practice during the introduction of CCGT in recent years it was possible to achieve quite high efficiency – more than 64%, for example, at Keadby-2 power plant in Great Britain. The article gives a brief overview of the world's leading practices in the field of construction and research in the field of CCGT.

In our country the modernization of existing domestically produced steam turbines by building them with gas turbines and HRSGs is very urgent. This significantly reduces the cost of the project compared to the construction of a completely new power unit.

The article considers the possibility of using the gas turbine SGT5-9000HL (Siemens) with the capacity of 593 MW and modernized steam turbine K-300-240-1 (LMZ), with steam generation in a three-circuit HRSG. The possibility of steam turbine operation at the expense of heat of GTU exhaust gases was substantiated.

 

62 Application of producer gas instead of natural gas: how it affects the main equipment of a CCGT

Coal is an underrated resource capable of supplying energy to the world and Russia for centuries. The development of energy generation technologies based on coal fuel is key to ensuring the country's energy security and a potential driver for the economic development of remote regions where gasification is technically and economically challenging. The aim of this study was to investigate the impact of using syngas derived from coal, based on Russian technology for coal gasification in a fixed bed with air blowing, on the performance indicators of the main equipment of a combined cycle gas turbine (CCGT) plant when burned in the combustion chamber (CC) of the gas turbine unit (GTU). The performance indicators of the main elements were calculated using material and heat balance equations, as well as known chemical reaction equations. The work compares the performance indicators of the CCGT equipment when operating on natural gas and syngas, taking into account the integration of gasification system components into the CCGT scheme. Based on the obtained data, it is shown that the primary factor affecting the plant's operation is the 6.8-fold increase in fuel consumption in the CC, which in turn leads to an increase in the plant's power output. Integrating a gas cooler (GC) into the CCGT scheme through connection with the heat recovery steam generator (HRSG) results in reduced heat utilization but also lowers the risk of erosion on the final heating surfaces. The additional heat from the GC introduced into the cycle increases the power output of the steam turbine by 11.3%.

 

70 Trends in the development of last-stage turbine blades for TPP and NPP taking into account patent analytics

In recent years, despite the fact that efforts have been made in many countries to accelerate the energy transition to green energy instead of traditional energy, these attempts have not been successful. Currently, it can already be said that an erroneous development strategy was chosen, which led to multiple energy crises, both in European countries and in the United States. Mainly due to these circumstances, there has been a significant revision of energy development plans and a return to the development of traditional energy sources. It became clear that fossil-fuel power plants are needed, as well as energy storage systems should be created to ensure reliable energy supply. It also includes the transfer of nuclear generation to the category of green energy and the resumption of plans for the construction of nuclear power plants (NPP). In some countries, ultra-supercritical (USC) units are under mass construction. In these circumstances, when a number of countries have never abandoned traditional energy and continued to develop both nuclear and thermal energy, patent analytics can help identify development trends in some areas and reveal possible technology leaders who will appear in the coming years.

 

76 Utilization of low-potential heat using heat pump systems to improve the energy efficiency of data centers

The paper considers the problem of utilization of low-potential heat generated during the operation of server equipment of data processing centers (DPC). The authors propose an innovative solution based on a two-stage cooling system combining a heat pumping unit (HPU) and an absorption refrigeration machine (ARM). Theoretical calculations and modeling in the software complex Thermoflex for different brands of freons, such as R600, R717, R134a and RC318, with determination of key thermodynamic parameters have been carried out. COP (Coefficient of Performance) is chosen as the main energy efficiency indicator, the analysis of which showed the advantages of the proposed system compared to conventional refrigeration methods.

The study includes temperature parameters for different types of server racks (IT and ODM), as well as an assessment of the influence of climatic conditions on the system efficiency. The results show that the use of a two-stage cooling system can reduce energy consumption by 8-13%, reduce operating costs and improve environmental friendliness. Special attention is paid to the prospects of implementing trigeneration technologies in data centers, which contributes to the sustainable development of digital infrastructure. The article is of interest to energy efficiency specialists, data center designers and researchers dealing with heat loss utilization.

 

84 Distributed generation based on GPU. PRC gas piston units in the Russian Federation market: analyzing competitive advantages and key aspects

The article is devoted to the analysis of the state and prospects of development of distributed generation based on Chinese-made internal combustion engines. The article considers the market trends, when GPUs become the main source of energy from a backup one. On the basis of data on import of GPU in 2023-2024, it is noted that the market of distributed generation in the Russian Federation is estimated at 1900 MW/year. At the same time, 900 MW is accounted for by GPUs, mainly with 1-2 MW capacity. More than 85% of the import of GPUs with capacity over 600 kW is provided by the People's Republic of China. The article classifies GPUs by speed (low-speed, medium-speed, high-speed), fuel type (natural gas, associated petroleum gas, biogas, landfill gas) and mother platform (automotive, marine, power generation).

Competitive advantages are highlighted: modern control systems, optimized design to reduce operating costs, developed service support. Special attention is paid to the compliance of the GPUs with ISO 3046 and GOST R 52517-2005 standards. The prospects of mastering the production and maintenance of foreign GPUs in the Russian Federation as key factors of long-term competitiveness are considered. Mastering the production of GPU in the Russian Federation, which will reduce dependence on imports and meet the needs in spare parts. The article emphasizes the importance of the combination of technical characteristics, compliance with GOST, and availability of service infrastructure to strengthen the positions of Chinese GPUs in the Russian market.

 

88 Analysis of the effect of nozzle unit design on the operation of a radial-centripetal turboexpander

Decentralized generation is a topical issue for the whole world, including our country. One of the examples of this type of power generation is the use of turbo detanders. The analysis of the reviewed literature has shown that at present low-power detanders are poorly developed despite the fact that for various objects of gas transportation and gas distribution networks there is a need for a generation source of less than 1 kW. One of the variants of such machines are radial centripetal low-flow turbo-detanders. To date, there is little experience in the development of these machines, which makes the development of key elements of the flow part of these machines, in particular, nozzle apparatuses, urgent. In this article the influence of nozzle shape on turboexpander performance is considered by means of numerical experiment.

The purpose of this paper was to obtain the best nozzle channel geometry to obtain close to nominal flow and power characteristics of turboexpander. The methodology includes consideration of different nozzle channel designs and evaluation of the influence of their geometric dimensions on the operation process.