6 From overhaul and production of hot section components to production of gas turbines

Having mastered the technology of repairing and manufacturing spare parts for foreign-made gas turbine engines, Russian enterprises are confidently moving on to the production of small, medium, and large industrial gas turbines.The key topic of this issue is devoted to STGT, a company whose main activity is manufacturing products and providing high-tech services for high-power gas

turbines.You can learn about the production and technological capabilities of STGT LLC, as well as its plans for development, from an interview published in the magazine with Alexander Valeryevich Tanichev, CEO of Inter RAO – Machine Building LLC, which is part of the Modern Gas Turbine Technologies group of companies.12 Ural Vibration Laboratory: 10 years of progress and development

 

12 Integration of the new ATS-10STM stationary gas turbine unit into the GTK-10-4 gas turbine unit

CenterEngineering LLC, in collaboration with Gazprom, is implementing a project to create a highly reliable stationary gas turbine unit with a capacity of 10 MW on magnetic bearings.

 

16 MGTT LLC: from blade repair to complete manufacture of hot section components

The restoration of hot section components remains one of the most dynamically developing areas of activity for MGTT LLC. A new production facility has been built for the manufacture of hot section components. It will be fully commissioned next year, with serial productionset to begin in 2027.

 

20 From wear and tear to reliability: modernization of the current supply system for the TVF-180-2U3 turbogenerator

The experience of modernizing the current-carrying unit of a turbogenerator carried out by the unitary enterprise AES-Komplekt with technical support from specialists at ELSIB NPO is presented.

 

22 Repair and maintenance of gas turbines at MGTT LLC: experience and new technologies

Thanks to MGTT LLC's in-house engineering expertise and many years of experience in servicing and repairing power equipment, the company performs major and routine repairs of gas turbine units in a timely manner.

 

26 Conducting an off-site inspectionof the combustion chamber of the SGT-800 gas turbine

The manufacturer of SGT-800 gas turbines, Siemens, requires mandatory factory repair of combustion chambers during level B and C inspections. This requirement obliges equipment owners to have a spare combustion chamber available to ensure component rotation during inspections.

Based on its experience in operating and maintaining gas turbines of this type, TurboService Rus offers an alternative option: conducting on-site inspections of combustion chambers at power plant sites.

 

30 Production of a localized high-power gas turbine at MGTT – a task for the near future

The MGTT production complex has a 10-year history of successful production of high-power gas turbines. During this time, 10 turbine groups and 17 sets of 2000E combustion chambers have been manufactured.

The company is equipped with the necessary production equipment, constantly improves it’s technological processes, and builds its human resources from experienced professionals.

The MGTT production complex, covering an area of 12,700 m2, is equipped with modern specialized machines for manufacturing gas turbines. It houses technological processes for welding, machining, and assembling gas turbine components.

 

32 Improving the efficiency of the TM16M2 through the comprehensive use of promotional cooling, regeneration and heat utilization

Using the example of the TM16M2 gas turbine with pre-cooling, the possibility of increasing the efficiency of the gas turbine cycle is considered through the comprehensive use of waste gas heat and pre-cooling heat in ORC superstructures in combination with traditional waste gas heat regeneration for compressed air heating. The study was carried out using a specially developed computational model of a gas turbine with superstructures. The computational model was verified by comparison with published data and showed minimal differences in calculations using both methods.

Various options for modernizing the GTE were investigated, including the introduction of additional devices separately and in combination. It was established that maximum efficiency can be achieved by simultaneously introducing regeneration using the heat of pre-cooling and the heat of the GTE exhaust gases in the ORC  superstructure. For the proposed option of organizing the working process, the optimal degree of pressure increase in the compressor was determined. It was shown that the proposed cycle is at least not inferior to the combined cycle calculated for the same GTE parameters.

 

38 Combined cycle power plantsbased on G50 and G15 turbines (part 1)

The article describes the technical characteristics of the G50 and G15 gas turbine units and combined cycle units developed by the Chinese company Dongfang Electric Corporation (DEC), one of the world's largest developers and manufacturers of power equipment and energy solutions.

 

42 Development of measures to improve the reliability of axial compressor rotor blades in gas pumping units

This paper presents the results of research aimed at resolving the issue of systematic failure of rotor blades in a specific stage of an axial compressor within a gas turbine engine. A comprehensive approach, involving combined computational and experimental gas-dynamic studies and a detailed strength analysis using the Finite Element Analysis (FEA), identified the root causes of the failures: dangerous proximity to resonant conditions corresponding to the first bending mode, a critical stress-strain state of the blade, and an increased fluid-dynamic load on the stage.

Based on parametric studies, a modified rotor blade design was developed and validated, which ensures the required vibrational margin and an increased safety factor.

The results of the numerical model validation are presented, along with recommendations for application.

 

48 Preparation of equipment by Stand JSC to tests of domestic GTE-110 gas turbines

The article discusses the history of the test bench's creation, its development, and the reasons for its prolonged downtime. It outlines the prospects for the test bench's development with the increase in the production of domestically manufactured gas turbine units. The study identified key issues preventing the rapid launch of the test bench after downtime and proposed ways to resolve them. Particular attention is paid to the process of preparing the permits required to carry out production activities at a facility classified as a hazardous production facility.

The feasibility of changing the main type of activity of the enterprise related to loading and operating modes was analyzed, which made it possible to reduce the need for watch personnel from four watches to two when forming the staffing table. The change in the type of activity also opened up the possibility of changing the category of negative environmental impact (NEI); it enabled work with the system operator to include the equipment in a single energy system for the duration of the tests. Work was carried out to certify the thermal and electrical equipment.

 

60 Repair of the internal liningof the chimney after the gas turbine unit: technologies, complexities, and significance of the work

The features of repairing the lining of a gas turbine power plant chimney are considered. It is shown that the use of high-quality materials in combination with the participation of qualified contractors significantly reduces the risk of significant financial losses associated with forced equipment downtime.

 

62 Current trends and solutions in construction and renovation of energy facilities in the Russian Federation

The article examines current trends and solutions in the construction and reconstruction of energy facilities in the Russian Federation, with an emphasis on standard designs and modular approaches.

It analyzes the experience of implementing the Capacity Supply Agreement Program (CSA) and identifies systemic errors, including excess capacity and dependence on imported equipment. The need to standardize facilities and equipment in order to reduce costs and improve technological continuity is justified.

A comprehensive modular concept is presented, combining digital transformation, standardization, unification, and optimization of equipment at all stages of the life cycle, which ensures an improvement in technical, economic, and operational performance. A new draft federal law is described, providing for the creation of the public-law company Rosenergoproekt for standard design, cost management, and control of the implementation of electric power facilities, which contributes to the formation of a sustainable and technologically advanced energy infrastructure.

 

70 Repair of gas turbinesat Huadian-Teninskaya CHPP carried out by Russian companies

Repair work on the main and auxiliary equipment of two GTU-160 gas turbine units manufactured by JSC Power Machines at the Huadian-Teninskaya CHPP has been fully completed by specialists from Russian companies – TurboService Rus LLC in cooperation with RENN-K LLC.

 

72 Modeling of the fuel supply control system of the NK-16-ST gas turbine unit in the Repeat environment

The article discusses digital modeling of the fuel supply control system for the NK-16-ST gas turbine unit using Repeat software. The aim of the work is to create a dynamic diagram reflecting the logic of the operation of actuators, regulators, and parameters of the gas turbine unit in transient modes.

The structural diagram of the model is presented, the principle of operation of the blocks is described, and the implemented fuel supply control algorithms are described, taking into account the restrictions on pressure and rotor speed. Transient characteristics are calculated for different values of the set rotational speed, and graphs of fuel consumption, pressure in the main line, and output power are analyzed.

Based on the analysis of the graphs, conclusions are made about the dynamic stability of the system, its accuracy, and adequacy to physical processes. The presented model can be used for training, verification, and testing of new gas turbine control algorithms.

 

78 ROLT Group – a comprehensive approach to servicing and repairing gas piston power plants

ROLT Turbo is a division of ROLT Energo Service (part of the ROLT Group) established in 2017 and includes a turbocharger repair shop, an aggregate repair shop, and a metalworking shop.

The turbocharger repair shop performs scheduled maintenance and major repairs. The unit repair shop performs all types of maintenance on gas piston engine cylinder heads, including major repairs. The metalworking shop was created on the basis of the ROLT Turbo division to produce spare parts and replace imported components of foreign-made equipment.

 

82 The concept of translating hydraulic units for repair due to technical condition

This article proposes a general concept for transferring hydroelectric units from scheduled preventive maintenance to condition-based maintenance. The purpose of the concept is to outline an algorithm by which the transfer of hydroelectric units to condition-based maintenance can be safely accomplished without compromising the reliability of hydroelectric equipment. Therefore, the first stage of the algorithm is restrictive: it describes a number of preconditions that must be met when transfer-ring hydroelectric units to condition-based maintenance.

The second stage of the algorithm is devoted to predicting the technical condition of hydroelectric units. At the current stage of technological development, predicting can only be statistical, based on information about equipment defects recorded during previous periods of operation; it is shown that the distribution law according to which defects arise should be assumed exponential. The third stage of the algorithm is the creation of a diagnostic system for the technical condition of hydroelectric units.

Currently, despite the rapid development of monitoring systems, ensuring reliable operation of a hydroelectric unit is impossible without periodic drainage and inspection of the turbine's flow path – such inspections must be an integral part of diagnostic procedures. A proof-of-concept study conducted on four full-scale hydroelectric units demonstrated that transferring to condition-based maintenance allows for an increase in the period between major overhauls to 48 000–80 000 hours, with diagnostic procedures lasting approximately 3–5 days per year.

 

90 Theoretical rationale for increasing the power of a free-flowing hydraulic turbine with a shaft inclination

The article presents a theoretical and numerical study of an innovative design of a free-flow hydro turbine with a non-collinear axis of rotation, i.e., tilted relative to the direction of the water flow. The relevance of the work is driven by the growing demand for environmentally friendly and adaptive energy sources, especially for small watercourses where the construction of traditional hydroelectric power plants is not cost-effective.

The main hypothesis of the study is that tilting the turbine shaft increases the active area of interaction between the impeller and the flow, potentially enhancing the unit's energy efficiency.

The work analyzes existing technical solutions and identifies their shortcomings.

A range of promising layouts for the hydroelectric unit is developed and evaluated, including configurations with the generator placed on the surface, underwater, and on a bottom platform. The increase in the active area of the impeller when tilted is theoretically substantiated and quantitatively assessed, showing an increase of up to 41.4%. For a repeller-type impeller, a detailed calculation of velocity triangles was performed, accounting for the axis tilt and the non-uniform velocity distribution over the depth, which confirmed the improvement in energy characteristics.

 

96 Hydrogen-containing gas pumping unit manufactured by INGK LLC

Since 2015, INGK has been developing andmanufacturing gas pumping units of the Irtysh series with gas turbine and electric drives. Depending on customer requirements, INGK LLC manufactures units in hangar, modular, container shelters, or without shelters for installation in existing or newly constructed customer workshops. In 2021-22, the production and engineering company INGK implemented a project to develop, manufacture, supply, and install a gas pumping unit for the needs of NNK – Khabarovsk Oil Refinery JSC , a leading producer of motor fuel in the Far Eastern Federal District of the Russian Federation. The plant's products are supplied to the northern regions of Russia, Khabarovsk Territory, and Primorsky Krai.

 

100 Analysis of contemporary approaches to the design of power equipment

The paper analyzes the transition of the Russian electric power industry and power engineering to a qualitatively different level of design, in which power units are laid out from the outset taking into account standard solutions, modular designs and digital life cycle support tools. The creation of the Rosenergoproekt Design and Construction Center and the preparation of a relevant federal law are shaping an institutional environment in which standard designs with pre-established technical and economic targets are becoming the norm rather than the exception.

The reference base for determining the target parameters of technical and economic indicators is the T-63/76-8.8 steam turbine and the SGT5-2000E gas turbine: their characteristics set the bar for promising domestic steam and gas installations. The modular design principle, which assumes a high degree of standardization of assemblies and components, makes it possible to reduce design preparation for production, lower labor intensity, improve maintainability, and simplify the replication of solutions for a series of similar facilities.

The authors cite the concept of the «domino effect»: the earlier promising technology (standardization, modularity, digital twins, IoT, or machine learning algorithms) is incorporated into a project, the greater the cumulative effect it has by reducing downtime, optimizing modes, and increasing maintenance intervals throughout the entire life cycle.

 

108 LXXII scientific and technical session of the Russian Academy of Sciences

The Russian Academy of Sciences' scientific and technical session on gas turbine issues, Scientific and technical problems of full localization, design, production, and maintenance of stationary gas turbine installations in the Russian Federation» was held in conjunction with the Second Scientific and Technical Conference «Promising areas for the development of gas thermal spraying and laser cladding technologies».