6 Russian gas turbine engines: steady progress forward

Today, Russia is facing not only great challenges, but also enormous opportunities, which for developers and manufacturers of gas turbine engines for aviation and the fuel and energy complex in the country's recent history has led to increased efforts and results in the creation and serial production of products. Let's take stock of 2025, noting the most notable events in the Russian gas turbine industry.

 

8 Unified digital platform for power unit operation management

Distributed energy generation always faces the challenge of how to ensure the uninterrupted operation of dozens of remote facilities scattered across different regions. The traditional approach, based on responding to situations that have already occurred, often leads to unplanned equipment downtime and high costs for urgent repairs.

 

12 Use of composite materials for AFCS elements: the impact of product shape on capital expenditures

A comparative analysis of manufacturing air ducts with different cross-sectional shapes (round, square, and rectangular) is presented. The study identifies the economic feasibility of switching from rectangular to round ducts to reduce material consumption. Additionally, the effect of optimizing air delivery to the compressor is analyzed. A comparison of ducts with equivalent diameters and an assessment of their aerodynamic resistance impact on gas turbine engine power are provided.

The article describes the experience of designing and manufacturing composite air ducts for the GTE-110 gas turbine engine, using polyester resin and fiberglass, and replacing part of an existing intake tract. An alternative method for fabricating and installing a perforated air duct is considered. This duct can also replace or entirely eliminate noise suppression panels due to the sound insulation and absorption properties of the composite material.

 

18 Combined cycle power plants based on G50 and G15 turbines (part 2)

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.

 

24 Determining the composition of spare parts for service of high-power gas turbines using the example of GTE-170

The paper describes a comprehensive approach to determining the composition of spare parts kits for commissioning and further service maintenance of high-capacity gas turbines in the context of the development, production, and commissioning of a new gas turbine, using the example of the GTE-170.1 gas turbine from JSC Power Machines. This task was addressed as part of the implementation of the research and development project «Development of Repair Technology and Repair Documentation for the Service Maintenance of the GTE-170 Gas Turbine». The comprehensive approach involves a multi-level classification of gas turbine components, followed by an assessment of their design and technological features to determine whether they should be included in the spare parts list and the required quantities. Special attention is given to various fastening elements within the gas turbine, particularly on the horizontal and vertical joints of the housings, as well as the challenges of ensuring accurate assembly during repairs in the context of changing the type of interchangeability between assembly units. The proposed approach is based on years of experience in repairing high-capacity gas turbines from foreign manufacturers, as well as methods used in the technical maintenance of aviation gas turbines.

 

32 Development of a stand for balancing impellers of electric ducted fans based on MPU-6500

The article presents the development of a compact automated stand for dynamic balancing of small electric duct fan impellers (up to 120 mm in diameter and 1 kg in mass) using an MPU-6500 six-axis motion sensor and an STM32/Arduino-based microcontroller.

The relevance of the study is determined by the need to reduce vibration levels and improve the reliability of duct fans under conditions of limited dimensions of balancing equipment. The aim of the research is to develop an integrated hardware and software system capable of measuring amplitude – phase characteristics of rotor imbalance and automatically calculating corrective masses with accuracy sufficient for practical applications. The methodology combines mechanical design, elastic shaft deflection analysis, and digital signal processing of vibration data. A two-support balancing stand with cantilever-mounted impeller is proposed, with vibration sensors installed near the bearing supports to register radial accelerations.

Recommendations for sensor connection, power supply, signal filtering, and measurement parameters are provided. A preliminary static blade balancing procedure and an automated dynamic balancing algorithm based on spectral and phase analysis of the first harmonic are described. The main sources of measurement errors are analyzed, and practical measures to improve balancing accuracy are proposed.

 

38 Assessment of temperature conditions in planned main gas pipelines

The progress of gas transportation technologies usually requires a certain adjustment of calculation methods for determining parameters and indicators of projected main gas pipelines.

The article discusses current methodological approaches to performing design thermal engineering calculations of main gas pipelines in connection with an increase in design operating pressure.

The tendency of the thermodynamic properties of natural gases and their mixtures to influence the temperature state of a gas pipeline is shown with an increase in operating pressure, the use of pipes with an internal smooth coating and a change in the component composition.

The possibility of using a polytropic (thermodynamic) approach considering the main gas pipeline as an «expansion machine with an external heat exchanger» is considered.

The results of the analysis of the variability of the parameters of the thermal interaction of the gas flow with the environment and their effect on the design capacity of the gas pipeline and the required capacity of compressor stations are presented.

Based on the factor analysis, an assessment of the uncertainty (accuracy) of calculating the temperature state of the main gas pipeline for the evaluation and clarifying methods was performed.

The result of a study of changes in the ratio of the hydraulic (compressor) capacity of a section of main gas pipelines and the heat exchange capacity with the environment with an increase in the design operating pressure is presented.

The possibility of using generalized indicators for thermal engineering calculations of sections of main gas pipelines at the preliminary stages of technological design of gas pipelines is shown.

 

46 TurboService Rus and RENN-K completed a large amount of work at CHPP-1 and CHPP-2 in Kazan.

The work included inspections and repairs of the PG 6111 FA gas turbines themselves, thermomechanical equipment, and fuel gas preparation station units. The equipment underwent the necessary refurbishment, was accepted by the customer, and was put into commercial operation.

 

49 The production of honeycomb seals for GTD-110M is carried out by ROTEK CM LLC.

ROTEK Components and Materials has begun serial production of high-tech honeycomb seals for the GTD-110M gas turbine engine. The components were ordered by the Rybinsk-based company ODK-Saturn, which manufactures GTD-110M gas turbines.

 

52 Primeline: quality, reliability, professionalism

Primeline LLC is a manufacturing and engineering company founded in 2019.

The company specializes in turnkey projects and has experience and expertise in engineering, construction, project management, and the manufacture of high-tech equipment and structures.

 

58 Study of transient modes of operation of nuclear power plants with VVER reactors

Since the early 2000s, the System Operator of the Unified Energy System of Russia (JSC SO UES) has begun to apply new requirements to new NPP power units to ensure the operation of nuclear power plants in the modes of primary regulation of the frequency of electric current in the energy system and in the modes of following the load in the energy network [1].

For the process of regulating the unevenness of daily load schedules with a range of regulation from 100 to 50 percent of the nominal power level of the NPP power unit [2], the main difficulty is to change the power of the reactor plant both in unloading or loading mode and in the regulation mode the frequency of electric current. It is proposed to minimize the unloading or loading of the reactor in frequency control mode and increase the «corridor» of steam pressure of the second circuit in front of the turbine during unloading or loading mode in order to reduce the negative effect of the reactor plant operation in this mode. At the same time, by increasing the range of steam pressure in front of the turbine, the electrical load should be changed in frequency control mode without changing the parameters of the primary circuit and the reactor.

If the power developed by steam turbines is insufficient, the frequency of the network decreases; if there is an excess of power, it increases. In normal operating conditions, the control of the power unit must maintain the generator's power in accordance with the dispatcher schedule (planned load) and compensate for random fluctuations in the load (unplanned component of the load). The power balance indicator is the stability of the network frequency (50 Hz).

 

66 Development of Chinese gas engine gensets and their application in the Russian market

Driven by the global energy transition and carbon neutrality goals, gas power generation, as a crucial component of clean energy, faces unprecedented development opportunities. Being strategic partners, China and Russia continue to develop their cooperation in the energy sector. This study is focused on the current status and development prospects of Chinese-made gas gensets in the Russian market, based on an in-depth analysis of technical features and advantages of the equipment made by leading Chinese manufacturers, as well as specifics of the Russian market demand, this study aims to provide theoretical guidance and practical suggestions for Russian companies in selecting Chinese gas gensets.

The research indicates that Chinese gas gensets demonstrate strong competitiveness in the Russian market due to their cost advantages, process applicability, and flexible service system.

Leading Chinese companies such as Jichai, Weichai, and Yuchai have secured significant positions in the Russian market through continuous technological innovation and product upgrades.

However, there remain certain challenges, including differences in the technical standards, insufficient brand recognition, and the establishment of service networks.

 

76 Power automation for electric drive GPU series Irtysh

INGK's Irtysh series electric gas pumping units are designed to compress gas at gas and oil industry facilities using a centrifugal gas compressor driven by an electric motor via a multiplier. Depending on the conditions of use at the operating facility, the Irtysh series EGPU can be located in the customer's compressor shop building, in an open area of the compressor station (in a container design), or in an individual shelter as part of the station (in a modular design).

 

82 Industry 6.0: From steam engines to autonomous «modular» production

The article highlights the need for humanity to shape the profile of «future manufacturing». For example, this will be a vector towards the target state of Industry 6.0, in which physical, digital, and biological systems are integrated to create autonomous, self-organizing, cognitive production ecosystems, which predetermines the use of biotechnologies and biomaterials in production processes; systems with advanced AI capable of self-learning and adaptation; neurointerfaces for direct interaction between humans and robots; autonomous systems capable of self-diagnosis and self-repair. Let us note that only a modular physical system, accompanied by a modular AI system with synchronized architectures, will allow for the autonomous assembly of Industry 6.0 production systems, which will be assembled autonomously and automatically without human involvement and will fulfill orders for the development and production of products with optimal design, optimal life cycle, and minimal costs.

Emphasis is placed on the theses of the modular concept as a tool and approach for building the target architecture of Industry 6.0.

 

87 Distributed Power Generation – Great Achievements

А ceremony was held in Moscow to present the international award Distributed Power Generation –

Great Achievements Engineering companies working in the field of distributed energy were invited to participate in the competition. Over a two-month period, the award organizing committee received 65 applications from 16 regions of Russia.