4 Turbines and Diesels magazine: yesterday, today, tomorrow.

Turbines and Diesels information and technical magazine has been published since 2005. During this time 108 issues of the magazine, 18 catalogues of power equipment - the world's most comprehensive technical reference book on equipment for energy production have been published. Initially, one of the main topics of the magazine was distributed power generation and everything related to it. These are generation equipment – engines of various types, gas and steam turbines, electric generators, power plants, fuel gas booster compressors, air treatment systems, drive and station control systems, oil supply and cooling systems and many others. The topic of the use of engines of various types as a mechanical drive as part of compressor and pumping stations, blowers was constantly covered. The issues of power generation are inextricably linked with the efficient operation of all main and auxiliary generating equipment, therefore, new approaches to the maintenance of complex equipment, the use of modern fuels and oils have always been presented on the pages of the magazine.

6 The basis of energy security of the capital region.

The Central mechanical repair plant is the largest specialized enterprise in the Moscow region for diagnostics, repair and post-repair maintenance of power plant equipment. The plant was established on July 8, 1948 by Order No. 216a of the Ministry of power stations in connection with the increased volumes of standard repair work of power supply system and the shortage of wear-out spare parts for the equipment of power plants. Already in the year of its foundation the company accepted six Moscow power stations for maintenance, the company's employees repair 24 boilers and 11 turbines.

10 Improvement of technical and economic indicators of steam turbine plants: improvement of installation, commissioning and operation.

Key words: steam turbine, steam turbine plant, combined cycle power plant, industrial heating, life cycle, updating commissioning and operation, modular design, algorithms for operation, improvement of efficiency

Abstract

The article shows the importance of analyzing the possibilities and increasing the recoverable technical and economic effect from the introduction and improvement of the design and schemes of steam turbine plants at the stages of the equipment life cycle after the design and technological preparation of production.

The author examines the issues of improving the life cycle of the main and auxiliary equipment of the Steam turbine plants at its different stages through the introduction of technical solutions for regime optimization. An example of solving the problem of increasing the efficiency of the exhaust gas temperature reduction system of a HRSG while increasing the power and efficiency of a heating plant by reducing the power consumed for circulating water pumping through a condensate cooler is described.

The issues of improving the design of the main and auxiliary equipment, improving technical and economic indicators at all stages of the life cycle are important, including at the stages of installation, commissioning and operation, there is a significant potential for improvement and obtaining a large absolute economic effect.

Calculation and experimental determination of the maximum technical and economic indicators of steam turbine equipment with possible joint and autonomous operation in variable modes with the development of algorithms for operation with automatic or semi-automatic maintenance of indicators at the established optimal level are necessary.

16 Efficiency analysis and optimization of MGT-30 gas turbine operation under various conditions using inlet air precooling systems.

Key words: efficiency, operational characteristics, gas turbine MGT-30, precooling, optimization

Abstract

The study presents an analysis of the impact of different air-cooling systems on the efficiency and power of the compressor in the MGT-30 gas turbine unit (GTU). The MGT-30, manufactured by the Iranian company Mapna Group Company, serves as a driver for various applications, including gas booster units, pumps, ejectors, and stationary or mobile power plants in Iran.

A significant milestone was reached in October 2022 with the signing of an export agreement between Iran and the Russian Federation for the supply of 40 units of GTU, marking a historic moment in the country's technological export endeavors.

The objective of this research is to determine the optimal parameters of the incoming air to the compressor and its associated cooling systems. The calculations and optimization of the operating parameters of the MGT-30 were conducted using MATLAB, GT PRO software, and the specialized A2GTP program for the assessment of technical characteristics.

The results obtained from the study demonstrate the favorable influence of incorporating a pre-cooling system for the air, showcasing improvements in the thermal efficiency of the GTU and uncovering potential avenues for further enhancement.

24 Online monitoring of turbine oils: how it works.

LUKOIL is not only the largest producer of lubes and greases in Russia, but also a key player in forming the market for service solutions in this area. Having deep expertise, the company offers enterprises comprehensive technical solutions that increase the reliability of the operating equipment.Among such solutions is an online monitoring system for the condition of lubricants. It can be used for a wide variety of equipment.

26 Strength investigation of stage B rotor blade of GTN-16 axial compressor by Finite Element Method in Fidesys CAE system.

Key words: disk, Ansys, static calculation, modal analysis, Campbell diagram, natural frequency

Abstract

The paper describes the loads acting on the rotor blades during engine operation, as well as the methods used to assess the strength of the impeller. An analysis of the results of static and modal calculations of a working blade with a disk of an axial compressor of a GTN-16 gas turbine plant in the domestic Fidesys CAE system by the finite element method is presented.

Also, the calculation data were verified using the Ansys software package, as the most common system in the world for the numerical simulation of physical processes. Pictures of the stress-strain state of the blade with the disk are obtained.

The zones of stress concentration in the model are identified and the safety factors of the blade and disk are determined. The six first frequencies of natural oscillations of the structure are found and the Campbell diagram is constructed.

Possible options for improving the vibration reliability of the design of the considered axial compressor are outlined. A comparative analysis of the results of finite element modeling in the Fidesys and Ansys software systems was carried out.

32 Verification of the software methodology for calculating the strength of axial compressor discs.

Key words: axial compressor, disk, strength calculation, software methodology

Abstract

The purpose of this work was to create a program based on the methods of classical strength theory and compare the results obtained with the results of numerical calculation in the Ansys software package. In the course of the study, digital tests were performed on the strength of the axial compressor disk at different revolutions and stress distribution graphs were obtained along the radius of the design area.

The main calculation methods are based on empirical methods. They include a long analysis of the system under study, preparation of calculation schemes, conducting sequential calculations according to formulas and subsequent processing of the results obtained. To automate this process, simplify obtaining input and output parameters, the use of programming languages has become widely used. With the help of programming languages, it is possible to fully automate the calculation process, the researcher is only required to set the necessary initial conditions.

In the course of the work, the stress calculation was performed in a special software written in the Python programming language. By superimposing the values of the points in the control sections calculated according to the program on the stress distribution graph along the radius, the model was verified.

38 A digital approach to the detection and evaluation of the impact of blade row defects on the characteristics of turbomachines.

Key words: defect, blade row, axial turbomachines, machine learning, neural network, YOLOv8s, numerical experiment

Abstract

The present study is aimed at developing approaches to detecting and classifying defects in the blade apparatus of turbomachines and assessing the manifestation of defects on the characteristics of the installation. The relevance of the work is connected with the use of digital technologies in the problem of defectoscopy of the blade row apparatus.

In the course of the study, a YOLOv8s convolutional neural network model was prepared and trained on two data sets: with artificially visualized images of defects and photographs of blades after operation. Based on the analysis of the results of training and testing of the YOLOv8s model on a database with artificial images of defects in the blade row, an accuracy of 97.8% was achieved. On the prepared real data set, YOLOv8s has an average accuracy of mAP0.5 = 0.84.

The paper also describes an approach to assessing the effect of blade defects on the characteristics of turbomachines based on the results of numerical experiments and the use of machine learning methods to predict the development of defects or evaluate changes in the characteristics of turbomachines with defects.

The study shows the promise of using a digital approach to detecting and evaluating the impact of blade defects on the performance of turbomachines.

44 Import substitution of power equipment as part of a lifetime service.

UEC–Aviadvigatel JSC was the first in Russia to introduce a program of branded repair and maintenance of gas turbine power plants during the life cycle with payment for the actual machine-hour worked and the provision of a full guarantee for the equipment during the designated resource. This approach allows customers to plan engine operating costs, reduce equipment insurance costs, and optimize the composition of spare parts. At the same time, fixed deadlines for troubleshooting and malfunctions are taken into account and the time for performing repair and maintenance is reduced, deep diagnostics, continuous monitoring of equipment parameters and its systems are used.

48 New engineering competencies of Central Mechanical Repair Plant.

Since its foundation in 1948, the main task of the Central Mechanical Repair Plant has been to ensure reliable and uninterrupted operation of the energy system of Moscow and the Moscow region. With this in mind, the company performs scheduled preventive and emergency repairs of all transportable equipment of PJSC Mosenergo. In 2019, an Engineering and Technical Center was opened on the basis of the CMRP as part of the implementation of the Mosenergo initiative for the solution of engineering tasks and the development of engineering activities.

52 Conference on the problems of service life retaining and improving the reliability of gas turbine plants.

The conference held in May at the site of NPO CKTI, was devoted to improving the efficiency of air treatment at the inlet to the compressor of a gas turbine engine and gas turbine lubricating fluids, reducing operating costs, and improving the reliability of hydraulic systems.

The organizers of the event were NPO CKTI, EMW Filtertechnik rus LLC and Filtration technical company LLC. V. E. Mikhailov, General Director of NPO CKTI addressed the participants with a welcoming speech. He noted the importance of the event, a cycle of such annual conferences is planned for the anniversary of the institute.

56 Jichai gas engine plants for the Russian market.

The withdrawal of European and American companies from Russia has created unique opportunities for equipment manufacturers from China. Intertechelectro Group of Companies, one of the leaders in the Russian energy engineering market, was among the first to announce strategic cooperation with a Chinese manufacturer of piston engines – CNPC Jichai Power Company Ltd. The agreement signed by the two companies defined the main directions and principles of cooperation in the use and promotion of Jichai products in Russia.

62 Stationary axial compressors manufactured by Nevsky Zavod JSC.

Key words: stationary axial compressor, row of blades, insulated profile, purging of flat gratings, model stage, CFD calculation

Abstract

An axial compressor usually consists of a series of sequentially arranged stages. The connection of the axial stages in the compressor is very simple and provides sufficient straightness of the flow part, which contributes to high efficiency compared to centrifugal compressors.

The working conditions of a stage in a group differ from the working conditions of an isolated stage. The previous stages create a certain unsteadiness of theflow, which changes the flow around the subsequent stages, affects their pressure and efficiency.

When designing the flow part of air axial compressors for general industrial purposes, the method of calculating the blade unit developed at the Central Research and Design Institute of Boiler Turbine named after I.I. Polzunov is mainly used. However, with a limited selection of tested wheels, it is notalways possible to design a new compressor for the specified parameters.

Given the insufficient amount of theoretical and experimental materials, one should be guided by design methods that allow either to fully use theexisting prototype according to the methods of similarity theory, or to use the previously accumulated experience of testing flow parts with introduction minimum possible changes requiring additional tests. Thus, improving of existence design methods of flow parts with the aim of design brand new high efficiency axial compressors is a topical issue.

This article presents the results of CFD-calculations of gas flow in the blade unit of a two-stage axial compressor. Calculated flow parameters are compared with the test ones.

70 Development Methods and Experience in Optimal Design of Centrifugal Compressors for Gas-Pumping and Turbo-Expander Units.

Key words: pipeline unit, centrifugal compressor, replaceable flow path, CFD-optimization, modernization

Abstract

In 1990–2000 polytechnic scientists were involved in the gas-dynamic design of newgeneration compressors and replaceable flow paths as part of the «Ural–Gazprom» program. Possessing their own engineering method of optimal design and calculation, the polytechnics solved the problem by creating, together with industrial partners, compressors and replaceable flow paths with an efficiency of 3-4% higher than that of analogs. A new stage of modernization is currently relevant. Scientists – polytech-nics by this time transferred to industrial partners more than 50 projects of new compressors and replaceable flow paths and accumulated a lot of experience. At the expense of the National Technological Initiative Center of Excellence in New Manufacturing Technologies SPbPU, the test rig ECC – 55 was built to test the most important and innovative projects. CFD optimization techniques have confirmed their effectiveness in relation to flow path stator elements.

78 The Sirius control system is a new development of INGK-Promtech.

The modern oil and gas industry requires maximum automation of technological processes, the main goals of which are the exact implementation of technological regulations, the elimination of personnel errors, ensuring industrial safety and remote control and management of production complexes from the upper management level. INGK–Promtech has been developing and manufacturing automatic control systems for the oil and gas industry for more than eight years - several dozen systems have been delivered during this time. Since 2020 the company has started the production of control systems under the brand name of Sirius Information Management System. In the same year Sirius system was tested for the purpose of approving the type of measuring instrument and in December 2020 it was included in the register of approved measuring instruments of the Federal Information Fund for Ensuring the Uniformity of Measurements FGIS Arshin (certificate of approval of measuring instruments type No. 80247-20).

82 Design of small-scale steam turbine plants for heat recovery behind gas turbines in the organic Rankine cycle.

Key words: steam turbine, flow path, organic Rankine cycle (ORC), isopentane, heat recovery, gas pumping units (GPU), combined cycle power plant (CCPP)

Abstract

The prospects for the extraction and processing of hydrocarbons in the Arctic zone raise the question of the feasibility of reliable energy supply and increasing the efficiency of industrial facilities of gas processing and gas transportation enterprises. One of the possible solutions is the introduction of a utilization thermal energy complex (UTEC) at compressor stations and gas turbine power plants, using the waste heat of the exhaust gases of a gas turbine plants. The novelty of the considered utilization circuit is the use of a steam turbine plant with an organic working fluid (with a low boiling point and a low freezing point), which increases the reliability of the equipment of the steam turbine circuit under the low temperatures of the Arctic zone. The article gives estimates of the energy characteristics of a steam turbine that can be used to work as part of the UTEC, and various variants of its design are considered. The possibility of heat recovery of exhaust gases behind a gas turbine plant (GTP), which is part of a gas pumping unit (GPU) or a gas turbine power plant (GTPP) in a utilization circuit, including a steam turbine plant with an organic working fluid – isopentane, is shown. Based on the data from the operated GTPs, an analysis was made of the most rational range of electric capacities of the steam turbine to meet the own needs of the gas turbine plants. The option of complete utilization of heat of the exhaust gases of the GTP is also considered on the example of the T32 GTP with a capacity of 32 MW, and an estimate of the maximum electrical power of the utilization circuit is given. The question of optimal parameters of the working fluid before the turbine is considered – both from the point of view of thermodynamic efficiency and technical feasibility.

The principal features of isopentane used as a working fluid for a steam turbine plant and the corresponding design options for a steam turbine are shown. As a result of the calculations carried out, the predicted parameters of the flow parts for various design variants of a steam turbine with isopentane as the working fluid were obtained.

88 Promising diffusion aluminide coatings for turbines of the III-IV generation.

Key words: chemical vapor deposition, heat-resistance coatings, aluminizing Watt electrolyte, diffusion barrier

Abstract

NiAl coatings are considered to protect the rotor blades of the modern high-pressure turbine blades (III-IV gen.) from high-temperature oxidation. To significantly increase oxidation resistance, the intermetallide β(NiAl) is doped with zirconium by preliminary galvanic plate of the Ni-Zr composite in the Watt electrolyte, followed by homogenization annealing.

The reduction of the undesirable diffusion interaction of the coating with the superalloy is achieved with a rhenium-based barrier. Alternatively, a tungsten-based barrier has been studied.

The composition of the saturating mixture for contact powder alitizing and heat treatment modes are given. Data on comparative isothermal tests of working blades made of CHS88U-VI alloy with coatings VSDP-11 (Ufa), MZP-1+MKTP-1 (Nikolaev), β(NiAl) Zr and SVS+KDP-1 (Lytkarino) are presented.

It was found that the heat-resistant properties of β(NiAl) Zr significantly exceed VSDP-11. The SVS slip coating showed satisfactory results when working as a connecting sublayer under the electron beam condensation coating KDP-1.

92 Sustainable power industry development based on the achievements and modern developments of the Russian power-plant engineering.

In May, the Ural Turbine Plant in Yekaterinburg hosted Sustainable Energy Development based on the achievements and modern developments of Russian Power Engineering international scientific and technical conference. It was dedicated to the 85th anniversary of the Ural Turbine Plant, which is celebrated in October this year. The conference brought together more than 150 specialists – representatives of industrial enterprises, engineering companies, research institutes, operating energy organizations from all over Russia, Belarus and Kazakhstan. Ural Turbine Plant presented new products and developments for the modernization of power equipment, the experience of implementing modern projects was analyzed, new approaches to maintenance were discussed in detail separately.