6 Russian companies are realizing their designs to life!

The power engineering industry in the Russian Federation is actively developing today – young engineers are joining design schools. The most advanced design and testing technologies are being actively introduced. The strategic goal is to match the level of the world's advanced developments.

Today, the government is paying great attention to the restoration of stable positions of the domestic power engineering industry: the creation of new equipment is being financed, market rules are being formed to prioritize the use of domestic equipment.

Mikhail Igorevich Ivanov, Deputy Minister of Industry and Trade of the Russian Federation,

outlined the most important conditions for the development of the power engineering industry in an interview given to the editorial board of the magazine and published in this issue.

 

12 Devices for measuring total gas parameters

The temperature and pressure of hot gas are among the key parameters characterizing the operation of a gas turbine. Measuring gas parameters in a turbine allows not only to confirm the declared characteristics of a gas turbine, but also to verify calculation models and methods. Measuring devices are used to measure gas parameters, the main problem of creating which is to ensure operability at high gas temperatures, which for modern gas turbines can exceed 1500 ^oC.

The aim of the work was to create a device for measuring gas parameters that would ensure high measurement accuracy, maintain operability at high gas temperatures, be easy to manufacture and ensure ease of installation and fixation at an acceptable cost.

During the development of the measuring device, a number of design options for the device housing with a flow braking chamber were considered. Devices with cooling channels, as well as from heat-resistant materials (ceramics) without cooling.

The main disadvantages of cooled structures are the limited maximum permissible metal temperature, as well as the possible effect of the housing on thermocouple readings due to the cooling of the gas flow during heat exchange. The main disadvantages of ceramic structures are the difficulties in fixing the device, caused by the fact that the ceramic material cannot be fixed using standard fixation methods (welding, brazing). The disadvantages of ceramic structures also include low resistance to temperature changes.

Analysis of various designs of measuring devices allowed us to choose a cooled metal design, since such a design better meets all the requirements.

 

18 Import substitution energy: Russian companies complete the project on localization of SGT-800 working blade

For large power generating companies and oil and gas sector enterprises, the issue of maintaining and ensuring the life cycle of imported gas turbine equipment, including such high-tech parts as turbine blades, is still relevant and remains strategically important.

For a long time capital parts of the hot path of foreign-made gas turbines were almost entirely produced abroad. Full-fledged technologies of their production were transferred to Russia only in exceptional cases, which complicated operation and maintenance of such equipment.

Today the lack of domestic production of critical components of turbine hot path is one of the main problems of GTU service maintenance.

TurboService Rus LLC is a leader in gas turbine plant maintenance in Russia, implementing turnkey service solutions for power gas turbines of major manufacturers (Siemens, GE, Ansaldo), including field work, component refurbishment, supply of parts and consumables, including in-house production.

 

22 Heating Fuel before Combustion in GTU as a way to improve thermal efficiency of combined cycle power units

This article examines the impact of fuel preheating on the thermal efficiency of combined cycle condensing power plants (CCPPs). The main fuel preheating methods are analyzed, including recuperative heating, the use of intermediate heat transfer fluids, electric heating, and combined approaches. A review of CCPP projects with fuel preheating implemented at thermal power plants in Russia is conducted. The study explores technological parameters, fuel supply schemes, and the

integration of heating units into the main technological process of CCPPs.

To assess the impact of fuel preheating on gas turbine unit (GTU) performance, mathematical models were developed and implemented in the Thermoflow software package. The results show that fuel preheating reduces the specific consumption of natural gas and increases the efficiency of CCPPs. Acceptable limits for fuel preheating temperature variations for different natural gas compositions were determined based on the Wobbe Index range constraints for various types of GTU combustion chambers.

The influence of fuel preheating on the thermal efficiency indicators of 460 MW and500 MW CCPPs, based on GTE-170.1 and GTE-170.2 gas turbines, was analyzed. The obtained data can be applied in the design and modernization of CCPP power units.

 

30 Analysis of changes in key parameters gas turbine GTE-170.1

Today, the development of the energy complex using domestic equipment occupies a very important position in the development of our country. At the moment, there are only 2 companies that are implementing projects to create serial high-power gas turbines: Power Machines JSC with the latest GTE-170 turbine (Figure 1), created based on the experience of manufacturing the SGT5-2000E turbine (GTE-160) under a Siemens license, and the company ODK-Saturn PJSC with the installation of GTE-110M.

Along with the development and serial production of high-power gas turbines, the relevance of researching possible options for upgrading such turbines is increasing.

The article discusses the modernization of the cooling system of the GTE-170.1 turbine, which consists in the use of a combined steam-air cooling system instead of the currently used air one. A thermogasodynamic calculation of the GTU is carried out in the ThermoGTE program, according to the results of which changes in the main important parameters are analyzed, such as power at the terminals of the generator, electrical efficiency, temperature in front of the turbine.

 

36 Gas turbine power plants produced by KADVI PJSC for small-scale energy projects in Russia

This article is devoted to the experience of KADVI PJSC in the field of production of gas turbine power plants powered by associated petroleum gas. The author notes the characteristics of a gas turbine power plant and its components, reflecting the advantage of the development of KADVI PJSC over other types of power plants.In addition, special attention is paid to the method of processing associated petroleum gas and its subsequent conversion into an energy source for the operation of a gas turbine engine in a power plant. In the final part of the article, the author provides practical examples of the implementation of a gas turbine power plant at customer facilities.

 

38 Possibility of boosting parameters of GTU compressor of high capacity by increasing the load on the input stage unit

The article presents an overview of the calculations conducted as part of the project for the development of a high-efficiency high-capacity gas turbine unit (GTU). The prototype of compressor is GTU-170.2 axial compressor.

The modernization of the compressor was carried out through the redesign of the inlet stage block and was performed in several steps:

• redesign of blade stagger angle only;
• redesign of blade stagger angle and the shroud wall.

The computational tools used for the aerodynamic redesign of the inlet stage group included: Siemens NX10, NUMECA AutoGrid5 and Ansys CFX.

The computational models of the modernized GTU-170.2 axial compressor were created. Compressors ensure all requirements of the scope of wok. Compressor map, load distributions across the stages, and efficiency characteristics were established.

Stall margin of the compressor was estimated at the design point and part load conditions.

As a result of the modernization of the inlet stage block of the GTU-170.2, two geometry compressor flow path were obtained. These models can be further used as baseline options in the design of compressors for high-capacity GTU.

 

42 Supply of energy equipment - it is responsible and not easy at all

Working in the energy industry implies a very serious attitude to fulfillment of responsibilities in the implementation of small and large projects.

This allows us to build respectful and long-term partnerships with our customers.

In No. 1-2025 of the magazine, we introduced one of our new partners - group of companies RENN.

We discussed with Rustem Rafikovich Khusnutdinov, Deputy General Director of the company, about what approaches and requirements to work he considers the main.

In 15 years, an extensive diversified business has been created and the development does not stop.

The main activities of the company are supply of complex process equipment to power engineering, petrochemical and oil refining enterprises, construction, installation and commissioning works, service.

 

48 Design and manufacturing experience industrial steam turbines

This article presents a comprehensive study of the design features of the modern model range of steam turbines developed and produced at the production facilities of Kaluga Turbine Works PJSC in the period from 2017 to 2023. The following turbine models were analyzed in detail – K-12-1,2; PR-16-9,4/2,6/0,4; K-2,4-4,9P; K-22-8,8P; TG5,0/10,5 PR2,3/1,3/0,5.

In the course of the study the design features of each model were described in detail, including features of the flow part, regulation system and auxiliary equipment. Special attention was paid to technical characteristics of the units, their power, steam parameters and operational indicators. When developing the new models, the developments and technological solutions tested on the previous generations of the company's turbines were used. This made it possible to create reliable equipment with improved performance characteristics meeting modern industrial requirements.

The article considers in detail technological processes and production cycles of those industrial facilities where these plants have been implemented. Special emphasis is made on the specifics of customer enterprises, their technological features and requirements to power equipment. The main technical requirements of the customers, which were taken into account in the design and manufacture of turbines, were analyzed in detail. Among them: the need to ensure high reliability and durability, energy efficiency requirements, specifics of integration into existing technological schemes, the need for automation of control, environmental performance of the equipment.

 

54 Сontrol of starting modes of steam turbines by thermal stress state of the rotor

Automation of starting modes of steam turbines is one of the most important parts of automation of control of technological processes of power units. In this article, it is proposed to use the value of equivalent temperature stresses in the control stage as one of the key parameters characterizing the reliability of starting a steam turbine. The author presents the principles of developing a model for heating a steam turbine rotor to automate start-up control and continuous monitoring of its thermally stressed state using a personal computer in real time. A preliminary study of the thermally stressed state of the rotor, conducted using a universal CAE program using the finite element method, allowed us to hypothesize that maximum temperature stresses can be calculated with sufficient accuracy based

on information about «characteristic» temperature differences inside the rotor using the regression analysis formula. The typical use of FEM programs involves «offline» computing, but the rapid pace of computer technology development has become the main incentive to consider the possibility of real-time modeling based on FEM models.

It is proposed to evaluate the thermally stressed state using a regression dependence on the «characteristic» temperature differences of the temperature field in real time. An example of the entire complex of necessary computational studies for the creation of modules for the T-110/120-130 steam turbine control device is given. The modules have been tested in the Matlab Simulink environment.

 

60 Modern heat exchange and auxiliary equipment developed and manufactured by Kaluga Turbine Works PJSC

The article provides an overview of heat exchange and auxiliary equipment developed and manufactured by Kaluga Turbine Plant PJSC (hereinafter referred to as KTP PJSC). By constantly improving serial equipment, Kaluga Turbine Plant PJSC implements new developments in heat exchange equipment. An overview of serial capacitors is presented, as well as the latest developments, taking into account many years of experience in designing and operating equipment. Their technical characteristics and design description are given. The KP-650 condenser is described, the main feature of which is the lateral steam supply for the layout of a turbine unit with an axial exhaust pipe.

The design features of capacitors designed to operate on seawater are indicated. The description of the block air condensation unit «Fog 4K» is presented. The nomenclature of low and high pressure heaters, oil coolers is given. An overview of serial steam jet main ejectors, steam extraction ejectors from seals, as well as a block of ejectors is presented. Their technical characteristics and description are given.

 

68 Development of the program complex for design and efficiency analysis flow parts of steam turbines

With the development of digital technologies, the opportunities for automation of design processes in power engineering are expanding. Modern computers open new approaches to calculations with the processing of large amounts of data, allowing to reduce time and increase the number of considered options in the design process. For this purpose, it is necessary to develop calculation algorithms and software that will allow rapid data processing and control of key results at all stages of the project. Designing the flow part of a steam turbine cylinder requires solving a number of interrelated problems, iterating the calculations and refining the results.

The article considers a software package developed at the Department of Steam and Gas Turbines named after A.V. Shcheglyaev and allows to perform gas-dynamic calculation of the flow part and visualize the results obtained. It is possible to perform calculations with a large number of variants of the flow part of a steam turbine, analyze the results and change the parameters to obtain the maximum efficiency of each cylinder.

The software system consists of tools and interfaces that allow you to select the number of sections for profiling steps in height depending on the twist laws.

 

74 Composition solutions for installation and operation steam turbogenerator units in Arctic conditions

The development of the Arctic's energy infrastructure requires the use of specialized solutions that take into account extreme climatic conditions, complex logistics, and the specifics of equipment operation in remote regions. The unfavorable natural and climatic conditions of the permafrost zone negatively affect the infrastructure of the Arctic regions. This significantly increases the cost of construction and operation of buildings and structures, and also forces us to constantly look for new approaches and technologies for the construction of infrastructure facilities to ensure their sustainability. This article is devoted to the analysis of layout solutions for the installation and operation of steam turbine generating units with a capacity of up to 5 MW designed for low-power nuclear power plants in the Arctic. The main focus is on the basement-free layout, minimizing construction and installation work, increasing the transport accessibility of equipment and its adaptation to difficult operating conditions. The block-modular design of the vocational school is also being considered, providing compactness, ease of installation and high operational reliability. The presented solutions are aimed at increasing the efficiency of using local energy resources, reducing transportation and installation costs, as well as improving the operational characteristics of installations in the Far North.

 

84 For the first time in the territory of the RF a complete cycle of reconditioning repair of SGT5-4000F gas turbine engine parts was carried out

Mastering the repair of the hot part of high-tech power equipment of large capacity is undoubtedly a significant contribution to the development of import substitution and ensuring the technological sovereignty of the country as the main benchmark for achieving the national development goals of the Russian Federation until 2030, and also confirms the readiness of domestic business to solve the most complex tasks at a high world level.

 

86 Determination of the limits of various electropneumatic actuator structures with discrete pneumatic valves and sliding controls

This study presents a comparative analysis of the efficiency of 3-, 5-, and 7-mode sliding control of an electro-pneumatic actuator with discrete on/off valves. The research is based on the construction and analysis of Pareto fronts, enabling an objective evaluation of the trade-off between positioning accuracy and the switching frequency of the vales.

A mathematical model of the pneumatic actuator has been developed, accounting for the nonlinear dynamics of the pneumatic system and the discrete nature of the control actions. A methodology for multi-objective optimization of control algorithm parameters is proposed, utilizing surrogate models to reduce computational complexity.

Numerical simulation results demonstrate that increasing the number of control modes from 3 to 5 reduces the average switching frequency of the valves by approximately 34%, while maintaining comparable positioning accuracy. The effectiveness regions of different control modes have been identified based on the required positioning accuracy.

The findings can be used in the design and optimization of electro-pneumatic actuators with on/off valves for various industrial applications. The proposed approach to comparative analysis using Pareto fronts can be applied to investigate other types of control systems with conflicting quality criteria.

 

92 Russian small capacity GTUs for distributed power generation

Industrial gas turbine engines are being developed in Russia in all power ranges – small, medium and large. Application of low-power GTUs for distributed power generation is very important. Such GTUs are traditionally used in the oil and gas industry, at industrial enterprises, in the municipal sector.

Power units operate in base and standby modes, using natural and associated gas.

The main engine components are the inlet and compressor, ignition system and combustion chamber with fuel manifold, turbine, rotor bearing assembly, a set of sensors for monitoring GTE parameters and turbine/gearbox coupling.

A full-scale exhibition sample of the turbine was presented at the company's stand, which fully demonstrates it’s design features.

 

94 Comparative analysis of modern power plants for power generation

The article presents a comparative analysis of different types of power plants used in power plants of the world power complex. The structure of installed capacity by types of power plants is considered. A significant sector of the energy structure is occupied, despite a number of disadvantages, by thermal power, including steam, gas, combined cycle, diesel and gas piston power plants, which account for more than 57% of the world energy production. Green energy accounts for 37,1% of the installed capacity. The share of nuclear power is about 5% of the installed capacity.

Different types of modern power plants used in the world power industry are considered, the technical and economic characteristics of power plants achievable at the moment, their main advantages and disadvantages, as well as manufacturers are presented.

The analysis of the structure of installed capacity, technical characteristics and efficiency of different types of power plants allows to get a comprehensive view of the current state and prospects of development of the energy sector.

 

100 Operation of TPU TPP in Kolomna produced by TMH Energy Solutions

The Kolomna Plant, part of TMH Energy Solutions, has mastered serial production of new domestic gas piston power plants production of new domestic gas piston power plants. This makes a significant contribution to the development of the Russian market of distributed power generation.

One plant is capable of generating 900 kW of electricity and 1100 kW of heat. In terms of total heat production, the two plants can fully supply the Kolomna Plant with hot water.

 

102 Our teachers. G.S. Zhiritsky – the energy of service

Successful realization of research and development work, with the active creative participation of young people, would be impossible without the accumulated experience, passed on to us by our teachers, without the scientific, methodological and experimental base, laid in the past years.

This article opens the cycle of publications about outstanding turbine engineers. and is timed to the 95th anniversary of the National Research University MPEI.Today the department has the leading laboratory in the country for the study of gas-dynamic processes in the flow parts of turbomachines, including research in the field of two-phase media, equipped at the level of the best research centers in the world. Research works are carried out with the financial support of the Russian Foundation for Basic Research, under contracts with domestic and foreign firms.