6 The first human spaceflight marked a new era in human history

This issue is dedicated to the 65th anniversary of the first human spaceflight. On April 12, 1961, Soviet cosmonaut Yuri Alekseyevich Gagarin became the first person in the world to travel into space aboard the Vostok-1 spacecraft. Let’s read, reminisce, and learn the facts about the flight and the spacecraft. We’re proud!

 

8 Investing in the future: a new classroom has been opened at Ural Federal University

At the Ural Federal University, in the Turbines and Engines department of UralENIN, a ceremony was held to mark the opening of a lecture hall that was modernized with the support of TurboService Rus the leader in the Russian gas turbine maintenance market.

 

10 RENN-K LLC: evolution from service contractor to technology partner in a cyclical manner

Rustem Rafikovich Khusnutdinov, General Director of RENNES-K LLC, spoke in an interview with our publication about how the geography of projects has changed, why the company entered the import substitution market for critical components of energy equipment and what production facilities were involved.

 

14 Comprehensive solutions for the design and manufacture of GPU AIS and Irtysh power units

This article describes the stages of work carried out by INGС LLC on the development and manufacture of air intake systems (AIS) for gas-handling units and high-power energy units, and highlights their main features. The article examines the CFD software suite and multi-step calculation methods used to address design challenges, determine structural solutions, justify design optimization, and reduce the aerodynamic drag of the system. It presents a concept for selecting the design and standardizing the components of modularly constructed air intake systems.

A number of features and technical solutions aimed at improving the reliability and energy efficiency of structural elements are highlighted. Particular attention is paid to structural components for high-power energy units; the design features and characteristics of completed projects are described. Issues related to the technology and quality of manufacturing structural components are examined, along with the advanced methods of manufacturing, inspection, and testing employed.

 

22 A new method for reverse engineering gas turbine blades instead of traditional reverse engineering

This paper examines existing reverse engineering (RE) methodologies for high-tech components, using turbine blades as a primary case study.

Based on a comprehensive literature review and practical experience in reverse engineering hot gas path components of foreign-made turbines, a structured RE methodology is proposed. This approach ensures that the reconstructed turbine blade is not designed in isolation from the overall gas turbine unit (GTU), but rather incorporates thermal, gas-dynamic, and structural analyses, all validated through CFD/FEA simulations and, ultimately, field testing.

Reverse engineering is viewed from two perspectives: on the one hand, as the traditional approach to reverse engineering used by most companies, and on the other hand, as a method of sequential calculations that describe processes and operating conditions.

The concluding part of the article presents a unique roadmap detailing the sequential stages of turbine blade reverse engineering. Rather than delving into the minutiae of a single stage, this work focuses on defining the framework of the new methodology and justifying why the conventional approach is insufficient for high-performance components.

 

28 Components and elements of the AIT and AIS systems in GTU: their impact on the efficiency of GTU

Modern power engineering is characterized by a steady trend toward increasing the share of gas turbine and combined cycle gas turbine plants in the structure of generation capacities. High operational flexibility, relatively low capital costs, and environmental friendliness make GT units one of the key elements of modern energy infrastructure. The development of combined-cycle generation is enshrined in the official Low-Carbon Development Strategy up to 2050, where CCGT plants are defined as one of the crucial technologies for meeting growing electricity demand while reducing emissions. During operation, a gas turbine unit processes a large volume of atmospheric air through the compressor.

For modern GT units with capacities of 100...300 MW, the mass flow rate of air may reach 300...800 kg/s. It should be noted that each component of the air intake duct has a specific aerodynamic resistance determined by various factors such as its function, design, geometry, and layout.

This paper examines the elements of the air intake tract and provides their characteristics. A classification of complex air cleaning devices based on design features is presented.

A block diagram illustrating the influence of tract elements on the technical and economic performance indicators of a gas turbine unit has been developed.

 

36 The application of additive technologies in gas turbine engine manufacturing: experience, challenges and prospects

The development of gas turbine engine manufacturing in Russia amid sanctions-related restrictions requires the search for new technological solutions that ensure independence from imports and enhance the competitiveness of domestic products. Kaluga Engine PJSC is actively pursuing the implementation of additive technologies in gas turbine engine manufacturing.

A distinctive feature of power plants manufactured by PJSC KADVI is their ability to operate on associated petroleum gas with a high impurity content. This makes it possible to address environmental challenges by utilizing gas that was previously flared and to ensure power supply to remote fields.

 

38 Modeling of a hybrid power plant based on GTE-65 and high-temperature fuel cells

This work aims to improve the efficiency of a gas turbine plant by developing a hybrid power plant based on the GTE-65 gas turbine manufactured by Power Machines JSC and high-temperature fuel cells. During the research, a methodology was developed for calculating solid oxide fuel cells, with data validation based on experimental results and thermodynamic equations, taking into account internal losses in the fuel cell. A mathematical model was developed for the comprehensive calculation of the hybrid power plant under various steam supply loads from the fuel cell to the combustion chamber of the gas turbine.

The advantages and disadvantages of the internal reforming method via steam conversion of methane for hydrogen production were analyzed. Under specified parameters, an increase in electrical efficiency to 39% and power output to 286 MW was achieved. It is shown that the integration of high-temperature fuel cells into the gas turbine plant configuration leads to a significant increase in the efficiency of the gas turbine plant, accompanied by an increase in fuel costs. As directions for further research, it is proposed to study emissions from fuel cells and the gas turbine, as well as to perform calculations of technical and economic parameters to determine the feasibility of implementing a hybrid plant.

 

44 The effect of layer-by-layer wire deposition on the structure and properties of the VT6 titanium alloy

This paper presents the results of an experimental study conducted at UEC-Aviadvigatel JSC on the effect of layer-by-layer wire cladding on the structure and mechanical properties of the VT6 titanium alloy used in gas turbine engine (GTE) blades. The relevance of this work stems from the need to improve manufacturing efficiency, as well as the reliability and performance of modern domestic gas turbine engines, while simultaneously reducing their weight and production costs.

The objective of the study is to investigate the effect of layer-by-layer wire cladding technology on the properties of the VT6 titanium alloy. During the study, comprehensive fatigue tests were conducted on 18 blade samples, followed by inspection and metallographic analysis of the tested samples.

The results showed that the fatigue life of the blade samples with the deposited layer exceeds that of the samples without the deposit by 15%. At the same time, the stress range during fatigue testing for the samples with cladding is significantly lower (22% versus 44%).

Metallographic analysis revealed isolated areas of incomplete fusion up to 0.25 mm deep, which do not affect fatigue strength.

 

48 A comparative analysis of the performance of domestic turbocharger units for the UKL-7

The efficiency of process turbocharger units (PTUs) is primarily determined by the air flow rate required for the process and the specific costs of compressing and pumping the air.

At the same time, the efficiency of PTUs is also directly linked to the parameters and specific condition of the process line.

Years of development, refinement, and the accumulation of operational and maintenance experience with the GTT-3-type TTKA (developed by NZL), as well as a significant modernization of the UKL-7 technology, along with the elimination of obvious defects, led to adaptations that allowed leading manufacturers to achieve a significant increase in design capacity, energy efficiency, and equipment reliability despite the turbocharger’s complex thermal scheme.

 

52 Impeller of a low-speed centrifugal pump with a movable blade cascade

Centrifugal pumps with low specific speed are widely used in industry; however, they are characterized by low energy efficiency due to their design features. This paper proposes an approach to improving energy efficiency based on the ability of each blade to rotate relative to its own axis, which allows for changes in the diffuseness of the interblade channel and the output angles, improving the alignment of flow regimes. The calculation methodology for the adaptive blade system includes impeller design and development of a blade-rotation mechanism. CFD simulations showed that, with increasing flow rate, the blade wrap angle should decrease while the outlet angle should increase, whereas the leading edge remains unchanged.

Visual analysis demonstrated that an appropriate blade rotation can produce a similar effect. Further calculations refined the allowable range of blade rotation angles and established the dependence of blade position on flow rate. Subsequent numerical studies and full-scale experiments confirmed that changing blade positions leads to an increase in the energy efficiency of the pump unit. In addition, a movable blade cascade significantly modifies the shape of the head–flow characteristic, which can be used for pump control within a limited operating range. The obtained results confirm the promise of the adaptive blade system as a technical solution for improving the target performance characteristics of pump units.

 

58 TMH gas-diesel power unitswill be installed on Shikotan Island

The Kuril Islands are in the process of converting their power grid to natural gas.

The modernization of the islands’ power grid is being carried out in accordance with instructionsfrom Russian President Vladimir Putin.

 

62 Study of the blade assembly of the PR-20-90/10-09M turbine beyond the product's service life

This article examines the main criteria for the design and manufacture of blade assemblies at Kaluga Turbine Plant PJSC. It focuses on the factors influencing the selection of specific blade geometries during the design documentation phase currently in use at Kaluga Turbine Plant.

The history of the modernization and continued operation of the PR-20-90/10-09M steam turbine, manufactured by the plant, at Voronezh CHPP-1 is presented; this turbine has been in operation to this day beyond its guaranteed service life.

The defect analysis of the 15th stage of the PR-20-90/10-09M steam turbine, which had operated in the flow path for 42 years prior to the product’s overhaul, is described.

The characteristics and material used for the blades of the 15th stage of the PR-20-90/10-09M steam turbine are specified, and the working fluid parameters in the stage are provided.

The residual properties of the blade material are analyzed for compliance of the chemical composition and mechanical properties with the current regulatory standards for this material, which Kaluga Turbine Plant PJSC currently uses for the manufacture of the blade assembly.

The microstructure of the material of the 15th-stage steam turbine blade is presented and analyzed at various magnifications, and the most severe defects that occurred during the operation of the PR-20-90/10-09M steam turbine are shown.

A conclusion has been reached regarding the suitability of the material used for the 15th-stage steam turbine blade PR-20-90/10-09M after the product has exceeded its service life.

 

68 Development and implementation electromechanical turning gear device for the PR-30/35-8.8/1.0 turbine at the Severskaya CHPP

This article presents a comprehensive technical analysis of the design features of modern turning gear devices integrated into steam turbine units. The high relevance of this research stems from the need to significantly improve the operational reliability and durability of critical power generation equipment under conditions of variable load schedules. The author examines in detail the functional purpose of these components, which ensure strictly uniform cooling of the massive rotor following a planned or emergency shutdown of the unit, thereby completely eliminating the risk of dangerous thermal deformation (thermal deflection).

An overview of existing engineering solutions is provided, during which the key operational advantages and disadvantages of traditional designs are identified and systematized. Particular attention is paid to an innovative development the design and implementation of a fundamentally new KTP PJSC, equipped with a high-tech electromechanical drive. This solution represents a qualitative transition from outdated hydraulic or purely mechanical systems to more precise, energy-efficient, and fully automated methods of intelligent control of the shaft rotation at ultra-low speeds.

 

74 Autofrettage of turbine discs

This article examines the autofrettage process as applied to steam turbine discs, which are subjected to significant mechanical stresses during operation. The focus is on analyzing the stress distribution in the disc material following the autofrettage procedure, as well as evaluating the impact of this technology on improving the fatigue life and reliability of the structure.

The authors examine the theoretical foundations of the method, including the mechanisms of residual compressive stress formation and their influence on the distribution of working tensile forces. The article provides information on the method used at Kaluga Turbine Plant PJSC to reduce stresses in the turbine disk hub in order to improve the operational reliability of this component and extend its service life. Experimental relationships between the disk rotation speed during autofrettage and the material’s yield strength are presented. The design of the setup for the autofrettage of turbine discs manufactured by the Kaluga Turbine Plant and its operating principle are described. The main advantages of using autofrettage in the manufacture of flow-through parts for the plant’s steam turbine model range are highlighted.

This article is intended for design engineers, researchers, and specialists involved in the development and design of high-load components for power generation equipment, as well as senior undergraduates and graduate students in related fields. It is of interest both as a fundamental study in the fields of mechanical engineering and materials science and as a guide to the practical implementation of technologies for improving the quality of turbine plant components.

 

82 The first domestically developed laser-electrical discharge machining equipment and hybrid processing technologies

This article examines the current challenge of drilling deep cooling holes in the blades of gas turbine and turbojet engines made of heat-resistant nickel alloys with modern thermal-protective ceramic coatings.

Global and domestic approaches to solving this problem, including hybrid technologies, are analyzed in detail. The main focus is on the development and implementation of a domestic system for hybrid laser-erosion processing, combining laser ablation of ceramics and electrical discharge machining (EDM) of holes on a single coordinate system controlled by a single CNC.

Key technical solutions are described: the use of a picosecond laser for «cold» processing, the creation of a proprietary control system for the erosion process with feedback, and the development of algorithms for precise alignment of hole geometries during complex 5-axis machining.

The results of the development of a domestic complex for hybrid laser discharge machining, implemented by specialists from UEC-Saturn PJSC and Lasers and Equipment LLC, are presented. The paper describes technical solutions, the advantages of the equipment, control algorithms, and capabilities that enable improved quality, productivity, and flexibility in the production of critical aircraft engine components.

 

88 Intelligent cloud platform for the operation and maintenance of microgrids and power plants

The Fortrust cloud platform for operation and maintenance represents another step toward meeting customer needs, combining a cutting-edge solution for integrating power generation units, cloud-based monitoring tools, and a suite of on-site maintenance services. The maintenance methods used are better aligned with customer needs: on-site and cloud-based equipment operation and maintenance, ensuring a reliable power supply, extending equipment service life, reducing the cost of electricity.

 

92 The repair of the gasturbine shrouds was carried out by ROTEK СM

ROTEK Components and Materials (ROTEK CM), a leading Russian manufacturer of high-tech components for the power and aviation turbine industries, has completed repairs on the annular stator components of the flow path (shrouds) for a General Electric gas turbine installed at the power units of the power generation.
The work was carried out as part of comprehensive inspection programs for gas turbine units. Specialists from ROTEK СM performed a comprehensive restoration of the shrouds, including the restoration of surface geometry and the replacement of honeycomb gaskets. Shrouds in gas turbine units are segments that, when installed in the turbine, are assembled into a ring and form the outer boundary of the turbine’s flow path.

 

94 Selecting turbine oils: from traditional testing to real-world performance

Modern gas turbine units and compressors place high demands on turbine oils. The reliable operation of this complex and expensive equipment depends on the reliability of the lubricants.

Independent international studies and practical experience indicate that there are a number of systemic issues involved in selecting lubricants and assessing their quality. These include the following: a simplistic approach to selection; the inadequacy of traditional tests; the gap between laboratory results and real-world performance. One of the studies that served as the basis for this article was conducted by Elona Rista, a technical support specialist at Solar Turbines, and Greg Livingston, Director of Innovation at Fluitec, and presented at the OilDoc-2023 conference.

 

100 Study of the influence of the geometry of flow path elements on the biosafety of hydro turbines

The article investigates how the axial hydraulic turbine rotor affects energy performance and fish-passage biosafety when fish transit through the flow passage. A parametric 3D-model was developed in ANSYS Workbench to study, in a single-criterion manner, how modifications introduced into a conventional runner design influence biosafety. The varied parameters were, sequentially, the blade thickness, blade wrap angle, and the number of runner blades. Mesh convergence of the computational model was assessed using hydraulic efficiency. The CFD simulations were carried out in a steady-state formulation employing the k–e turbulence model. The reliability of the CFD results was confirmed by test-bench experiments on the hydroturbine rig at the National Research University MPEI, with an overall discrepancy of about 2%.

Biosafety was evaluated using an algorithm based on the analysis of hydrodynamic stressors that govern injury risk, namely pressure fluctuations, shear stresses, and the probability of blade contact.

The simulation campaign produced «power–biosafety» relationships that quantitatively describe the trade-off between power output and environmental constraints.

 

106 B.M. Troyanovsky represents 1,500 engineers and more than 60 years of scientific and technical innovation

March 2026 marked the 107th anniversary of the birth of the distinguished professor, renowned scientist, and recipient of the USSR State Prize and the Polzunov Prize, B.M. Troyanovsky, of the Department of Steam and Gas Turbines. As long as Boris Mikhailovich was able to move about on his own, he actively participated in the life of his Department of Steam and Gas Turbines.

Boris Mikhailovich Troyanovsky – a renowned scientist, recipient of the USSR State Prize and the Polzunov Prize, an outstanding educator, and professor in the Department of Steam and Gas Turbines – was born in March 1919 in Kharkiv.

 

110 65 years of the first human space flight

One of the main developers of the spacecraft was K. P. Feoktistov, head of the Design Department (later cosmonaut). The spacecraft's control system was developed under the supervision of Deputy Chief Designer B.E. Chertok, and the orientation system was created by designers B.V. Rauschenbach and V.P. Legostaev.

 

116 From 1680 to 1882

Russian inventors and engineers created the world's first samples of turbine, propulsion and rocket technology, which allowed humans to explore the corners of the Earth and outer space, achieving goals with record results.

This publication opens a series dedicated to the key achievements of our engineers and scientists since the 17th century.

 

122 A coal-fired thermal power plant

A new section of the magazine, which will present the design of fuel and energy complex facilities, energy equipment, systems and nodes