Southern Turbine Industrial Manufacturing Company. The main foreign manufacturers of modern gas turbine engines. JSC Kaluga Turbine Plant

The difficult international situation is forcing Russia to speed up import substitution programs, especially in strategic industries. In particular, to overcome dependence on imports in the energy sector, the Ministry of Energy and the Ministry of Industry and Trade of the Russian Federation are developing measures to support domestic turbine construction. Are you ready? Russian manufacturers, including the only specialized plant in the Urals Federal District, to meet the growing need for new turbines, the RG correspondent found out.

At the new Akademicheskaya CHPP in Yekaterinburg, a turbine manufactured by UTZ operates as part of the CCGT unit. Photo: Tatyana Andreeva/RG

Chairman of the State Duma Energy Committee Pavel Zavalny notes two main problems in the energy industry - its technological backwardness and the high percentage of wear and tear on existing capital equipment.

According to the Ministry of Energy of the Russian Federation, in Russia over 60 percent of power equipment, in particular turbines, have reached the end of their service life. In the Urals Federal District, in Sverdlovsk region There are more than 70 percent of them, however, after the commissioning of new capacities this percentage decreased somewhat, but still there is a lot of old equipment and it needs to be changed. After all, energy is not just one of the basic industries, the responsibility here is too high: imagine what will happen if you turn off the light and heat in winter,” says Doctor of Technical Sciences Yuri Brodov, head of the department of “Turbines and Engines” at the Ural Energy Institute of UrFU.

According to Zavalny, the fuel utilization factor at Russian thermal power plants is slightly above 50 percent, the share of combined cycle gas plants (CCGTs) considered to be the most efficient is less than 15 percent. Let us note that CCGT units were put into operation in Russia in the last decade - exclusively on the basis of imported equipment. The situation with Siemens’ arbitration claim regarding the allegedly illegal supply of their equipment to Crimea showed what a trap this is. But it is unlikely that the problem of import substitution will be solved quickly.

The fact is that while domestic steam turbines have been quite competitive since the times of the USSR, the situation with gas turbines is much worse.

When the Turbomotor Plant (TMZ) in the late 1970s - early 1980s was tasked with creating a power gas turbine with a capacity of 25 megawatts, it took 10 years (three samples were manufactured, requiring further development). The last turbine was taken out of service in December 2012. In 1991, they began to develop a power gas turbine in Ukraine; in 2001, RAO UES of Russia somewhat prematurely decided to organize serial production turbines at the Saturn company site. But the creation of a competitive machine is still far away, says Valery Neuymin, candidate of technical sciences, who previously worked as deputy chief engineer of TMZ for new technology, and in 2004-2005, developed the concept of technical policy of RAO UES of Russia.

Engineers are able to reproduce previously developed products; there is no talk of creating a fundamentally new one

We are talking not only about the Ural Turbine Plant (UTZ is the legal successor of TMZ - Ed.), but also about other Russian manufacturers. Some time ago, at the state level, a decision was made to buy gas turbines abroad, mainly in Germany. Then the factories curtailed the development of new gas turbines and switched mostly to the production of spare parts for them, says Yuri Brodov. - But now the country has set the task of reviving the domestic gas turbine industry, because it is impossible to depend on Western suppliers in such a responsible industry.

The same UTZ has been actively involved in the construction of combined cycle gas units in recent years - supplying steam turbines for them. But along with them, gas turbines of foreign production are installed - Siemens, General Electric, Alstom, Mitsubishi.

Today, two and a half hundred imported gas turbines operate in Russia - according to the Ministry of Energy, they are 63 percent of the total number. To modernize the industry, about 300 new machines are required, and by 2035 - twice as many. Therefore, the task has been set to create worthy domestic developments and put production on stream. First of all, the problem is in high-power gas turbine plants - they simply do not exist, and attempts to create them have not yet been successful. So, the other day the media reported that during tests in December 2017, the last sample of GTE-110 (GTD-110M - jointly developed by Rusnano, Rostec and InterRAO) fell apart.

The state has high hopes for the Leningrad Metal Plant (Power Machines), the largest manufacturer of steam and hydraulic turbines, which also has a joint venture with Siemens to produce gas turbines. However, as Valery Neuymin notes, if initially our side in this joint venture had 60 percent of the shares, and the Germans had 40, today the ratio is the opposite - 35 and 65.

The German company is not interested in Russia developing competitive equipment - this is evidenced by years of joint work - Neuymin expresses doubts about the effectiveness of such a partnership.

In his opinion, to create own production gas turbines, the state must support at least two enterprises in the Russian Federation so that they compete with each other. And you shouldn’t develop a high-power machine right away - it’s better to first bring to life a small turbine, say, with a capacity of 65 megawatts, work out the technology, as they say, get your hands on it, and then move on to a more serious model. Otherwise, money will be thrown away: “it’s the same as entrusting an unknown company to develop spaceship, because a gas turbine is by no means a simple thing,” the expert states.

As for the production of other types of turbines in Russia, not everything is going smoothly here either. At first glance, the capacity is quite large: today only UTZ, as RG was told at the enterprise, is capable of producing energy equipment with a total capacity of up to 2.5 gigawatts per year. However, the machines produced by Russian factories can be called new very conditionally: for example, the T-295 turbine, designed to replace the T-250 designed in 1967, is not fundamentally different from its predecessor, although a number of innovations have been introduced into it.

Today, turbine developers are mainly engaged in “buttons for a suit,” says Valery Neuymin. - In fact, now there are people at the factories who are still able to reproduce previously developed products, but there is no talk of creating fundamentally new technology. This is a natural result of perestroika and the turbulent 90s, when industrialists had to think about simply surviving. To be fair, we note: Soviet steam turbines were extremely reliable; a multiple safety margin allowed power plants to operate for several decades without replacing equipment and without serious accidents. According to Valery Neuimin, modern steam turbines for thermal power plants have reached the limit of their efficiency, and the introduction of any innovations into existing designs will not radically improve this indicator. But we cannot yet count on a quick breakthrough for Russia in gas turbine construction.

In Russia, on behalf of the President, the government is preparing a large-scale program for the modernization of thermal power plants (TPP), which is estimated at 1.5 trillion rubles and could start in 2019. One of its main conditions will be the use of Russian equipment. Is it possible to renew the electric power industry using domestic developments? The general director of Power Machines, Timur Lipatov, who headed the company three months ago, spoke about the development of new turbines, export potential and the necessary state support in an interview with the Prime agency.

- What is Power Machines focusing on now? Will you work mainly for the thermal power industry due to the upcoming modernization program?

For anyone. We cannot neglect any niche; the situation in the industry is not the best: markets are shrinking, competition is growing. Therefore, we make almost the entire range of equipment for nuclear, thermal and hydropower.

- What demand from Russian electric power companies is Power Machines ready for as part of the thermal power plant modernization program?

In the first competitive selection Projects with a total capacity of 11 GW will be selected for modernization, first of all, this will be the reconstruction of our traditional steam power equipment. Our production capacity allows us to produce up to 8.5 GW of turbine equipment per year, the same volume of generators, and about 50 thousand tons of boiler equipment.

We have well-developed projects for modernizing the K-200 and K-300 turbines, and we have a project for modernizing the K-800. These projects allow us to increase power, efficiency, extend service life, and respond flexibly to what the client needs. But the program is not limited only to condensing units (that is, generating electricity - ed.) with a capacity of 200 and 300 MW, so we are concentrating on the heating turbines PT-60 and PT-80. Their design has been revised, including improving the design of the body part and steam distribution. At the same time, solutions have been developed for replacing and upgrading turbines from third-party manufacturers. First of all, we are talking about the machines of the Kharkov Turbine Plant.

- It is planned to include in the TPP modernization program a provision for 100% localization in Russia of the production of the necessary equipment. If we don't talk about gas turbines, what kind of equipment still needs to be localized?

In my opinion, the only problem in the production of generating equipment in Russia remains large-sized casting and the production of large forgings (a metal billet obtained as a result of forging or hot stamping - ed.).

Historically, there were three manufacturers of castings in the USSR, two of which - in the Urals and St. Petersburg - were closed Foundry. As a result, there is only one supplier left in Russia, which does not always provide the required quality, and we are forced to purchase large-sized cast billets abroad, where their quality is more stable. We believe in the potential of Russian metallurgical enterprises, we believe that with appropriate government support and the emergence of guaranteed demand they will be able to restore competencies and provide the power engineering industry with high-quality cast billets and forgings. This is a parallel process, it is part of the thermal power plant modernization program, although it may not be on the surface right now.

- Power Machines announced plans to develop a domestic high-power gas turbine. Are you discussing partnerships with Russian or foreign companies?

The basic option is independent development of gas turbines, since the localization that any foreign company talks about is, as a rule, localization “by hardware”. We see our task not as repeating in Russia the production of an outdated foreign gas turbine model, but as restoring the domestic school of gas turbine construction.

Our ultimate goal is to restart the gas turbine production cycle by organizing a design bureau, creating calculation methods, a bench base, and thereby protecting the Russian energy industry from various negative external manifestations.

- What is the share of gas turbines from foreign manufacturers in Russia?

According to our estimates, if we take existing combined cycle gas turbine units (CCP) and gas turbine units (GTU), more than 70% are supplies from foreign manufacturers, another 24% are gas turbines produced by Interturbo (a joint venture of the Leningrad Metal Plant created in the 90s and Siemens).

At the same time, despite the presence of joint ventures, the production of the most significant elements of gas turbines - hot path components (fuel combustion chambers, turbine blades - ed.) and control systems - is not localized in Russia. Production is limited only to the assembly and manufacture of individual components, which are not critical for the performance of the gas turbine plant and the energy security of Russia as a whole.

- What line of gas turbines would Power Machines like to produce?

We are starting with 65 MW F-Class and 170 MW E-Class machines. In the future, it is planned to create a high-speed turbine of 100 MW with a free power turbine. Subsequently, it is possible to develop a 300-400 MW F or H-class gas turbine unit at 3000 rpm using scaling principles for some components.

- If Power Machines independently develops a turbine, then at what production site?

Here, at our production facilities in St. Petersburg.

- How much do you estimate R&D costs in general? What might be the startup costs? industrial production? And how long can this take?

We estimate the entire project for 65 and 170 MW machines at 15 billion rubles. This amount includes costs for R&D and technology development, development and technical re-equipment of design and technological services, modernization of the experimental research and production base. The production facility will be ready to produce prototype turbines in just two years.

- Why do you think that you will be able to develop a turbine? In Russia, other companies have many years of experience with unsuccessful attempts.

At one time, we were in the trend for gas turbines. The first such machine with a capacity of 100 MW was made at LMZ (Leningrad Metal Plant, part of Power Machines - ed.) in the 60s. And it was fully consistent with the technologies of that time. This foundation, unfortunately, was lost during the perestroika period. This area of power engineering in the world has become so technologically advanced, it has gone so far that in the 90s, an easier way to restore it was to acquire the right to use intellectual property and localize production in Russia. As a result, in the 1990s, in partnership with Siemens, LMZ created the joint venture Interturbo, from which the modern STGT grew (a joint venture between Siemens and Power Machines - ed.). Equipment production was located at the LMZ facilities and reached an honest 50% localization. As part of Interturbo, we gained experience in the production of gas turbine components, which is very correlated with our current work.

In the recent past, Power Machines independently, no longer as part of a joint venture, implemented a project for the development and production of the GTE-65 gas turbine with a capacity of 65 MW. The machine went through a full cycle of cold tests, reaching the so-called “full speed, no load” tests, but due to the lack of an experimental thermal power plant for testing and running the technology, it was not put into commercial operation.

- What, in your opinion, will contribute to the rapid development of gas turbine production technology in Russia?

I will name three fundamental factors. The first is preferences in the development of production of Russian gas turbines as part of the thermal power plant modernization program. Thanks to the reasonable dialogue between the Ministry of Industry and Trade and the Ministry of Energy, we believe this goal has been achieved. We hope that as part of the subsequent selection of projects for participation in the modernization program, restrictions on maximum capital costs for projects using domestic gas turbines will be lifted. This will make objects with domestic gas turbines more investment attractive.

The second factor is the possibility of Power Machines constructing, independently or with a partner, experimental thermal power plants with a total capacity of 1.4 GW within the framework of the KOM NGO mechanism (guarantees investors the payback of projects for the construction of new power plants due to increased payments from consumers for power - ed.). This is necessary in order to bring prototype gas turbine samples ready for industrial operation and to obtain the necessary experience and competencies for all possible implementations - single-shaft, two-shaft and three-shaft CCGT units for gas turbines of all types.
And thirdly, the speedy release of government decree No. 719 (amendments to the decree regulating the issues of localization of production in the Russian Federation - ed.), which will put all manufacturers, both domestic and foreign, on equal terms.

- As part of the TPP modernization program, do you expect to conclude contracts not only for specific power plants, but also for companies, perhaps for the entire duration of the program?

Of course, we are interested in long-term cooperation, but as part of the modernization program, the generating companies themselves will only have to participate in competitive selections.

At the same time, from my point of view, concluding such long-term contracts is a normal practice that will allow us to plan production program and not let counterparties meet deadlines if their projects are selected.
Currently, the main discussions concern framework agreements for repair and maintenance services and the supply of spare parts. When evaluating annual and three-year plans for repair campaigns, we typically see the potential to reduce the cost of spare parts and services provided by up to 15% by aligning production schedules.

- What kind of discussions are being held, are there any obstacles to the development of the service area?

The main obstacle to development is “garage production”. In the Soviet Union, drawings were often in free circulation; in the 90s, insufficient attention was paid to the protection of intellectual property. It is not surprising that as a result, a huge number of fly-by-night companies have arisen, where people in makeshift conditions, literally in a garage, produce outdated spare parts, with deviations from the standard dimensions, and materials that do not meet the physical and mechanical characteristics.

We receive a large number of requests from consumers asking us to agree on certain deviations in the working documentation from the original design during repairs. I see serious risks in this, since the reason for the failure of our equipment may be the use of non-original spare parts made with deviations. There are few serious players who can ensure proper deadlines and quality of work.

- How big is the problem of counterfeit products?

The market is filled with non-original spare parts, including counterfeit ones. We work to protect our technology, return intellectual property and prohibit its use by other players, using the opportunities that civil and criminal codes give us. They did not bear the costs of R&D (research and development work - ed.), do not guarantee quality, and damage our reputation. We count on support in this matter from Rostechnadzor, as well as other manufacturers.

- In the medium term, will the company focus on the domestic market or foreign projects? Which countries are you considering first for work? What technologies are in demand abroad?

- Power Machines has great export and technological potential. The main share of our projects abroad now is either nuclear and hydraulic, where we compete on equal terms with global manufacturers, or steam power units (reconstruction of previously supplied machines, production of equipment for burning fuels such as fuel oil and crude oil). The share of exports varies, but on average is about 50%.

To increase exports, we must master two fundamentally important technologies that Russia does not currently have. First, restore the production of domestic gas turbines of medium and high power. Secondly, make a pulverized coal boiler and a steam turbine for super-supercritical steam parameters (SSCP). Existing technologies make it possible to achieve fairly high efficiencies of 45-47% per steam turbines ah, working for the USSR. This is a reasonable alternative to the combined-cycle cycle, taking into account the relatively low cost of coal, and often due to the lack of gas in the region. We have already developed design documentation for the SSKP turbine with a capacity of 660 MW - and are ready to put it into production as soon as an order appears.

In order for new products to be in demand abroad, they must first be manufactured and introduced on the home market, in Russia. The presence of references will allow us to enter our traditional markets - in Asia, Latin America, and the Middle East. One of the ways to obtain the necessary competencies is the construction of experimental stations within the framework of the KOM NGO mechanism. In addition, you need governmental support– through the channels of intergovernmental agreements, with the attraction of export financing, preferential lending. This is what was done in the Soviet Union, and this is what our competitors abroad are doing now.

-What other directions do you see for the company’s development?

One of the areas will be support for small technology companies. There are a huge number of startups on the market that are complementary to our technological chain and sales channels. We intend to actively support the development of such companies by entering into their share capital, financing R&D and technology, and guarantees. The transfer of control will allow shareholders to generate significantly greater income by increasing sales volumes and expanding their channels. I ask everyone to consider this an official invitation; we will be happy to consider proposals. There are already examples of such successful interaction.

Transcript

1 UDC Khakimullin B.R. student, Department of PTE, Institute of Heat and Power Engineering Zainullin R.R. Candidate of Physical and Mathematical Sciences, senior lecturer of the Department of PES of the Federal State Budgetary Educational Institution of Higher Education "Kazan State Economic University" Russia, Kazan MAIN FOREIGN MANUFACTURERS OF MODERN GAS TURBINE ENGINES The article discusses the main advantages of foreign manufacturers of modern gas turbine engines in Russian market. Key words: gas turbine engine, unit power, foreign manufacturer, combined cycle plant. MAIN FOREIGN PRODUCERS OF MODERN GAS TURBINE ENGINES Hakimullin B.R., Zainullin R.R. In the article the main advantages of foreign producers of modern gas turbine engines in the Russian market are considered. Keywords: gas turbine engine, single power, foreign producer, steam-gas unit. Currently, the only area in the thermal energy industry in which Russian manufacturers are far behind the world's leading manufacturers is high-power gas turbines of 200 MW and above. Moreover, foreign manufacturers have not only mastered production

2 gas turbines with a unit capacity of 400 MW, but they have also successfully tested and are using a single-shaft arrangement of combined cycle gas turbine units (CCGT), when a gas turbine with a capacity of 400 MW and a steam turbine with a capacity of 200 MW have a common shaft (CCP-600). Moreover, Russian manufacturers of gas turbines are able to produce all the main components of combined cycle gas turbines (steam turbines, boilers, turbogenerators), but modern gas turbines are not yet available. Although back in the 70s, our country was a leader in this direction, when supercritical steam parameters were mastered for the first time in the world. Such large and advanced concerns as Siemens and General Electric, which often win tenders for the supply of energy equipment, are actively and very successfully operating in our market. There are already many generating facilities in the Russian energy system (Kazan CHPP-2, planned CHPP-1, CHPP-3), to one degree or another, equipped with the main power equipment produced by Siemens, General Electric, etc. However, their total capacity does not yet exceed 15% of the total capacity of the Russian energy system. The number of enterprises producing gas turbines in our country is very limited, there are no more than ten. There are even fewer enterprises producing ground-based equipment based on gas turbines. Among them are Nevsky Plant CJSC, NPO Saturn PJSC, UEC Gas Turbines OJSC and UEC-Perm Motors JSC. At the same time, in general, the nominal generated power of serial products of these enterprises does not exceed 25 MW. There are several machines with a unit capacity of 110 MW put into operation based on the developments of PJSC NPO Saturn, but today the design of the hot part of these industrial turbines continues to be refined.

3 General Electric (USA) is the world's largest manufacturer of aircraft, land and marine gas turbine engines (GTE). The General Electric Aircraft Engines (GE AE) division is currently engaged in the development and production of various types of dual-circuit aviation gas turbine engines turbojet engine(TF39, CF6-6, CF6-50, CF6-80C2), two-circuit turbojet engine with afterburner (turbojet engine F101, F110, F404, F414, F120), turboprop engine (TVD) and helicopter gas turbine engines (ST7, T58, T700 ). The range of thrusts and powers of these engines is very wide: turbofan engines from 40 to 512 kW, turbofan engines from 80 to 190 kW, turboprop engines and helicopter gas turbine engines from 900 to 3500 kW. General Electric Energy develops and manufactures aircraft-derived stationary gas turbine engines for power, mechanical and marine propulsion in the power range from 2 to 510 MW. This department also carries out marketing and supply of all types of onshore and offshore gas turbine engines from GE. Industrial and marine gas turbine engines are represented by the following range of models: gas turbine engines converted from aircraft engines LM500, LM1600, LM2000, LM2500, LM2500+, LM5000, LM6000; stationary gas turbine engines PGT5, PGT10, PGT25, MS5000, MS6000, MS7000, MS9000. Another large manufacturer is Siemens (Germany). The profile of this large company is stationary land-based gas turbine engines for power and mechanical drive and marine applications in a wide power range from 4 to 400 MW. The main brands of gas turbine engines developed and produced: Typhoon, Tornado, Tempest, Cyclone, GT35, GT10B/C, GTX100, V64.3A, V94.2, V94.2A, V94.3A, W501D5A, W501F, W501G. Among Russian manufacturers, one can highlight NPO Saturn PJSC (Rybinsk), which develops and produces military turbofan engines in the kn thrust class, turboprop engines and helicopter gas turbine engines with a power of

4 kW, as well as power gas turbine engines in the MW power class. The main brands of GTD are AL-31ST, AL-31STE, GTD-4, GTD-6, GTD-8, GTD-6.3, GTD-10, GTD-110. The traditional segment of the Russian gas turbine market is focused on generation facilities in oil and gas fields and gas pipelines. Gas turbine power plants make it possible to effectively utilize associated petroleum gas, solving not only the problem of energy supply, but also the rational use of hydrocarbon resources. For this reason, high-power turbines for creating large generation facilities are supplied mainly by foreign companies. US energy giant General Electric and France's Électricité de France (EDF) said they have completed production of one of the world's largest and most efficient gas turbines, the 9HA, at the Belfort turbine plant in France. The power of the first 9HA gas turbine will be 575 MW, the 9HA cold start to rated load occurs in less than 30 minutes, the efficiency is more than 61%. In the foreseeable future, the most common way of using gas turbines will still remain their usual combination with steam turbines as part of combined cycle gas plants. Sources used: 1. Gafurov A.M., Gafurov N.M. Ways to improve the efficiency of modern gas turbines in a combined cycle. // Energy of Tatarstan (37). S Gafurov A.M., Osipov B.M., Titov A.V., Gafurov N.M. Software environment for conducting energy audits of gas turbine units. // Energy of Tatarstan (39). WITH

5 3. General Electric Company. Turbines. Electronic resource/ Access mode: 4. Siemens gas turbines. Electronic resource / Access mode: 5. PJSC NPO Saturn. Electronic resource / Access mode: 6. GE has manufactured the latest 9HA gas turbine. Electronic resource / Access mode:

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M. Vasilevsky

Today, leading foreign power engineering companies, primarily such giants as Siemens and General Electric, are actively working on the Russian gas turbine equipment market. Offering high-quality and durable equipment, they represent serious competition domestic enterprises. Nevertheless, traditional Russian manufacturers are trying not to yield to world standards.

At the end of August this year, our country became a member of the World Trade Organization (WTO). This circumstance will inevitably lead to increased competition in the domestic power engineering market. Here, as elsewhere, the law applies: “change or die.” Without revising technology and carrying out deep modernization, it will be almost impossible to fight the sharks of Western engineering. In this regard, issues related to the development of modern equipment operating as part of combined cycle gas plants (CCGTs) are becoming increasingly relevant.

In the last two decades, steam-gas technology has become the most popular in the world energy sector - it accounts for up to two-thirds of all generating capacities commissioned on the planet today. This is due to the fact that in combined cycle gas plants the energy of the burned fuel is used in a binary cycle - first in a gas turbine, and then in a steam turbine, and therefore the CCGT is more efficient than any thermal power plants (CHPs) operating only in the steam cycle.

Currently, the only area in the thermal energy industry in which Russia critically lags behind the world's leading manufacturers is high-power gas turbines - 200 MW and above. Moreover, foreign leaders have not only mastered the production of gas turbines with a unit capacity of 340 MW, but have also successfully tested and are using a single-shaft CCGT layout, when a gas turbine with a power of 340 MW and a steam turbine with a power of 160 MW have a common shaft. This arrangement makes it possible to significantly reduce the construction time and cost of the power unit.

In March 2011, the Russian Ministry of Industry and Trade adopted the “Strategy for the Development of Power Engineering in the Russian Federation for 2010-2020 and until 2030,” according to which this direction in the domestic power engineering receives solid support from the state. As a result, by 2016, the Russian power engineering industry must carry out industrial development, including full-scale testing and refinement on its own test benches, of advanced gas turbine units (GTU) with a capacity of 65-110 and 270-350 MW and combined cycle gas units (CCGT) at natural gas with an increase in their coefficient of performance (efficiency) up to 60%.

Moreover, Russia is able to produce all the main components of CCGT units - steam turbines, boilers, turbogenerators, but a modern gas turbine is not yet available. Although back in the 70s, our country was a leader in this direction, when supersupercritical steam parameters were mastered for the first time in the world.

In general, as a result of the implementation of the Strategy, it is assumed that the share of power unit projects using foreign main power equipment should be no more than 40% by 2015, no more than 30% by 2020, no more than 10% by 2025 . It is believed that otherwise the stability of the Russian unified energy system may become dangerously dependent on the supply of foreign components. During the operation of power equipment, replacement of a number of components and parts operating under conditions of high temperatures and pressures is regularly required. However, some of these components are not produced in Russia. For example, even for the domestic gas turbine GTE-110 and the licensed GTE-160, some of the most important components and parts (for example, disks for rotors) are purchased only abroad.

Such large and advanced concerns as Siemens and General Electric, which often win tenders for the supply of energy equipment, are actively and very successfully operating in our market. The Russian energy system already has several generating facilities, to one degree or another equipped with basic energy equipment produced by Siemens, General Electric, etc. However, their total capacity does not yet exceed 5% of the total capacity of the Russian energy system.

However, many generating companies that use domestic equipment when replacing it still prefer to turn to companies with which they have been accustomed to working for decades. This is not just a tribute to tradition, but a justified calculation - many Russian companies have carried out a technological upgrade of production and are fighting on an equal footing with the world's power engineering giants. Today we will talk in more detail about the prospects of such large enterprises, such as JSC Kaluga Turbine Plant (Kaluga), CJSC Ural Turbine Plant (Ekaterinburg), NPO Saturn (Rybinsk, Yaroslavl region), Leningrad Metal Plant (St. Petersburg) , Perm engine-building complex (Perm region).

JSC Kaluga Turbine Plant

OJSC Kaluga Turbine Plant produces low and medium power steam turbines (up to 80 MW) for driving electric generators, drive steam turbines, block turbogenerators, geothermal steam turbines, etc. (Fig. 1).

Fig.1

The plant was founded in 1946, and four years later the first 10 turbines of its own design (OP300) were produced. To date, the plant has produced more than 2,640 power plants with a total capacity of 17,091 MW for energy facilities in Russia, the CIS countries and foreign countries.

Today, the enterprise is part of the Power Machines power engineering concern. One of the practical results of the affiliation was the implementation in January 2012 of the SAP ERP information solution based on the existing prototype, successfully used at OJSC Power Machines, instead of the Baan system previously used at KTZ. The information system being created will allow the enterprise to reach a new level of production automation, modernize its business processes based on the best practices of world leaders in the engineering industry, and increase the accuracy and efficiency of management decisions.

The plant's products are in stable demand in Russia and abroad. The company has a large portfolio of orders for gas turbine and steam turbine equipment. In 2011, for Ufa CHPP No. 5, two T-60/73 steam turbines were manufactured and presented to the Customer - the most powerful units produced by KTZ OJSC today. One of the latest projects is the contract with OJSC Energy Construction Corporation Soyuz, within the framework of which KTZ manufactured two steam turbines for the branch of OJSC Ilim Group in Bratsk (Irkutsk region), intended for the reconstruction of the turbine department of TPP-3 . Under the terms of the contract, two back-pressure turbines - R-27-8.8/1.35 with a capacity of 27 MW and R-32-8.8/0.65 with a capacity of 32 MW - were delivered this summer.

In recent years, the world has increasingly used non-traditional energy sources, including geothermal steam. Geothermal power plants (GEP) can be called one of the cheapest and most reliable sources of electricity, since they do not depend on delivery conditions and fuel prices. The initiator of the development of geothermal energy in Russia in recent years has been the Geotherm company. Kaluga Turbine Plant OJSC acted as the base enterprise for the supply of power plants for orders from this company. The appeal to KTZ was not accidental, since the enterprise had practically solved one of the main problems of geothermal turbines - operation on wet steam. This problem boils down to the need to protect the last stage rotor blades from erosion. A common method of protection is the installation of special linings made of erosion-resistant materials. To protect against erosion, KTZ uses a method based on combating not the effect, but the very cause of erosion - coarse moisture.

In 1999, the Verkhne-Mutnovskaya GeoPP in Kamchatka with a capacity of 12 MW was put into operation - all the equipment of the power units for the station was supplied from Kaluga under a contract with Geotherm. Almost all turbine units supplied for geothermal power plants in Russia (Pauzhetskaya, Yuzhno-Kurilskaya on Kushashir Island, Verkhne-Mutnovskaya, Mutnovskaya GeoPP) were manufactured by the Kaluga Turbine Plant. To date, the company has accumulated extensive experience in creating geothermal turbine units of any size from 0.5 to 50 MW. Today, JSC Kaluga Turbine Plant is the most qualified geothermal turbine plant in Russia.

CJSC "UTZ" (Ural Turbine Plant)

The company is historically located in Yekaterinburg and is part of the Renova group of companies. The first AT-12 steam turbine with a power of 12 thousand kW was assembled and tested by Ural turbine builders in May 1941. Despite the fact that it was the first UTZ turbine, it operated reliably for 48 years.

Now the Ural Turbine Plant is one of the leading in Russia machine-building enterprises for the design and production of medium and high power steam heating turbines, condensing turbines, back pressure steam turbines, compressed steam turbines, gas pumping units, power gas turbine units, etc. Turbines produced by UTZ account for about 50% of all heating turbines operating in Russia and the CIS . Over more than 70 years of operation, the plant has supplied 861 steam turbines with a total capacity of 60 thousand MW to power plants in various countries.

The company has developed a whole family of steam turbines for steam power plants different types. In addition, UTZ specialists are developing and preparing the production of turbines for combined cycle gas plants - options for combined cycle gas plants with a capacity of 95-450 MW have been worked out. For installations with a capacity of 90-100 MW, a single-cylinder steam heating turbine T-35/47-7.4 is proposed. For a double-circuit combined cycle gas plant with a capacity of 170-230 MW, it is proposed to use a T-53/67-8.0 cogeneration steam turbine, which, while maintaining the design and depending on the steam parameters, can be marked from T-45/60-7.2 to T- 55/70-8.2. Based on this turbine, the plant can produce condensing steam turbines with a capacity of 60-70 MW.

According to the first deputy general director CJSC "UTZ" Denis Chichagin, domestic machine tool and mechanical engineering at the moment does not reach the world level. To modernize enterprises, it is necessary to give the green light to high-tech equipment, so the company is currently changing its technology policy. In close cooperation with specialists from JSC ROTEC and the Sulzer company (Switzerland), the plant is modernizing management and technological schemes for the successful development and adaptation of foreign advanced technologies, which will significantly strengthen the company’s position in the market. The company continues to develop optimal design solutions for the main turbine equipment, while offering the customer modern service solutions, including those based on long-term post-warranty maintenance of steam and gas turbines. In 2009-2011 The plant invested more than 500 million rubles in technical re-equipment programs. to ensure the existing portfolio of orders and reach the design capacity of 1.8 GW of turbine equipment per year. In February 2012, as part of this program, UTZ acquired high-performance metalworking equipment for the production of turbine blades - two 5-axis CNC machining centers model MILL-800 SK with a rotary spindle (Fig. 2) from Chiron-Werke GmbH & Co KG (Germany )

Fig.2

Specialized software supplied with the equipment allows you to reduce machine time by up to 20-30% compared to universal CAM systems. Installation and commissioning of new machines was carried out by Chiron specialists. As part of the agreement, testing of teleservice was carried out - remote diagnostics of machines, prevention or correction of errors and accidents. Using a secure dedicated channel, Chiron service engineers record the operation of the equipment online and issue recommendations for the production of UTP.

Turbine equipment produced by UTZ consistently finds customers even in conditions of fierce competition from foreign manufacturers. At the end of February 2012, the Ural Turbine Plant manufactured a new steam turbine with a capacity of 65 MW for the Barnaul CHPP-2 of OJSC Kuzbassenergo. The new turbine T-60/65-130-2M No. 8 has successfully passed tests on a shaft turning device at the UTZ assembly stand. The test report was signed by the customer's representatives without any comments. New equipment is being installed to replace the exhausted and decommissioned T-55-130 turbine, also produced at the Ural Turbine Plant. It should be noted that the two-cylinder turbine T-60/65-130-2M is a serial model produced by UTZ CJSC - a continuation of the serial line of steam turbines T-55 and T-50, which have proven themselves over many years of operation at thermal power plants in Russia and the CIS. The new turbines use modern components and modified elements that increase the technical and economic performance of the turbine unit (Fig. 3).

Fig.3

UTZ supplied a similar turbine for the Abakan Thermal Power Plant (Khakassia). The turbine will be the basis of the new power unit of the Abakan Thermal Power Plant: with its launch, the total capacity of the station should increase to 390 MW. The commissioning of the new power unit will increase electricity production by 700-900 million kWh per year and significantly increase the reliability of energy supply to the region. Commissioning of the installation is planned at the end of next year. The turbine is equipped with two PSG-2300 network water heaters and a KG-6200 condenser group, as well as a TVF-125-2U3 turbogenerator with hydrogen cooling produced by NPO ElSib.

Recently, the UTZ assembly stand successfully tested a new single-cylinder steam turbine T-50/60-8.8, manufactured for Petropavlovskaya CHPP-2 (SevKazEnergo JSC). The new Ural-made turbine should replace the previously operating two-cylinder Czech turbine R-33-90/1.3 from Skoda, and will be mounted on the same foundation. The project for replacing the turbine was prepared by the institute of JSC KazNIPIEnergoprom, with which JSC UTZ has been collaborating fruitfully for a long time. Long-standing ties with the former Soviet republics are not weakening either: for example, the issue of supplying several Ural turbines for thermal power plants in Kazakhstan is currently at the negotiation stage.

NPO "Saturn"

NPO Saturn is a developer and manufacturer of industrial gas turbine equipment of low, medium and high power for use in thermal power plants, industrial enterprises and oil and gas fields. This is one of the oldest industrial enterprises in Russia: in 1916, a decision was made to create five automobile plants on the basis of a state loan, including in the city of Rybinsk (JSC Russian Renault). In the post-revolutionary years, the plant worked on the development and production of aircraft engines. In the early 90s. The Rybinsk Engine Plant was transformed into OJSC Rybinsk Motors. In 2001, after its merger with the Rybinsk Engine Design Bureau (JSC A. Lyulka-Saturn), the company received its modern name and began producing gas turbines for the energy and gas industries. In the line of products, first of all, industrial gas turbines GTD-6RM and GTD-8RM should be mentioned, used to drive electric generators as part of gas turbine units GTA-6/8RM, which are used in gas turbine thermal power plants of medium power (from 6 to 64 MW and above) . The company also produces a family of unified gas turbines GTD-4/6.3/10РМ for use in gas pumping units and thermal power plants (from 4 MW and above). For low-power power plants (from 2.5 MW and above), the DO49R unit is produced - a single-shaft gas turbine with a built-in coaxial gearbox. In addition to “land-based” installations, the company produces marine gas turbines M75RU, M70FRU, E70/8RD, used to drive electric generators and gas compressors as part of offshore and coastal industrial facilities of low and medium power (from 4 MW and above).

In 2003, interdepartmental tests of the GTD-110 installation, the first Russian gas turbine with a capacity of more than 100 MW, were carried out (Fig. 4).

Fig.4

GTD-110 is a single-shaft gas turbine for use as part of high-power power and combined-cycle plants (from 110 to 495 MW and above), created within the framework of the Federal target program“Fuel and Energy” for the needs of the domestic energy system and is so far the only Russian development in the field of high-power gas turbine engineering. Currently, five GTD-110 are in operation at Gazpromenergoholding (GEH) and Inter RAO. However, according to Inter RAO specialists, only the newest installation, launched in early March, is operating normally. The rest are currently operating unstable and are serviced under the manufacturer's warranty.

According to Alexander Ivanov, director of gas turbine and power plants at NPO Saturn, as is the case with any new high-tech product, this is a completely natural process when defects are identified and the company is actively working to eliminate them. During Maintenance the most critical components are checked, and if necessary, the manufacturer replaces parts at his own expense without stopping the operation of the turbine.

Recently, JSC Engineering Center “Gas Turbine Technologies” (JSC NPO Saturn together with JSC INTER RAO UES) won the competition of JSC RUSNANO to create an engineering center that will deal with innovative products, in particular the creation of GTD-110M (Fig. 5), modernized gas turbine engine GTD-110 with a power of 110 MW.

Fig.5

In fact, the new engineering center will bring the technical and economic characteristics of the GTD-110 to the best world standards in this power class; The engine will be improved and refined; it is planned to create a combustion chamber that will ensure an acceptable level of harmful NOx emissions of 50 mg/m3. In addition, in the production of the engine it is planned to use nanostructured coating technologies, which will increase the reliability of the hot part of the turbine, increase the service life of the most wearing parts and the entire engine as a whole. GTD-110M will become the basis for the creation of Russian high-power CCGT units. All complex work on the GTD-110M project is designed for 2-3 years.

JSC "Leningrad Metal Plant"

Leningrad Metal Plant is a unique enterprise. The plant dates its history back to 1857, when the personal Decree of Emperor Alexander II “On the establishment of the Joint Stock Company “St. Petersburg Metal Plant” on the basis of the Charter” was issued. The production of steam turbines here began in 1907, hydraulic turbines in 1924, and gas turbines in 1956. To date, LMZ has manufactured more than 2,700 steam turbines and over 780 hydraulic turbines. Today it is one of the largest power engineering enterprises in Russia, which is part of OJSC Power Machines, which designs, manufactures and services a wide range of steam and hydraulic turbines of various capacities. Among the plant's recent developments is the GTE-65 gas turbine unit with a capacity of 65 MW. It is a single-shaft unit designed to drive a turbogenerator and capable of carrying base, half-peak and peak loads both independently and as part of a combined cycle unit. The GTE-65 gas turbine unit can be used in various types of combined cycle gas units for the modernization of existing and construction of new condensing and cogeneration power plants. In terms of price and technical characteristics, the GTE-65, as a medium-power machine, meets the capabilities and needs of domestic power plants and energy systems.

In the early 2000s. OJSC LMZ signed an agreement with Siemens for the right to manufacture and sell the gas turbine unit GTE-160 with a capacity of 160 MW in the Russian Federation and Belarus (Fig. 6).

Fig.6

The prototype of the installation is the V94.2 gas turbine from Siemens, the documentation of which has been changed taking into account the capabilities of LMZ OJSC and its partners. It was this turbine, produced at Leningrad Metal Plant OJSC, that was delivered to Perm CHPP-9 last summer under the contract between IES CJSC and Power Machines OJSC.

Cooperation with German turbine manufacturers continues. In December 2011, OJSC Power Machines and Siemens signed an agreement to create a joint venture in Russia for the production and service of gas turbines, Siemens Gas Turbine Technologies. This project was carried out on the basis of Interturbo LLC, which has been a joint venture of partners since 1991. The new company is engaged in the research and development of new gas turbines, localization of production in Russia, assembly, sales, project management and service high-power gas turbines of classes E and F with a capacity from 168 to 292 MW. This area of activity of Siemens Gas Turbine Technologies is linked to the requirement of the “Strategy for the Development of Power Engineering of the Russian Federation for 2010-2020 and for the period up to 2030.” to organize in the near future at the Leningrad Metal Plant large-scale production of licensed high-power gas turbine units (about 300 MW) with a transition from the GTE-160 (V94.2) developed by Siemens in the 80s. to more modern gas turbines.

Russia has found a way to circumvent Western sanctions for the sake of the most important state task - the construction of Crimean power plants. The turbines produced by the German company Siemens, necessary for the operation of the stations, were delivered to the peninsula. However, how did it happen that our country was unable to develop such equipment itself?

Russia has supplied two of four gas turbines to Crimea for use at the Sevastopol power plant, Reuters reported yesterday, citing sources. According to them, turbines of the SGT5-2000E model from the German concern Siemens were delivered to the port of Sevastopol.

Russia is building two power plants with a capacity of 940 megawatts in Crimea, and previously the supply of Siemens turbines for them was frozen due to Western sanctions. However, apparently, a solution was found: these turbines were supplied by some third-party companies, and not by Siemens itself.

Russian companies mass-produce only turbines for low-power power plants. For example, the power of the GTE-25P gas turbine is 25 MW. But modern power plants reach a power of 400–450 MW (as in Crimea), and they need more powerful turbines – 160–290 MW. The turbine delivered to Sevastopol has just the required power of 168 MW. Russia is forced to find ways to circumvent Western sanctions in order to implement a program to ensure the energy security of the Crimean Peninsula.

How did it happen that in Russia there are no technologies and sites for the production of high-power gas turbines?

After the collapse of the USSR in the 90s and early 2000s, the Russian power engineering industry found itself on the brink of survival. But then a massive program for the construction of power plants began, that is, there was a demand for the products of Russian machine-building plants. But instead of creating their own product in Russia, a different path was chosen - and, at first glance, a very logical one. Why reinvent the wheel, spend a lot of time and money on development, research and production, if you can buy something that is already modern and ready-made abroad.

“In the 2000s, we built gas turbine power plants with GE and Siemens turbines. Thus, they hooked our already poor energy sector on the needle of Western companies. Now huge amounts of money are paid for servicing foreign turbines. An hour of work for a Siemens service engineer costs the same as the monthly salary of a mechanic at this power plant. In the 2000s, it was necessary not to build gas turbine power plants, but to modernize our main generating capacities,” says Maxim Muratshin, CEO of the engineering company Powerz.

“I am involved in production, and I was always offended when senior management used to say that we would buy everything abroad, because ours couldn’t do anything. Now everyone has woken up, but time is lost. There is no longer enough demand to create a new turbine to replace the Siemens one. But at that time it was possible to create your own high-power turbine and sell it to 30 gas turbine power plants. That's what the Germans would have done. And the Russians simply bought these 30 turbines from foreigners,” the source adds.

Now the main problem in power engineering is the wear and tear of machinery and equipment in the absence of high demand. More precisely, there is demand from power plants, where outdated equipment urgently needs to be replaced. However, they don't have the money for this.

“Power plants do not have enough money to carry out large-scale modernization in the conditions of a strict tariff policy regulated by the state. Power plants cannot sell electricity at a price at which they could earn money for rapid modernization. We have very cheap electricity compared to Western countries“says Muratshin.

Therefore, the situation in the energy industry cannot be called rosy. For example, at one time the largest boiler plant in the Soviet Union, Krasny Kotelshchik (part of Power Machines), at its peak produced 40 high-power boilers per year, and now only one or two per year. “There is no demand, and the capacity that was in the Soviet Union has been lost. But we still have the basic technologies, so within two to three years our factories can again produce 40-50 boilers per year. It's a matter of time and money. But here they drag it out until the last minute, and then they want to do everything quickly in two days,” Muratshin worries.

The demand for gas turbines is even more difficult, because generating electricity using gas boilers is expensive. No one in the world builds their energy sector solely on this type of generation; as a rule, there is the main generating capacity, and gas turbine power plants supplement it. The advantage of gas turbine stations is that they quickly connect and supply energy to the network, which is important during peak periods of consumption (morning and evening). Whereas, for example, steam or coal boilers require several hours of cooking. “In addition, there is no coal in Crimea, but it has its own gas, plus a gas pipeline is being pulled from the Russian mainland,” Muratshin explains the logic according to which a gas-fired power plant was chosen for Crimea.

But there is another reason why Russia bought German, and not domestic, turbines for the power plants being built in Crimea. The development of domestic analogues is already underway. We are talking about the GTD-110M gas turbine, which is being modernized and modified at the United Engine Corporation together with Inter RAO and Rusnano. This turbine was developed in the 90s and 2000s, it was even used at the Ivanovo State District Power Plant and the Ryazan State District Power Plant in the late 2000s. However, the product turned out to have many “childhood diseases”. In fact, now NPO Saturn is engaged in their treatment.

And since the project of the Crimean power plants is extremely important from many points of view, apparently, for the sake of reliability, it was decided not to use a crude domestic turbine for it. UEC explained that they would not have time to finalize their turbine before the construction of stations in Crimea began. By the end of this year, only a pilot industrial prototype of the modernized GTD-110M will be created. While the launch of the first units of two thermal power plants in Simferopol and Sevastopol is promised by the beginning of 2018.

However, if not for sanctions, there would be no serious problems with turbines for Crimea. Moreover, even Siemens turbines are not a purely imported product. Alexey Kalachev from Finam Investment Company notes that turbines for Crimean thermal power plants could be produced in Russia, at the St. Petersburg plant of Siemens Gas Turbine Technologies.

“Of course, this is a subsidiary of Siemens, and most likely some of the components are supplied for assembly from European factories. But still this is a joint venture, and production is localized at Russian territory and under Russian needs", says Kalachev. That is, Russia not only buys foreign turbines, but also forced foreigners to invest in production on Russian territory. According to Kalachev, it is precisely the creation of a joint venture in Russia with foreign partners that makes it possible to overcome the technological gap most quickly and effectively.

“Without the participation of foreign partners, the creation of independent and completely independent technologies and technological platforms is theoretically possible, but will require significant time and money,” explains the expert. Moreover, money is needed not only for the modernization of production, but also for personnel training, R&D, engineering schools, etc. By the way, it took Siemens 10 years to create the SGT5-8000H turbine.

The real origin of the turbines supplied to Crimea turned out to be quite understandable. As stated by the Technopromexport company, four sets of turbines for power facilities in Crimea were purchased on the secondary market. And, as you know, he is not subject to sanctions.

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