Problems and prospects of the gas turbine market in Russia. Russian market of gas turbines Production of gas turbines

In Russia, on the instructions of the president, the government is preparing a large-scale program for the modernization of thermal power plants (TPPs), which is estimated at 1.5 trillion rubles and can start in 2019. One of its main conditions will be the use of Russian equipment. Is it possible, due to domestic developments, to renew the electric power industry, 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 necessary state support in an interview with Prime agency.

- What are Power Machines focused on now? Will you work mainly for the thermal power industry due to the upcoming program of its modernization?

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

- To what demand from the electric power companies of Russia are Power Machines ready for the modernization program for thermal power plants?

In the first competitive selection for modernization, projects with a total capacity of 11 GW will be selected, first of all, it will be the reconstruction of the steam-powered equipment that is traditional for us. Our production capacities allow us to produce up to 8.5 GW of turbine equipment per year, the same volume of generators, about 50 thousand tons of boiler equipment.

We have well-developed projects for the modernization of the K-200 and K-300 turbines; there is a project for the modernization of K-800. These projects allow you to increase power, efficiency, extend the resource, flexibly respond 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 concentrate on PT-60 and PT-80 heating turbines. Their design has been revised, including improving the design of the hull and steam distribution. In parallel, solutions were developed for the replacement and modernization of third-party turbines. First of all, we are talking about the machines of the Kharkov Turbine Plant.

- It is planned to include a norm on the 100% localization in Russia of the production of necessary equipment in the TPP modernization program. Apart from gas turbines, what equipment is yet to be localized?

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

Historically, in the USSR there were three manufacturers of cast billets, two of which - in the Urals and St. Petersburg - closed the foundry. As a result, Russia remained the only supplier who does not always ensure the necessary quality, and we are forced to purchase large cast billets abroad, where their quality is more stable. We believe in the potential of Russian metallurgical enterprises, we believe that with appropriate state support and the emergence of guaranteed demand they will be able to restore competencies and provide power engineering with high-quality cast billets and forgings. This is a parallel process, it is part of the TPP modernization program, although it may not be located on the surface.

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

The basic option is the independent development of gas turbines, since the localization, which any foreign company speaks of, is, as a rule, localization "by iron". But we see our task not in repeating in Russia the production of an outdated foreign model of a gas turbine, but in 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 stand base, and thereby protect the Russian energy industry from various negative external manifestations.

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

According to our estimates, if we take the existing combined cycle (CCGT) and gas turbine (GTU) plants, more than 70% are supplies from foreign manufacturers, another 24% are gas turbines manufactured by Interturbo (a joint venture of the Leningrad Metal Plant established in the 1990s) and Siemens).

At the same time, despite the existence of joint ventures, in Russia the manufacture of the most significant elements of gas turbines - components of the hot path (combustion chamber, turbine blades - ed.) And control systems, has not been localized. Production is limited only to the assembly and manufacture of individual components that are not critical for the operability of gas turbines and the energy security of Russia as a whole.

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

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

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

Here at our production facilities in St. Petersburg.

- How much do you generally estimate the costs of R&D? What could be the cost of starting an industrial production? And how long can it take?

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

- Why do you think that you will be able to develop a turbine? Other companies in Russia have many years of experience in failed attempts.

At one time, we were trending for gas turbines. The first such machine with a capacity of 100 MW was made at the LMZ (Leningrad Metal Plant, part of Power Machines - ed.) In the 60s. And it is fully consistent with the technology of that time. This backlog, unfortunately, was lost during the perestroika period. This area of \u200b\u200bpower engineering in the world has become so technologically advanced that it has gone so far that in the 1990s, an easier way to restore it was to acquire the right to use intellectual property and to localize production in Russia. As a result, in the 1990s, in partnership with Siemens, LMZ created a joint venture, Interturbo, from which the modern STGT grew (a joint venture of Siemens and Power Machines - Ed.). Equipment production was located at the facilities of LMZ and reached an honest 50% of 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 a gas turbine GTE-65 with a capacity of 65 MW. The machine went through a full cycle of cold tests, reached the so-called “full speed, no load” tests, but due to the lack of an experimental thermal power plant for testing and rolling in 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 the production of Russian gas turbines as part of the TPP modernization program. This goal, thanks to a reasonable dialogue between the Ministry of Industry and Trade and the Ministry of Energy, we believe has been achieved. We hope that in the framework of the subsequent selection of projects for participation in the modernization program, the restrictions on marginal capital costs for projects using domestic gas turbines will be removed. This will make facilities with domestic gas turbines more investment attractive.

The second factor is the possibility that Power Machines can construct independently or with a partner experimental thermal power plants with a total capacity of 1.4 GW as part of the KOM NGO mechanism (guarantees investors the payback of projects for building new power plants at the expense of increased consumer payments for capacity - ed.). This is necessary in order to bring the main samples of gas turbines to readiness for industrial operation and to obtain the necessary experience and competencies for all possible implementations - single-shaft, two-shaft and three-shaft CCGTs for gas turbines of all types.
And thirdly, the speedy exit of government decree No. 719 (amendments to the decree governing localization of production in the Russian Federation - ed.), Which will put all manufacturers, both domestic and foreign, on an equal footing.

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

Of course, we are interested in long-term cooperation, but within the framework 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, the conclusion of such long-term contracts is normal practice, which will allow us to plan the production program and not let the contractors in time if their projects are selected.
The main discussions now concern framework agreements for repair and maintenance services and the supply of spare parts. Assessing the annual and three-year plans for repair campaigns, we usually see the potential to reduce the cost of spare parts and services by up to 15% due to the alignment of production schedules.

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

The main obstacle to development is the "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 one-day companies emerged, where people in artisanal conditions, literally in a garage, produce obsolete spare parts, with deviations from the formal dimensions, mismatch of materials according to their physical and mechanical characteristics.

We receive a large number of requests from consumers with a request to coordinate those or other deviations in the working documentation from the original design during repairs. I see this as a serious risk, since the cause of 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 the proper time 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 are working to protect our technologies, return intellectual property and prohibit its use by other players using the opportunities that the civil and criminal code gives us. They did not bear the costs of R&D (research and development work - ed.), Do not guarantee quality, damage our reputation. We look forward to support in this matter from Rostekhnadzor, 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 have a large export and technological potential. The main share of our projects abroad now is either the atomic and hydraulic topics, where we compete on an equal footing with global manufacturers, or steam power units (reconstruction of previously delivered machines, production of equipment for burning such fuels, for example, fuel oil and crude oil). The share of exports varies, but averages about 50%.

In order to increase exports, we must master two fundamentally important technologies that are currently not available in Russia. Firstly, to 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 sufficiently high efficiencies of 45-47% on steam turbines operating on SSCP. This is a reasonable alternative to the combined cycle cycle - given the relatively low cost of coal, and often due to the lack of gas in the region. We have already developed the design documentation for the 660 MW SSKP turbine - and are ready to put it into production as soon as the order appears.

In order for new products to be in demand abroad, you must first make and introduce them in the domestic market, in Russia. The presence of references will allow us to enter our traditional markets - in Asia and Latin America, in 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, state support is needed through intergovernmental channels, with the attraction of export financing, and soft loans. This was done in the Soviet Union, as our competitors abroad are doing now.

-What other directions do you see for the company?

One of the directions will be the support of small technology companies. There are a huge number of startups on the market that are complementary to our process 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, guarantees. The transfer of control will allow shareholders to receive significantly greater income by increasing sales and expanding their channels. I ask everyone to consider this an official invitation, we will gladly consider the proposals. There are already examples of such successful interactions.

M. Vasilevsky

Today, the leading foreign energy machine-building companies are active in the Russian gas turbine equipment market, primarily giants such as Siemens and General Electric. Offering high-quality and durable equipment, they constitute a serious competition to domestic enterprises. Nevertheless, traditional Russian manufacturers are trying to keep up with 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 market of power engineering. Here, as elsewhere, the law applies: "change or die." Without revising the technology and without conducting a deep modernization, it will be practically 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 plants (CCGTs) are becoming increasingly relevant.

In the past two decades, gas-vapor technology has become the most popular in the world energy industry - 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 plants, the energy of combusted fuel is used in a binary cycle - first in a gas turbine, and then in a steam cycle, and therefore CCPs are more efficient than any thermal stations (TPPs) operating only in the steam cycle.

Currently, the only area in the thermal energy industry in which Russia is critically behind the world's leading manufacturers is gas turbines of high power - 200 MW and above. Moreover, foreign leaders not only mastered the production of gas turbines with a unit capacity of 340 MW, but also successfully tested and apply the single-shaft design of CCGT units when a gas turbine with a capacity of 340 MW and a steam turbine with a capacity of 160 MW share a common shaft. This arrangement can significantly reduce the creation time and cost of the power unit.

The Ministry of Industry and Trade of Russia in March 2011 adopted the “Strategy for the Development of Power Engineering of the Russian Federation for 2010–2020 and for the Prospect until 2030”, in accordance with which this direction in domestic power engineering receives solid support from the state. As a result, by 2016, the Russian power engineering industry should carry out industrial development, including full-scale testing and refinement at its own test benches, of improved gas turbine units (GTU) with a capacity of 65-110 and 270-350 MW and combined-cycle plants (CCGT) using natural gas with an increase their coefficient of performance (COP) 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 has not yet been given. Although back in the 70s, our country was a leader in this direction, when the super-supercritical parameters of steam 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 a dangerous dependence of the stability of the unified energy system of Russia on the supply of foreign components may occur. During the operation of power equipment, it is regularly required to replace a number of units and parts operating at high temperatures and pressures. However, some of these components are not produced in Russia. For example, even for the domestic gas turbine GTE-110 and 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 are actively and very successfully working in our market, which often win tenders for the supply of power equipment. Several generating facilities already exist in the Russian energy system, to one degree or another, equipped with the main energy equipment manufactured by Siemens, General Electric, etc. True, their total capacity does not exceed 5% of the total capacity of the Russian energy system.

However, many generating companies that use domestic equipment to replace it still prefer to turn to companies with which they have been accustomed to work for decades. This is not just a tribute to tradition, but a justified calculation - many Russian companies have carried out technological upgrades of production and are fighting the world’s power engineering giants on an equal footing. Today we will talk in more detail about the prospects of such large enterprises as Kaluga Turbine Works OJSC (Kaluga), Ural Turbine Works OJSC (Yekaterinburg), NPO Saturn (Rybinsk, Yaroslavl Region), Leningrad Metal Plant (St. Petersburg), Perm Engine Engineering Complex (Perm Territory).

OJSC Kaluga Turbine Plant

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

Fig. 1

The plant was founded in 1946, and four years later the first 10 turbines of their own design (OR300) were produced. To date, the plant for energy facilities in Russia, the CIS countries and far abroad has produced more than 2640 power plants with a total capacity of 17091 MW.

Nowadays, the company is part of the Power Machines concern Power Machines. One of the practical results of the affiliation was the introduction in January 2012 of the SAP ERP information solution based on the existing prototype successfully used by 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 machine-building 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, two T-60/73 steam turbines were manufactured and presented to the Customer for the Ufa CHPP No. 5 - the most powerful installations manufactured by KTZ OJSC today. One of the latest projects is the contract with OJSC Soyuz Energy Construction Corporation, within the framework of which KTZ manufactured two steam turbines for the branch of OJSC Ilim Group in Bratsk (Irkutsk Region), intended for reconstruction of the turbine section of TPP-3 . Under the terms of the contract, two counterpressure 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, unconventional energy sources, including geothermal steam, have been increasingly used in the world. Geothermal power plants (GeoES) 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 become the company "Geotherm". Kaluga Turbine Works OJSC acted as the base enterprise for the supply of power plants for the orders of this company. The appeal to KTZ was not accidental, since one of the main problems of geothermal turbines — wet steam operation — was practically solved at the enterprise. This problem boils down to the need to protect working blades of the last stages from erosion. A common method of protection is the installation of special pads made of materials resistant to erosion. To protect against erosion, KTZ uses a method based on the struggle not with the consequence, but with the very cause of erosion - with coarse moisture.

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

UTZ CJSC (Ural Turbine Plant)

The enterprise is historically located in the city of Yekaterinburg and is part of the Renova group of companies. The first AT-12 steam turbine with a capacity 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 reliably worked for 48 years.

Now the Ural Turbine Plant is one of the leading machine-building enterprises in Russia for the design and manufacture of medium and high-capacity steam cogeneration turbines, condensing turbines, backpressure steam turbines, crushed steam turbines, gas pumping units, power gas turbine units, etc. Turbines produced by UTZ, make up about 50% of all cogeneration turbines operating in Russia and the CIS. For more than 70 years of operation, the plant 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 of various types. In addition, UTZ specialists are developing and preparing the production of turbines for combined cycle plants - options for combined cycle plants with a capacity of 95-450 MW have been developed. For installations with a capacity of 90-100 MW, a T-35 / 47-7.4 single-cylinder steam heating turbine is offered. For a dual-circuit combined-cycle 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 parameters of the steam, can be marked from T-45 / 60-7.2 to T- 55 / 70-8.2. On the basis of this turbine, the plant can produce condensing steam turbines with a capacity of 60-70 MW.

According to the first deputy general director of UTZ CJSC Denis Chichagin, the domestic machine tool and machine building industry currently does not reach the world level. For the modernization of enterprises, it is necessary to give green light to high-tech equipment, which is why the company is currently changing its technological policy. In close cooperation with specialists of ROTEK CJSC and Sulzer (Switzerland), the plant is modernizing management and technological schemes for the successful development and adaptation of advanced foreign 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 the customer is offered 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 reaching the design capacity of producing 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 of the MILL-800 SK model with a rotary spindle (Fig. 2) by Chiron-Werke GmbH & Co KG (Germany )

Fig.2

Specialized software supplied with the equipment allows to reduce machine time by 20-30% in comparison with universal CAM-systems. Installation and commissioning of new machines was carried out by specialists of the company Chiron. Within the framework of the agreement, the teleservice was tested - remote diagnostics of machines, prevention or correction of errors and accidents. Through a secure dedicated channel, Chiron service engineers record the operation of the equipment online and issue recommendations for the production of UTZ.

The turbine equipment manufactured by UTZ stably finds customers even in the 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 TPP-2 of OJSC Kuzbassenergo. The new turbine T-60 / 65-130-2M st.number 8 was successfully tested on a shaft-turning device at the UTZ assembly stand. The test report was signed by customer representatives without comment. New equipment is being installed to replace the T-55-130 turbine, which has also been exhausted and decommissioned, 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 of production of 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. In new turbines, modern units and modified elements are used that increase the technical and economic performance of the turbine unit (Fig. 3).

Fig.3

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

Recently, the UTZ assembly bench successfully tested a new T-50 / 60-8.8 single-cylinder steam turbine manufactured for the Petropavlovsk TPP-2 (SevKazEnergo JSC). A 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 turbine replacement project was prepared by the Institute of KazNIPIEnergoprom JSC, with which UTZ CJSC has long and fruitfully cooperated. The long-standing ties with the former Soviet republics are not weakening: for example, the issue of supplying several Ural turbines for Kazakhstan’s thermal power plants is currently under negotiation.

NPO Saturn

NPO Saturn is a designer and manufacturer of industrial gas turbine equipment of small, 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 factories on the basis of a state loan, including in Rybinsk (Russian Renault JSC). In the post-revolutionary years, the plant worked on the development and production of aircraft engines. In the early 90's. Rybinsk Motor Plant was transformed into OJSC "Rybinsk Motors". In 2001, after its merger with the Rybinsk Design Bureau of Motor Engineering (OJSC A. Lyulka-Saturn), the company got its modern name and began to produce gas turbines for the energy and gas industries. In the product line, first of all, the GTD-6RM and GTD-8RM industrial twin-shaft gas turbines used to drive electric generators as part of the GTA-6 / 8RM gas-turbine units, which are used in medium-power gas turbine power plants (from 6 to 64 MW and above), should be mentioned first of all. . The company also produces a family of GTD-4 / 6.3 / 10RM unified gas turbines for use in gas pumping units and thermal power plants (from 4 MW and above). For power plants of low power (from 2.5 MW and above), the DO49R unit is produced - a single-shaft gas turbine with an integrated coaxial gearbox. In addition to ground-based installations, the company manufactures offshore gas turbines M75RU, M70FRU, E70 / 8RD, used to drive electric generators and gas compressors as part of offshore and coastal industrial facilities of small and medium power (from 4 MW and above).

In 2003, interagency 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 a part of power and combined-cycle plants of high power (from 110 to 495 MW and above), created as part 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 high-power gas turbine engineering. Currently, five gas turbine engines-110 are in operation at Gazpromenergoholding (GEC) and Inter RAO. However, according to Inter RAO specialists, only the latest installation, launched in early March, is functioning normally. The rest are currently unstable and are serviced under the manufacturer's warranty.

According to the director of gas turbine and power plants NPO Saturn Alexander Ivanov, as in the case of 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 the parts at his own expense without stopping the operation of the turbine.

Recently, the Gas Turbine Technologies Engineering Center OJSC (NPO Saturn OJSC together with INTER RAO UES OJSC) won the competition of RUSNANO OJSC for the creation of an engineering center that will deal with innovative products, in particular, the creation of GTD-110M (Fig. . 5), the modernized gas turbine engine GTD-110 with a capacity 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 finalized, it is planned to create a combustion chamber that provides an acceptable level of harmful emissions of NOx 50 mg / m3. In addition, it is planned to use nanostructured coating technologies in engine production, which will increase the reliability of the hot part of the turbine and increase the service life of the most worn parts and the engine as a whole. The GTD-110M will become the basis for the creation of Russian large combined cycle power plants. All comprehensive work on the GTD-110M project is designed for 2-3 years.

OJSC Leningrad Metal Plant

Leningrad Metal Plant is a unique enterprise. The plant dates back to 1857, when a 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 - in 1924, gas - in 1956. To date, more than 2700 steam and over 780 hydraulic turbines have been manufactured at LMZ. 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. Of the recent developments of the plant - gas turbine unit GTE-65 with a capacity of 65 MW. It is a single-shaft unit designed to drive a turbogenerator and capable of bearing the base, half-peak and peak loads both autonomously and as part of a combined cycle gas turbine unit. The GTE-65 gas turbine unit can be used in various types of combined-cycle gas turbines to modernize existing and build new condensation and heating plants. In terms of price and technical characteristics, GTE-65, as a medium-power machine, meets the capabilities and needs of domestic power plants and power systems.

In the early 2000s. LMZ OJSC signed an agreement with Siemens on the right to manufacture and sell a 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 a gas turbine V94.2 from Siemens, the documentation of which has been changed taking into account the capabilities of OAO LMZ and its partners. It was such a turbine produced at OJSC Leningrad Metal Plant that was delivered to Perm TPP-9 last summer under a contract between CES CJSC and Power Machines OJSC.

Collaboration with German turbine builders continues. In December 2011, Power Machines and Siemens signed an agreement on the establishment in Russia of a joint venture for the production and servicing of gas turbines, Siemens Gas Turbine Technologies. This project was implemented on the basis of Interturbo LLC, which has been a joint venture of partners since 1991. The new company is engaged in research and development of new gas turbines, localization of production in Russia, assembly, sale, project management and maintenance of high-power gas turbines of Class E and F with capacity from 168 to 292 MW. This area of \u200b\u200bactivity of Siemens Technology of Gas Turbines is linked to the requirement of the “Strategy for the development of power engineering in the Russian Federation for 2010-2020 and for the long term until 2030” to organize in the near future at the Leningrad Metal Plant a large-scale production of licensed gas turbines of high power (about 300 MW) with the transition from GTE-160 (V94.2) developed by Siemens of the 80s. to more modern gas turbines.


This industry, for various purposes, belongs to the type of engineering that produces goods with high added value. Therefore, the development of this direction is consistent with the priorities of the leadership of our country, which tirelessly declares that we need to "get off the oil needle" and actively enter the market with high-tech products. In this sense, the production of turbines in Russia may well become one of the drivers of the domestic economy along with the oil industry and other types of mining industry.

Production of turbines of all types

Russian manufacturers produce both types of turbine units - for energy and transport. The former are used to generate electricity in thermal power plants. The second are supplied to enterprises in the aviation industry and shipbuilding. A feature of the production of turbines is the lack of specialization of plants. That is, the same enterprise produces, as a rule, equipment of both types.

For example, the St. Petersburg Production Association Saturn, which began in the 1950s with the release of only power machines, later added gas turbine units for marine vessels to its nomenclature. And the Perm Motors plant, which initially specialized in the manufacture of aircraft engines, switched to the additional production of steam turbines for the electric power industry. Among other things, the lack of specialization indicates the wide technical capabilities of our manufacturers - they can produce any equipment with guarantees of quality assurance.

Dynamics of turbine production in the Russian Federation

According to BusinesStat, turbine production in Russia between 2012 and 2016 increased by about 5 times. If in 2012, enterprises in the industry produced a total of about 120 units, then in 2016 this figure exceeded 600 units. The increase was mainly due to the growth of power engineering. The dynamics were not affected by the crisis and, in particular, the appreciation of the exchange rate.

The fact is that turbine plants practically do not use foreign technologies and do not need import substitution. In the manufacture of turbine equipment, only our own materials and equipment are used. By the way, this is an additional point that makes this sector of engineering a competitor to the oil industry.

If oil companies require foreign technologies to develop new oil fields and, especially, the Arctic shelf, then manufacturers of gas turbine plants do their best. This reduces the cost of producing turbines and, accordingly, reduces the cost, which in turn improves the competitiveness of our products.

Cooperation with foreign manufacturers

The above does not mean at all that our manufacturers pursue a policy of closure. On the contrary, the trend of recent years is to strengthen cooperation with foreign vendors. The need for this is dictated by the fact that our manufacturers are not able to establish the production of high-power gas turbines. But such flagships as some European companies have the necessary resources. The pilot project was the opening of a joint venture of the St. Petersburg plant Saturn and the German company Siemens.

Yes, cooperation with distant partners is intensifying cooperation in the field of turbine production, which cannot be said about cooperation with close allies. For example, due to the events in Ukraine, our manufacturers have practically lost touch with the Kiev, Dnepropetrovsk and Kharkov production associations, which have supplied components since the Soviet era.

However, here, our manufacturers manage to positively solve problems. So, at the Rybinsk Turbine Plant in the Yaroslavl Region, which produces power plants for the ships of the Russian Navy, they switched to the production of their own components to replace those that had previously come from Ukraine.

Change in market conditions

Recently, the demand structure has changed towards the consumption of low-power devices. That is, the production of turbines in the country has intensified, but more low-power units have become available. At the same time, an increase in demand for low-power products is noted both in the energy sector and in transport. Today, low-power power plants and small vehicles are popular.

Another 2017 trend is to increase steam turbine production. This equipment, of course, loses in functionality to gas turbine units, but is preferable in terms of cost. For the construction of diesel and coal power plants, these devices are purchased. These products are in demand in the Far North.

In conclusion, two words about the prospects for the industry. According to experts, the production of turbines in Russia will grow by 2021 to 1000 products per year. All necessary prerequisites are seen for this.

Tests of Russia's first high-power gas turbine were suspended due to an accident. This will delay the start of its production and require new investments - Power Machines can join the project as an investor

GTD-110M gas turbine installation (Photo: Russian Engineering Union)

Tests of the first gas turbine of high power GTD-110M (up to 120 MW) in Russia were stopped due to malfunctioning mechanisms, the TASS agency reported. This was confirmed by RBC representatives of the Gas Turbine Technologies engineering center, which conducted the tests, and its two shareholders - Rusnano and the United Engine Corporation (UEC) Rostec.

“In the course of test tests of the GTD-110M gas turbine unit, an accident occurred, as a result of which the turbine was really damaged,” a representative of the Gas Turbine Technologies IC told RBC. The purpose of the tests was to identify design flaws in order to avoid serious incidents during industrial operation in the power system, he added. The UEC representative said that a number of mechanisms failed in December 2017, so the tests had to be stopped until the problems were fixed.

The development of its own high-power turbine in Russia was carried out for a long time, but without much success, and in 2013 the subsidiary of UEC UEC-Saturn signed an investment agreement with Rusnano and Inter RAO to create a new generation turbine - GTD-110M, which was developed by IC Gas Turbine Technologies. Inter RAO received 52.95% in this project, the Rusnano Infrastructure and Educational Programs Fund - 42.34%, UEC-Saturn - 4.5%, the remaining 0.21% from the non-profit partnership of Center for Electronic Technologies and Technologies. "Was supposed to finance the project and contribute 2.5 billion rubles to the authorized capital," Interfax "wrote in 2013, citing a source close to one of the parties. The corporation participated in the financing of the project, confirms its representative. According to SPARK, the authorized capital of the engineering center is 2.43 billion rubles. In 2016, Gas Turbine Technologies also received a subsidy of the Ministry of Industry and Trade of 328 million rubles. for partial compensation of R&D costs in priority areas, follows from the system data.

Sanction Turbines

Russia urgently needs a large-capacity domestic gas turbine. Last year, due to the lack of proprietary technologies, the Rostec subsidiary Technopromexport, despite the sanctions, was forced to deliver German Siemens turbines to new power plants in Crimea, which led to an international scandal. Siemens announced the suspension of work with Russian state-owned companies, while Technopromexport, as well as its head Sergei Topor-Gilka and two officials of the Ministry of Energy - Andrei Cherezov and Evgeny Grabchak - were subject to European and American sanctions.

It was planned that the tests will be completed in 2017, but then this period was postponed for six months - in the middle of 2018, the launch of the equipment in serial production was also planned for this year, recalls

There are no more than ten enterprises producing gas turbines in our country. Manufacturers of ground equipment based on gas turbines are even smaller. Among them are Nevsky Zavod CJSC, Saturn Gas Turbines OJSC and Perm Motor Plant OJSC (part of UEC of Rostec Corporation).

In Russia, all conditions have been formed for the rapid development of the market for gas turbines for ground-based applications, according to EnergyLand.info analysts. The need for distributed generation, based not on diesel fuel, but on cleaner sources, is becoming more and more urgent. There are almost no doubts about the effectiveness of combined cycle plants.

However, there are no more than ten enterprises producing gas turbines in our country. Manufacturers of ground equipment based on gas turbines are even smaller.

In the Soviet Union, reliance was placed on coal, oil and other heating sources. Therefore, the first gas turbines were released only in the 1950s. And primarily in relation to aircraft construction.

In the 1990s, the development of energy gas turbines based on engines created by NPO Saturn for aircraft began.

Today, the production of ground-based power equipment based on the engines of NPO Saturn is handled by Saturn Gas Turbines. Perm Motor Plant has mastered the production of gas turbine power plants based on the development of Aviadvigatel OJSC.

Moreover, the nominal capacity of serial production of these enterprises on average does not exceed 25 MW. There are several machines with a unit capacity of 110 MW based on the development of NPO Saturn, but today they are being refined.

High power turbines are supplied mainly by foreign companies. Russian enterprises strive to enter into cooperation with world leaders.

However, not all world leaders are interested in organizing the production of gas turbines in Russia. One reason is the unstable demand for products. And he, in turn, largely depends on the level of energy consumption. Since 2010, energy consumption in Russia has been growing steadily. But soon, according to experts, stagnation may come. And the increase in demand in 2013-2014 will be only about 1% per year or even less.

According to Dmitry Solovyov, Deputy Chief Designer of Saturn - Gas Turbines, similar reasons prevent Russian companies from developing production of high-power gas turbines. “The production of high-power gas turbine units (GTU) requires special equipment, large-diameter machines, and installations for welding in a vacuum with chambers of the order of 5 by 5 m,” he says. - To create such a production, you must be confident in the market. And for this, the country should have a long-term program for the development of energy, perhaps then enterprises will begin to invest in upgrading the base. ”

However, the absence of predictable prospects does not mean the absence of demand at all. Demand, of course, is. Both for turbines with a capacity of more than 150 MW, and for small gas turbines, which require less capital expenditure, but are quite able to cope with issues of increasing energy efficiency and payback.

The growth of the sales market may be due to the development of regional energy and the commissioning of generating facilities of medium capacity. And gas turbines with a capacity of 4, 8, 16, 25 MW are a segment in which Russian manufacturers mainly work, who have already felt the market trend.

In developed countries, low-power cogeneration plants are commonplace. In Russia, their number is still significantly lower. The main difficulty for companies supplying low-power turbines is the insufficient solvency of potential customers.

Another traditional segment of the gas turbine market is generation facilities at oil and gas fields and gas mains. Gas turbine power plants can effectively utilize associated petroleum gas, solving not only the problem of energy supply, but also the rational use of hydrocarbon resources.

According to the observations of specialists of Saturn Gas Turbines, in the pre-crisis years 2006-2008 there was a surge in the interest of oil workers in domestic gas turbines. Today, this demand is at a stable level.

Current trends in improving gas turbines are largely related to innovations for the oil industry. But not only. Challenges facing manufacturers:
- increase in efficiency,
- reduction in the number of nodes in the turbine,
- increase in reliability,
- reduced maintenance,
- reducing the duration of downtime during the diagnosis of the technical condition.

The above can solve the problem of the high cost of service.

In addition, the creators of turbines strive to achieve their unpretentiousness to the gas used and the possibility of working on liquid fuel

And in the West, they are also worried that, regardless of the gas composition, the turbine should have good environmental characteristics.

A very important - promising - direction for improving gas turbines is related to renewable energy sources (RES) and the prospects for the introduction of smart grids. Initially, gas turbines were created as equipment providing constant power output. However, the introduction of renewable energy into the energy system automatically requires flexibility from other generation facilities. This flexibility allows you to provide a stable level of power in the network with insufficient renewable energy, for example, on calm or cloudy days.

Accordingly, a turbine for an intelligent power system should easily adapt to changes in the network and be designed for regular starts and stops without loss of life. In the case of traditional gas turbines, this is not possible.

Abroad, certain successes in this direction have already been achieved. For example, the new FlexEfficiency gas turbine is capable of reducing power from 750 MW to 100 MW and then gaining initial values \u200b\u200bin 13 minutes, and when used with solar power plants it will have an efficiency of up to 71%.

Nevertheless, in the foreseeable future, the most common way to use gas turbines will still be their usual combination with steam turbines as part of combined-cycle plants. In our country, the market for such cogeneration facilities is by no means full and is waiting for saturation.

United Engine Corporation (UEC) - A company comprising more than 85% of the assets of Russian gas turbine equipment. An integrated structure producing engines for military and civil aviation, space programs, installations of various capacities for the production of electric and thermal energy, gas pumping and ship gas turbine units. In total, more than 70 thousand people work in UEC. The company is headed by Vladislav Evgenievich Masalov.

 

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