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

In Russia, on behalf 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 to upgrade the electric power industry at the expense of domestic developments, Timur Lipatov, General Director of Power Machines, who headed the company three months ago, spoke about the development of new turbines, export potential and the necessary support from the state 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 are Power Machines ready for within the framework of the modernization program for thermal power plants?

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 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 K-200 and K-300 turbines, and there is a project for the modernization of K-800. These projects allow you to increase power, efficiency, extend the resource, respond flexibly to what the client needs. But the program is not limited to 200 and 300 MW condensing units (i.e. generating electricity - ed.), so we are concentrating on the PT-60 and PT-80 cogeneration turbines. Their design has been revised, including improving the design of the hull and steam distribution. In parallel, solutions have been 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 100% localization of production in Russia in the TPP modernization program necessary equipment. Apart from gas turbines, what equipment is still to be localized?

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

Historically, there were three manufacturers of cast billets in the USSR, two of which - in the Urals and in St. Petersburg - were closed Foundry. As a result, he remained in Russia sole supplier, 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 state support and the emergence of guaranteed demand, they will be able to restore mechanical 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 on the surface right now.

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

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

Our final goal- to restart the production cycle of gas turbines 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 of foreign manufacturers in Russia?

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

At the same time, despite the presence of joint ventures, the manufacture of the most significant elements of gas turbines - components of the hot path (fuel combustion chamber, turbine blades - ed.) and control systems is not localized in Russia. Production is limited only to the assembly and manufacture of individual components that are not critical for the performance 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 high-speed turbine for 100 MW with a free power turbine. Subsequently, it is possible to develop a 300-400 MW F or H-class 3000 rpm gas turbine using scaling principles for a part of the components.

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

Here, at our production facilities in St. Petersburg.

- How much do you estimate the cost of R&D in general? What are the startup costs industrial production? And how long can it take?

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

- Why do you think that you will be able to develop a turbine? In Russia, other companies have many years of failed 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 Works, part of Power Machines - ed.) in the 60s. And it fully corresponded to the technologies of that time. This backlog, unfortunately, was lost during the perestroika period. This area of ​​power engineering in the world has become so technologically advanced, has gone so far that in the 90s more in a simple way its restoration was the acquisition of the right to use intellectual property and the localization of production in Russia. As a result, in the 1990s, in partnership with Siemens, LMZ created the Interturbo joint venture, from which the modern STGT grew (a joint venture between Siemens and Power Machines - ed.). The production of equipment was located at the facilities of the LMZ and reached an honest 50% localization. As part of Interturbo, we have 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 within the framework 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 testing 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 for mastering 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 as part of the subsequent selection of projects for participation in the modernization program, restrictions on the marginal capital costs for projects using domestic gas turbines will be lifted. This will make facilities with domestic gas turbines more investment-attractive.

The second factor is the possibility of construction by Power Machines on its own or with a partner of experimental TPPs with a total capacity of 1.4 GW within the framework of the KOM NGO mechanism (it guarantees investors the payback of projects for the construction of new power plants due to increased consumer payments for capacity - ed.). This is necessary to bring prototype gas turbines to readiness for commercial operation and to gain the necessary experience and competencies for all possible implementations - single-shaft, two-shaft and three-shaft CCGT 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 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, 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, the conclusion of such long-term contracts is a normal practice that will allow us to plan production program and not to let the contractors down in time if their projects are selected.
Now the main discussions concern framework contracts for repair and maintenance and supply of spare parts. When evaluating 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 any obstacles to the development of the service sector?

The main obstacle to development is "garage production". In the Soviet Union, drawings were often in free circulation; in the 1990s, little attention was paid to the protection of intellectual property. It is not surprising that as a result, a huge number of one-day firms have arisen, where people in artisanal conditions, literally in the garage, produce obsolete spare parts, with deviations from the formulary sizes, inconsistencies in materials in terms of physical and mechanical characteristics.

We receive a large number of requests from consumers with a request 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 the proper timing 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 codes give us. They did not bear the cost of R & D (research and development work - ed.), do not guarantee quality, damage our reputation. We count on 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? What countries are you primarily considering for work? What technologies are in demand abroad?

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

In order to increase exports, we must master two fundamentally important technologies that are not currently available in Russia. First, to restore the production of domestic gas turbines of medium and large capacity. Secondly, to make a pulverized coal boiler and a steam turbine for super-supercritical steam parameters (SSCP). Existing technologies make it possible to achieve sufficiently high efficiency of 45-47% per steam turbines ah, working for the SSPC. 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 an order appears.

In order for new products to be in demand abroad, they must first be manufactured and introduced in the home 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, you need governmental support– through the channels of intergovernmental agreements, with the involvement of export financing, concessional lending. This is how it was done in the Soviet Union, this is how our competitors abroad are doing now.

- What other directions of the company's development do you see?

One of the directions will be to support 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 joining their share capital, R&D and technology financing, guarantees. The transfer of control will allow shareholders to earn significantly more income by increasing sales volumes and expanding their channels. I ask everyone to consider this an official invitation, we will gladly consider proposals. There are already examples of such successful interaction.

M. Vasilevsky

Today, leading foreign power engineering companies, primarily such giants as Siemens and General Electric, are actively working on the Russian market of gas turbine equipment. Offering high-quality and durable equipment, they are a serious competitor domestic enterprises. Nevertheless, traditional Russian producers try 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 carrying out a 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 plants (CCGTs) are becoming more and more urgent.

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

Currently, the only area in the thermal power industry in which Russia critically lags behind the world's leading manufacturers is high-capacity gas turbines - 200 MW and more. Moreover, foreign leaders have not only mastered the production of gas turbines with a unit capacity of 340 MW, but also successfully tested and use a single-shaft CCGT layout, when a gas turbine with a capacity of 340 MW and a steam turbine with a capacity of 160 MW have a common shaft. This arrangement allows to significantly reduce the construction time and the 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 Russian Federation for 2010-2020 and for the period up to 2030”, according to which this direction in the domestic power engineering industry receives solid support from the state. As a result, by 2016 the Russian power engineering industry should carry out industrial development, including full-scale tests and refinement on its own test benches, improved gas turbine plants(GTU) with a capacity of 65-110 and 270-350 MW and combined-cycle plants (CCGT) at natural gas with an increase in their coefficient of performance (COP) up to 60%.

Moreover, Russia is able to produce all the main components of the CCGT - 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 for the first time in the world supercritical steam parameters were mastered.

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, and no more than 10% by 2025 . It is believed that otherwise there may be a dangerous dependence of the stability of the unified energy system of Russia on the supply of foreign components. During the operation of power equipment, it is regularly necessary to replace a number of components and parts operating at high temperatures and pressures. At the same time, 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.

In our market, such large and advanced concerns as Siemens and General Electric are actively and very successfully operating, which often win tenders for the supply of power equipment. There are already several generating facilities in the Russian energy system, to some extent equipped with the main energy equipment manufactured by Siemens, General Electric, etc. True, 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 firms 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 carried out a technological renovation 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, as Kaluga Turbine Plant JSC (Kaluga), Ural Turbine Plant CJSC (Yekaterinburg), NPO Saturn (Rybinsk, Yaroslavl Region), Leningrad Metal Plant (St. Petersburg) , Perm Motor Building Complex (Perm Territory).

OJSC "Kaluga Turbine Plant"

OJSC Kaluga Turbine Works 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 our 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 far abroad.

Today, the enterprise is part of the power machine building concern Power Machines. One of the practical results of the affiliation was the implementation since January 2012 of the SAP ERP information solution based on the current prototype, successfully used at Power Machines OJSC, instead of the Baan system previously used at KTZ. Created Information system will allow the company to reach a new level of production automation, modernize its business processes based on the best practices of world leaders in the engineering industry, improve 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 Ufimskaya CHPP No. 5 - the most powerful units manufactured by KTZ OJSC today. One of recent projects can be called a contract with OJSC Soyuz Energy Construction Corporation, under 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, non-traditional energy sources, including geothermal steam, have been increasingly used in the world. Geothermal power plants (GeoPS) 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 was the firm "Geotherm". OJSC "Kaluga Turbine Plant" acted as the base enterprise for the supply of power plants for the orders of this company. The appeal to KTP was not accidental, since one of the main problems of geothermal turbines - operation on wet steam - was practically solved at the enterprise. This problem boils down to the need to protect the blades of the last stages from erosion. A common method of protection is the installation of special overlays made of erosion-resistant materials. To protect against erosion, KTZ applies a method based on combating not the consequence, but the very cause of erosion - with coarse moisture.

In 1999, the Verkhne-Mutnovskaya GeoPP in Kamchatka with a capacity of 12 MW was put into operation - all the equipment of power units for the station was supplied from Kaluga under a contract with Geoterm. 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 enterprise has accumulated extensive experience in creating geothermal turbine plants of any size from 0.5 to 50 MW. Today OJSC "Kaluga Turbine Plant" is the most qualified turbine plant in Russia in terms of geothermal topics.

CJSC "UTZ" (Ural Turbine Works)

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

Now the Ural Turbine Works is one of the leading plants in Russia engineering enterprises for the design and production of steam cogeneration turbines of medium and high power, condensing turbines, steam turbines with back pressure, crumpled steam turbines, gas compressor units, power gas turbine units, etc. Turbines manufactured by UTZ account for about 50% of all cogeneration turbines operating in Russia and the CIS . For more than 70 years of operation, the plant has delivered 861 steam turbines with a total capacity of 60,000 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, UTW 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 worked out. For installations with a capacity of 90-100 MW, a single-cylinder steam cogeneration turbine T-35 / 47-7.4 is offered. For a double-circuit steam-and-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. 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 CEO CJSC "UTZ" Denis Chichagin, domestic machine-tool and mechanical engineering at the moment does not reach the world level. For the modernization of enterprises, it is necessary to give a green light to high-tech equipment, so the company is currently changing its technology policy. In close cooperation with specialists from CJSC ROTEK and Sulzer (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 enterprise 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, within the framework of this program, UTZ purchased high-performance metalworking equipment for the production of turbine blades - two 5-axis CNC machining centers 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, teleservice was tested - remote diagnostics of machine tools, 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.

Turbine equipment manufactured by UTZ consistently finds customers even in the face of fierce competition from foreign manufacturers. At the end of February 2012, the Ural Turbine Works manufactured a new steam turbine with a capacity of 65 MW for the Barnaul CHPP-2 of OAO Kuzbassenergo. The new T-60/65-130-2M turbine, st. no. 8, was successfully tested on a barring device at the UTZ assembly stand. The test report was signed by the customer's representatives without comment. The new equipment is being installed to replace the exhausted and decommissioned T-55-130 turbine, also manufactured at the Ural Turbine Plant. It should be noted that the T-60/65-130-2M two-cylinder turbine is a serial model produced by CJSC UTZ - 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 improve the technical and economic performance of the turbine plant (Fig. 3).

Fig.3

UTZ supplied a similar turbine for the Abakan CHPP (Khakassia). The turbine will be the basis of the new power unit of the Abakan CHPP: with its launch, the total capacity of the station should increase to 390 MW. The commissioning of the new power unit will increase electricity generation by 700-900 million kWh per year and significantly improve the reliability of the region's energy supply. Commissioning of the plant is planned for 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 hydrogen-cooled turbogenerator manufactured by NPO ElSib.

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

NPO Saturn

NPO Saturn is a developer and manufacturer of industrial gas turbine equipment of small, medium and high power for use at thermal power plants, industrial enterprises and oil and gas fields. This is one of the oldest industrial enterprises Russia: in 1916, it was decided to create five automobile plants on the basis of a state loan, including in the city of Rybinsk (Russian Renault JSC). In the post-revolutionary years, the plant worked on the development and production of aircraft engines. In the early 90s. The Rybinsk Motor-Building Plant was transformed into Rybinsk Motors OJSC. In 2001, after its merger with the Rybinsk Engine Design Bureau (JSC A. Lyulka-Saturn), the company received its current name and began to produce gas turbines for the energy and gas industries. In the line of manufactured products, first of all, it is necessary to name industrial gas twin-shaft turbines GTD-6RM and GTD-8RM, 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 / 10RM for use as part of gas compressor units and thermal power plants (from 4 MW and above). For low power plants (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" units, the company manufactures 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 testing of the GTD-110 unit, the first Russian gas turbine with a capacity of more than 100 MW, was carried out (Fig. 4).

Fig.4

GTD-110 is a single-shaft gas turbine for use as part of power and steam-gas plants of high power (from 110 to 495 MW and more), 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 in the field of high power gas turbine engineering. Currently, five GTD-110s are operated by Gazpromenergoholding (GEH) and Inter RAO. However, according to Inter RAO specialists, only the newest unit, launched in early March, is operating normally. The rest are currently unstable and serviced under the manufacturer's warranty.

According to the director for 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 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), a modernized gas turbine engine GTD-110 with a capacity of 110 MW.

Fig.5

In fact, the new engineering center will bring technical and economic characteristics GTD-110 to the best world models 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, increase the resource of the most worn parts and the entire engine as a whole. GTD-110M will become the basis for the creation of Russian high-capacity CCGTs. All complex work on the GTD-110M project is designed for 2-3 years.

OJSC "Leningrad Metal Works"

The Leningrad Metal Works is a unique enterprise. The history of the plant dates 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 - in 1924, gas - in 1956. To date, more than 2,700 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. Among the recent developments of the plant 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, semi-peak and peak loads both independently and as part of a combined cycle unit. The GTE-65 gas turbine plant can be used in various types of steam-gas units for the modernization of existing and construction of new power plants of condensing and cogeneration type. By price and technical specifications GTE-65 as a medium power machine meets the capabilities and needs of domestic power plants and power systems.

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

Fig.6

The prototype of the unit is the gas turbine V94.2 from Siemens, the documentation of which has been changed taking into account the capabilities of OAO LMZ and its partners. Just such a turbine, produced at JSC "Leningrad Metal Works", within the framework of the contract between CJSC "IES" and JSC "Power Machines" was delivered last summer to Perm CHPP-9.

Cooperation with German turbine builders continues. In December 2011, OJSC Power Machines and Siemens signed an agreement to establish a joint venture in Russia for the production and maintenance 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. New company is engaged in research and development of new gas turbines, localization of production in Russia, assembly, sales, project management and after-sales 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 Power Engineering Development Strategy of the Russian Federation for 2010-2020 and for the period up to 2030. organize in the near future at the Leningrad Metal Plant large-scale production of licensed high-capacity gas turbines (about 300 MW) with the transition from GTE-160 (V94.2) developed by Siemens in the 80s. to more modern gas turbines.

Such an industry, as for various purposes, refers to the type of engineering that produces goods with high added value. Therefore, the development of this area is consistent with the priorities of the leadership of our country, which tirelessly declares that we need to “jump off the oil needle” and more 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 extractive industries.

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 at thermal power plants. The latter are supplied to enterprises of the aviation industry and shipbuilding. A feature of the production of turbines is the lack of specialization of factories. 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 50s with the production of only power machines, later added gas turbine units to its range for sea ​​vessels. And the Perm Motors plant, which at first 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 speaks of 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 the publication BusinesStat, the production of turbines in Russia in the period from 2012 to 2016 increased by about 5 times. If in 2012 the enterprises of 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, by the increase in 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 area of ​​engineering a competitor to the oil industry.

If the oil industry needs foreign technologies to develop new oil fields and, especially, the Arctic shelf, then the manufacturers of gas turbine plants make do with their own developments. This reduces the cost of producing turbines and therefore 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 are pursuing a policy of secrecy. On the contrary, the trend of recent years is the strengthening of cooperation with foreign vendors. The need for this is dictated by the fact that our manufacturers are not able to organize the production of gas turbines with increased power. But such flagships, like some European companies, have the necessary resources. The pilot project was the opening of a joint venture between the St. Petersburg Saturn plant and the German company Siemens.

Yes, cooperation with distant partners in the field of turbine production is intensifying, which cannot be said about cooperation with close subcontractors. For example, due to the events in Ukraine, our manufacturers have practically lost ties with the Kiev, Dnipropetrovsk and Kharkov production associations, which have been supplying components since Soviet times.

However, here, too, our manufacturers manage to solve problems positively. So, at the Rybinsk Turbine Plant in Yaroslavl region, which manufactures power plants for ships of the Russian Navy, switched to the production of its own components to replace those that previously came from Ukraine.

Changing market conditions

Recently, the structure of demand 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 been produced. At the same time, an increase in demand for small-capacity products is observed both in the energy sector and in transport. Small power plants and small vehicles are popular today.

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

In conclusion, a few words about the prospects of the industry. According to experts, the production of turbines in Russia will grow to 1,000 units per year by 2021. All the necessary prerequisites are considered for this.

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

Gas turbine plant GTD-110M (Photo: Union of Machine Builders of Russia)

Tests of Russia's first high-capacity gas turbine GTD-110M (up to 120 MW) have been halted due to failed mechanisms, the TASS news agency reported. This was confirmed to RBC by representatives of the engineering center "Gas Turbine Technologies", which conducted the tests, and two of its shareholders - "Rosnano" and the United Engine Corporation (UEC) "Rostec".

“During the test testing of the GTD-110M gas turbine unit, an accident occurred, as a result of which the turbine was actually damaged,” a representative of the Gas Turbine Technologies Research Center told RBC. The purpose of the tests was to identify design flaws in order to avoid serious incidents during commercial operation in the power grid, he added. The UEC representative clarified 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 has been 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 the Gas Turbine Technologies Research Center. Inter RAO received 52.95% in this project, the Fund for Infrastructure and educational programs Rosnano - 42.34%, UEC-Saturn - 4.5%, the remaining 0.21% from the non-profit partnership CIET. Rosnano was supposed to finance the project and contribute to authorized capital 2.5 billion rubles, Interfax wrote in 2013, citing a source close to one of the parties. The corporation participated in financing the project, its representative confirms. According to SPARK, the authorized capital of the engineering center is 2.43 billion rubles. In 2016, Gas Turbine Technologies also received a subsidy from the Ministry of Industry and Trade in the amount of 328 million rubles. for partial compensation of R&D costs in priority areas, follows from the data of the system.

Sanctioned turbines

Russia is in dire need of a domestic high-capacity gas turbine. Last year, due to the lack of its own technologies, Rostec's subsidiary Technopromexport, despite the sanctions, was forced to supply 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, and Technopromexport, as well as its head Sergei Topor-Gilka and two officials from the Ministry of Energy - Andrey Cherezov and Evgeny Grabchak - fell under European and American sanctions.

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

There are no more than ten enterprises producing gas turbines in our country. There are even fewer manufacturers of ground equipment based on gas turbines. Among them are ZAO Nevsky Zavod, OAO Saturn - Gas Turbines and OAO Perm Motor Plant (part of the UEC of Rostec Corporation).

In Russia, all the conditions have been formed for the rapid development of the gas turbine market for land-based applications, analysts at EnergyLand.info believe. The need for distributed generation that is not based on diesel fuel, and on cleaner sources, everything is more relevant. 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. There are even fewer manufacturers of ground equipment based on gas turbines.

In the Soviet Union, stakes were placed on coal, oil and other calorific sources. Therefore, the first gas turbines were produced only in the 1950s. And first of all in relation to aviation construction.

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

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

At the same time, the nominal capacity of the serial production of these enterprises does not exceed 25 MW on average. There are several machines with a unit capacity of 110 MW based on the developments of NPO Saturn, but today they continue to be refined.

Turbines of high power are supplied mainly by foreign companies. Russian enterprises seek to enter into cooperation with world leaders.

However, not all world leaders are interested in organizing the production of gas turbines in Russia. One of the reasons is unstable demand for products. And it, in turn, largely depends on the level of energy consumption. Since 2010, energy consumption in Russia has grown steadily. But soon, according to experts, stagnation may occur. 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 OAO Saturn - Gas Turbines, similar reasons prevent Russian companies from mastering the production of high-capacity gas turbines. “The production of powerful gas turbine units (GTP) requires special equipment, large-diameter machines, vacuum welding units with chambers of the order of 5 by 5 m,” he says. - To create such a production, you need to be confident in the sales market. And for this, the country should have a long-term program for the development of the energy sector, perhaps then enterprises will begin to invest in the modernization of the base.”

However, the absence of predictable prospects does not mean that there is no demand at all. Demand is definitely there. Both for turbines with a capacity of more than 150 MW, and for small gas turbines that require less capital costs, but are quite capable of increasing energy efficiency and payback.

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

IN developed countries low power cogeneration plants are commonplace. In Russia, their number is still significantly lower. The main difficulty for companies supplying small-capacity 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 main 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.

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

Modern trends in the improvement of gas turbines are largely associated with innovations for the oil industry. But not only. Challenges facing manufacturers:
- increase in efficiency,
- reducing the number of nodes in the turbine,
- increase in reliability,
- reduction of maintenance volumes,
- reduction of downtime during diagnostics of the technical condition.

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

In addition, the creators of turbines strive to make them unpretentious to the gas used and the ability to work on liquid fuel.

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

A very important - promising - direction for improving gas turbines is associated with renewable energy sources (RES) and the prospects for the introduction of "smart grids". Initially, gas turbines were created as equipment that provides constant power output. However, the introduction of RES into the energy system automatically requires flexibility from other generation facilities. This flexibility makes it possible to ensure a stable power level in the network when there is insufficient renewable energy generation, for example, on calm or cloudy days.

Accordingly, a smart grid turbine should easily adapt to changes in the network and be designed for regular starts and stops without loss of resource. This is not possible with conventional gas turbines.

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 performance in 13 minutes, and when used with solar power plants will have an efficiency of up to 71%.

However, 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 complete and is waiting for saturation.

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

 

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