In Russia, on behalf of the President, the government is preparing a large-scale program for the modernization of thermal power plants (TPP), which is estimated at 1.5 trillion rubles and could start in 2019. One of its main conditions will be the use of Russian equipment. Is it possible to update the electric power industry using domestic developments? The general director of Power Machines, Timur Lipatov, who headed the company three months ago, spoke about the development of new turbines, export potential and the necessary state support in an interview with the Prime agency.
- What is Power Machines focusing on now? Will you work mainly for the thermal power industry due to the upcoming modernization program?
For anyone. We cannot neglect any niche; the situation in the industry is not the best: markets are shrinking, competition is growing. Therefore, we make almost the entire range of equipment for nuclear, thermal and hydropower.
- What demand from Russian electric power companies is Power Machines ready for as part of the thermal power plant modernization program?
In the first competitive selection, projects with a total capacity of 11 GW will be selected for modernization, first of all, this will be the reconstruction of our traditional steam power equipment. Our production capacity allows us to produce up to 8.5 GW of turbine equipment per year, the same volume of generators, and about 50 thousand tons of boiler equipment.
We have well-developed projects for modernizing the K-200 and K-300 turbines, and we have a project for modernizing the K-800. These projects allow us to increase power, efficiency, extend service life, and respond flexibly to what the client needs. But the program is not limited only to condensing units (that is, generating electricity - ed.) with a capacity of 200 and 300 MW, so we are concentrating on the heating turbines PT-60 and PT-80. Their design has been revised, including improving the design of the hull part and steam distribution. At the same time, solutions have been developed for replacing and upgrading turbines from third-party manufacturers. First of all, we are talking about the machines of the Kharkov Turbine Plant.
- It is planned to include in the TPP modernization program a rule on 100% localization of production in Russia necessary equipment. If we don't talk about gas turbines, what kind of equipment still needs to be localized?
In my opinion, the only problem in the production of generating equipment in Russia remains large-sized casting and the production of large forgings (a metal billet obtained as a result of forging or hot stamping - ed.).
Historically, there were three manufacturers of castings in the USSR, two of which - in the Urals and St. Petersburg - were closed foundry. As a result, he stayed in Russia sole supplier, which does not yet always provide required quality, and we are forced to purchase large-sized cast billets abroad, where their quality is more stable. We believe in the potential of Russian metallurgical enterprises, we believe that with appropriate government support and the emergence of guaranteed demand, they will be able to restore competence and provide the power engineering industry with high-quality cast billets and forgings. This is a parallel process, it is part of the thermal power plant modernization program, although it may not be on the surface right now.
- Power Machines announced plans to develop a domestic high-power gas turbine. Are you discussing partnerships with Russian or foreign companies?
The basic option is 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 as repeating in Russia the production of an outdated foreign model of a gas turbine, but as restoring the domestic school of gas turbine construction.
Our final goal– restart the gas turbine production cycle by organizing a design bureau, creating calculation methods, a bench base, and thereby protect the Russian energy industry from various negative external manifestations.
- What is the share of gas turbines from foreign manufacturers in Russia?
According to our estimates, if we take existing combined cycle gas turbine units (CCP) and gas turbine units (GTU), more than 70% are supplies from foreign manufacturers, another 24% are gas turbines produced by Interturbo (a joint venture of the Leningrad Metal Plant created in the 90s and Siemens).
At the same time, despite the presence of joint ventures, the production of the most significant elements of gas turbines - hot path components (fuel combustion chambers, turbine blades - ed.) and control systems - is not localized in Russia. Production is limited only to the assembly and manufacture of individual components, which are not critical for the performance of the gas turbine plant and the energy security of Russia as a whole.
- What line of gas turbines would Power Machines like to produce?
We are starting with 65 MW F-Class and 170 MW E-Class machines. In the future, it is planned to create a high-speed turbine of 100 MW with a free power turbine. Subsequently, it is possible to develop a 300-400 MW F or H-class gas turbine unit at 3000 rpm using scaling principles for some components.
- If Power Machines independently develops a turbine, then at what production site?
Here on our production facilities in St. Petersburg.
- How much do you estimate R&D costs in general? What might be the startup costs? industrial production? And how long can this take?
We estimate the entire project for 65 and 170 MW machines at 15 billion rubles. This amount includes costs for R&D and technology development, development and technical re-equipment of design and technological services, modernization of experimental research and production base. The production facility will be ready to produce prototype turbines in just two years.
- Why do you think that you will be able to develop a turbine? In Russia, other companies have many years of experience with unsuccessful attempts.
At one time, we were in the trend for gas turbines. The first such machine with a capacity of 100 MW was made at LMZ (Leningrad Metal Plant, part of Power Machines - ed.) in the 60s. And it was fully consistent with the technologies of that time. This foundation, unfortunately, was lost during the perestroika period. This area of power engineering in the world has become so technologically advanced, it has gone so far that in the 90s more than 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 joint venture Interturbo, from which the modern STGT grew (a joint venture between Siemens and Power Machines - ed.). Equipment production was located at the LMZ facilities and reached an honest 50% localization. As part of Interturbo, we gained experience in the production of gas turbine components, which is very correlated with our current work.
In the recent past, Power Machines independently, no longer as part of a joint venture, implemented a project for the development and production of the GTE-65 gas turbine with a capacity of 65 MW. The car passed full cycle 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 in mastering the production of Russian gas turbines as part of the thermal power plant modernization program. Thanks to the reasonable dialogue between the Ministry of Industry and Trade and the Ministry of Energy, we believe this goal has been achieved. We hope that as part of the subsequent selection of projects for participation in the modernization program, restrictions on maximum capital costs for projects using domestic gas turbines will be lifted. This will make objects with domestic gas turbines more investment attractive.
The second factor is the possibility of Power Machines constructing, independently or with a partner, experimental thermal power plants with a total capacity of 1.4 GW within the framework of the KOM NGO mechanism (guarantees investors the payback of projects for the construction of new power plants due to increased payments from consumers for power - ed.). This is necessary in order to bring prototype gas turbine samples ready for industrial operation and to obtain the necessary experience and competencies for all possible implementations - single-shaft, two-shaft and three-shaft CCGT units for gas turbines of all types.
And thirdly, the speedy release of government decree No. 719 (amendments to the decree regulating the issues of localization of production in the Russian Federation - ed.), which will put all manufacturers, both domestic and foreign, on equal terms.
- As part of the TPP modernization program, do you expect to conclude contracts not only for specific power plants, but also for companies, perhaps for the entire duration of the program?
Of course, we are interested in long-term cooperation, but as part of the modernization program, the generating companies themselves will only have to participate in competitive selections.
At the same time, from my point of view, concluding such long-term contracts is a normal practice, which will allow us to plan the production program and not let our counterparties meet deadlines if their projects are selected.
Currently, the main discussions concern framework agreements for repair and maintenance services and the supply of spare parts. When evaluating annual and three-year plans for repair campaigns, we typically see the potential to reduce the cost of spare parts and services provided by up to 15% by aligning production schedules.
- What kind of discussions are being held, are there any obstacles to the development of the service area?
The main obstacle to development is “garage production”. In the Soviet Union, drawings were often in free circulation; in the 90s, insufficient attention was paid to the protection intellectual property. It is not surprising that the result was huge amount fly-by-night companies where people, in makeshift conditions, literally in a garage, produce outdated spare parts, with deviations from the standard dimensions, and materials that do not meet the physical and mechanical characteristics.
We receive large number 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 proper deadlines and quality of work.
- How big is the problem of counterfeit products?
The market is filled with non-original spare parts, including counterfeit ones. We work to protect our technology, return intellectual property and prohibit its use by other players, using the opportunities that civil and criminal codes give us. They did not bear the costs of R&D (research and development work - ed.), do not guarantee quality, and damage our reputation. We count on support in this matter from Rostechnadzor, as well as other manufacturers.
- In the medium term, will the company focus on the domestic market or foreign projects? Which countries are you considering first for work? What technologies are in demand abroad?
- Power Machines has great export and technological potential. The main share of our projects abroad now is either nuclear and hydraulic issues, where we compete on equal terms with global manufacturers, or steam power units (reconstruction of previously supplied machines, production of equipment for burning such types of fuel, for example, fuel oil and crude oil). The share of exports varies, but on average is about 50%.
To increase exports, we must master two fundamentally important technologies that Russia does not currently have. First, restore the production of domestic gas turbines of medium and high power. Secondly, make a pulverized coal boiler and a steam turbine for super supercritical steam parameters (SSCP). Existing technologies make it possible to achieve fairly high efficiencies of 45-47% per steam turbines ah, working for the USSR. This is a reasonable alternative to the steam-gas cycle, taking into account the relatively low cost of coal, and often due to the lack of gas in the region. We have already developed design documentation for the SSKP turbine with a capacity of 660 MW - and are ready to put it into production as soon as an order appears.
In order for new products to be in demand abroad, they must first be manufactured and introduced on the home market, in Russia. The presence of references will allow us to enter our traditional markets - in Asia, Latin America, and the Middle East. One of the ways to obtain the necessary competencies is the construction of experimental stations within the framework of the KOM NGO mechanism. In addition, government support is needed - through intergovernmental agreements, with the attraction of export financing, and preferential lending. This is what was done in the Soviet Union, and this is what our competitors abroad are doing now.
-What other directions do you see for the company’s development?
One of the areas will be support for small technology companies. There are a huge number of startups on the market that are complementary to our technological chain and sales channels. We intend to actively support the development of such companies by entering into their share capital, financing R&D and technology, and guarantees. The transfer of control will allow shareholders to generate significantly greater income by increasing sales volumes and expanding their channels. I ask everyone to consider this an official invitation; we will be happy to consider proposals. There are already examples of such successful interaction.
Kremensky Sergey © IA Krasnaya Vesna
According to Russian and foreign media reports, in December 2017, a gas turbine with a capacity of 110 MW did not pass endurance tests at the Saturn plant in Rybinsk.
Foreign media, in particular Reuters, citing their sources, stated that the turbine had collapsed and could not be restored.
The head of Gazprom Energoholding Denis Fedorov at the Russian International Energy Forum, which took place at the end of April 2018, said even more radically - that the development of a domestic high-power gas turbine must be abandoned: “It’s pointless to practice this any further.”. At the same time, he proposes to completely localize foreign turbine production, that is, to buy a plant and licenses from Siemens.
I remember the cartoon “The Flying Ship”. The Tsar asks Boyar Polkan if he can build a Flying Ship, and in response he hears: “I’ll buy it!”.
But who will sell it? In the current political environment of the “war of sanctions,” not a single Western company will dare to sell a plant and technology to Russia. Even if he sells it, it’s high time to learn how to make gas turbines at domestic enterprises. At the same time, the media are publishing a completely adequate position of an unnamed representative of the United Engine Corporation (UEC), which includes the Rybinsk Saturn plant. He believes that “difficulties during the tests were expected, this will affect the completion time of the work, but is not fatal for the project”.
For the reader, we will explain the advantages of modern combined cycle gas plants (CCPs), which are replacing traditional large thermal power plants. In Russia, about 75% of electricity is generated by thermal power plants (TES). To date, more than half of thermal power plants use natural gas as fuel. Natural gas can be directly burned in steam boilers and, using traditional steam turbines, generate electricity, while the coefficient of fuel energy use for electricity production does not exceed 40%. If the same gas is burned in a gas turbine, then the hot exhaust gas is sent to the same steam boiler, then the steam to the steam turbine, then the coefficient of fuel energy use for electricity production reaches 60%. Typically, one combined cycle gas plant (CCGT) uses two gas turbines with generators, one steam boiler and one steam turbine with a generator. With the combined production of electricity and heat at one power plant, both a CCGT and a traditional CHPP, the fuel energy utilization factor can reach 90%.
In the 1990s and early 2000s, work on the serial production of high-power gas turbines was stopped in Russia due to fierce competition from Western companies and the lack of state support promising developments.
A similar situation has arisen with the civil aviation industry and other branches of mechanical engineering.
However, not everything is so bad; in 2004-2006, a single order of two GTD-110 gas turbines was completed for the Ivanovo PGU, but this order turned out to be unprofitable for the Rybinsk plant and was not profitable. The fact is that during the manufacture of the first GTD-110 turbines according to the project of the Mashproekt Institute (Nikolaev, Ukraine), it was not possible to place an order in Russia for the forging of the central part of the turbine, since special melting metal was required, and this grade of steel was several years old no one ordered it, and Russian metallurgists charged a price many times higher than in Germany or Austria. No one promised the plant orders for a series of turbines. The production planning horizon of 2-3 years did not allow the Rybinsk plant to master the technology of mass production of GTD-110 back in 2004-2006.
Since 1991, Russia has adopted a strategy of entering the common European home, the market, and in the logic of this market there was no point in developing its technologies from a lower position. And the competitive bidding mechanism, directly applied by the main customer - RAO UES of Russia, led to the victory of Western competitors. The essence of the mechanism is formal one-stage open tenders, without any preferences for Russian manufacturers. No self-respecting country in the world can afford this type of trading.
A similar situation arose at factories in St. Petersburg that are part of the Power Machines association, where back in Soviet times it was planned to manufacture gas turbines with a capacity of over 160 MW.
The position of the representative of the United Engine Corporation (UEC) is absolutely correct: it is necessary to continue fine-tuning the manufacturing technology in Rybinsk and St. Petersburg. Involving Inter RAO in the work is necessary, since its branch Ivanovskiye PGU has a test stand and operates the first Russian-made gas turbine units.
Thus, we see that Reuters is wishful thinking, reporting the failure of import substitution and modernization. Apparently they are afraid that Russian machine builders will succeed. Reuters' insinuations are a pitch for our internal liberals in the economic bloc. In a conventional war, this is identical to scattering leaflets “Give up. Moscow has already fallen".
When creating new types technical equipment So-called “childhood diseases” usually manifest themselves in the design, which are successfully eliminated by engineers.
Resource tests are necessary stage in the creation of new equipment, which is carried out to determine the operating time of the structure before defects appear that prevent further operation. It is normal to identify problematic issues during life tests work situation when mastering new technology.
In Soviet times, the Rybinsk Motors plant specialized in the production of aircraft engines and gas turbines for compressor units with a capacity of up to 25 MW.
Currently, the plant is part of the NPO Saturn association, which has successfully mastered the production of powerful marine gas turbines and is working on the creation and serial production of high-power power turbines.
Before the introduction of sanctions against Russia, the production of our own gas turbines for power stations was slowed down by the fact that the Russian economy was being integrated into global market, in which Western engineering companies occupied a monopoly position.
The current situation in the world requires persistence in continuing work on the project. Creating a line of powerful energy gas turbines will require 2-3 years of hard work, but it is justified in any case, regardless of whether Russia is under sanctions or not, this is real import substitution. The gigantic energy market of Russia will ensure the utilization of the mechanical engineering industry, special steel metallurgy and will give a multiplier effect in related industries.
The huge volume of the energy market is due to the fact that in the next twenty years the country's thermal power plants will be modernized. Hundreds, thousands of gas turbines will be required. It is necessary to stop burning such valuable fuel as natural gas with an energy utilization rate of 35-40%.
There are no more than ten enterprises producing gas turbines in our country. There are even fewer manufacturers of ground-based equipment based on gas turbines. Among them are CJSC Nevsky Plant, OJSC Saturn - Gas Turbines and OJSC Perm Motor Plant (part of the UEC of Rostec Corporation).
In Russia, all conditions have been created for the rapid development of the market for land-based gas turbines, according to analysts at EnergyLand.info. The need for distributed generation, based not on diesel fuel, but on cleaner sources, is increasingly 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. There are even fewer manufacturers of ground-based equipment based on gas turbines.
In the Soviet Union, the emphasis was placed on coal, oil and other heating sources. Therefore, the first gas turbines were produced only in the 1950s. And primarily in relation to aviation construction.
In the 1990s, the development of power gas turbines began based on engines created by NPO Saturn for aircraft.
Today, the production of ground-based power equipment based on NPO Saturn engines is carried out by OJSC Saturn - Gas Turbines. The Perm Motor Plant has mastered the production of gas turbine power plants based on the developments of Aviadvigatel OJSC.
At the same time, the rated power of serial products of these enterprises on average does not exceed 25 MW. There are several machines with a unit capacity of 110 MW based on the developments of NPO Saturn, but today they are still being fine-tuned.
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 of the reasons is the 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 set in. 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 OJSC Saturn - Gas Turbines, similar reasons are holding back Russian companies from mastering the production of high-power gas turbines. "For the production of powerful gas turbine units(GTU) requires special equipment, machines of large diameters, installations for vacuum welding, having chambers of about 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 must have a long-term program for energy development, perhaps then enterprises will begin to invest in modernizing the base.”
However, the absence of predictable prospects does not mean the absence of demand at all. There is certainly a demand. Both for turbines with a capacity of more than 150 MW, and for small gas turbine units that require less capital costs, but can fully cope with the 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 medium-capacity generating facilities. And gas turbines with a capacity of 4, 8, 16, 25 MW are the segment in which they mainly operate Russian manufacturers, 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 remains the insufficient solvency of potential customers.
Another traditional segment of the gas turbine market is generation facilities in 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 specialists from OJSC Saturn - Gas Turbines, in the pre-crisis years of 2006-2008 there was a surge of interest among oil workers in domestic gas turbines. Today this demand is at a stable level.
Modern trends in improving gas turbines are largely related to innovations for the oil industry. But not only that. Challenges facing manufacturers:
- increased efficiency,
- reduction in the number of components in the turbine,
- increased reliability,
- reduction of maintenance volumes,
- reducing the duration of downtime during technical condition diagnostics.
The above can solve the problem of high cost of service.
In addition, the creators of turbines strive to make them unpretentious to the gas used and the ability to operate on liquid fuel
And in the West they are also concerned that, regardless of the composition of the gas, the turbine has good environmental characteristics.
A very important - promising - direction for improving gas turbine units is related to renewable energy sources (RES) and the prospects for the introduction of “smart grids”. Initially, gas turbines were created as equipment that provides constant power. However, the introduction of renewable energy sources 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 RES energy production, for example, on calm or cloudy days.
Accordingly, a turbine for a smart grid must easily adapt to changes in the network and be designed for regular starts and stops without loss of resource. This is not possible with traditional 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 ramping up 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 of using gas turbines will still remain their usual combination with steam turbines as part of combined cycle gas plants. In our country, the market for such cogeneration facilities is by no means complete and is awaiting saturation.
United Engine Corporation (UEC)- a company that includes more than 85% of Russian gas turbine equipment assets. Integrated structure producing engines for military and civil aviation, space programs, installations of various capacities for the production of electrical and thermal energy, gas pumping and ship gas turbine units. In total, more than 70 thousand people work at UEC. The company is headed by Vladislav Evgenievich Masalov.
M. Vasilevsky
Today on Russian market Leading foreign power engineering companies are actively working on gas turbine equipment, primarily such giants as Siemens and General Electric. Offering high-quality and durable equipment, they pose serious competition to domestic enterprises. However, traditional Russian manufacturers are trying not to yield to world standards.
At the end of August this year, our country became a member of the World Trade Organization (WTO). This circumstance will inevitably lead to increased competition in the domestic power engineering market. Here, as elsewhere, the law applies: “change or die.” Without revising technology and carrying out deep modernization, it will be almost impossible to fight the sharks of Western engineering. In this regard, issues related to the development of modern equipment, operating as part of combined cycle gas turbine units (CCGTs).
In the last two decades, steam-gas technology has become the most popular in the world energy sector - it accounts for up to two-thirds of all generating capacities commissioned on the planet today. This is due to the fact that in combined cycle gas plants the energy of the burned fuel is used in a binary cycle - first in a gas turbine, and then in a steam turbine, and therefore the CCGT is more efficient than any thermal power plants (CHPs) operating only in the steam cycle.
Currently, the only area in the thermal energy industry in which Russia critically lags behind the world's leading manufacturers is high-power gas turbines - 200 MW and above. Moreover, foreign leaders have not only mastered the production of gas turbines with a unit capacity of 340 MW, but have also successfully tested and are using a single-shaft CCGT layout, when a gas turbine with a power of 340 MW and a steam turbine with a power of 160 MW have common shaft. This arrangement makes it possible to significantly reduce the construction 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 Russian Federation for 2010-2020 and for the future until 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 must carry out industrial development, including full-scale testing and refinement on its own test benches, of advanced gas turbine units (GTU) with a capacity of 65-110 and 270-350 MW and combined cycle gas units (CCGT) at natural gas with an increase in their coefficient of performance (efficiency) up to 60%.
Moreover, Russia is able to produce all the main components of CCGT units - steam turbines, boilers, turbogenerators, but a modern gas turbine is not yet available. Although back in the 70s, our country was a leader in this direction, when super-supercritical steam parameters were mastered for the first time in the world.
In general, as a result of the implementation of the Strategy, it is assumed that the share of power unit projects using foreign main power equipment should be no more than 40% by 2015, no more than 30% by 2020, no more than 10% by 2025 . It is believed that otherwise the stability of the Russian unified energy system may become dangerously dependent on the supply of foreign components. During the operation of power equipment, it is regularly necessary to replace a number of components and parts operating in high temperatures and pressure. However, some of these components are not produced in Russia. For example, even for the domestic gas turbine GTE-110 and the licensed GTE-160, some of the most important components and parts (for example, disks for rotors) are purchased only abroad.
Such large and advanced concerns as Siemens and General Electric, which often win tenders for the supply of energy equipment, are actively and very successfully operating in our market. The Russian energy system already has several generating facilities, to one degree or another equipped with basic energy equipment produced by Siemens, General Electric, etc. However, their total capacity does not yet exceed 5% of the total capacity of the Russian energy system.
However, many generating companies that use domestic equipment when replacing it still prefer to turn to companies with which they have been accustomed to working for decades. This is not just a tribute to tradition, but a justified calculation - many Russian companies have carried out a technological upgrade of production and are fighting on an equal footing with the world's power engineering giants. Today we will talk in more detail about the prospects of such large enterprises, such as JSC Kaluga Turbine Plant (Kaluga), CJSC Ural Turbine Plant (Ekaterinburg), NPO Saturn (Rybinsk, Yaroslavl region), Leningrad Metal Plant (St. Petersburg) , Perm engine-building complex (Perm region).
JSC Kaluga Turbine Plant
OJSC Kaluga Turbine Plant produces low and medium power steam turbines (up to 80 MW) for driving electric generators, drive steam turbines, block turbogenerators, geothermal steam turbines, etc. (Fig. 1).
Fig.1
The plant was founded in 1946, and four years later the first 10 turbines of its own design (OP300) were produced. To date, the plant has produced more than 2,640 power plants with a total capacity of 17,091 MW for energy facilities in Russia, the CIS countries and foreign countries.
Today, the enterprise is part of the Power Machines power engineering concern. One of the practical results of the affiliation was the implementation in January 2012 of the SAP ERP information solution based on the existing prototype, successfully used at OJSC Power Machines, instead of the Baan system previously used at KTZ. Created information system will allow the company to reach new level production automation, modernize your business processes based on best practices world leaders in the engineering industry, increase the accuracy and efficiency of management decisions.
The plant's products are in stable demand in Russia and abroad. The company has a large portfolio of orders for gas turbine and steam turbine equipment. In 2011, for Ufa CHPP No. 5, two T-60/73 steam turbines were manufactured and presented to the Customer - the most powerful units produced by KTZ OJSC today. One of the latest projects is the contract with OJSC Energy Construction Corporation Soyuz, within the framework of which KTZ manufactured two steam turbines for the branch of OJSC Ilim Group in Bratsk (Irkutsk region), intended for the reconstruction of the turbine department of TPP-3 . Under the terms of the contract, two back-pressure turbines - R-27-8.8/1.35 with a capacity of 27 MW and R-32-8.8/0.65 with a capacity of 32 MW - were delivered this summer.
In recent years, the world has increasingly used non-traditional energy sources, including geothermal steam. Geothermal power plants (GEP) can be called one of the cheapest and most reliable sources of electricity, since they do not depend on delivery conditions and fuel prices. The initiator of the development of geothermal energy in Russia in recent years has been the Geotherm company. Kaluga Turbine Plant OJSC acted as the base enterprise for the supply of power plants for orders from this company. The appeal to KTZ was not accidental, since the enterprise had practically solved one of the main problems of geothermal turbines - operation on wet steam. This problem boils down to the need to protect the last stage rotor blades from erosion. A common method of protection is the installation of special linings made of erosion-resistant materials. To protect against erosion, KTZ uses a method based on combating not the effect, but the very cause of erosion - coarse moisture.
In 1999, the Verkhne-Mutnovskaya GeoPP in Kamchatka with a capacity of 12 MW was put into operation - all the equipment of the power units for the station was supplied from Kaluga under a contract with Geotherm. Almost all turbine units supplied for geothermal power plants in Russia (Pauzhetskaya, Yuzhno-Kurilskaya on Kushashir Island, Verkhne-Mutnovskaya, Mutnovskaya GeoPP) were manufactured by the Kaluga Turbine Plant. To date, the company has accumulated great experience creation of geothermal turbine units of any size from 0.5 to 50 MW. Today, JSC Kaluga Turbine Plant is the most qualified geothermal turbine plant in Russia.
CJSC "UTZ" (Ural Turbine Plant)
The company is historically located in Yekaterinburg and is part of the Renova group of companies. The first AT-12 steam turbine with a power of 12 thousand kW was assembled and tested by Ural turbine builders in May 1941. Despite the fact that it was the first UTZ turbine, it operated reliably for 48 years.
Now the Ural Turbine Plant is one of the leading machine-building enterprises in Russia in the design and production of medium- and high-power steam heating 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 heating turbines operating in Russia and the CIS. Over 70 summer job 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 different types. In addition, UTZ specialists are developing and preparing the production of turbines for combined cycle gas plants - options for combined cycle gas plants with a capacity of 95-450 MW have been worked out. For installations with a capacity of 90-100 MW, a single-cylinder steam heating turbine T-35/47-7.4 is proposed. For a double-circuit combined cycle gas plant with a capacity of 170-230 MW, it is proposed to use a T-53/67-8.0 cogeneration steam turbine, which, while maintaining the design and depending on the steam parameters, can be marked from T-45/60-7.2 to T- 55/70-8.2. Based on this turbine, the plant can produce condensing steam turbines with a capacity of 60-70 MW.
According to the first deputy general director CJSC "UTZ" Denis Chichagin, domestic machine tool and mechanical engineering at at the moment does not reach the world level. To modernize enterprises, it is necessary to give the green light to high-tech equipment, so the company is currently changing its technology policy. In close cooperation with specialists from JSC ROTEC and the Sulzer company (Switzerland), the plant is modernizing management and technological schemes for the successful development and adaptation of foreign advanced technologies, which will significantly strengthen the company’s position in the market. The company continues to develop optimal design solutions for the main turbine equipment, while offering the customer modern service solutions, including those based on long-term post-warranty maintenance of steam and gas turbines. In 2009-2011 The plant invested more than 500 million rubles in technical re-equipment programs. to ensure the existing portfolio of orders and reach the design capacity of 1.8 GW of turbine equipment per year. In February 2012, as part of this program, UTZ acquired high-performance metalworking equipment for the production of turbine blades - two 5-axis CNC machining centers model MILL-800 SK with a rotary spindle (Fig. 2) from Chiron-Werke GmbH & Co KG (Germany )
Fig.2
Specialized software, supplied complete with the equipment, allows you to reduce machine time by up to 20-30% compared to universal CAM systems. Installation and commissioning of new machines was carried out by Chiron specialists. As part of the agreement, testing of teleservice was carried out - remote diagnostics of machines, prevention or correction of errors and accidents. Using a secure dedicated channel, Chiron service engineers record the operation of the equipment online and issue recommendations for the production of UTZ.
Turbine equipment produced by UTZ consistently finds customers even in conditions of fierce competition from foreign manufacturers. At the end of February 2012, the Ural Turbine Plant manufactured a new steam turbine with a capacity of 65 MW for the Barnaul CHPP-2 of OJSC Kuzbassenergo. The new turbine T-60/65-130-2M, no. 8, has successfully passed tests on a shaft turning device at the UTZ assembly stand. The test report was signed by the customer's representatives without any comments. New equipment is being installed to replace the exhausted and decommissioned T-55-130 turbine, also produced at the Ural Turbine Plant. It should be noted that the two-cylinder turbine T-60/65-130-2M is a serial model produced by UTZ CJSC - a continuation of the serial line of steam turbines T-55 and T-50, which have proven themselves over many years of operation at thermal power plants in Russia and the CIS. The new turbines use modern components and modified elements that increase the technical and economic performance of the turbine unit (Fig. 3).
.jpg)
Fig.3
UTZ supplied a similar turbine for the Abakan Thermal Power Plant (Khakassia). The turbine will be the basis of the new power unit of the Abakan Thermal Power Plant: with its launch, the total capacity of the station should increase to 390 MW. The commissioning of the new power unit will increase electricity production by 700-900 million kWh per year and significantly increase the reliability of energy supply to the region. Commissioning of the installation is planned at the end of next year. The turbine is equipped with two PSG-2300 network water heaters and a KG-6200 condenser group, as well as a TVF-125-2U3 turbogenerator with hydrogen cooling produced by NPO ElSib.
Recently, the UTZ assembly stand successfully tested a new single-cylinder steam turbine T-50/60-8.8, manufactured for Petropavlovskaya CHPP-2 (SevKazEnergo JSC). The new Ural-made turbine should replace the previously operating two-cylinder Czech turbine R-33-90/1.3 from Skoda, and will be mounted on the same foundation. The project for replacing the turbine was prepared by the institute of JSC KazNIPIEnergoprom, with which JSC UTZ has been collaborating fruitfully for a long time. Long-standing ties with the former Soviet republics are not weakening either: for example, the issue of supplying several Ural turbines for thermal power plants in Kazakhstan is currently at the negotiation stage.
NPO "Saturn"
NPO Saturn is a developer and manufacturer of industrial gas turbine equipment of low, medium and high power for use in thermal power plants, industrial enterprises and oil and gas fields. This is one of the oldest industrial enterprises Russia: in 1916, it was decided to create five automobile factories on the basis of a state loan, including in the city of Rybinsk (JSC Russian Renault). In the post-revolutionary years, the plant worked on the development and production of aircraft engines. In the early 90s. The Rybinsk Engine Plant was transformed into OJSC Rybinsk Motors. In 2001, after its merger with the Rybinsk Engine Design Bureau (JSC A. Lyulka-Saturn), the company received its modern name and began producing gas turbines for the energy and gas industries. In the line of products, first of all, industrial gas turbines GTD-6RM and GTD-8RM should be mentioned, used to drive electric generators as part of gas turbine units GTA-6/8RM, which are used in gas turbine thermal power plants of medium power (from 6 to 64 MW and above) . The company also produces a family of unified gas turbines GTD-4/6.3/10РМ for use in gas pumping units and thermal power plants (from 4 MW and above). For low-power power plants (from 2.5 MW and above), the DO49R unit is produced - a single-shaft gas turbine with a built-in coaxial gearbox. In addition to “land-based” installations, the company produces marine gas turbines M75RU, M70FRU, E70/8RD, used to drive electric generators and gas compressors as part of offshore and coastal industrial facilities of low and medium power (from 4 MW and above).
In 2003, interdepartmental tests of the GTD-110 installation, the first Russian gas turbine with a capacity of more than 100 MW, were carried out (Fig. 4).
Fig.4
GTD-110 is a single-shaft gas turbine for use as part of high-power power and combined-cycle plants (from 110 to 495 MW and above), created within the framework of the Federal Target Program “Fuel and Energy” for the needs of the domestic energy system and is so far the only Russian development in the field of high-power gas turbine engineering. Currently, five GTD-110 are in operation at Gazpromenergoholding (GEH) and Inter RAO. However, according to Inter RAO specialists, in normal mode Only the newest installation, launched in early March, is operational. The rest are currently operating unstable and are 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 the GTD-110M (Fig. 5), a modernized gas turbine engine GTD-110 with a power of 110 MW.
Fig.5
In fact, the new engineering center will bring technical and economic characteristics GTD-110 up to the best world standards in this power class; The engine will be improved and refined; it is planned to create a combustion chamber that will ensure an acceptable level of harmful NOx emissions of 50 mg/m3. In addition, in the production of the engine it is planned to use nanostructured coating technologies, which will increase the reliability of the hot part of the turbine, increase the service life of the most wearing parts and the entire engine as a whole. GTD-110M will become the basis for the creation of Russian high-power CCGT units. All complex work on the GTD-110M project is designed for 2-3 years.
JSC "Leningrad Metal Plant"
Leningrad Metal Plant is a unique enterprise. The plant dates its history back to 1857, when the personal Decree of Emperor Alexander II “On the establishment Joint stock company"St. Petersburg Metal Plant" on the basis of the Charter." The production of steam turbines here began in 1907, hydraulic turbines in 1924, and gas turbines in 1956. To date, LMZ has manufactured more than 2,700 steam turbines and over 780 hydraulic turbines. Today it is one of the largest power engineering enterprises in Russia, which is part of OJSC Power Machines, which designs, manufactures and services a wide range of steam and hydraulic turbines of various capacities. Among the plant's recent developments is the GTE-65 gas turbine unit with a capacity of 65 MW. It is a single-shaft unit designed to drive a turbogenerator and capable of carrying base, half-peak and peak loads both independently and as part of a combined cycle unit. The gas turbine unit GTE-65 can be used in various types steam-gas units for the modernization of existing and construction of new condensing and heating power plants. By price and technical specifications GTE-65, as a medium-power machine, meets the capabilities and needs of domestic power plants and energy systems.
In the early 2000s. OJSC LMZ signed an agreement with Siemens for the right to manufacture and sell the gas turbine unit GTE-160 with a capacity of 160 MW in the Russian Federation and Belarus (Fig. 6).
Fig.6
The prototype of the installation is the V94.2 gas turbine from Siemens, the documentation of which has been changed taking into account the capabilities of LMZ OJSC and its partners. It was this turbine, produced at Leningrad Metal Plant OJSC, that was delivered to Perm CHPP-9 last summer under the contract between IES CJSC and Power Machines OJSC.
Cooperation with German turbine manufacturers continues. In December 2011, OJSC Power Machines and Siemens signed an agreement to create a joint venture in Russia for the production and service of gas turbines, Siemens Gas Turbine Technologies. This project was carried out on the basis of Interturbo LLC, which has been a joint venture of partners since 1991. New company is engaged in the research and development of new gas turbines, localization of production in Russia, assembly, sales, project management and service of high-power gas turbines of classes E and F with a capacity from 168 to 292 MW. This area of activity of Siemens Gas Turbine Technologies is linked to the requirement of the “Strategy for the Development of Power Engineering of the Russian Federation for 2010-2020 and for the period up to 2030.” to organize in the near future at the Leningrad Metal Plant large-scale production of licensed high-power gas turbine units (about 300 MW) with a transition from the GTE-160 (V94.2) developed by Siemens in the 80s. to more modern gas turbines.
Such an industry, as a miscellaneous industry, refers to the type of mechanical 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 “get 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 aviation and shipbuilding enterprises. A feature of turbine production 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-generating machines, later added gas turbine units for sea vessels to its product range. And the Perm Motors plant, which initially specialized in the production of aircraft engines, switched to additional production of steam turbines for the electric power industry. Among other things, the lack of specialization speaks to the broad technical capabilities of our manufacturers - they can produce any equipment with quality assurance guarantees.
Dynamics of turbine production in the Russian Federation
According to BusinesStat, turbine production in Russia increased approximately 5-fold between 2012 and 2016. If in 2012 industry enterprises 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 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 mechanical engineering a competitor to the oil industry.
If oil workers require foreign technologies to develop new oil fields and, especially, the Arctic shelf, then manufacturers of gas turbine units make do with their own developments. This reduces the cost of producing turbines and, accordingly, reduces production costs, 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 secrecy. On the contrary, the trend in recent years has been increased 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, as well as 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 allies. For example, due to the events in Ukraine, our manufacturers have practically lost ties with Kyiv, Dnipropetrovsk and Kharkov production associations, which have been supplying components since Soviet times.
However, here too our manufacturers manage to solve problems positively. Thus, at the Rybinsk Turbine Plant in Yaroslavl region, which produces power plants for ships of the Russian Navy, switched to producing their own components to replace those that previously came from Ukraine.
Changing market conditions
IN lately 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 begun to be produced. At the same time, an increase in demand for low-power products is observed both in the energy sector and in transport. Today, low-power power plants and small vehicles are popular.
Another trend in 2017 is the increase in steam turbine production. This equipment, of course, is inferior in functionality to gas turbine units, but is preferable in terms of cost. These devices are purchased for the construction of diesel and coal power plants. These products are in demand in the Far North.
In conclusion, a few words about the industry's prospects. According to experts, the production of turbines in Russia will increase by 2021 to 1,000 products per year. All the necessary prerequisites are provided for this.
Loading...
