The production of turbines in Russia is gaining momentum. Russia stopped the test of a gas turbine of high power due to an accident plant for the production of gas turbines

Respondent: A. S. Lebedev, Doctor of Technical Sciences

- On June 18, the opening of a new high-tech plant for the production of gas turbine plants was held. What tasks are before the enterprise?

The main task is the introduction of gas turbine technologies on the Russian market and the maximum localization of the production of large gas turbines with a capacity of 170, 300 MW for power plants operating in the vapor-gas cycle.

I would suggest to take a step back and make a short excursion to the story so that it was clear from where we appeared how the joint venture was organized by Siemens and the power machines. It all started in 1991, when a joint venture was created - then the LMZ and Siemens - on the assembly of gas turbines. The technology transfer agreement was concluded on the then Leningrad Metal Plant, which is now included in the Power Machine OJSC. At this joint venture, 19 turbines were collected in 10 years. Over the years, LMZ has accumulated production experience so that these turbines will learn not only to collect, but some components have been made independently.

Relying on this experience, in 2001 a license agreement was concluded with Siemens on the right of production, sales and after-sales service of the turbine of the same type. They received the Russian marking of GTE-160. These are turbines that give 160 MW, and in the vapor-gas blocks of 450 MW, that is, it is essentially a joint work of a gas turbine with steam turbines. And here such turbines GTE-160 under the Siemens license was manufactured and sold 35, of which 31 for the Russian market. They are quite widely used in St. Petersburg, in particular, on the North-West CHP, on the Southern CHP, Right Bank CHP, in Kaliningrad, in South Siberia, in Moscow 6 such turbines work in the vapor-gas blocks. You can even say without false modesty that this is the most common gas turbine in the Russian Federation today. It is a fact. In such a quantity, no one has released such a series of powerful gas turbines.

And now relying on this experience of joint production, a new agreement was concluded and a new joint venture "Siemens Gas Turbine Technology" was created. It happened three more than a year ago, in December 2011. Now we will produce turbines at our own factory. The tasks remain the same - to master the production, achieve maximum localization and fit into the government development program for import substitution.

- That is, in fact, did you become a competitor to power machines?

In terms of gas turbines, we are not competitors. Because the power machines produce only steam and hydraulic turbines since 2011. The entire gas turbine business with engineers, with a continuation of the execution of contracts, was transferred to the joint venture. We are 35 percent of the power machines and 65 percent of Siemens. That is, we all the gas turbine part of the power machines entered this joint venture. In other words, we are business partners, not competitors.

— What is the differencegas turbines Siemens. From domestic analogs?

In this capacity class, the only sample of domestic products is the Rybin NGO Turbine Saturn - GTD-110 with a capacity of 110 MW. Today it is the most powerful turbine of its own production in the Russian Federation. Pretty widely represented in Rossi turbines up to 30 MW on the basis of the conversion of aircraft engines. Here is a very extensive field for competition, and Russian products are main in this capacity class. For large gas turbines, today there is no such competitive product in Rossi. 110 MW is all that is, today such installations are made by 6 pieces. From the customer, there are certain complaints to their operation. Since this is a competitor in a certain sense, I would not like to comment on the results of its activities.

- What newest developments do you use?

All possible developments of Siemens. We are an enterprise that basically belongs to this corporation, as a result of this, the documentation and all the results of the scientific research of Telska activities introduced into those gas turbines to which we have a license are 170 and 307 MW. Documents in the amount of production organized in the burner are available to us without any restrictions, they allow you to introduce the newest developments.

Along with this, we ourselves participate in these developments. An example is our cooperation with a Polytechnic University. The university is now divided into institutions, and the Institute of Energy and Electrical Engineering is the Department of Turbines, Hydromachines and Aviation Engines, this is one of the units of the Institute. Here with this and with one department, we have agreements and conduct joint research and development activities. In one case, we experience an element of a gas turbine - an output diffuser. Within two years, quite interesting work on the stand has already been done. The bench, which we actually paid and helped create.

On the same department, but in the subdivision of hydromachin, we spend another research research. Why on the subject of hydromachin? The fact is that gas turbines are equipped with hydraulic drives, and at this very department has accumulated extensive experience in research on the drive of various elements. Elements that control the process of operation of the gas turbine and hydroturgic. And for the sake of this cooperation, the department participated in a serious contest, where he won its main competitors from the University of China.

In addition to the joint research work with these two departments, we also read lectures, try to maintain and prepare yourself frames on a student bench.

- Are your main customers - Russian or foreign enterprises?

We have a license with the right of production and sales to Russia and the CIS. In coordination with the main founder, Siemens Corporation, we can sell to other countries. And without any additional coordination, we sell gas turbines into Russian energy buildings, this Gazprom Energoholding, Inter RAO, Fortum and other energy owners.

- In your opinion, what is the key difference between the organization of engineering work at your enterprise?

It seems to me that there are no fundamental differences from the Russian production industry about the enterprise. Probably because over the past 20 years, Russian enterprises have become a bit similar to Western - West Management has appeared, borrowed technological process management systems and quality have been introduced. That is, the revolutionary difference is not felt.

But I would have allocated two differences. The first is specialization, that is, the engineer is engaged in purely technical, more even creative activities. There is no such defined scattering in the activity of an engineer, as a typical Russian enterprise, when it is used almost everywhere.

We will demonstrate on the example of engineering - such engineering on Siemens at least three: one main engineering on the product, for example, on a gas turbine, where the gas turbine plant itself is created, all its insides, all its technical solutions are being implemented. The second engineering is a service engineering, which is engaged in modernizations, revisions, inspections, and it is not engaged in creating a new product. The third engineering can be characterized as technical solutions in system integration that the gas turbine enters the station's equipment - all air preparation devices for its operation, fuel feeds, gas economy, which must be connected to other elements of the power plant. And he again does not create a new product, but focuses on the area outside the main gas turbine.

The second principal difference of our production is due to the fact that Siemens is a global company. And it is good, and not easy at the same time. In the Global Cymens Corporation, all procedures, rules governing documents must be universal for Latin American countries, Finland, China, Russia and other countries. They must be quite voluminous, rather detailed and they need to follow. And it is necessary to get used to this in the global company - to a variety of global processes and rules prescribed very detail.

- What role in the development of the enterprise is playing in engineering forums, such as, for example, as the Engineering Assembly of Russia? Do you plan to participate in the upcoming November event?

Yes, we plan to participate. We would like not only to declare ourselves that we are a company with developed engineering, a company that works with scientific institutions, and its own developments are doing with Siemens. We would still like to some kind of search for partners in the topics of interest, for example, to localize production. Probably, we just do not know about the possibilities that really exist. We need more to operate with some databases, be more flexible in search of sub-supporters, suppliers, materials, components or vice versa, engineering services. Because now such a difficult time, when you need to evaluate everything from an economic point of view when you need to weigh again, what to do it yourself, and what services it is better to buy, estimating at the same time as far as it is advantageous not only at the moment, but also in perspective. Maybe it is necessary to make certain investments and further master some kind of production or services independently. In order for this horizon to acquire, participation in such conferences and meetings is very important. So we will definitely participate.

Zabottina Anastasia

Enterprises producing gas turbines in our country no more than ten. Manufacturers of ground equipment based on gas turbines and is less. Among them, CJSC Nevsky Plant, Saturn - Gas Turbines OJSC and Perm Motor Plant OJSC (including Rostex Corporations).

In Russia, all conditions have been formed for the rapid development of ground-use gas turbines market, Energyland.info analysts are considered. The need for distributed generation, based not on diesel fuel, but on cleaner sources, everything is more relevant. There is almost no doubt about the effectiveness of the volatile installations.

However, enterprises producing gas turbines, in our country no more than ten. Manufacturers of ground equipment based on gas turbines and is less.

In the Soviet Union, the rate was done on coal, oil and other calorific sources. Therefore, the first gas turbines were issued only in the 1950s. And primarily in relation to aviation construction.

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

Today, the release of terrestrial energy efficiency on the basis of NPO engines "Saturn" is engaged in Saturn - Gas Turbines OJSC. The "Perm Motor Plant" mastered the release of gas turbine power plants based on the development of OJSC Aviadvigitel.

At the same time, the rated power of serial products of these enterprises on average does not exceed 25 MW. There are several cars with a single capacity of 110 MW based on the development of NGO "Saturn", but today their finishes continue.

Large-capacity turbines 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 gas turbines in Russia. One of the reasons is the unstable demand for products. And he, in turn, largely depends on the level of energy consumption. Since 2010, energy consumption has grown consistently in Russia. 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 OJSC Saturn - Gas Turbines, and there are similar reasons for both Russian companies from mastering the production of gas turbines of high power. "To produce powerful gas turbine installations (GTU), special equipment, large diameter machines, installations for welding in vacuum, having a chamber of about 5 to 5 m," he says. - To create such production, you need to be confident in the sales market. And for this in the country there should be a long-term program for the development of energy, possibly the enterprises will begin to invest in the modernization of the base. "

Nevertheless, the absence of predictable prospects does not mean the lack of demand at all. Demand is definitely there. As a turbine with a capacity of more than 150 MW and for small GTU, which require less capital expenditures, but quite cope with issues of energy efficiency and payback.

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

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

Another, the traditional segment of the gas turbine market - the objects of generation on oil and gas fields and main gas pipelines. Gas turbine power plants make it possible to effectively dispose of associated petroleum gas, solving not only the problem of energy supply, but also the rational use of hydrocarbon resources.

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

Modern trends in improving gas turbines are largely related to innovations for the oil market. But not only. Tasks facing manufacturers:
- increase efficiency,
- reduction of the number of nodes in the turbine,
- increasing reliability,
- reduction of maintenance volumes,
- Reduced downtime during the diagnosis of technical condition.

Listed may solve the problem of the high cost of service.

In addition, the creators of turbines seek to achieve unpretentiousness from them to the gas used and the possibility of working on liquid fuel

And in the West is also worried about, regardless of the composition of the gas, the turbine had good environmental characteristics.

Very important - promising - the direction of improvement of GTU is associated with renewable energy sources (renewable) and prospects for the introduction of "smart networks". Initially, gas turbines were created as equipment that ensures the issuance of constant power. However, the introduction to the EN energy system automatically requires flexibility from other generation objects. Such flexibility makes it possible to provide a stable power level in the network with insufficient energy generation of renewable energy, for example, in windless or cloudy days.

Accordingly, the turbine for the intelligent power system should be easily adapted to changes in the network and be designed for regular starts and stops without loss of resource. In the case of traditional gas turbines it is impossible.

Abroad, certain successes in this direction have already been achieved. For example, the new gas turbine FlexEfficiency is able to reduce power from 750 MW to 100 MW and then typing the initial indicators in 13 minutes, and when used with solar power plants will have effectiveness up to 71%.

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

Joint Engineering Corporation (ADC) - A company, which includes more than 85% of the assets of Russian gas turbine techniques. Integrated structure producing engines for military and civil aviation, space programs, installation of different power for the production of electrical and thermal energy, gas pumping and ship gas turbine aggregates. In total, more than 70 thousand people work in the ADC. Vladislav Evgenievich Masualov is headed by Vladislav.

M. Vasilevsky

Today, leading foreign energy-building companies are actively working on the Russian gas turbine equipment market, first of all, such giants like Siemens and General Electric. Offering high-quality and durable equipment, they constitute a serious competition to domestic enterprises. Nevertheless, traditional Russian manufacturers are trying not to yield to international standards.

At the end of August of this year, our country has become a member of the World Trade Organization (WTO). This circumstance will inevitably lead to increased competition in the domestic market of energy engineering. Here, as elsewhere, the law is valid: "Change or Dyrey." Without revising the technology and without conducting deep modernization, it would be almost impossible to deal with the sharks of Western Engineering. In this regard, there are all the urgent issues related to the development of modern equipment, working as part of the vapor-gas installations (PSU).

In the past two decades, the vapor-gas technology has become the most popular in world energy - it accounts for up to two thirds of all generating capacity today on the planet. This is due to the fact that in the vapor-gas installations, the energy of burning fuel is used in the binary cycle - first in the gas turbine, and then in steam, and therefore the PSU is more efficient than any thermal stations (TPP) operating only in the vapor cycle.

Currently, the only area in the thermal energy in which Russia is critically lagging behind the world's leading manufacturers is the gas turbines of high power - 200 MW and higher. Moreover, foreign leaders not only mastered the production of gas turbines with a single capacity of 340 MW, but also successfully tested and apply a single PSU 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. Such a layout makes it possible to significantly reduce the deadlines for the creation and cost of the power unit.

The Ministry of Industry and Trade of Russia in March 2011 adopted a "strategy for the development of the energy sector of the Russian Federation for 2010-2020 and for the future to 2030", in accordance with which this direction in domestic energy engineering receives solid support from the state. As a result, Russian energy engineering by 2016 should carry out industrial development, including full-scale tests and refinement on their own test stands, improved gas turbine plants (GTU) with a capacity of 65-110 and 270-350 MW and vapor-gas installations (PSU) on natural gas with an increase their efficiency (efficiency) to 60%.

Moreover, Russia knows how to produce all the main nodes of the PGU - steam turbines, boilers, turbogenerators, but the modern gas turbine is not yet given. Although in the 70s, our country was the leader in this direction, when the super-super-critical 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 projects of power units using foreign main energy equipment should be made by 2015 - no more than 40%, by 2020 - no more than 30%, by 2025 - no more than 10% . It is believed that otherwise there may be a dangerous dependence of the stability of the unified energy system of Russia from the supply of foreign components. During the operation of the energy equipment, a series of nodes and parts operating under high temperatures and pressures is regularly required. At the same time, part of such components in Russia is not produced. For example, even for the domestic gas turbine of GTE-110 and the licensed GTE-160, some of the most important components and parts (for example, discs for rotors) are purchased only abroad.

In our market, such large and advanced concerns as Siemens and General Electric are actively and very successfully successfully working, which often win in tenders for the supply of power equipment. In the Russian energy system, there are already several generating facilities, in one degree or another, equipped with the main energy equipment of the production of Siemens, General Electric et al. True, their total power does not yet exceed 5% of the total power of the Russian energy system.

However, many generating companies using domestic equipment when it is replaced, prefer to contact the firms with which they are accustomed to work not one decade. This is not just a tribute to tradition, but justified the calculation - many Russian companies conducted a technological renewal of production and are in equal in the struggle with world energy-building giants. Today we will describe in more detail about the prospects for such large enterprises, as Kaluga Turbine Plant OJSC (Kaluga), Ural Turbine Plant CJSC (Yekaterinburg), Saturn NPO (Rybinsk, Yaroslavl Reg.), Leningrad Metal Plant (St. Petersburg), Perm Motor-Building Complex (Perm Territory).

JSC "Kaluga Turbine Plant"

OJSC "Kaluga Turbine Plant" produces steam turbines of small and medium power (up to 80 MW) to drive electrical generators, drive vapor turbines, block turbogenerators, steam geothermal turbines, etc. (Fig. 1).

Fig.1

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

Nowadays, the enterprise is part of the power engineering concern "Power Machines". One of the practical results of affiliation was the introduction of the SAP ERP information solution from January 2012, based on the current prototype, successfully used in Power Machines, instead of the Baan system previously used on the KTZ. The information system created will allow the enterprise to enter a new level of production automation, modernize its business processes based on the best practices of world leaders of the machine-building industry, improve the accuracy and efficiency of management decisions.

The plant's products use stable demand in Russia and abroad. The company has a large portfolio of orders for gas turbine and parroid turbine equipment. In 2011, the T-60/73 steam turbines T-60/73 were made for Ufa CHPP No. 5 - the most powerful of the settings produced by OJSC "KTZ" today. One of the latest projects can be called a contract with OJSC "Soyuz Energy Building Corporation", within the framework of which KTZ made two steam turbines for the branch of Ilim Group OJSC in Bratsk (Irkutsk Region), designed to reconstruct the Turbine Branch of TPP-3 . Under the terms of the treaty, two refractive turbines - P-27-8.8 / 1.35 with a capacity of 27 MW and P-32-8.8 / 0.65 with a capacity of 32 MW - were delivered in the summer of this year.

In recent years, non-traditional energy sources are increasingly used in the world, including geothermal pairs. Geothermal power plants (geoes) can be called one of the cheapest and reliable sources of electricity, since they do not depend on the terms of delivery and fuel prices. The initiator of the development of geothermal energy of Russia in recent years has become the company "Geoterm". As a basic enterprise for the supply of power plants for orders of this company, OJSC Kaluga Turbine Plant was performed. The appeal to the KTZ was not accidental, because at the enterprise, one of the main problems of geothermal turbines were practically solved - work on a wet pair. This problem is reduced to the need to protect the last steps from erosion. A common protection method is the installation of special linings made from materials resistant to erosion. KTZ to protect against erosion uses a method based on the struggle not with a consequence, but with the very cause of erosion - with large-dispersed moisture.

In 1999, the Verkhne-Mutnovskaya geoes on Kamchatka with a capacity of12 MW was put into operation - all equipment of power units for the station under a contract with Geoterm was supplied from Kaluga. Almost all the turbo systems set for geothermal power plants of Russia (Pujetskaya, South Kurilskaya on about. Kushashir, Verkhne-Mutnovskaya, Mutnovskaya geoes), made by Kaluga turbine factory. To date, the company has gained extensive experience in creating geothermal turbosets of any size from 0.5 to 50 MW. Today, the Kaluga Turbine Plant OJSC is the most qualified Turbine Plant for Geothermal Topics in Russia.

ZAO "ITZ" (Ural Turbine Plant)

The company 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 collected and tested by the Urals turbo builders in May 1941. Despite the fact that it was the first turbine cliff, it reliably worked for 48 years.

Now the Ural Turbine Plant is one of the leading engineering enterprises in the design and production of steam heating turbines of medium and high power, condensing turbines, steam turbines with backpressure, turbine steam, gas pumping units, energy gas turbine installations, etc. Turbines produced by ITE, There are about 50% of all the heat turbines operating in Russia and the CIS. For more than 70 years of work, the plant put 861 steam turbines with a total capacity of 60 thousand MW at the power plants of various countries.

The company has developed a whole family of steam turbines for steamile attitudes of different types. In addition, ITE specialists are being developed and preparation of the production of turbines for the steamers - worked out options for vapor-gas settings with a capacity of 95-450 MW. For installations with a capacity of 90-100 MW, a single-cylinder steam heating turbine T-35 / 47-7.4 is proposed. For a two-circuit vapor unit with a capacity of 170-230 MW, the use of thermal steam turbine T-53 / 67-8.0, which, when constructing, and, depending on the parameters, the steam may be marked from T-45 / 60-7.2 to 55 / 70-8.2. On the basis of this turbine, condensing steam turbines with a capacity of 60-70 MW can be produced.

According to the First Deputy Director General of ZAO, Denis Chichagin, Domestic Stanko- and Mechanical Engineering at the moment does not reach world level. For modernization of enterprises, it is necessary to give green light high-tech equipment, so currently the company changes technological policies. In close cooperation with specialists from CJSC Rotek and Sulzer (Switzerland), the plant provides modernization of management and technological schemes for the successful development and adaptation of foreign progressive technologies, which will significantly strengthen the position of the enterprise in the market. The company continues the development of optimal design solutions for the main turbine equipment, while the customer offers modern solutions for the service, including those based on long-term post-warranty maintenance of steam and gas turbines. In 2009-2011 The plant has invested in technical re-equipment programs more than 500 million rubles. To provide an existing portfolio of orders and access to the design capacity of the release of 1.8 GW of turbine equipment per year. In February 2012, as part of this program, IT has acquired high-performance metalworking equipment for the production of turbine blades - two 5-thicker machining center with CNC models MILL-800 SK with a rotary spindle (Fig. 2) of Chiron-Werke GmbH & Co Kg (Germany )

Fig.2

Specialized software supplied with the equipment allows you to reduce machine time up to 20-30% compared with universal CAM systems. Installation and commissioning of new machines was made by Chiron specialists. Within the framework of the contract, television testing was tested - remote diagnostics of machine tools, preventing or corrected errors and accidents. According to the protected dedicated channel, Chiron service engineers record the operation of equipment online and issued recommendations for the production of clock.

Tourban equipment, manufactured by IT, consistently finds customers even in conditions of tough 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 Barnaul CHP-2 OJSC Kuzbassenergo. The new T-60 / 65-130-2m T-60-26 T-60 Town Turbine has successfully passed the tests on the grinding device on the assembly stand of the IT. The test report was signed by customer representatives without comments. The new equipment is established instead of its resource that has exhausted and the T-55-130 turbine derived from operation, also produced in the Ural Turbine Plant. It should be noted that the two-cylinder turbine T-60 / 65-130-2m is the production model of the production of UROT CJSC - the continuation of the serial line of steam turbines T-55 and T-50, which have proven themselves for many years of operation at the CHP of Russia and the CIS. Modern nodes and finalized elements that increase the technical and economic indicators of the turbo set (Fig. 3) are used in new turbines.

Fig. 3.

Another TEZ turbine set for Abakan CHP (Khakassia). The turbine will be the basis of the new power unit of Abakan CHP: with its launch the total power of the station should increase to 390 MW. The commissioning of a new power unit will increase the production of electricity to 700-900 million kWh per year and significantly increase the reliability of the region's energy supply. Installation is planned at the end of next year. The turbine includes two PSG-2300 network water heater and the Condenser group of KG-6200, as well as the TWF-125-23 turbogenerator with hydrogen cooling of the ELSIB NGO.

Recently, at the assembly stand, the UTZ held successful tests of the new steam single-cylinder turbine T-50 / 60-8.8, made for Petropavlovsk CHP-2 (Svkazenergo JSC). The new Turbine of the Ural production should be replaced by a previously worked two-cylinder Czech turbine of the R-33-90 / 1.3 company Skoda, and will be mounted on the same foundation. The project for replacing the turbine was prepared by the institute of KazNIPIENGOPROM JSC, with which ZAO "ITZ" has long been and fruitfully cooperates. No long-standing ties with the former allied republics are not weakened: so, at the moment there is a question of the supply of several Ural turbines for the CHP of Kazakhstan.

NPO "Saturn"

NGO "Saturn" is a developer and manufacturer of industrial gas turbine equipment with small, medium and high power for use on thermal power plants, industrial enterprises and oil and gas fields. This is one of the oldest industrial enterprises of Russia: in 1916, it was decided to create five car factories on the basis of a state loan, including in Rybinsk (Russian Renault JSC). In the post-revolutionary years, the plant worked on the development and production of aircraft engines. In the early 90s. The Rybinsky Motor-Building Plant was transformed into Rybinsk Motors. In 2001, after his association with the Rybinsky Design Bureau of Motor Building (OJSC "A. Lulk-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, industrial gas dual-walled turbines of GTD-6RM and GTD-8RM, used to drive electric generators as part of GTA-6 / 8RM gas turbine units, which are used in gas turbine power plants of medium power (from 6 to 64 MW and higher) . Also, the company produces a family of unified gas turbines of GTD-4 / 6.3 / 10RM to use as part of gas pumping units and thermal power plants (from 4 MW and higher). For low power power plants (from 2.5 MW and higher), the installation of the up to49r is available - a single gas turbine with a built-in coaxial gearbox. In addition to the "terrestrial" installations, the enterprise manufactures the gas turbines of the M75RU, M70FRA, E70 / 8RD, used to drive electrical generators and gas compressors in the composition of marine and seaside industrial facilities of small and medium power (from 4 MW and higher).

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

Fig.4.

GTD-110 is a single gas turbine for use in the composition of energy and vapor-gas plants of high power (from 110 to 495 MW and higher), created within the framework of the federal fuel and energy target program for the needs of the domestic power system and is the only Russian development in The sphere of gas turbine engineering high power. Currently, five GTD-110 are in operation in Gazpromenergyholding (GEH) and Inter RAO. However, according to Inter RAO specialists, only the newest installation launched in early March is functioning in normal mode. The remaining at the moment work is unstable and serviced under the manufacturer's guarantee.

According to the director of gas turbine and energy installations of Saturn, Alexander Ivanov, as in the case of any new high-tech product, is a completely natural process when defects and an enterprise are detected actively working on their elimination. During the maintenance, the most critical components are checked, and, if necessary, the manufacturer replaces the parts at its own expense without stopping the operation of the turbine.

Recently, OJSC "Engineering Center" Gasoturbine Technologies "(NPO Saturn OJSC, jointly with JSC INTER RAO UES) won the competition of OJSC Rosnano to create an engineering center, which will be engaged in innovative products, in particular the creation of GTD-110M (rice . 5), an upgraded GTD-110 gas turbine engine with a capacity of 110 MW.

Fig.5

In fact, the new engineering center will bring the technical and economic characteristics of GTD-110 to the best world samples in this capacity class; The engine will be improved and finalized, it is planned to create a combustion chamber that ensures the permissible level of harmful emissions of NOx 50 mg / m3. In addition, in the manufacture of the engine it is planned to apply the technologies of nanostructured coatings, which will increase the reliability of the hot part of the turbine, will increase the resource of the most wenged parts and the entire engine as a whole. The GTD-110M will be the basis for creating Russian PSU high power. All comprehensive work on the draft GTD-110M is designed for 2-3 years.

JSC "Leningrad Metal Plant"

Leningrad Metal Plant - a unique enterprise. The plant has its own history since 1857, when the registered decree of Emperor Alexander II was published "On the establishment of the Joint-Stock Company" St. Petersburg Metal Plant "on the basis of the Charter." The production of steam turbines began here in 1907, hydraulic - in 1924, gas - in 1956. To date, more than 2,700 steam and more than 780 hydraulic turbines are manufactured at LMZ. Today, this is one of the largest energy-building enterprises in Russia, which is part of OJSC "Power Machines", carrying out the design, manufacture and maintenance of a wide range of steam and hydraulic turbines of different power. Of the recent developments of the plant - gas turbine installation of GTE-65 with a capacity of 65 MW. It is a single unit intended for a turbogenerator actuator and capable of carrying the base, semi-touch and peak load both autonomously and as part of the vapor-gas unit. GTE-65 gas turbine plant can be applied in various types of vapor-gas blocks for the modernization of existing and construction of new power plants of condensation and heat-type. According to the price and technical characteristics of GTE-65 as an average power machine corresponds to the possibilities and needs of domestic power plants and power systems.

In the early 2000s. OJSC LMZ signed an agreement with Siemens on the right of production and sale in the Russian Federation and Belarus GTE-160 gas turbine installation with a capacity of 160 MW (Fig. 6).

Fig.6.

The installation prototype is the gas turbine V94.2 of Siemens, the documentation of which is changed, taking into account the possibilities of OJSC LMZ and its partners. It was this turbine that produced at JSC "Leningrad Metal Plant", as part of the contract between CPP CJSC and OJSC Power Machines, was delivered to the Perm CHP-9.

Cooperation with German turbinositants continues. In December 2011, Siemens OJSC and Siemens signed an agreement on the establishment of a joint venture for the production and service of gas turbines gas turbines in Russia. "Siemens Gas Turbine Technology" This project was carried out on the basis of LLC InterTurbo, which is a joint venture company since 1991. A new company is engaged in the research and development of new gas turbines, localization of production in Russia, assembly, sale, project management and service of gas turbines of high power of classes E and f with a capacity of 168 to 292 MW. This line of activity "Siemens Gas Turbine Technology" is linked to the "Strategy for the Development of Energy Energy Station of the Russian Federation for 2010-2020 and for the future until 2030" To organize in the near future in the Leningrad Metal Plant Large-scale production of high-power licensing GTU (about 300 MW) with the transition from GTE-160 (V94.2) of the development of Siemens 80s. To more modern gas turbines.

Non-easy international situation forces Russia to force import substitution programs, especially in strategic industries. In particular, to overcome dependence on imports in the energy sector of the Ministry of Energy and the Ministry of Industry and Development of the Russian Federation, develop measures to support domestic turbo buildings. Are Russian manufacturers ready, including the only profile factory in the URFO, to ensure the growing need for new turbines, found out the "RG" correspondent.

At the new CHP "Academic" in Yekaterinburg, a turbine production of an OTZ works in the PSU. Photo: Tatyana Andreeva / RG

Chairman of the State Duma Energy Committee Paul Zavalny notes two main problems of the energy industry - its technological backwardness and a high percentage of wear of the current main equipment.

According to the Ministry of Energy of the Russian Federation, in Russia over 60 percent of energy equipment, in particular turbines, a parking resource has developed. In the URFO, in the Sverdlovsk region there are more than 70 percent, however, after entering new capacities, this percentage declined somewhat, but still a lot of old equipment and it needs to be changed. After all, the energy is not just one of the basic industries, here is too high.

According to the rational, the fuel use rate on Russian CHPs is slightly higher than 50 percent, the share of those considered the most efficient vapor-gas installations (PSU) is less than 15 percent. Note, PGU was commissioned in Russia in the last decade - exclusively on the basis of imported equipment. The situation with the arbitration claim Siemens about the alleged illegal delivery of their equipment in Crimea showed what the Western it is. But to solve the problem of import substitution is hardly unlikely to succeed.

The fact is that if domestic steam turbines from the time of the USSR are rather competitive, then with gas it is much worse.

When in front of the turbo plant (TMZ) in the late 1970s - early 1980s, the task of creating an energy gas turbine with a capacity of 25 megawatts was set up for 10 years (three samples were made, requested further finishing). The last turbine is derived from exploitation in December 2012. In 1991, the development of the energy gas turbine in Ukraine began, in 2001 RAO "UES of Russia" several prematurely decided to organize the mass production of the turbine at the Saturn site. But before the creation of a competitive car is still far away, "Valery Neuimin, who has previously worked as Deputy Chief Engineer, TMZ, tells, who has previously worked as Deputy Chief Engineer, the Developer of the Concept of Technical Policy of RAO" UES of Russia "in 2004-2005.

Engineers are able to reproduce previously developed products, the creation of a fundamentally new speech does not go

We are not only about the Ural Turbine Plant (IT - successor TMZ. - Note.), But also about other Russian manufacturers. Some time ago at the state level, it was decided to buy gas turbines abroad, mainly in Germany. Then the factories turned the development of new gas turbines, they switched to the most part for the manufacture of spare parts for them, "says Yuri Brodov. - But now in the country there is a task to reanimate the domestic gas turbulence, because it is impossible to depend on Western suppliers in such a responsible industry.

In recent years, the same IT has been actively involved in the construction of steam-gas blocks - supplies steam turbines for them. But together with them, gas turbines of foreign production are installed - Siemens, General Electric, Alstom, Mitsubishi.

Today in Russia there are two and a half hundreds of imported gas turbines - according to the Ministry of Energy, their 63 percent of the total. For the modernization of the industry requires about 300 new machines, and by 2035 - twice as much. Therefore, the task is to create decent domestic developments and put production on the flow. First of all, the problem in gas turbine installations of high power is simply no, and attempts to create them still have not been crowned with success. Thus, the other day, the media reported that during the tests in December 2017, the last sample of GTE -110 collapsed (GTD-110M - joint development of Rosnano, Rostech and Interrao).

The state imposes high hopes for the Leningrad Metal Plant ("Power Machines") - the largest manufacturer of steam and hydraulic turbines, which has a joint venture with Siemens for the release of gas turbines. However, as Valery Nesimin notes, if, initially, our part of this SP had 60 percent of the shares, and the Germans are 40, today the ratio of the opposite is 35 and 65.

The German company is not interested in the development of Russia's competitive equipment - this is evidenced by the years of collaboration, - expresses absent in the effectiveness of such partnership.

In his opinion, to create its own production of gas turbines, the state should support at least two enterprises in the Russian Federation so that they compete. And you should not develop a large power machine - it is better to first bring to mind a small turbine, say, with a capacity of 65 megawatt, to work out technology, which is called, fill the hand and then go to a more serious model. Otherwise, the money will be thrown into the wind: "It's like to assign a spacecraft to anyone who is not a well-known firm, because the gas turbine is not a simple thing," the expert states.

As for the production of other types of turbines in Russia, there is also not everything smooth here. At first glance, the capacity is quite large: today it is only an image, as the "RG" in the enterprise reported, is able to produce energy equipment with a total capacity of up to 2.5 gigavats per year. However, it is possible to call new ones produced by Russian plants with Russian plants: say, the T-295 turbine, designed to replace the T-250 designed in 1967, does not differ fundamentally from the predecessor, although a number of innovations have been made to it.

Today, turbine developers are mainly engaged in the "buttons to the costume," says Valery Oborimin. - In fact, people who are still able to reproduce previously developed products remaining at the factories, but does not go on the creation of a fundamentally new technique of speech. This is a natural result of restructuring and dashing 90s, when industrialists had to think about just surviving. For the sake of justice, we note: Soviet steam turbines were extremely reliable, a multiple margin of strength allowed power plants to work out several decades without replacing equipment and without serious accidents. According to Valery Obiminine, modern steam turbines for TPP reached the limit of their economy, and the introduction of any innovations into existing structures will not radically improve this indicator. And on the fast breakthrough of Russia in gas turbulence, it is not yet necessary to count on.

In August 2012, our country has become a member of the World Trade Organization (WTO). This circumstance will inevitably lead to increased competition in the domestic market of energy engineering. Here, as elsewhere, the law is valid: "Change or Dyrey." Without revising the technology and without conducting deep modernization, it would be almost impossible to deal with the sharks of Western Engineering. In this regard, there are all the urgent issues related to the development of modern equipment, working as part of the vapor-gas installations (PSU).

Currently, the only area in the thermal energy, in which manufacturers of gas turbines from Russia critically lags behind the leading world manufacturers - are gas turbines of high power - 200 MW and higher. Moreover, foreign leaders not only mastered the production of gas turbines with a single capacity of 340 MW, but also successfully tested and apply a single PSU 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. Such a layout makes it possible to significantly reduce the deadlines for the creation and cost of the power unit.

Moreover, manufacturers of gas turbines from Russia can produce all the main nodes of the PGU - steam turbines, boilers, turbogenerators, but the modern gas turbine is not yet given. Although in the 70s, our country was the leader in this direction, when the super-super-critical steam parameters were mastered for the first time in the world.

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