Russia has successfully manufactured and tested an upgraded version of its powerful domestically developed industrial gas turbine, marking another important step in reducing the country’s dependence on imported power-generation equipment. The new GTE-170.2, which was developed by Power Machines (Silovye Mashiny) in St. Petersburg, is capable of producing up to 171 MW of nominal power, while also reducing natural gas consumption and improving efficiency. The turbine is designed for large thermal power plants and state district power stations (GRES), where it can replace foreign equipment, such as the Siemens SGT5-2000E series from Germany.
Russia has been working to establish an independent industrial gas turbine manufacturing capability in response to the withdrawal of major Western equipment suppliers. Consequently, the successful factory tests are of particular importance. The most recent update expands upon the GTE-170 platform, providing a greater output without necessitating a new turbine architecture.
GTE-170.2: More Power and Better Efficiency
The most important improvement in the upgraded turbine is its increased generating capacity. The nominal power of the most recent GTE-170.2 has been increased to 171 MW, a major increase of approximately 16 MW, compared to the original GTE-170, which delivered approximately 155 MW.
Efficiency has also improved. The manufacturer has reported that the turbine’s efficiency has increased by one percentage point to 35.1%, rather than the previous modification’s rate of approximately 34.1%. Although this may seem like a comparatively small enhancement, it can result in major savings when the equipment is operated continuously at a large power station.
According to Power Machines, the improved performance will result in a reduction of approximately 3% in fuel consumption. This translates to an annual reduction of approximately 10 million cubic meters of natural gas under the appropriate operating conditions.
The operational expenditure of electricity generators is directly influenced by the reduction in fuel consumption. Even a relatively minor increase in turbine efficiency can generate substantial financial benefits over the course of a generating unit’s operational life, as gas is one of the primary inputs in thermal power generation.
Therefore, the upgraded turbine provides two significant benefits: an increase in electricity generation capacity and a decrease in fuel consumption. These enhancements are especially pertinent for Russian power stations that are striving to modernize their outdated equipment while simultaneously guaranteeing consistent electricity supply.
Designed to Replace Imported Siemens Turbines
One of the primary goals of the GTE-170 program is to offer a domestic alternative to the foreign industrial gas turbines that were previously installed in Russian power stations.
The Siemens SGT5-2000E, a heavy-duty industrial gas turbine in the approximately 170 MW class, has been employed in the production of large-scale electricity. The Russian energy industry faced considerable difficulties in maintaining and replacing such equipment as a result of the deterioration of relations between Russia and Western equipment suppliers.
The GTE-170 platform was developed with dimensions and installation characteristics intended to facilitate the replacement of comparable foreign installations. This is crucial because the replacement of an industrial gas turbine is not as straightforward as installing a machine with comparable output.
Power stations must consider foundations, connections, auxiliary systems, generators, control equipment, and the overall configuration of the combined-cycle power unit. The complexity, cost, and duration of modernization projects can be reduced by a turbine that is domestically manufactured and can be integrated into an existing installation with minimal structural modifications.
Engineering Changes Behind the Upgrade
The improvement in performance necessitated the modification of several critical components of the original turbine. The development program included modifications to the blade-cooling system, guide vanes, turbine blades, and multiple compressor stages.
These components are particularly important because industrial gas turbines operate under extremely demanding temperatures and mechanical loads. Improvements to compressor performance and the cooling of turbine blades can help increase operating efficiency while maintaining component reliability.
Additionally, the company has been investing in the development of domestic manufacturing capabilities for turbine components that are essential. The program involves collaboration with Russian scientific and engineering organizations, such as research institutes that specialize in aviation engines, turbine technology, and materials science.
The GTE-170 program is a major industrial undertaking in its own right. Power Machines has allocated approximately 25 billion rubles to the advancement of domestic gas turbine production, which encompasses research and development, engineering infrastructure, and manufacturing equipment.
First Applications in Russian Power Stations
The GTE-170.2’s successful testing is inextricably linked to Russia’s ongoing initiative to modernize its thermal power generation infrastructure.
The modernization of the Kashira State District Power Station in the Moscow region is an important project. The project consists of two combined-cycle power units that incorporate four Russian GTE-170 turbines: two GTE-170.1 units and two updated GTE-170.2 units. The new power units are scheduled for commissioning in 2027.
The assembly facility of the Leningrad Metal Plant in St. Petersburg has successfully completed the factory acceptance testing of the most recent GTE-170.2. The program involved the presence of representatives from the consumer to verify the rotation of the turbine rotor using a turning gear. The machine is currently being prepared for shipment.
It is crucial to differentiate between these factory acceptance tests and the full operational testing conducted at a power station. The factory program’s successful completion is a significant manufacturing milestone; however, its performance and reliability will be further demonstrated through commercial operation.
Production Expansion and More Powerful Turbines
Additionally, Power Machines is exploring alternatives to the GTE-170 family. At present, its manufacturing facilities are configured to manufacture approximately eight large gas turbines annually. From 2029, the organization intends to boost this capacity to ten units annually.
The engineering foundation of the GTE-170 is being used to develop the GTE-190, the next major development. An efficiency exceeding 36% is anticipated for the new turbine, which is expected to generate approximately 190 MW. The objective of enhancing fuel economy while simultaneously increasing output is reflected in its development.
Additionally, Power Machines has initiated preliminary development work on the much larger GTE-300, which is designed for the industrial gas turbine market’s higher-power segment.
These initiatives are crucial because Russia requires more than a single turbine model that is manufactured domestically. It necessitates a comprehensive family of machines that cater to various power requirements, enabling generating companies to replace imported equipment and construct new power stations using domestic technology.
In conclusion,
The GTE-170.2 is an important development in Russia’s endeavor to reestablish its capacity to manufacture large industrial gas turbines. The GTE-190 and GTE-300 programs indicate an even more ambitious future for Russian power engineering, while the domestic alternative to imported Siemens equipment is strengthened by its increased output, improved efficiency, and lower fuel consumption.