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Steam
l Turbine Works
CJSC The Ura 17,
, F ro nt ov yk h Brigad st., 6200
18 sia
rin bu rg , S ve rd lovsk region, Rus
Ekate 333-56-75
48 -4 8, 32 6- 49 -25 fax: +7 343
tel.: +7 343 326- z.ru www.utz.ru
e-mail: mail@ut
2013
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Steam Turbines
URAL
TURBINE
WORKS
Being initiated in 1938, the production of turbines has been European countries, Italy, Egypt, Mongolia, China, Korea, India,
successfully continued by Ural Turbine Works CJSC which was and Japan.
established in 2004. Having inherited trademark TMW from its The Ural gas-compressor units are used in world-famous gas
forerunner Turbomotor Works OJSC, the Ural Turbine Works pipelines, including the Urengoy-Pomary-Uzhgorod pipeline sup-
enterprise has also adopted the authority of one of the leading plying gas to the Western European countries.
Russian machine-building companies designing and producing Having a wide range of machines and many years of experi-
power equipment. Being a part of the RENOVA Group, the enter- ence in designing turbines, UTW CJSC meets the needs of differ-
prise is currently specialising in producing cogeneration steam ent customers. In spite of the variety of produced models, the UTW
turbines, gas turbines, and gas-compressor units for transporting specialists use only well-tried solutions, structurally unied units
natural gas. and parts, which ensures sufcient serial production, increases
In the Ural region it has been produced more than a half (in reliability and serviceability of turbines, and facilitates their repair.
terms of capacity) of cogeneration turbine plants operating in The enterprises quality management system is in compliance
Russia and in 14 neighbouring countries, former Soviet repub- with ISO 9001:2000, which was approved by the British Standards
lics. The turbines marked as TMW are installed in the Eastern Institute (BSI).
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DELIVERY OF
2 MODERNISATION AND
EQUIPMENT SERVICE OF EQUIPMENT
SERVICE
STEAM MAINTENANCE OF
MODERNISATION AND SERVICE OF
STEAM TURBINE FOR STEAM POWER TURBINES FOR GASTURBINE AS
STEAM TURBINES PRODUCED BY UTW
UNITS COMBINED- PART OF
AND OTHER MANUFACTURES
CYCLE PLANTS COMBINED-CYCLE
PLANT
LOCALISATION OF
CONDENSERS PRODUCTION OF
UNITS AND PARTS
HEATERS SUPPLY OF
SERVICES ASPER
FABRICATED METALS SPARE PARTS TECHNOLOGIES
PETROCHEMICAL EQUIPMENT OF WORLD
MANUFACTURES
Business development strategies in UTW CJSC Service maintenance of gas turbines as a part of the combined-
At the present time, one of the enterprises most important tasks cycle plant in Russia;
is the development of new products and the change of technology Heaters, condensers, and metallic structures.
policy. Jointly with the specialists of Sulzer, the Swiss company, and
ROTEK CJSC the UTW specialists are modernising management
and technological schemes for successful mastering and adaptation
of foreign advanced technologies, which will considerably strengthen
the enterprises position in the market. The company is still develop-
ing optimal design solutions as far as its principal turbine equipment
is concerned. The UTW customers receive only modern solutions,
including those based on long-term post-guarantee service of steam
and gas turbines. Together with ROTEK CJSC we offer our Custom-
ers many effective service programs for steam and gas turbines.
UTW CJSC is currently developing the following products and of-
fering the following services:
Steam turbines for steam power plants (SPP) from 30 to 300 MW;
Steam turbines for combined-cycle power plants (CCPP) from
17 to 200 MW;
Modernisation and service of steam turbines produced by UTW
CJSC and by other manufactures with capacity of up to 250 MW;
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Steam Turbines
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Production
Ural Turbine Works CJSC is basically an enterprise with a
2
complete industrial cycle. Its production includes forging, thermal,
welding, tool-making, and mechanical assembly production and
consists of 4 divisions:
Turbine production
Blade production
Test bench of balancing of rotors
Blank production
Turbine production
The product range of the steam turbine production (STP) in-
cludes parts of steam turbines, adjustment units, spare parts for
power equipment.
The steam turbine production is divided into the following parts:
preliminary stator, nal stator, iron rings, and diaphragms, rotor
and gear-cutting, inserts, auxiliary.
The steam turbine production has assembly and test bench-
es for steam turbines -90/120-130/10-1, -100/120-130,
-140/165-130/15-2, -60/65-130-2, -185/210-130, -250/300-240,
and adjustment units. The site is equipped with universal machines
for carrying out adjusting activities in the process of assembly and
with cranes which allow transporting units of up to 125 tons.
The main equipment of the steam turbine production includes
the following: turning machines (diameter of processed parts
up to 2 m, length up to 10 m), turning and boring machines (di-
ameter of processed parts up to 12.5 m, length up to 5 m),
milling and boring machines Skoda with the height of processing of
up to 5 m, rotor and milling machines, and gear treating machines.
The steam turbine production produces adjustment units for
steam and gas turbines: servomotors (HP, MP, and LP parts),
pumping groups, valves of the disengaging clutch, different drives,
and adjustment units.
Blade production
Ural Turbine Works CJSC produces blades of various sizes:
from 50 mm to 1000 mm, both for steam turbines of its own pro-
duction and for steam turbines of other manufacturers.
The principal technological equipment includes specialised
machines of Swiss companies Lichty, Schaublin, Koher, Chiron
having high processing level and being approved by a number
of leading manufacturers of power equipment and turbine blades.
The modernisation of the blade complex started in 2006. Over
the years the site designed for high-speed processing of blades
was created and expanded. The introduction of modern equipment
in the blade production considerably speeds up the manufacture
of new blades, decreases the duration and labour intensiveness of
processing, the amount of adjusting and manual operations, and
makes the products more qualitative.
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Test bench of balancing of rotors The balancing of rotors of other manufactures weighing up to 80
The test bench of balancing of rotors (TBBR) is used for activi- tons and with maximum speed of rotation in the vacuum chamber of
ties on blading, assembly, and balancing of rotors of steam and gas 18,000 rpm is possible.
turbines.
The main processes include the following:
Testing of moment weight scales of working blades; Blank production
Blading of mounted disks and solid-forged parts of rotors of The blank production includes welding, forging, and thermal ac-
steam turbines as well as blading of iron rings, rotors of the compres- tivities.
sor and rotors of gas turbines; The welding production species metal cutting and welding of
Assembly of rotors (attachment of disks and bushings, instal- metallic structures for turbines (condensers, heaters, associated and
lation of half-couplings, adjustment of the high pressure rotor to the accessory equipment).
pump rotor and adjustment of the disengaging clutch); In most cases the production of welding constructions is a process
Fitting and mechanical activities, including turning of bladed rotors; completely connected with UTW CJSC. The process of production
Static balancing of working wheels, dynamic vacuum balancing begins from preparation of metal and severing of ats and bars and
of rotors of steam and gas turbines at balancing bench -10 (max ends in tests and separate operations.
of a balanced part 5,000 mm, max length between supports The forging and thermal activities include forged pieces for steam
10,000 mm, max weight of a part 80 tons, max number of rotations and gas turbines both at mechanical sites of UTW CJSC and for third-
4,500 rpm, with a step-up reducer 9,000 rpm); party customers as well as heat treatment of workpieces and parts
Repair of rotors, including disassembly of a rotor, re-blading, after preliminary machining and welding.
fault detection, blading, assembly, and balancing.
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extraction
pressure,
process
-35-1,6* - 35 35 - 1,6 - - -
-110-1,6* 2009 110 110 110 1,6 - - -
-55-1,6* - 55 55 55 16,3 285 325 325
-17-1,6* 2002 17 17 17 1,6 118 220 220
Condensing
* Pressure is at MPa
**** In denominator start of production with index
** At t/h
*5 Its possible process steam extraction 45 t/h with pressure 0,78 P (8 kgf/sm2)
*** Two-stage heating available
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, t/h Thermal load Extraction pressure adjustment range, kgf/cm2 Cooling water
0,5-2,5 ***
- 285 - - - 13500 27 -
0,5-2,5***
- 285 - - - 0,5-2,5*** - - -
- 285 - - - - 0,5-2,5*** 27000 20 -
325 - - - - - - - 13500 27
220 - - - - - - - 8000 20 105
265 - - - - - - - 8000 20 -
390 - - - - - - - 13500 27 -
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* Design temperature of live steam and intermediate superheating steam for the base turbine and three of its modications is 540 , whereas for turbine type
-285/335-240 this temperature is 560 .
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Number of stages:
HPC 12 11 12 12 12
IPC-1 10 10 10 10 10
IPC-2 62 62 52 62 52
LPC 32 32 32 32 32
Cooling water:
design temperature, 20 20 20 20 20
design ow rate, m3/h 28,500 28,500 28,500 28,500 28,500
Condenser cooling surface
14,000 14,000 14,000 14,000 14,000
area, m2
Regenerative system structural
3HPH+D+5LPH 3HPH+D+5LPH 3HPH+D+4LPH 3HPH+D+5LPH 2HPH+5LPH
formula
Design temperature of feed
265 273 265 265 265
water,
Maximum ow rate of heating-
8,000 8,000 8,000 16,000 8,000
system water, m3/h
Note: The equipment at the power plant includes two modernized turbines -250/300-240, which, after modernization, correspond, in terms of their param-
eters, to turbines -265/305-240-
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Parameter Modication 2
-185/220-130-2 -185/220-130-2
Power, MW:
Number of stages:
HPC 13 13
IPC 9 9
LPC 32 22
Cooling water:
design temperature, 20 27
* This turbine was designed as part of a group of turbines with live steam ow rate of approximately 800 ton per hour. The group includes turbines -185/220-130,
-140/165-130/15 and -100-130/15; these turbines have identical HPCs, each of the turbines has two shut-off valves, and there are several other common
conceptual and design solutions
** When process steam extractions are used, the heating thermal load and electrical power of the turbine decrease
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Parameter Modication 2
* This turbine was designed as part of a group of turbines with live steam ow rate of approximately 800 ton per hour. The group includes turbines -185/220-130,
-140/165-130/15 and -100-130/15; these turbines have identical HPCs, each of the turbines has two shut-off valves, and there are several other common
conceptual and design solutions
** In conditions of independent pressure adjustment in both heating steam extraction circuits, pressure in the upper heating steam extraction may vary within
the limits of 0.9 to 2.5 kgf/cm2
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Power, MW:
nominal - 200 -
maximum 90 270 60
* This turbine was designed as part of a group of turbines with live steam ow rate of approximately 800 ton per hour. The group includes turbines -185/220-130,
-140/165-130/15 and -100/130/15; these turbines have identical HPCs, each of the turbines has two shut-off valves, and there are several other common
conceptual and design solutions
** At zero process steam extraction
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* This turbine was designed as part of a group of turbines with similar live steam ow rates and several other common conceptual and design solutions. The
group includes turbines -100-130, -50-130, -50-130/7, -40-130/31 and -50-130-6 (rotational speed of 3600 RPM)
Note: Non-controlled steam extraction of up to 50 ton per hour in addition to regeneration from the steam extraction pipeline to LPH No.3 is possible in all the
turbines
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Parameter Modication
-115/125-130-1 -115/125-130-2 -115/125-130-3
Power, MW:
nominal 115* 115* 115*
maximum 125 125 125
at condensing conditions 115 125 125
Live steam ow rate, t/h:
nominal 490 490 490
maximum 500 500 500
Live steam parameters:
pressure, kgf/cm2 (MPa) 130 (12.8) 130 (12.8) 130 (12.8)
temperature, 555 555 555
Thermal load:
process steam extraction, t/h:
nominal 70 70 70
maximum 70 70 70
Heating steam extraction, GCal/h:
nominal 180 180 160
maximum 185** 185** 185**
ditto, with HPHs turned off 210 210 210
Extraction pressure adjustment range, kgf/cm2:
process steam extraction 12-18 12-18 12-18
upper heating steam extraction 0.6-2.5 0.6-2.5 0.6-2.5
lower heating steam extraction 0.5-2.0 0.5-2.0 0.5-2.0
Last stage blade length, mm 550 660 940
Number of stages:
HPC 9 9 9
LPC 16 16 17
Cooling water:
design temperature, 27 27 20
design ow rate, m3/h 8,000 13,500 13,500
Condenser cooling surface area, m2 3,100 6,000 6,000
Regenerative system structural formula 2HPH+D+3LPH 2HPH+D+3LPH 2HPH+D+4LPH
Design temperature of feed water, 228 228 228
* The turbine was designed as a part of turbine group which includes the family -90/120-130/10
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For example, the turbine indexed 1 having the last stage blades efficiency of turbines of T-110-130 family. The design temperature 2
550 mm long is appropriate in the case of large thermal loads of cooling water is 20 C.
(small steam flow rates in the condenser), which are preserved, Basic characteristics of the turbines -115/125-130 group are
to a certain extent, in summer period. Such usage is appropriate given in Table 7 and Table 8 for the steam pressure p0= 130 kgf/cm2
because this turbine is most efficient under large thermal loads (12.8 MPa) and p0= 90 kgf/cm2 (8.8 MPa) respectively. See also
(low losses at the blades of the low-pressure section): it requires the note for the turbine -120/130-12,8.
only 8000 m3/h cooling water and can operate under the thermal
regime with the built-in condenser bank being cooled either with
make-up or heating-system water. However, at low thermal load
and, all the more so, under straight-condensing conditions, this
turbine is inferior to the other turbines in efficiency. Note also that
the condensing power of the turbine is limited to 115 MW.
The turbine indexed 2 has the last stage blades 660 mm
long. It is less efficient than the turbine indexed 1 under full ther-
mal load but is more profitable under small thermal loads and un-
der straight-condensing conditions. The condensing power of the
turbine 2 is 125 MW. The cooling water flow rate is 13,500 m 3/h.
When working under the thermal regime, only make-up water can
be passed through the built-in bank (system water is excluded).
The design temperature of cooling water of the turbines
1 and 2 is 27 C.
The turbine indexed 3 is equipped with last stage blades
940 mm long. The turbine is fit for continuous operation under
straight condensing conditions. Here its efficiency approximates
Table 8: Basic characteristics of the turbines type -115/125-130 operating on live steam with 0= 90 kgf/cm2
(8.8 MPa), t0= 535 C
Modication
-90/100-90-1 -90/105-90-2 -90/109-90-3 -100/110-88*
70 70 70 70
70 70 70 70
9 9 9 9
16 16 17 16
27 27 20 27
8,000 13,500 13,500 8,000
3,100 6,000 6,000 3,100
2HPH+D+3LPH 2HPH+D+3LPH 2HPH+D+4LPH 2HPH+D+3LPH
228 228 228 228
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Table 9: Basic characteristics of the turbines type -90/120-130/10 Table 10. Basic characteristics of the
turbines type -90/120-130/10* oper-
2
ating on live steam with 0= 90 kgf/cm2
(8.8 MPa), t0= 535 C
Power, MW:
nominal 90 90 90 65 65
Thermal load:
maximum
Heating steam extraction,
GCal/h:
nominal 80 80 92.5 65 65
ditto, with HPHs turned off 145 145 159 145 145
Extraction pressure adjustment
range, kgf/cm2:
process steam extraction 8-13 8-13 8-13 8-13 8-13
Number of stages:
HPC 9 9 9 9 9
LPC 16 16 14 16 16
Cooling water:
design temperature, 27 27 - 27 27
design ow rate, m /h 3
8,000 13,500 - 8,000 13,500
Condenser cooling surface
3,100 6,000 - 3,100 6,000
area, m2
Regenerative system structural
2HPH+D+3LPH 2HPH+D+3LPH 2HPH+D+3LPH 2HPH+D+3LPH 2HPH+D+3LPH
formula
Design temperature of feed
228 228 228 228 228
water,
Note: Similar to the turbines -115/125-130, the turbines -90/120-130/10-1 and -90/125-130/10-2 * Similar to the turbines -115/125-130, the
allow process steam extraction up to the 70 t/h at the pressure of 12-18 kgf/cm2 turbines allow process steam extraction up to the
70 t/h at the pressure of 12-18 kgf/cm2
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dium- and small-size cities and towns. The turbines type -60/65-130,
-50/60-130/7, -50-130-6 (rotational speed of 3600 RPM) and
-40-130/31 form, together with the turbine T-100-130, a single group
united by common principal and design approaches.
The turbines type T and have the two-stage heating of heating-
system water. The pressure at the heating and process steam extrac-
tions is maintained with the help of regulating revolving diaphragms
installed in the LPC. The turbines types T and are housed in two
cylinders. The turbine type P is a single-cylinder unit.
The turbine type P-40-130/31 has the following parameters of the
live steam: p0= 130 kgf/cm2 (12.8 MPa) and t0= 555 . The maximum
steam ow rate is 470 t/h, the nominal power is 40 MW, and the nomi-
nal back-pressure equals 31 kgf/cm2.
The turbines type -30/35-90/10 and its modication The turbine -30/35-90/10 can be installed instead of -25-4
-30/35-90/10/1,2 have been designed. They have single-cylinder and -25-3 turbines, after expiry of their service life, on the exist-
design and the single-stage heating of heating-system water. The ing foundation.
pressure at the heating and process steam extractions is maintained Basic characteristics of the turbines types , and are given
with regulating revolving diaphragms in Table 11.
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Parameter 2 Modication
Power, MW:
nominal 50 60 50 50 30 30 40
maximum 60 65 60 60 35 35 50
at condensing conditions 50 65 50 60 30 - 50
Rotor speed, RPM 3600 3000 3000 3000 3000 3000 3000
pressure, kgf/cm2 (MPa) 130 (12.8) 130 (12.8) 130 (12.8) 90 (8.8) 90(8.8) 90 (8.8) 90 (8.8)
Thermal load:
nominal - - 118 97 83 83 64
Extraction pressure
adjustment range, kgf/cm2:
Number of stages:
HPC (HPS) 9 9 9 16 10 16 10
Cooling water:
design temperature, 20 20 20 18 20 - 20
design ow rate, m /h 3
8,000 8,000 7,000 8,000 5,000 - 5,000
* At t/h
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Steam turbine model CCPP model Example of implementation of the steam turbine project
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2 PH SCVU
PH SCVU process heating
HP SCVU
stop-control valves unit
HP SCVU high pressure
stop-control valves unit
GH gland heater
GE gland ejector
HP SCVU
ME main ejector
CC condensate cooling
DWH district-heating
water heaters
to GH
to GE
to GH
to GH
to GE
CGH condensate gas heater
to GE
PH process heating
Condensers
steam from deaerator
reserve
steam input
PH HP IP LP direct
district water DWH-2 DWH-1
recovery boiler
CC GH GE ME
}
return Condenser
district water dilator to atmospheric
drenage collector
Table 12: Basic characteristics of turbines for combine cycle power plants
Parameter Modication
-35/47-7,4 -35/40-8,8 -40/50-8,8 -53/67-8,0 -63/76-8,8** -113/145-12,4*
Power MW: nominal / maximum 35.6/47.5 35/40 40.2/49.6 53/66.5 63/75.5 113/145.7
condensing conditions 47.5 40 49.6 66.5 75.5 145.7
HP steam ow rate, t/h: nominal
146 150 165 212.5 237 316.7
/ maximum
HP steam parameters:
pressure, kgf/cm2 (MPa) 75.5 (7.4) 90 (8.8) 90 (8.8) 78.5(7.7) 89.8 (8.8) 126(12.35)
temperature, 498 500 550 488 502.8 557.6
LP steam ow rate, t/h: nominal
36 51 15.6 57.2 35 50.2
/ maximum
LP steam parameters:
pressure, kgf/cm2 (MPa) 5.8(0.57) 6.12 (0.6) 7.2 (0.71) 7.14(0.7) 14.25 (1.4) 4.8(0.475)
temperature, 229 210 208.2 208 296 247.7
Thermal load, GCal/h: nominal /
93 80 65.5 136 90 220
maximum
Extraction pressure
adjustment range**, kgf/cm2
rst (lower) 0.5-2.0 0.5-2.5 0.5-2.5 0.5-2.0 0.5-2.0 0.5-2.0
second (upper) 0.6-2.5 - - 0.6-2.5 0.6-2.5 0.6-2.5
Last stage blade length, mm 550 550 550 550 660 940
Cooling water:
Design temperature,
nominal conditions 20 15 11 20 20 12
condensing regime 20 28.5 20 20 20
design ow rate, m3/h 8,000 8,000 8,000 8,000 13,500 27,000
Condenser cooling surface
3,100 3,100 3,100 3,100 6,000 12,020
area, m2
Number of stages: HPC/LPC
21/2 15/2 20/2 10/15 19/2 11/13/32
(HPS/LPS)
* The turbine has 3 circuits and process heating that is overlapping with IP circuit with parameters: ip= 30.7 (3.0) kgf/cm2 (MPa); tip= 554 ; ow rate = 63.7 t/h
** Upon the customers request, provisions for process steam extraction from the turbine may be introduced (with the amount of steam = up to 50 ton per hour
and with a pressure = approximately 13 kgf/cm2)
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The extraction steam turbines designed to work on live steam with For example, when the base turbine type -140/165-130/15 works
pressure of 130 kgf/cm2 (12.8 MPa) and temperature of 555 are on live steam with pressure of 90 kgf/cm2 (8.8 MPa), it turns into the
capable of operating continuously on live steam with p0= 90 kgf/cm2 turbine -100/130-90/13 after a slight modication.
(8.8 MPa) and t0= 535 without any modications made in the tur- To improve characteristics of the turbine operating on low-param-
bine design. This is important for power plants where the turbine hall eter steam, certain design changes can be made. If necessary, the
is reequipped without replacement of the boiler equipment. In this turbine can be switched back to operation on live steam with pressure
case the turbine parameters (live steam ow rate, electric power, of 130 kgf/cm2 (12.8 MPa). This option is realized in the family of tur-
process steam ow rate, and heating load) lower correspondingly. bines Tn-115/125-130 and -90/120-130/10.
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Cooling water:
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bines. They work from heating collectors and process steam extrac-
tion of turbines , , , , and T when they are not loaded
to its purpose. Process steam extraction for heating can be organ-
ized from the turbines worked from the collector. Incomplete load-
ing of heating extraction can exist in spring-autumn period; during
summer, the loading can be zero. Absence of steam consumption
from exhaust of the turbine type P leads to full stop. Decrease of
process steam extraction from turbine types , and P reduces
turbo-generator set power. In these cases exhaust-steam turbines
installation allows a complete loading of the turbines and provides
their work at an efcient design condition. Besides, electric power
of power plants increases due to new turbines at comparatively low
capital inputs, because installation of new power-generating boilers
is not necessary.
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2
basic ow diagram of turbine plant with turbine K-110-1,6
to GE
to GE
to D
to GE
to GE
H4 H3 H2 H1 GE ME
valves
to HPH P-100
recirculation
Parameter Modication
-70/110-1,6 -70-1,6 -35/55-1,6 -35-1,6 -110-1,6 -55-1,6 -17-1,6
Power, MW:
nominal 70 70 35 35 110 55 17
pressure, kgf/cm2 (MPa) 16.3 (1.6) 16.3 (1.6) 16.3 (1.6) 16.3 (1.6) 16.3 (1.6) 16.3 (1.6) 1.6 (0.16)
Last stage blade length, mm 660 375 660 305 660 660 660
Cooling water:
design temperature, 27 - 27 - 20 27 20
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538 434
1
2
1
2 10
1 10
4
3
3
4
3
3
4
6 41
4
10
10
20
14
14
45 53
45 14
65
1
2
5
34
2
Tu r b i n e s
Steam
l Turbine Works
CJSC The Ura 17,
, F ro nt ov yk h Brigad st., 6200
18 sia
rin bu rg , S ve rd lovsk region, Rus
Ekate 333-56-75
48 -4 8, 32 6- 49 -25 fax: +7 343
tel.: +7 343 326- z.ru www.utz.ru
e-mail: mail@ut
2013