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How Russian turbines supplanted Siemens, by Alena Zadorozhnaya for VZGLYAD. 05.10.2024.
Expert Frolov told how Russia managed to create its own high-power gas turbine.
For the first time in many years, Russia managed to achieve independence from the West in the production of high-power gas turbines. The government called this achievement an important milestone, and the expert community called it a fundamentally important success against the background of the confrontation with NATO countries. Energy expert Alexander Frolov told the VZGLYAD newspaper about the path Russian specialists had to go through to make a domestic turbine.
Russia has overcome its dependence on the supply of foreign-made high-power gas turbines. This was stated by the head of the Rostec state corporation Sergei Chemezov at a meeting with Prime Minister Mikhail Mishustin in early May, TASS reports . What is important is that we are talking about serial production of domestic turbines.
“We are installing a high-power turbine GTD-110M at the Udarnaya station, which is being built on the Taman Peninsula. This is the first production turbine. We are confident that we can be independent from Siemens and General Electric. We built three stations. This is the third one. Two stations were built in Crimea and one on the Taman Peninsula - “Udarnaya”, which we will fully launch this year,” Chemezov noted.
In response, Mishustin called the achievement “an important milestone.” “I know how the corporation worked on this for a long time in order to replace all analogues of Western powerful turbines,” the prime minister was quoted as saying by RIA Novosti . Experts, in turn, calculated : if in Soviet times such equipment was mainly produced on the territory of the Ukrainian SSR, then after 1991 Russia’s dependence on foreign turbines could reach 90%.
And since there are currently about 310 gas turbine units operating in the country, in the near future they will require not only maintenance and repair, but also replacement. In addition, given the active development of energy in the Far East and plans for the industrialization of new regions, the demand for turbines will grow.
Alexander Frolov, Deputy General Director of the Institute of National Energy, editor-in-chief of the industry media InfoTEK, spoke in an interview with the VZGLYAD newspaper about how Russia moved towards creating its own high-power gas turbines and in what direction this industry will develop in the future.
VZGLYAD: Prime Minister Mikhail Mishustin described the appearance of the Russian gas turbine as an important milestone. Why has this achievement become possible only now?
Alexander Frolov : To understand the background, I suggest you dream up a little. Imagine holding a tender. Several companies are participating. One of them - Russian - declares equipment with the following conditional characteristics: overhaul intervals - a certain X, and energy losses - 40%. And then, say, a German manufacturer comes along: its equipment has a much longer service life between repairs and higher energy efficiency.
In addition, the German player promises, as part of the agreement, to systematically update the software for the operation of the equipment, maintain direct communication with Russia and promptly make all necessary changes. Siemens offered an objectively more profitable, interesting and effective agreement. And until a certain time we could not win this race.
VZGLYAD: Did this situation develop only in the field of manufacturing high-power gas turbines?
A.F.: Unfortunately, no. Similar scenarios have been observed in a number of industries. To be fair, it should be said that they tried to change the situation. Somewhere this was done by directive. For example, Gazprom entered into agreements with our pipe companies, which were guaranteed a certain volume of orders, and also financed the modernization of enterprises. Largely thanks to this, Nord Streams and a number of other gas pipelines were built. But back in the 2000s, the backlog of our pipe makers was monstrous.
The second option, which helped turn the situation around, was licensing or the creation of joint ventures (JVs). The bottom line is that we bought some foreign equipment, but with the condition of complete localization of production. An example is the gas pumping unit GPA-32 “Ladoga”, which we began producing in 2009. By the way, turbines are the “heart” of this equipment.
But the unit was made under license from General Electric. The agreement implied that we would localize production and gradually begin to replace foreign components with domestic ones. The process was extended over time, but now localization is at the highest level. We can fully service the equipment ourselves.
We also had a joint venture with the same Siemens. Our largest enterprises producing power machines organized joint projects with a German manufacturer in order to jointly create a certain product. We have arrived at 2022 with this reality.
VZGLYAD: And at the same time, in Russia, were you engaged in your own developments in this industry?
A.F.: We were working on it. There were prototypes; in the 2010s, our companies invested serious money in this, and the first progress could be observed back in 2021. There were even statements that the country would soon begin producing its own high-power units.
I will say more - if we did not have our own developments, we would not now be able to boast of our own turbine. Carrying out this kind of work in two years from scratch is not impossible, but extremely difficult.
However, it is worth noting here a contradiction that we have faced for many years. On the one hand, the state really wanted to develop its own production. But on the other hand, there were very strict requirements for compliance with tender procedures. Let me remind you that at the competitions the choice was made in favor of the cheapest, but at the same time the most effective offer.
In this case, Siemens and other foreign players, who had not stopped production cycles for many decades, had a more advantageous position. They trained on dozens and even hundreds of projects, improving and perfecting their equipment. And Russia, having interrupted its own production in the 1990s, could not compete with such rivals. Our potential has seriously suffered in the first 15 years in the history of New Russia, and we are forced to admit this.
VZGLYAD: At what point, in your opinion, did it become clear that completely relying on Western partners was a big risk?
A.F.: Since 2014, high dependence on foreign components has been perceived not only as a geopolitical, but also as an economic risk. The fact is that Russia is a large market for energy complex equipment. We are constantly rapidly updating gas pipelines and gas pumping equipment, building oil and gas complex facilities, developing new fields, and practicing advanced solutions in the field of mining.
Plus, not long ago the second program of power supply agreements (PDM-2) was launched, within the framework of which it was planned to modernize about 40 GW of thermal generation. And being in this position, we a priori had to think about producing our own equipment.
At a minimum, this would create additional jobs, make it possible to open new schools and train specialists. Economic logic and the desire for technological sovereignty precisely pushed towards achieving self-sufficiency.
And we have already approached 2022 with an understanding of the real picture. But our traditional relations with Western partners at that time were so captivating in their convenience that there was no full awareness of the whole problem.
VZGLYAD: But due to the changed geopolitical reality, awareness nevertheless came. What do we have today?
A.F.: Undoubtedly, it is very great that our production has coped with its tasks, albeit with a slight shift to the right. These solutions will be in great demand both in the domestic and foreign markets.
Russia has serious plans both to update its capacities and to build new ones. Equipment installed in existing power plants and manufactured by companies from unfriendly countries will also require updating at some point. You will also need spare parts. Ultimately, sooner or later the units will simply need to be replaced.
Now we have our own turbine, called GTD-110M. And judging by the stated parameters, this product meets all international standards. That is, it is not inferior to the solutions that could have been installed at our power plants if we had continued to cooperate with German partners.
VZGLYAD: Can we now completely eliminate the participation of foreign players in our market?
A.F.: I don’t think so. Not far from us there is a friendly state - Iran. Tehran also once collaborated with Siemens. But subsequently the company was forced to leave this market, but the equipment remained, as well as the production cycles. The Iranians studied this equipment, reengineered it and began producing their own products.
Back in 2022, Russia signed an agreement with Iran on the supply of their power plants for the needs of our electricity generation. Apparently, Moscow will not yet rely exclusively on domestic equipment, because it still needs to be produced in sufficient quantities.
We understand that we have a number of ongoing equipment repair and maintenance tasks that need to be addressed. It is impossible to shift the implementation deadlines in this matter. Therefore, we can use not only our technological solutions, but also resort to the help of friendly countries if such a need arises. I don’t see anything wrong with this; we also help them in many matters.
https://vz.ru/economy/2024/5/10/1266826.html
Expert Frolov told how Russia managed to create its own high-power gas turbine.
For the first time in many years, Russia managed to achieve independence from the West in the production of high-power gas turbines. The government called this achievement an important milestone, and the expert community called it a fundamentally important success against the background of the confrontation with NATO countries. Energy expert Alexander Frolov told the VZGLYAD newspaper about the path Russian specialists had to go through to make a domestic turbine.
Russia has overcome its dependence on the supply of foreign-made high-power gas turbines. This was stated by the head of the Rostec state corporation Sergei Chemezov at a meeting with Prime Minister Mikhail Mishustin in early May, TASS reports . What is important is that we are talking about serial production of domestic turbines.
“We are installing a high-power turbine GTD-110M at the Udarnaya station, which is being built on the Taman Peninsula. This is the first production turbine. We are confident that we can be independent from Siemens and General Electric. We built three stations. This is the third one. Two stations were built in Crimea and one on the Taman Peninsula - “Udarnaya”, which we will fully launch this year,” Chemezov noted.
In response, Mishustin called the achievement “an important milestone.” “I know how the corporation worked on this for a long time in order to replace all analogues of Western powerful turbines,” the prime minister was quoted as saying by RIA Novosti . Experts, in turn, calculated : if in Soviet times such equipment was mainly produced on the territory of the Ukrainian SSR, then after 1991 Russia’s dependence on foreign turbines could reach 90%.
And since there are currently about 310 gas turbine units operating in the country, in the near future they will require not only maintenance and repair, but also replacement. In addition, given the active development of energy in the Far East and plans for the industrialization of new regions, the demand for turbines will grow.
Alexander Frolov, Deputy General Director of the Institute of National Energy, editor-in-chief of the industry media InfoTEK, spoke in an interview with the VZGLYAD newspaper about how Russia moved towards creating its own high-power gas turbines and in what direction this industry will develop in the future.
VZGLYAD: Prime Minister Mikhail Mishustin described the appearance of the Russian gas turbine as an important milestone. Why has this achievement become possible only now?
Alexander Frolov : To understand the background, I suggest you dream up a little. Imagine holding a tender. Several companies are participating. One of them - Russian - declares equipment with the following conditional characteristics: overhaul intervals - a certain X, and energy losses - 40%. And then, say, a German manufacturer comes along: its equipment has a much longer service life between repairs and higher energy efficiency.
In addition, the German player promises, as part of the agreement, to systematically update the software for the operation of the equipment, maintain direct communication with Russia and promptly make all necessary changes. Siemens offered an objectively more profitable, interesting and effective agreement. And until a certain time we could not win this race.
VZGLYAD: Did this situation develop only in the field of manufacturing high-power gas turbines?
A.F.: Unfortunately, no. Similar scenarios have been observed in a number of industries. To be fair, it should be said that they tried to change the situation. Somewhere this was done by directive. For example, Gazprom entered into agreements with our pipe companies, which were guaranteed a certain volume of orders, and also financed the modernization of enterprises. Largely thanks to this, Nord Streams and a number of other gas pipelines were built. But back in the 2000s, the backlog of our pipe makers was monstrous.
The second option, which helped turn the situation around, was licensing or the creation of joint ventures (JVs). The bottom line is that we bought some foreign equipment, but with the condition of complete localization of production. An example is the gas pumping unit GPA-32 “Ladoga”, which we began producing in 2009. By the way, turbines are the “heart” of this equipment.
But the unit was made under license from General Electric. The agreement implied that we would localize production and gradually begin to replace foreign components with domestic ones. The process was extended over time, but now localization is at the highest level. We can fully service the equipment ourselves.
We also had a joint venture with the same Siemens. Our largest enterprises producing power machines organized joint projects with a German manufacturer in order to jointly create a certain product. We have arrived at 2022 with this reality.
VZGLYAD: And at the same time, in Russia, were you engaged in your own developments in this industry?
A.F.: We were working on it. There were prototypes; in the 2010s, our companies invested serious money in this, and the first progress could be observed back in 2021. There were even statements that the country would soon begin producing its own high-power units.
I will say more - if we did not have our own developments, we would not now be able to boast of our own turbine. Carrying out this kind of work in two years from scratch is not impossible, but extremely difficult.
However, it is worth noting here a contradiction that we have faced for many years. On the one hand, the state really wanted to develop its own production. But on the other hand, there were very strict requirements for compliance with tender procedures. Let me remind you that at the competitions the choice was made in favor of the cheapest, but at the same time the most effective offer.
In this case, Siemens and other foreign players, who had not stopped production cycles for many decades, had a more advantageous position. They trained on dozens and even hundreds of projects, improving and perfecting their equipment. And Russia, having interrupted its own production in the 1990s, could not compete with such rivals. Our potential has seriously suffered in the first 15 years in the history of New Russia, and we are forced to admit this.
VZGLYAD: At what point, in your opinion, did it become clear that completely relying on Western partners was a big risk?
A.F.: Since 2014, high dependence on foreign components has been perceived not only as a geopolitical, but also as an economic risk. The fact is that Russia is a large market for energy complex equipment. We are constantly rapidly updating gas pipelines and gas pumping equipment, building oil and gas complex facilities, developing new fields, and practicing advanced solutions in the field of mining.
Plus, not long ago the second program of power supply agreements (PDM-2) was launched, within the framework of which it was planned to modernize about 40 GW of thermal generation. And being in this position, we a priori had to think about producing our own equipment.
At a minimum, this would create additional jobs, make it possible to open new schools and train specialists. Economic logic and the desire for technological sovereignty precisely pushed towards achieving self-sufficiency.
And we have already approached 2022 with an understanding of the real picture. But our traditional relations with Western partners at that time were so captivating in their convenience that there was no full awareness of the whole problem.
VZGLYAD: But due to the changed geopolitical reality, awareness nevertheless came. What do we have today?
A.F.: Undoubtedly, it is very great that our production has coped with its tasks, albeit with a slight shift to the right. These solutions will be in great demand both in the domestic and foreign markets.
Russia has serious plans both to update its capacities and to build new ones. Equipment installed in existing power plants and manufactured by companies from unfriendly countries will also require updating at some point. You will also need spare parts. Ultimately, sooner or later the units will simply need to be replaced.
Now we have our own turbine, called GTD-110M. And judging by the stated parameters, this product meets all international standards. That is, it is not inferior to the solutions that could have been installed at our power plants if we had continued to cooperate with German partners.
VZGLYAD: Can we now completely eliminate the participation of foreign players in our market?
A.F.: I don’t think so. Not far from us there is a friendly state - Iran. Tehran also once collaborated with Siemens. But subsequently the company was forced to leave this market, but the equipment remained, as well as the production cycles. The Iranians studied this equipment, reengineered it and began producing their own products.
Back in 2022, Russia signed an agreement with Iran on the supply of their power plants for the needs of our electricity generation. Apparently, Moscow will not yet rely exclusively on domestic equipment, because it still needs to be produced in sufficient quantities.
We understand that we have a number of ongoing equipment repair and maintenance tasks that need to be addressed. It is impossible to shift the implementation deadlines in this matter. Therefore, we can use not only our technological solutions, but also resort to the help of friendly countries if such a need arises. I don’t see anything wrong with this; we also help them in many matters.
https://vz.ru/economy/2024/5/10/1266826.html
