JPRS ID: 8519 TRANSLATIONS ON USSR RESOURCES

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JPRS L/8519
15 June 1979
~
TRANSLATIONS ON USSR RESOURCES
(F'OUO l4/79)
,
l~. S. ,~OINt PUBLICATiONS RESEARCH SERVICE
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JPRS L/8519
15 June 1979
_ . ~
1'RANSLATIONS ON USSR RESOURCES
cFOVO 14/79)
CONTENTS PAG~
ELECTRIC POWER AND POWER EQUIPMENT
K-1200-2Lt0-3 Steam Turbine--A New Phase in Development
of Soviet Turbine Construction
(a. A. Shinshov, et al.; ENER(30MA5HINOSTRO~CEIJIYE~
Feb ?9) 1
State Symbol of Quality far Hydraulic Turbine Equipment
(M. I. (~a1'perin, M. A. Tsvetkov; ENERbOMASHINOSTttOYENIYE,
Feb 79) ............................o................... 13
Improvement of Steam ~trbines Built by I4iar~kov Turbine
Plant Imeni S. M. Kirov
(Yu. F. Kosyak, et al; EN~R~LiOMASHINOSTROYENIYE, Feb 79)� i5
Creation of a One Thousand Megawatt Steam and Gas Unit
With Gasification of Solid ~iel Under Pressure
(ENER(~OMASHII~OSTROYENIY'E, Feb ?9) 31
E.NERQY CON3ERVATION
Ecc+nomics Training For Power Workers
(V. S. ZemskQV, et al.; PRO?~fSHI.ENNAYA ENER~ETIKA,
~ Apr ?9) 34
Conf~:rence on Use of Primary~ Secondary Power Resourcea ~
(B. A. Konstantin~v; PR(~'IYSHLENNAYA ~;NER~3ETIKA, Apr 79). 37
.F
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- a - (III - USSR - 37 FOUOj
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~ F'OR 0~'FTCTAI. U5E OM.Y
ELECTRIC POW~Et AND pOWEIt EQUIPM~N'1' .
UDC 621.165
' ~ K-1200-240-3 S'TEnM TUR$INE--A NEW PHASE IN D~VELOPMENT OI' SOVI~T TURBYNE
" . CON5TRUCTIQN
Moscow ENE~tGOMASH2NOSTROYENIYE in Russian No 2~Feb 19 pp 2-6
[Article by Director General of the Production Association of Turbine
Construction, Leningrad Metals Plant, G. A. Shtnshov, engineers A. P.
Ogurtsov, P. V. Kruglov, V. K. Ryzhkov, S. N. Antonov, V. V. Merkulov,
, N. N. Berunov, V. M. Anfimov, I. I. Pichugin, V. N. Khokhulin]
[TextJ The main area of scientiiic and technical progress in thermal power
engineering is the farthest concentration of the electric power production
by consolidation of Che electric power plants wiCh installaCion of powerful,
highly economicul condensation power units at them. In order to ensure high
operating reliability of the units with high unit power, hi~h requirements
are imposed not only on the completed structural deaigns of Che equipment,
but also the quality of their plant manufacture and installation. ~ "
The successful assimilation of production and introduction of the series of
300, 500 and 800 megawatt turbines into operation on transcritical ateam
parameters was a prerequisite of creating the largest power unit wi*h 1200
megawatt capacity. ~
c
The indicated requirements were used as the basis for the entire organiza-
tional and process complex with respecC to the preparation of production
and the manufacture of ~he powerful K-1200-240-3 SovieC steam turbine designed ,
for installation at the Kostromskaya StaCe Regional Hydroelectric Pot~er
Plant and manufactured at the turbine construction production association
Leningrad Metals Plant.
The K-1200-240-3 turbine which was built considering the latest achievements
of science and engineering is a new high-quality ph~asa in the development
of Soviet power engineering, the base for creating an entire series of high-
power turbines operating both on organic and on nuclear fuel.
As a result of use of new structural solutions in the turbine design, it
was necessary to develop theoretically new technological proceases, raise
the technical level and the level of production equipment. The list of -
planned and manufactured spec3al equipment reckons more than 7,000 names.
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FGIt U!~ T~ 7:C IAI, U5L: ONT~Y
The l.ong cycle and large valume of eapenditures on thp tec:hnological
prep~ration of the production facility and the manufacture of the turbine
gave riae to special requiremenCs on the orgunizarion of the economic plnnning
and financial acCiv3ties of rhe aseociation enCerprises end proper organiza-
tion of the placement of the cooperarive suppliers. Tens of enterprises
and sciantific research institutes of the country participated in building
the rurbine.
The K-1200-24G-3 type rurbine is u single-shafC, five-cylinder unit made up
of c~ high-pressure cylinder, a double-flow medium preasure cylinder nnd three
low-presaure double-flow cylinders.
The turbine is designed for operation ~t an initial steam pressure of 23.5
MPa (240 kg-force/cm2) and a Cemperature of 813� K(540� C). It haa one
. intermediate steam guperheating to a temperature ~f 813� K(540� C); the
: pressure in the concentrator under normal conditions is 3.58 kPa (0.039
kg-force/cm2) at a cooling water temperarure of 285� k(12� C). For a rated
turbine power of 1200 Mwatts, provision was made for the possibility of ~
obtaining a peak load as a result of switching off the high-pressure heaters
and also the capacity over a long period of time Co develop a power of 1G00
megawarts. The total length of the turbine without Che generutor was 47.9
meters, with the generator it was 71.8 meters. The total maes of the turbine
was about 1900 tons (without the condenser, auxiliary equipment and pipe-
lines).
The main structural peculiarities of the turbine are the following: a new
design for the low-pressure cylinder with a unique exhaust in which a rotor
is used made of titanium alloy 1200 mm long; the welded structure of the `
low-pressure rotor weighs 80 tons and is used for the first time in practice
at the plant; the structure of the last stage diaphragms with the intra-
channel moisture separation; the placement of the bearing elements of the
rotors in the re~*~ote bearing housings installed directly on the foundation,
and so on. Wi~'h rE:spect to technical-economic indexes, the K-1200-240-3
turbine is s�.~perior to the earlier produced turbines.
The turbine installation with the K-1200-240-3 turhine has lower specific
area at the elecCric power plant and specific turbir~e and generator length
- which significantly reduces the cost of capital construction of the original
hydroelectric power plant. In addition, this turbine has minimun operating
expenses and provides the user with significant cost savings from using it _
instead of the K-800-240-2 turbine.
The levels of economical operation of the assemblies of the powerful turbine
installations and the admissible stresses in their elements have reached
~ such a high value that further increase in them is possible only with careful -
structural reworking of these units considering the operating experience,
a large voltane of scientific research work and improvement of the quality of
manufacturing them. In order to create advanced high-quality designs,
- improved materials and technological processes are required.
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I~UIt ~~1~ I't C I AL t1St? (1NI,Y
Let us di:~~uss in more der~+i] some ot t:li~ etr.uccurr~l pccul.inrieiea of: the
K-L200-x4U-3 ste~sm turbinc F~nd the problems whlcl~ must. be sol.ved when
manufacturing it.
'Che high and mediwn pressure r,Elrrs r.re :~CrucCurnlly nnalogous ~he ~ol`
reapond~.ng parts of the h:lgh�~~~res~ure cyl.inder ~nd the medium pressure
cy.linder of the K-800-?40-?. 1:~.,rbi.ne, but tl~e high pressure rotor of ttie
K-1200-'140-3 turbine h~s ii~crtfised dinmeCer with respecr to Che baae of the
vnnes, which offcred the pna5:bility of reducing rhe n~unber oE sCu~e~ of
Che rotor nnd raisin~ iCs cri.r..ical rpm. Ttiis hns made it poseible Co im-
prove the structural desi~;n oE the cylinder housin~ nnd improve ehe l~nndling
capabiliti.es of Che C~irbine which has ensured satisf~ctic~n of the require- .
~nents o� Ghe power system--~he necessary daily unloMding to the turbine to
6n percent and weakly shukdou~n oC it for weekends. Tn addition, lncreasing
tlie rigidity of thurbine nnd,`isrone~ofrthegmninCfmctorsninepreventtingh~eah-
o1d power of the t
low-pressure vibration of the drive sh~ft.
~+s the high-pressure ~nd medium-pressure rotor material, we s~lected the
R2M sreel developed by r.he T~lunt ~nd findi.ng broad npplicntion for the last
20 years in manuFacturing Cne rotors of u11 of the powerFul t~tenm turuine~.
The studies performed at t~i~ plant and the large amount of practical experi-
ence of the UZTM turbine plant with respect to the assimilation and productiun
of large forgings made from this type of steel have demonstrated that Che
_ R2M steel has ~O�~ndeensurESithe requiredilevelmofsmechanicalapropergiesib>>'
quality forgings a
As a result of the large dimensions and mass oi the high-pressure and
medium-pressure rotors o� the K-1200-240-3 turb[ne measures are required of
the metallurRical industry which will ensure q~~ality and uniformity of the
properties wi"h respect tu the entire volume uf forgings. The heat treat- ~
ment improved for this purpose was made up of the first normalization matched
witti cooling afrer forging and the final heat treatment--water and oil
quenching. In addition to the complete complex of Cests and the quality
control, in accordance with the technical conciitions, additional tests were
run on samples of rhe core metal and also for rntors made of a special ring
located in rhe cenCer of the forging.
For the first time in Soviet turbine building practice, a new dovetail con- -
nection of the stepped fork type was used for the rotors of the high-pressure
~ and medium-pressure cylinders operating in the high-temperature zone, for
the traditional T-type structure did not satisfy the strength condirions
for stages of this power. The transition to ttie new type of dovetail ~oint
with new dimensional network ensuring guaranteed clearances in the connection
required the developme~~~ of a new process for machining the rotors and the
creation of special process equipment.
In order to make several thousand holes 15 and ].8 mm in diameter for the
insta113tion of pins in the discs of the all-forged high and medium-pressure
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rotor~, ~~peci~l .laCtie-bnsed drill war~ built. CArbon drilling he~ds of
rwo rypes were desigiied and manufactured for preliminary drilling of the
holes in the rotor nnd for finnl machining of tlie upenings afCer Ulading
equipped with special drills,reams and Gountersinkg,
Thc high ~nd medtum-pressure direct-flow ~ecCions were designed coneidering
the ~pplication of tlie gas dynamically machined st~ges, the chnracteristics
- nnd efficiency of which Are defined by computer nnd they are checked out .
by model testing in the plnnt lnborntnry. In order Co ensure high economy
and improve the vibraCion reliability of the blading of the medium-pressure
cylinder, A new profile was developed and inveatigated in detail for Che
etatorg.
In order Co ensure economicolness, the roCore of ~11 stages of the turbine
have a shroud; on the blades of the high and medium-pressure cylindera and
ttie l~st three stages of the low-pressur~ cylinder the shroud webs are made
as a unit whole with the profile section.
The machining of the working part of rhe high and medium-pressure blades,
the fillets of the shank and webs oF. the ahruud was realized on milling
machines wiCh digital control. The sof.tware in Che development of the control
programs was executed with the active participution o� the plant--the
VTU7, under the production association of turbine building "Leningrad
Metals Plant."
For the first time in the plant practice in order to ensure Che required
vibration and strength char~cteristics the rotors of all stages of the high-
pressure cylinder and six stages of each flow of the medium-pressure cylinder
were connected by welding along the shroud and the shank sections into
packets. The complication consisted in the fact that the blade materials
~~re 15Kh11MF and 18KH11r~IlVFB steel that is difficult to weld; the working
parts of the blade are made finished size 6efore welding, and they have
surface roughness of class 9. The welding process must ensure high-quality
fusion along the shroud and shank section with minimum deformations, main-
tenance of the purity of the surface of the working part of the hlade.
The UL-118 electron beam welder was used by the Electric Welding Institute '
imPni Ye. 0. Paton of the Ukrainian SSR Academy of Sciences. Its original
design made it possible significantly to reduce the total time for creating
a vacuum in the chamber as a result of simultaneous loading of eigfit packets
into the chamber and welding the shroud and shank seams locaCed in different
planes by three electron-beam guns. The welding of th? packets of all
20 stages was accomplished by two types of universal attachments.
The results of the studies demonstrated thaC during electron beam welding
it is possible to do ao~ay with preliminary and accompanying heating, which
are mandatory when welding the given si.~c1 by oCher methods. This has made
it possible to select the welding procedure for the shank part of the blades
as counterwelds ensuring minimum residual deformations. A characteristic
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fe~Cure nf tl~e prc~cedure caneists .t.n ~he E~cC thfat the [irst senm is weld~d
~~bour GO percenC oE the thi.cknes~ oi the yh~nlc aectiun, nnd then n~eCOttd
weld From Ch~ oppasite gid~ is done to 65 percent of the thickn~sa, overl~pping
Ctle ftrsC by 4 to 5 mm,
A speci3lized section with Che UL-118 devicc also includes a special he~ting
furnace with conrrol~ble ahielditig ~tmo~phere which will mnice it pnssible
tc~ m~n:{.ntaiti the finish of the working part of the v~nes during he~t Creat-
ment.
The di.aphr~gms ot the high-pressure und mediwn-pressure cylinders ~re m~de
welded with millc:d solid ~tatnrs and sf~roud b~~nds. 'The requi:emenls of hlgh
reliability have given rise tn a~~ increase ln the momenr of resistunce of
qhe st~}tqrs, Che sh~nks ~cid ~he rims operaring in l�he high-pressure zone
anul also,khe use of high-temperatu~e ~Cee1 obt~ined by the metl~od oF electro-
slag.rerneltinb. Increased accur~cy of m~nufacturing the wetded grntea wxs
actiieved s~s a result of using a new technological process for punching rtie
shaped holes in the shroud bands bent along the r~di.us ~n the ~M-12 device
d~s~gned by the VI'Tlenergom~sh Institute and operating in the automatic
cycle.
An important measure ensuring operating reliability and improving thc
strength of th~: responsible parts of the turbines is the use of hillets
obtnined by refining melCing techniques, in particular, the method of
electroslag remelting. This methad ensures a higt~er degree of purity of
the metal, higti uniformity of the structure and properties with respect
to the billet cross-section, and improvemenr of the ductility characreris-
tics. The application of electroslag remelting for the rotor vanes made
of 20Kh13, 15Kh11MF and rP291 steel ensured that billets would be obtained
Pree of typical defects in the form of haix cracks essentially lowering
the ratigue strength of the rutar blades.
An ingot made of 15Kh1M1F steel m:nufactured by this methocl was used as
the initial billet for the welded-forged valve houaing of the automritic
high-pressure gate. WiCh a high level of inechanical properties of the
forging, the electroslag remeleed metal is character.ized by high uniformity
and isotropicity of the mechanical characteristics, low sulfur content and
low content of nor~ecallic inclusions.
A deficiency of the application of A5R steel for housing parts is the fact
that :he initial billets are ~btained in the form of large cubic or cylindrical
bars. Thus, for a finished part for the steam intake of the K-1200-240-3
turbine weighing 3 tons, the forged billet will weigh 12 tons.
The use of the method of electroslag smelting (~ESS~ made it possible to
obtain a high-quality billet and lower the consumption of inetal.
The 15Kh1M1FL steel traditionally used for the forgings of the housing
parts ~f rhe high-pressure and medium-pressure cylinder is characterized
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by suEficient stabil.iCy nf the structure and properties under Che prolonged
~ effect of operating temperatures to 843� K(570�C). However, the increase
in turbine power requires constant improvement of the meCnllurgical process
in all phases.
The improvement of rhe biller quallty is promoted by measures of a aCructural
nnture, defined orientation nnd direction oF pouring within the cross-sections
oF rhe part and al~o proper resolution of th~ contradictory requirements of
the structural elements and casting technology.
The ho~sings of the ourer and inner high-pressure and medium-pressure
cylinders were cast from steel made in the hasic open-hearth furnace: at the
traditional supplier planCs. The studies demonstrated Che advanCage of
forced cooling of Che ingots in special chamhers by comparison with hlow~.ng
with campressed air from three sides. The dispersion of the mechanical
properCies of Che metal and Che forgings decreased significantly.
The machining of the high-prE;sure and medium-pressure cylinders was carried -
out on the b~sis of the developed technological processes. The preliminary
machining of the planes of the horizonCal s1iC was carried ouC on the four-
spindle planomilling machine, and the finish machiningy on the planar with
finish passes using special broad cuCting tools. For broxcl~ing the cylinders, _
a special KU-64 model verCical lathe was used. The housing of the outer
high-pressure cylinder and exhaust sections of the medium-pressure cylinder
were broached on the all-purpose vertical lathes as. a result of the large
dimensions.
The low-pressure cylinder is unique with respect to its structural and
technological solutions. The creation of the last stage with a rotor blade
1200 mm long and an end area of the exhaust of 11.3 m2 required the per-
formance of a large volume of scientific research and planning and design
work. During the design process, the direct-flow section was worked out in
order to optimize the gas dynamic characteristics and select an efficient
form of ineridional outline. The application of the axiradial diverging
diffuser and separation of the exhaust flows from the upper and lower halfs
of the exhaust sections developed by the turbine construction production
association of "Leningrad Merals Plant" jointly with Moscow Power Engineering
Institute made it possible to reduce the magnitude of the losses in the
exhaust line of the turbine by comparison with the K-800-240-3 turbine.
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~~,~',i' I
. 1
i
r
, .
~ ~ 4~.,.
.
Figure 1. Mactiining the staCors of the fifth stage w~,th internal mo.iature
aep~ration. -
Figure 1 shows the processing of the statoes of the f:tfth stage with inCra-
ct~annel moisture separation. The tecating of the corr~actness of the solutions
was realized on the experimental steam turbines of th~a NPO Association of
the TsKTI Institute imeni I. I. Polzunov 6y investigation of models on a
1:3 scale. The tes=:~s were run in a wide range of variaCion of the volumetric
steam consumption and i~~ake it possible t~~ deCermine tliE~ level of economicalness
of Che stages, the compartments and the eritjre direct-El.ow section as a whole ~
and also the structure ot the flow in tt~e control cross-sections of the -
direct-flow section.
The vibration test demonstrated the pr~ssure of sufficient reserves of
resonance frequencies from the perturbing forces at operating rpm and the
relatively low stress level under transient conditions.
The operation of the direct-flow part of the low-pressure cylinder was checked
on the ETPN-2 experimental steam turbine specially built by the plant with a
~ compartment made up of the last four stages to a natural number. 'fhe progacam
for the experimental work included the dynamic and gas dynamic studiea,
obtaining the integral characteristics of the compartment, including in -
the no-load conditions and under small loads and also checking of Che corr�oaion
resiseance of the input edges of the last stage.
_ The last stage of the rotor vanes 1200 mm long was made of TC-5 titanium
steel (Figure 2) for the experience in operating the blades up to 960 mm
, long made of titanium steel demonstrated satisfactory results.
The high cost and great labor constnnption of machining the titanium alloys
required the development and investigation of new methods of machining,
including electrochemical machining of the stampings in order to remove tlie -
excessive machining allowance, the circular milling on the machine tools
of th e ST-215 type, grinding and polishing of the disc at reduced rpm in
several passes with the application of diamond pastes. Special methods of -
quality control on the surface layer have been developed.
The rotor blades of the fourth and fifth stages are joined along the
periphery using a shaped tooth made in the s~roud web for preventing the
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blades from turning. This connecCion reduced the number of wi.re c~uplings
i.n the prof~le section, -
~
yta ~ _
~
aa~ ,
. rw~~' ~ ~ 1' -
j t~~` ~k::k b~
W s.'~~~~ ~f~~ _
~ ~3;d~"f s;?' `.ia
~
br iY ~ aq
_ ~ ~ ~
~ ~ ~ :
i
_ ~ ~r
`x �'.1
4 ~ I
-,s7A r
~.i3 :i.r11:;
lj
' ~ � : t'~~
- +
i'r
~
A-~ . i
i
1 ~t
~ t,
~ y~ aek
i . ~ ~ ~l'~-~'
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~C.
Figure 2. StaCor of the fifth sCage of low-pressure rotor.
The machining with respect to the shroud of a complete set of rotor blades
- for each st~.ge was carried out together ~aith a special ~ttachment which made
~ it possible eo perform all of the fitting operations to basic assembly.
For the first time the plant used the Christmas type dovetail connecCion with
edge windin~, the optimal design of which was deCermined hy experimental
studies of its static and fatigue strength. This type of joint simplifies
assembly under the electric power plant conditions, it provides for rail-
road transportation of the low-pressure rotors. Figure 3 shows the blading
of the low pressure rotor. For machtning of the shaped grooves in the rotors
under the shanks of the blades, a heavy 1A671P14F1 lathe was used equipped
with two movable milling stocks, dividers and other devices.
Figure 3. Blading of the low-pressure rotor of the K-1200- 240-3 turhine.
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f~UR QFFTCLAI, USH ONL,Y
In nrder to redtice the cyc.le fo~� mfi1~uEacr?ir.in~; the rototti, ~hc ~rooves are _
' pnrtl~nl.].y ci?t 1t the produceian association "Khar' kov 'I'urh:tri~ I'lf~nt" imen:i
S . M . K~t rov .
The upplic~tion of inCr~ic:hannel, ewo--cltamber separatiori of molsture in the
diaplir~~gm oE ttie l~st stage nE t;~e system 1.s an acCive method of protecting
rhe rn~or blacles of erosj.on wear. 'This system is made up of a number oE
sl,its about 1 mm wide executec: on rhe input ~ection and the inside surface
of the bia~e prnfi:le and al~o }iates in the bLades, l-he hody atid the r~.m
through which the drop and Eilm moisture are diacharged to be Lapped for
regeneration and the condenser. 'I'he technological ~~rocess of protecting
c:he entrance edges of the rotor blades of ehe last stage hns .7l.so bcen
deveioped,
The 'inany years of experl.ence of the plant wi.ch respecC to ehe manufacture
of weld~d diaphragms has made it possible to use new theoretical solutions
created on the basis of them in the new turbine along with the old structurul-
t~chnologi..a1 flow charts checked oul in practice, Instead of the .tradition~il
cast iron diaphragms for t}~e low-pressure cylinder in the K-�1200-24G-3
turbine s~eel diaphragms a:e used. This has made it possi.ble to increase
their reliability, the possiUility or organization of rhe Lnterchannel
separation of ~he moisture and also it iias ensured furtkier appllcation of
the low-pressure cylinder ~in turbines aperating on nuclear fiiel.
- Tt1e matiufacture of the diaphragm of ttie last stage not having an analog ln
Soviet turbine cons~ruction presented special difficulti.es. 'I'tie mass of
one half of the diaphragm in the billet we~ 6.4 tons with ari outside diameter
of the diaphr.lgm of about 5 meters and height of the steam channel of 1200 mm.
The charac~eristic features of the special design of tt~e diaphragm also
includes the higti precision of its manufacture~ the use of tiigh-chrome steel
requiring special welding procedures. Slits were cut in the guide vanes
by the method of elecC:oerasive machining. The machining of the shaped part
oF ttie vane, the mass of wt~ich was 80 kg, and Che dimension alang the chord _
more than 300 mm, was carried out on a modified planar from the basic machine
shop.
All of the structural welds were made using high-nickel electrodes which
made it possible to do away with the comple.Y high-temperature heating in tt~e
welding process and direct h::at treatmen~ after welding. This of.Eers the
possibility not only of achieving improvement of the quality of the welds
as a result of introducing a number of welding procedures aimed at decreasing
the weldins strains and stresses but also improvement of the con.ditions oE
labor of the welders.
When creating welded diaz:hragms for the K-1200-240�3 turbine, more than 200
technological equipment units were designed and introduced in the assembly-
welding cycle alone. A significant role in the machining of the structural
elements, the technological process and the assimilation of the production
was played by the manufacture of diaphragms for the ETPN-2 experia~ental
natural turbine which made it possible to cut the basic production cycle
for the diaphragms in half.
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, ~OR d~~tCtAL U5~ ONi,Y
tt ig neres~nry tn t~ote thc speciql role dt welding productic~n in the
mr~nufr~r.ture di th~ K-1~U0-24-3 turbin~~ 'I'h~ ~p~rtfic w~ight of the welded
s.rur.tural elementg w~g 75 percent with r~~pp~t t~ the total weight nf th~
. turbine by compArigon with 52 p~rrent fnr the ~~ri~~-m~nufaeturpd turb~ne~.
One of th~ signifi~ent probl~m~ gnlved in Che turbin~ prdducti~n prne~~~
Wns th~ crention of the welded 1aw-pr~a~urp rotnr~. Thi~ w~rk wg~ per~irtpa-
ted in by th~ 1hn~ing ingtitures af th~ r~untry: th~ NPd 'CgNI2'~mtt~h,
the Iri~titute df ~lectric W~lding imeni Y~~ 0. p~ton nf the Ukr~init~n
SSR Acadhmy Sci~nces, th~ Np0 T~K'CI imeni I. I. Polzunov, V}''Tlty~zhm~gh
and also Che production ~~gr~cintinn Yzhorgkiy x~vdd imeni A~ A. xhd~nov and
the turbin~ bui.iding production ~sgocintinn Khar'knv ~'urbinp pl~nt imeni
S. M. K[rrv.
For the firgt tim~ in its prnctice, the plnnt did aw~y Wieh the trnditionolly
used and technologically ~ssimilat~d design of the 1ow-pres~~re rntbr wfth
adapter di.gcy. When using blad~s 1200 mm long, even thoge mnde vf titanium
alloy, the gCre85 lev~l in the C~~SCg rpnCh~s it~ limiting value fnr the
assimilated type of st~~l. As n result~ it wo~ nece~sary to dev~lop a
welding element fnr th~ rntor with fnrged di~cs without the c~ntral openings.
The c~mplexity of the problera consi~t~d in th~ exist~nce of a highcr etrees
level in the rotors in the K-1200-240-3 turbine det+~rmined by the large
size of the rotor and itg high rpm. The requirement~ of sufficient strength
cdmbinpd with increaged ductility, high r~~igtance to brittl~ rupture and
good weldability aere imposad on the mnt~rial of the inirial billecg for
the welded rotor. As a result af the scientific rege~~rch work perfor~ced
by the scientific end prnduction associetion of the TeI~IITmash IngtiCute
and the production assnciation Ixhnrskiy Plenr imeni A. A. Zhdanov, n new
type of steel was developed which has high mechgnic~l and gnod technological
properties. In order to ensure high quality of the metal and thr required ,
level of the entire set of necpssary propertiea, the method of electroslag
remelting was used, a theoretical process was developed for assembly and
welding of the rotors,~aethods of monitoring the welds and the he~t treatment
conditions of the welded billet were found. The generalization of the
result~ nf testing the experimental and regular fozgings, imvestigation of
the construction strength of the e2ement~ of the welded rotor, analysis of
the reliability of the welded joint considering the resigtance to crack
development and also the calculations performed by the method of finite
elements by the KISI prograsa on the BESM-6 computer illustrated a sufficient
level oi margin of strength, reliability of the eelected structural design
and the type of steel used.
For assembly and welding of the rotors, the specialists of che NPO Association
of the TsNIITwash aad the VPTltyazhmash institutes have designed a complex
nonstandard piece of equipmen[: a unit for building up a soft interlayer
on the discs and the shanks of the rotors, a stand for general assembly
and welding and a portal device. The production association for turbine
building Khar'kov Turbine Plant imeni S. M. Kirov and the experimental plants
of the NPO TsNIITmash and NPO TsKTI imeni I. I. Polzunov participated in
the manufacture of this equipment along with the turbine building production
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wc)It O~F'ICIAL U5~ ON1.Y -
asavci~~tinn l.enin~red Metale ['l~~iit. The equipm~nt for autom~ted nrgon
arr. welding atid welding under a flux layet', nnd the required hectcing uni.t~
werp de~ign~d end manufactured by ti~~ NI'0 'I'sN127'magh dnd rhE In~titut~ nt
l:lr.clrir. W~lding imeni Ye. 0. r~tan fo the Ukr~inian 55K Ac~dpmy hC 5cl~~ic~~.
`Chr final ~t~gr in thc~ ~neire gEt df ~p~rt~tion~ with reapect tn the a~~imlla- '
eion of t.he proce5s ~f m~nuf~r.turing th~ welded roter~ wng th~ u~~~mbly end
welding of ~ full-$c~~lc madel. The high-qu~lfty exe~utinn di the weldinp,
operntinns w~s ensured hy che following +nonitnring uper~~tions: brond
ut~2iz~tion of ultrasonic defectoscopy; radiometric mrniitaring nnd ~~mmn-
- examinatidn, visuc~l inspection of the r~utsicle ~ppearAn~e of the weld.and, in -
, p~tt, the in5i.ae fusion uf the edgcg of the root of the welded jc~lnt; uuto-
nhtSr rcrording and nnalysis of nll of the ergon ~rr. welding pnr$m~thrt~,
ttiickenin~ nf the out~id~ ~urf~cea ~~f th~ weldg nnd goft butlduN.
The ~evelvped procedut'e for the metrvlogic meugurementb when ~sg~mbling
the rntor ~nd monitorittg its distortion during the welding prncesg made it
pnssible to r~duce the rpsidual deformations to d minimum. `I'he p~rfermnnce
of ~ll of the weldin~ nU~rntinns ~nd the turning of the rotorq on n lAthe~
the m.~ss of w}iich in the billet ~nounted to mor~ than g0 tons wnt~ ~ccnmplished
at the Khbr'kov Turbine ~uilding plant imeni S. ;~t. Kirov Witf~ the direct
participation nf the specir~listg of the [urbine building productinn associatian
Lening rad Kerels Pl~nt, Che NPO TsNII'tmnsh Inqtitute nnd the Ingtitute of
~leccric Welding imeni Ye. 0. paton of the Ukrainian SSR Acndemy of 5ciences.
~'ti~~ltn~l step in the manufacture oE the K-12U0-240-3 turbine~ wa~ the _
asser~bly dnd testing on a new assembly teet st~tion. The prearnce o.f two
gpecially ciesigned semigantry craneg with a capacity of up tv 5 t~ns et~ch
madE~ ft possible to tinload the basic crane equipment ~uring the operationa
with respect to alignnent of the parts of the direct-flow sectiona. The
turbine was installed on supports specially mounted on a supporting floor.
Tr~e cylinder and bearin~ housiags and the parts of thp direct-flow sections
were aligr~ed with the ~pplicatinn of optical monic.oring means with high
precision tn exclude errors in measuring the coordinates of the control
holes.
The technological prncess ~f usse~bly and aligna?ent of the turbine Was
develvped wich the participation of the p'TI En~rgomont~zhproyekt Institut~,
and it was based on i~ie possible repeti[ion of assembly in installing Che
equipment under the conditions of electric power planCS and ca reduce che
duratinn ~nd cost of [he installation nperations. Here the structurnl
so2utfon af the turbine with the supports for the 1ow-pre~sure ro[ors
directly on the foundatior? is highly efffcient. This opens up the possibility
for the organ~za*_ia:~ af a broad front of preparatior. and installation
operations.
For correction of ttie developed general assembly procegs, a broad program
was carried out for natural measureiaents of the stability of the posieion
of che supporting floor and the housing parts durir?g assembly of the turbine,
the determination of the actual rigidity of the medium-pressure and
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~
~Oit nF~ICIA1. US~ ONLY
1nw-pre~~ur~ eylinders, th~ poeitinn~ nf th~ C~nec~rg of eh~ rnnCrnl opening~
in the hdu~ing p~rt~ and eh~ ~tetic bpr.ling oE ehp low-pregsur~ rotor.
T~~t~ werp run an the plant teet unitg tn deeermine ehe fitn~e~ of the
he~vy duty bp~ringg, dynamic teets were run on thp rotor~ in th~ renge of
0-303~0 rpm. The turbine underwene Control t~gting under operation on
a burring gegr, and th~ hydravli~ lif r for th~ roCora w~~ checked nut and
d~v~loped~
Summing up the re~ults nf th~ work done, it is n~cps~~ry ta nor~ ehac the
K-1200-240-3 eteam turbine ia a new gtep in the development of Soviet turbine
m~king~ Ae a reeult ef the l~rg~ volume of design and ~cientific research `
wdrk, n quglitatively flew ~Yit is the~bagpefor1th~Qfurtherid~v~lopm~ntcofn
th~ singl~-sh~fe ~xecurian.
pow~r ~ngineering and rhe developm~nt o� powerful ~nergy ~quipment operaCing
bnth on nrganic gnd on nuclear fuel. The uniquen~gg nf the srruCtural and
proces~ solutinng and absence of analogs reqUired thp developm~nt nf new
technological methods gnd means of prod~ction. The created base and the
acquired productinn experience Arp a guarantee of thp ~ucc~eseful impl~n~nta-
- tion of the program of gcientific ~nd technieal progresg in pawer machitte
building.
BIBLIOCitAF'NY
1. Neporozhniy, P. S. "Development of Thermal Power Enginee=~ing in the
'Centh ~'ive-Yegr Plan and th~ Problem of Scientif ic Etesearch
TEPLO~NERG~TIKA (Thermal Power Engineering), No 4. 1976, pp 2-S�
2. Ryzhkov, V. K., Sorokin, N. A., and Mikhaylov, M. F. "K-1200-240-3 _
Steam Turbine of the Leningrad Metals Plant," TEPLOENERGETIKA, No 5,
1976, PP 2-7.
3. Kolpishon, E. Yu., Chizhik, A. I., and Ivanova, I. G. "Study of the
Kotor Material of an ~xperimental Steam Tu~Bi~e~, ENEttGOMASHINOSTROYENIYE
(Pover Machine Building), No 16, 1978, pp
COPYEtIGHT: Izdatel'stvo "Mashinostroyeniy~". "Energomaehi~ostroyeniye"~
1979.
10845
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12
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FU~ O~~ICIAL U5~ ONI.Y
ELECTRIC POW~~ ANp pOW~R ~QLIpM~NT
UnC 621.ZZ.1/.9 ~
STA'.C~ SYMgOL OF QUALt~'Y ~'OR HYbItAULIC TURBIN~ ~QUIPMEN'1
Mng~dw ~NBR~OMA5NINO5rRUYENIY~ in ~tugsi~n Nd 2~Feb 79 p 22 `
~ .
(Article hy ~ngine~rg M. I. Gal'perin ~nd M. A. 'TsvptkovJ _
[`~ext~ The State Commigsian has rec~rtified the turbines delivered by the
producCion as~oCigtion nf the Leningrnd Metel~ Plant for the Ust'-Ilim
Hydroelectrfc �nwer P1ant and the electrohydraulic regulntere nf the
~Gtt a:~d ~GttK type for the subeeyupnC period nw~rdit~g a highcr quality
- category. Juat as all Che preceding unite, the last unic of Che firet
~hase of the Ust'-Ilim Hydroelectric power Plant--the Chird phase of the
Angar Cnscade--was accepted for operation on 22 October 1977 with an excel- ~
lent rgting. Th~ power of the 15 nnit~ of the first stage ia 3,675 mega-
watts.
The unit includes the vertical radial-axial turbine with a rotor diameter
of 5.5 meters directly connecced to the umbrella type generator. With the
same dtameter of the rotor, the installed power of the turbine at the 1Jst'-
Ilim Hydroelectric Power Plant is 245 megawatts with a calcult~ted head of
R5.5 meCers, which is 13 percent highEr than the power of the turbines from
the Bratsk Nydroelectric Power Plant with a calculated head of 96 meters.
The second phase di the Ust'-Ilim Hydroelectric Power Plant, which is the
lgst of the thr~e units, must be put into operation in 1980. Starting
theca up will make it possible to increaae the efficiency of the use of the
flux energy, it will expand the posgibil.ity of the participation of the
hydroelectric power plant in covering the peak part of the electric load
- chnrt.
The turbines of the Ust'-Ilim Hydroelectric Power Plant are distinguished
advantageously by the carefully developed flow cycle, the manufacture of
the rotor in a welded design With blades stamped from sheet atainless rolled
products. This r~tor design and manufacturing process have made it possible
to obtain more precision built blades identical in size and shape and to
corrertly place them for assembly and Welding of the xotor as a whole.
Th~ selected direct flow channel and the material used made it possible to
reduce the cav itation erosion to a minimum. It is necessary to note that
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~UR d~~ICLAL US~ ONLY
�dr ~t~~ fir~t rime with n rotor digmet~r nf th~ turta.in~ equal t~ 5~S m~Cers~
the pa~gibility w~s fdund for m~nufacturing .~n umbr~lia type gpner~ror~high
the Chru~e hearing on the ~upporC 1na~t~d on Ch~ top nf ehe eUxbine.
wag aChieved as a result ef u~ing the guide b~~ring of th~ ~egmpnt Cypt~
turbine wieh w~t~r lubricaeion which is more compaCt th~t ehe ~nnular one,
and is m~re convenient ro mnintgin and repair. Accordingly, on Ct~e
mg~drity of the n~wly built rurbines provi~inn i~ m~de fnr ~ guide benring
of thig ~eru~turnl degign~ '~h~g~ bearing~ h~ve be~n ug~cl Co replac~ thp
- guide b~aringg Phege�UentsiinCliquidtloilhlubriaatinnrEilledhwith~bnbhitc
power plants wit gm
meral.
At th~ pr~~ent time the co~t df electric pnwer generated by the units of
th~ UsC'-Ilim Hydrdel~ctrie Power plgne is Che low~st in :~e cnuntry.
With enmpletion of the con~tructinn of the Ugt'-Ilim tlyriro~leceric pdwer
Plant, the proj~cts have been wid~ly developed for the Congtructinn of the
foureh segge o� the Angnr Cascade--the Bogucharngkaya Hydroelectric Power
Plnnt. The production asgocietion of the Lentngrad Metalg P1ant hae ulso
bpen eharged with ehe building o� the turbine equipment for thig hydro-
electric power plant.
'The productinn usgoci~tion of rhe Leningrgd MeCals Plant is a unique enter-
prise in our country, producing elecCrohydraulic regulntors of the EGR and
~GRK type. For the first t~me these regulators have been awarded the high
quality category it: 1969, and then they were recertified in 1972 and 197:.
till of the turbSovietuand foreignehydroelectricupower plantsnaresequippedng
and plants for
with these regulators.
In connection with the ever increasing unit power of the units, the growth
of installed pnwer of the individual hydroelectric power plants and the
more rigid requirement on operation of the units in the powerful power
systems, the requirements on quaiity of electric power are also rising,
and the satisfaction of these requirementa is ensured primarily by therhe
machinery, units and equipment of the moniCoring and control system.
production association of Leningrad Metals Plant is working continuously
on improvement of the regulators, making them correspond to the modern
requirements on such equipment.
The awarding of the state symbol of quality to the hydroelectric turbine
equipment PrivecforbthehW rk ofcthenentireicollectiveeofnthedassociacionnt
is an incent
COPYRIGHT: Izdatel'stvo "Mashinostroyeniye". "Energomashinostroyeniye", 1979.
10845
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FOR OFFICIAL USE ONLY
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~dR b~~ICIAL US~ ONLY
EI.~CTitIC pOW~R AND POWER ~QUIPM~NT
UUC 621.165
IMPkOV~ri~N'T 0~ 5'T~AM 'TUItgIN~5 BUIL'~ ~Y KNAit'KOV TUE~I3IN~ pLANT IM~NI
S , rl, KII~OV
P'
t~pscaw ~"~N~RGd,[~A5HIN05'~ROY~NIY~ in Russian No 2~ F'eb 79 pp 32-38
~
, ~ , : 1 .
[Ar,tiale by Ca~iiiid~tes of TechnicAl 5ciences Yu. Kosyak, V. P. Sukhinin,
B. A. Arknd'yev~, engineers M. A~ Virchenko, A. N. Pot~pov, Sh. M. LineCSkiy,
Yu. p. Tomkov .tChe turbine building productinn asaociation Kher'kov Turbine
pl~nt irneni S.~ M. Kirnv)
, (Text) The dev~lopment nf steam turbine making at the Kharkov Turbine Plant ,
imeni S. M. Kirov is characterizpd by significant growth of unit powers,
improvement of the siructural elements and improvanent of the technical-
economic indexes of the manufactured turbines for electric power plants ~n
organic fuel and fnr nucleAr power plants (1-6j.
In the last 20 years the unit power of the turbines for electric power plants
(Figure 1) operating on organic fuel increased by five times. The power
built up at still faster rates for nuclear power plants. In 11 yeara,
beginningin 1966, the unit power of the turbines manufactured by the p1anC
for the nuclear power plants increas~d by 15 times, and at the present time
it has reached 1000 megawatts. The creation of turbine with a 1000 megawntt
unit power has become possible as a result of the mastery by the plant of the
prnduction of 1500 rpm turbines. The first two 1500 rpm turbines with a
power of 500 megawatts of the K-500-60/1500 type manufactured in 1916 ar~ .
being built to be started up at the Novovoronezhsk Nuclear Power Plant. The
turbine with a power of 1000 megawatts, type K-1000/60/1500 is in the pro-
duction atage. Still higher powered turbines are being developed.
At the present time the p1anC collective is preparing for the production of
turbines with a unit power of 750 megawatts for operation at 3000 rpm in
the unit with the RBrIIC-1500 type reactor. Thia unit power for high rpm tur-
bines of the nuclear power plants with operating exhaust and vacu~an of 0.035-
0.04 absolute atmospheres is the maxim~an.
~
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~OR OF~ICIAL US~ ONLY -
,r? '
~a~ K�rnoo�to~ugo
Unit power of ~
the turbine~ K�~~:~sL,~p
sno~ ~
s00~ ._.."_ssno- a0 ~I~ K`SOO�651uoa0
i ~
"~0F naoe tao t
~~A-uo� ~�t1o-~~j
f00~ + dRt-.M.~4 AR-10J
1. . 1 . 1 . . 1_.. . ....1 ......_L._
i~~o i~s ~~o t975 rsao ~as ~ear
Figure 1. Growth of ehe unit power of the turbinea at Che Khar'kov Turbine
Plant imeni S. M. Kirov: 1--For electric power planCg operating
on ~rganic fuels; 2--For electric power planCg operating on
nuclear fuel.
One of the basic gogls of Che plant collecCive is to improve the qunliCy of
� the ~nanufactured turbines. This problem is being solved with respect ro
the following basic areas: expansion and improvement of the production-
technological 6ase of the plant; comprehensive use of the design experience,
the manuf ~cture and insrallation and prolonged operation of the turbinea of ,
eaYlier production, broad unitization of the assembliea and parts; the
use of the resulta of the experimental research work of the laborgtory base
of the plant and other scientific research collectives. ,
As a result of the work done jointly with the collectivea of the electric ~
power plants in practice all of the steam turhinea manufactured by the
plant have received the State Symbol of Quality.
In recent years significant expansion and improvement of rhe production-
technological base of the �lant has taken place. The shops equipped with
unique metal working equipment, special devices for welding large low-pressure
cylinder rotors, and so on have been put into operation.
At the plant special attention has been given to the qualitative changes in
the structure of the process equipment fleet. For the manufacture of heavy ~
welded rotors a new section has been built, including the set of welding
units, heating furnaces and metal working machine tools. The lathe for
turning rotore weighing up to 200 tons has now been installed. Large
closed sections have been built for the machining of the housings of the
high and medium pressure cylinders and the housinge of the low-presaure
cylinder. Ae a rule, all pf the special equipment manufactured by the
technical specification:~ of the plant has increased precision and is out- .
fitted with digital program control. The equipment for the production of
turbine blades has been essentially renewed. The replacement of the universal
milling machines with new five-spindle copying milling machines has, along ~
with reducing the labor consumption, improved the equality of the manufacture Q
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,
~OIt UC~'tCIAL U5~ dNLY
g~id~ and rdtor v~n~g. A ypecLc~l section with pre~i~ion equlpment liu~ b~en
get up to build ~tie reguln~ion pares and ng~emhlief~,
- Tlte plnnl� coll~ceiv~ ~ointly wi.Ch th~ brnnch inHtitutes, the ttd~ustment
~ gnd r~geurch organizaeions is working cnnsrnntly on imprnving Ch~ r~liability
_ of the produced equipment. 'Chi~ fecror hn~ ncquired egpe~ially impnrtnnt
, gigni~ic~nce for modern lnrge turbines having lurge dimeneion~ end nparritiiig
- in the modular sy~temq.
~ The overwhelming mtt~oriCy of the turbines of the Kh~r'kov Turbine Duilding
Plane imeni S. ~i. Kirov satisfy the norms adnpted Eor these mnchin~g with
- regards to service life and operaeing eime between r~pHirs. The VK'~-100
K-160-130 (pVK-150) turbines nre nper~eing fnil-e~fe at the electric power
plgnts. Mnny of ehem hxve significantly increaged the cnlcul~ted np~ruCing
reserve--100,000 hours. Tl~e firet models of the K-~00-2G0 tUrbounit today
h~ve oper~hted up Co 50,000 tiours. As u r~~ult of the operc~ting exp~rience,
the ytudies and the nd~ustmenr of the turbines, con~tant work nn improving
the opernCing conditions und the structural design of the equipment elementa,
it hn~ been possible to uchieve high reliak~ility index nf the 300 m~g~wntt
units. 'fhe av~ilability factor for these turbine~ in 1976 wns 99.4 percent,
gnd the average work time per failure for the eneire fleet of K-300-240
turbicies of the Khar'kov Turbine $uilding P2ant imeni S, hi. Kirov corres-
ponds to 420d hours. The availability factor for the K-500-240-2 eurbine
at the Troitskaya 5tate Regional HydroelecCric Power Plant wns 100 percent
in 1976, nnd use cneificiet~t of the ingtulled power during opcration of
the unit wug 101 percent.
The Curbines for the K-220-44 and the K-500-65/3000 nuclear power plants
which are at the present time the core of nuclear power engineering in our
country are operating with high technical-economic indexes. The K-500-65/3000
turbines, the piloC models of which were installed at the Leningrad Nuclear
Power Plant have operated under full load in pracCice since first being
started up. The use coefficients of the calendar time during the firat
years of operation reached ~0 to 78 percent, which exceeds the world level
of reliability of the operation of units of this power. The experience
in opernting the K-S00-65/3000 turhines has mnde it pnssible to create
still more powerful units of the K-750-65/3000 type.
In recent years the plant has dune intense w~rk to improve the repnir
suitability of the manufactured turbines. As a result of exclusion of the
- operations with respect to dismanCling the receivers, the stnndardized
low-pressure cylinder developed for the 3000 rpm turbines with side steam
feed makes it possible to lower the labor consumption of repairs. A number
of ineasures have been introduced to decrease the expenditures of labor on
opening and repairing the bearings, the steam distribution units and the
direct-flow sections.
As a result of intense work to improve the economicalness of the K-300-240
turbines and to realize the accumulated experience in the studies and
structural improvements in the turbines of other types and sizes, the
17
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~bR 0~'~tCIAL US~ ONLY
thermnt ecdnoiny oC th~ unitH hhpnt~cnngump~iunCtotgenrrnten~leceriGUp~wer
'rher.~�or~ thh netu~l specific
Eor the K~300-740-7 turbinc unieg t~ ~~~~_2G~~ Z�CUrbinelrecalculaeedkfor/th~~
w~rti-h~ur), T11e eame index for th~ K 5
p~rameterg nf ehe K-300-240-2 Ckcal/kilowgtt`hour~g in gpit~Rof Che~facr ehaC
7613 kild~ouleg/kilowaCt (1g~3
et eh~ time nf the th~rmnl CegCir..~ t~W~grur~gne~ T~gul~tgofWthe~tesrgu~r~ee veg
hours ~nd ti~d 90 stnrtups and shutd
w~re discov~red fnr ~urther imprnvegechanflCpercenr~mi'~h~nrealization ofO~these
240-2 turbounit ~srimated nt no les
re~erves will be realized in the strucCurgl degign of the K-500-240-3 turbo-
unie, the degign nf which was stnreed by the plunt.
The tests run on th~ K-220-44 nnd Kforei~n elenericepower plnntghdem~ngtrated
65/3000 turbineg flt the Snviec and 8
th~t with regpect r:n level nf economiinlnes~highhas become~possible~masgAthe
most improved in world power engineer g
result of the introduction of ttie resuir~ce~flow sectiongtuespecially~Chee1d
of prufiling nnd aerodynamics of the d
low-potential section of Che turJe3i naCwitheresp~gt to 1tuYoutr~ndeprocess
and the Applicarion of advanced 8
conditions. 'The introduction of a modern experimental laboratory bnse nt
the plunt cooperation with the PdjustmOftChermalieconomy ofgthecturbineszations
will permit guarxnteeing a high level
manufgceured by the plant.
Improvement of the Structural Designs of the High-Speed Turbines for
ElecCric Power Plants Operating on Organic attd Nuclear Fuel
The development of structural designd nuclea~hfueleistcharacterizedlbytric
power plants operating on organic
systematic development of the assemblies and parts, improvement of theirA
quality, reliability, economy~ technological and operating equaliCies.
great deal of attention has bee~hei~~o orrionrofiwhicheistaueignificantgns
of the low-pressure cylinders, P P
par[ in the turbines for electrin theeturbines atetheinuclearrpower plants.
and it increases to 70 percent
It is possible to consider Che applicdtion of the following among the
structural peculiarities of theVhidoubleewallediconstzucti nhof,the housing
Building Plant imeni S. M. Kiro .
of all cylinders; welded diap~~rh8~h humidity~zones~nalloyedrsteel;prigidta,
and in the high temperature 8 h relia
welded And foYged rotors of the low-pressure cylinders having hig
bility; joinins of all of the rotors of the turb:~e and the generator with
rigid couplings; protectivurenfrom thendirectcflow~secti nainsthedzones .
systems for removing moist
with high moisture content; transverse two-way condensers.
18
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~o~ o~~rcrn~., usr orrLY
In Ch~ turbines pr~viougly m~de Uy C~ie p1anC opernting r?r 30n0 rpm, the
low-pre~,~ure cylinder.s with built-in guppnrts fnr the roeorg und housingg
w~re u~ed in whic:h th~ farr.e~ from gtmosphgrie prex~~rc nncl nlgn Erom thc~
Er.i~mc of the dinphragms and the rotor ~r~ t~ken by s~y~tem af mutually
p~rp~ndir.ular bnffles. Depending on the type ~nd sir.e oE eh~ turbine, the~~
low-presgure cylindprs havc ins~gnificac~t differences with respect eo numb~r
of rap~, method of rapping, structurnl design of Che geam intake nnd ehe
dir~r.C-~1ow mecrion with the eame theor~tic~l etruceural deaign and dimensions.
All ot tt~is has led to ~ r~duction in Pr�~ifferin~ffromeehe~lowrcylindersiof ~
eticli turbine had a low-presnure cylinder ~ ;
other tur6ines.
1'h~ problem nf lmproving Che teChnologiC~nl nneure and improving Che pro- :
ductiun efficiency wns solved by the plant by cretxCi~~g ~~r~nd~rdized 1dw- ,
pressur~ cylind~r suitable for nll nf the t~igh-rpm turbines manuf~crured by
Che p1attC. This cylinder wa~ developed and h~g been used for ti~e firet Cime
in the five-cylinder K-750-65/3000 turbine with four low-pressure cylindere.
The exheusr pipe of Chis cy].inder is a" honeycomb" design wirh improved
derodynamic qualities and dimensions as in Che existing unmc9ified degign.
'The loss coefficient of th~ connection ~ccnrding to the r.esults o~ blowing
M. Kirov
down Che models at the Khar'kov Turbine IIuilding Plnnt imeni S.
and ~t the 'fsKT2 Instieute imeni I. I. Polzunov is less thnn 1.
structural design was borrowed from the Leningrad Metals ~lanC imeni 22nd
Congress of the CPSU and provides for separate t~pping of the serun after
the l~st stage from the upper and lower halves of the housing with respect
to individual compartmenCs. By comparison with the prc~vious low-presaure
cylinders of the series turbines, the peripheral rim of th~ dirert-flow
For the
section has been improved in the vicinity of the last stage.
standardized low~-pressure cylinder, side feed of the steam was used with
the steam inlet located below the horizontal alit. The steam intake lines
1200 mm in diameter are connected on installation to the steam intake lines
of the housing of the low-pressure cylinder by welding. The adopted
structural design of the steam inlet assembly improves the repaira6ility
of Che turbine, for iC does not require disconnection of it when diamantling
the low-pressure cylinder. The steam inlet to the frame of the low-pressure
cylinder is made with installation of the guide ribs in Che feed cavity;
the location of the ribs is accomplished considering the aerodynamic studies
of Che model. The two-flow secCion af Che low-pressure cylinder has not
undergane any special changes by comparison with the low-pressure cylinder
of the K-500-240-2 turbine. IC t~as five stages esch in each flow and the
rotor blades of the last stage are 1030 mm long wiCh all-milled shrouds.
.
19
FOR OFFICIAL USE ONLY
~
APPROVED FOR RELEASE: 2007/02/09: CIA-RDP82-00850R000100060030-1

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FOR 0~'~YCIAI, USE ONLY
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20
FOR OFFICIAL USE ONLY
APPROVED FOR RELEASE: 2007/02/09: CIA-RDP82-00850R000100060030-1

APPROVED FOR RELEASE: 2007/02/49: CIA-RDP82-44850R000100064430-1
~'Oit OCI~ LCIAL U51: ONLY
On ~he b~~i~ ~~E the per[ormcd c.alculatton:~ wirt~ rc:;pc~ct ~u aprltnizuCinn of
the Chexmnl yystem consider.ing Che difterent typcy ~n~~ca ql.'Leti uf lurhlnee,
the nptimf~l sepnr~ting prewaure (p~ep ~ 5 ab:~olu~e ntmoapheres) ~nd nwnher.
of raps wcre udapted, From each law-pressure ~yllnder, three tups were
made a~eer the first, seeond and fourth s~a~;~s. In ~he exhau~t 11ne of the
haustng n sygtem is nrovided ~or cooti.ng it by in3ection a~ lhe cnndens~ee
during c~perfzliun of the turbine ~~t id1e. In nrder to prevenC coo~:ing of
the outside aurlc~ce uf the rim wtien thc moisture hits, it is shielded by
thin steel sheets with a clenrance of $-].U mm. This design pro~ecty tt~e
rim fr.om d~formatie~sia~ndovemenrgoEfrheeeco~omySOf.�thte~l~owrpres~ure8cylinder.
~o~i.nt which rromoC p
It is poysible eo expect further improvement of tt?e production efficiency,
~ decrease i.n lnbor consumption ~nd meral consumprion of this ~s~embly on
making the ttiansition ev ti~e srructural design o.E a rod ~ype low-pressure
cylinder wLth built-in supports, the deve:lopment of whicti is underwr~y at
the plant ar the presenC rime.
- As has been pointed oue, ~ characteristic .Eeature oE the turbines of the
Khar'kov Turbine Huilding Plant imeni 5. M, Kirov is hroac3 appl.ication of
the welded rotors of the low-pressure cylinder. This type ot rotor was
used for the first time in the PVK-150 tur6.ine, the pilot model of wl~ict~ wus
manuEactured in 1958. During the 20 year period the plant Accumulated a
great dealro~oTSpwhichchave r~~n~ena~a themselvesewellensta~highlymreliablece
of wel.ded o
element of the unit.
At the present time all oE the low-pressure cylinders of the high-speed tur-
bines built by tfie Khar'kov Turbine $uilding Plant imeni S. M. Kirov have
welded rotors. Thedrfrom sevenepartspreSixrofcthenannulartweldsrwithtpacking
(Figure 2) is welde
rings ~oining'the rotor elements have identical separation.
The discs of the first to the fifth stages are made without central openings;
the lasr two discs are made in the form of bodies of equal resistance. The
disc of the fifth stage is forged togert~er with the shank. In the existing
structural designs, the rotor is made with adaptive half couplings. In the
future consideration is being given to the transition to a structural design _
will all-forged half couplings. A great deal of attention is being given to
improving the blading of the turbines, improvement of their reliability and
economy. On maof theelowf ressureSCylinderu103~3mmalongnwith~allbmilled~f
the last stage P
shroud has been developed and introduced.
When creating the strucCural designs for the turbines for nuclear power
plants, K-220-44, K-50U-65/3000, K-750-65/300Q, b.road use was made of a
great deal of the operating experience of the wet-steam turbines, especi~lly _
with respect to improving the er~~sion strength of the elements of the direct
flow section. In these turbines provision is made for the removal of part
21
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FOR OFFICT.AL US~ ONLY
of the moiature ~o the re~enerari.ve tnps And rhrough rhe openings drilled
in Che fr,~mes of Che diaphragms. Proviaion wr~s ~l.so made for the peripheral
remov~l of moisture fron each stage ttirough rhe "rxap. ctiambers" dhove the
roeor blades. On the ro~:or blades with an angle S1 ~ 90�, in order to im- _
prove the moisture separ~~!:iar purC of the shroud wna cut off, as a result
af which Che intake edges of the 6lades were opened. The input slit of the
- trap wns .locaCed opposite the cut in the tur6ine sCaror. The axial dimen-
sions of the slit are selected in such a way as to ensure minimLan exhausr
of the gas phase and preven~ return of moisture ro the direct-flow section.
In the low-pressure cylinder stages a:~d in the last stages of the high-
pressure cylinder, the peripherul cross-sE;;tions of which nre mgde w3th
lrarge ~ntrnnce angles (S1 > 90�), Che .xir edges of the roCor blades open.
Considering that in the nexC Co the last stnge of the low-pressure cylinder
the roeor blades have sharply vartable cross-sections with respect to
height and that ehe peripheral moisture removal afCer them is inefficient,
the diaph ragm of the last stage is made with i:ntrechannel moisture separation.
In these diaphregm~eameandiwateramtxtureeisiremovedhtobthe bladeecavityrand
are hollow. Th
then drained into the condenser.
All of the rotor and guide blades of the turhines at the nuclear power
plants are made from chromium-containi:ng steel. which is resistant Co erosion
wear. On the rotor blades of the two last stages of the low-pressure cylinder,
in addition, the input edges are also hardened. In ordEi to preventincluding
the elements of the srators of the high and low pressure cylinders,
the diaphragm, are made of chromium-containing steel. Surfacing of Che
bearing surf aces and the split joints of the elemenCs of the stator of the
high-pressure cylinder in the dense steam zone by erosion-resistant steel
is also used. As the experience in long term operation has demonstrated,
the methods �arechiVhlanefficient andtensure relia~iletoperationf futheadirect-
power plants g y
flow section of the rurbines.
Slow-5peed Turbines--New Area of Development
A great deal of experience with respect to the creation of powerful saturaCed
steam turbines operating at 3000 rpm has naturally given rise to the pre-
ference for the structural designs of many of the elements also for low-
speed units. These elements include the high and low pressure rotors, welded
and rigid; Tiearings; and automatic barring gear; welded stainless steel
diaphragms; devices to protect the seats and slit ~oints of the housing
parts by surfacing or finishing with stainless steel.
However, a large number ~,f elements of s.low-speed turbines could not be
obtained by a proportional increase in size. The dimensions of many of the
parts of the high-speed turbines (f or example, the exhaust lines) are the
maximum for transportation by rail; a proportional increase in all of Che
dimensions would lead t~ extraordinarily heavy elements. Thus. for example.
22 '
FOR OFFICIAL USE ONLY
,
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APPROVED FOR RELEASE: 2007/02/49: CIA-RDP82-44850R000100064430-1
FOk OI'l~'1:C I AL US1: ONI~Y
on doublinR rhe exhaugt ~rea, the weight o.~ Che l~w--pre3aur~ cyllnder wnuld ~
~pprnximately triple; wiCh an iucrease in li:ne~r Jimension~ it is. mnre
di~[ic.ule tn erisur.e rigidityo uf the struceurul eleiuents ~ufficient f.nr
reli~ble a~.ignmenC of tlie tiurbine conaic~ering khe inczeuse lm m~~~ of the
turb:tne and the condenserg thecnselves. Iti addtrion, wirh ~n incren~~ in
over~ll dimensions, the deformarions cnused by ~rmnspheric pressure and
nonuniEarm hearing incrense; th~ gh~rply increasing dimensions oE the
candensers coroplicnte rhti buildins oE ~ fr:undation corresponding to the
static ~nd dynamic strength requirements and rigidity; u number of the
problems arise ~lso wiien designing ttie condenser ltselt.
The mosC iu~portant problem for the creatinn of the slnw-speed rurbines ig
the developm~nr of n structural design for Che 1ow-pre~sure cylinder en-
sur.ing its rigidity ~md reliabYe alignmenC. In the K-500-GO/15~~ tux'hine,
the low-pressure cyltnder wirh side location nf tl~e condensitrs is used for
, Che first time !n Sovier practice. The Curbine does noC t~ave a ri~id coupling
to Che candensers, which lends stability to the verticnl londing on the
Curbine f-oundation and independence of the defo rn~atinns of tite low-pressur~
cylinder huusing with respect to the vacuum in the condenser and the degree
Co which it is fill~d with water. Earrhqunke prooEiiess of Che turbine hng
beeii imprc+ved.
4nnn . ~
' I
! ~
1 7 J ~q ~ S 6
� ~ _ _ . ~ ~
~ ~ I ' : -
b ~ ~ ,
. _ r
=
~i ~ .r _
' ~r a c~;;~' ~ = - - ~ rY _ ! ''u S
k ' ' i,' . . '
'.4~_. ' . - �.r, } ~
f~
.~~;r / y :i~~ ~ i ` ~~J R_. ~J
1 ~ ~F`~ 5~ ?.y ~ � '
- ~ ='_4� = 3~;, 1 _ '..,,rr� _ .
`j~----~ - _ ~ 7'~, L. " - - .
~ : t> ~ i -
=i=
~ l; ~
< f:;~,;'~'~;` - - s~.
f1,~~Y,~ ~ L�r.:r;: ,~.:t~~/ `.r,'~~ ~
Figure 3. Transverse section of a turbine with side condensers: 1--Condenser;
2--Flexible supports, 3--Compensators~ 4--flearing housing; 5--
Housing of the 1.ow-pressure cylinder; 6--~eed water heater.
The condenser is supported on individual foundatlon:3 independently of the
turbine. The unbalanced horizontal forces arising frc:^_ the effect of at-
mospheric pressure on the outside vertical wall~ of the cundensers are
taken by the groups of flexible supports transferring this force to the
foundation of the turbine. The housing (frame) of the loF-pressure cylinder
23
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APPROVED FOR RELEASE: 2007/02/09: CIA-RDP82-00850R000100060030-1

APPROVED FOR RELEASE: 2007/02/49: CIA-RDP82-44850R000100064430-1
,
~0lt dt~'~'tCIAL USE: ~NLY '
m~de ~ingle-w~l], whf~h ensures the ~impl~~t cnnnectinn nf th~ rpG~ivr~r~
~nd the turbine~ fnr t~pping the ~te~m, it improveg the th~rm~1 in~ui~~ion,
it lnwerg rhp met~1 cdn~umptian ~nd l~bor cnn~uroptidn in th~ ~~n~nufacturing
proG~gg. The supporrg nf th~ b~~ringe and th~ hnu~ing ~f ChN low-prpeeur~
eylinder are in~rall~d dir~ctiy nn Che fo~nd~eion. InasmUCh ~a tt~~ pxh~u~t
lin~s gu~p~nd~d on the hdueing and el~stira~ly conneCted to th~ pnd ~Q818
f~~t~n~d t~ thp beAring 0upports do not p~rti~ip~te in thp ~lignm~nt of the
unit~ the alignment i~ nne di~turbed on varieCinn of the vgcuum dr h~~eing
of che conneet~ng line~.
'The conclen~~rg axe ingt~lled with rpgpect tn th~ turbine (~iqur~ 3) gnm~what
lnwer th~n in th~ knnwn on~lo~o~g F~r~ign dpgigng. Th~ ~~pargtion of ehe
c~nd~ns~r~ wieh r~ep~ct t~ height intn two levet~ permit~ th~ en~rgy con-
sumption f~r driving th~ circulgting pwnpg tn be r~dured to th~ 1~ve1
corr~~ponding t~ the ahaft condeng~r~ having low~r altitude of th~ turbine
~ystem and it gl~n engur~e the poggibility of np~ratfon with helf of th~
cdndenser di~conn~cted.
In all there ~r~ five.(nne horizontal ~nd four vertical) unwpldpd vacuwn
split ~nintg. The verei~al split ~nints ere mgde eo as td pneurp ~implicity
~f fitting. ~or thi~ purpos~, flexible hlements gre insr~ll~d dn both eid~g
of e~ch splir joint. The horizontal gplit ig approxim~t~ly on~ and a helf
times smaller than in the case of basement condenser. Th~ increage in the
total extent of thc split joint which ig 35 percent longer than in the r~ge
of the bas~menc condenser, is c~?mpeneated for to a eignificent degree ae a
r~sult nf this. It is necessary co note that the length of the vacutom
spiic joincs of the K-500-60/1500 turbin~ with gide cnndenaers ie 1~ percpnt
le4s than in the K-S00-65/3000 turbine.
The staad seals and rigid foundation petmit checking of the density of the
condenser, the housing of the low-pressure cylindez and th~ greater part of
the vacuum split ~oints by filling the total steam space, the connecting
lines and exhaust lines and the housing of the low-pressure cylinder with
water. The rigidity of the lines is sufficient to avoid extraordinary de-
formations.
In the concrete foundation under the turbine a tunnel is made in which the
oil lines and electric lines for the devices inatalled in the bearing supports
are laid. The aerodynamic studies performed at the TsKTI Inatitute imeni
I. I. Polzunov and at the Khar'kov Turbine Suilding Plant imeni S. M. Kirov
demonstrated that in the case of side placement of the condensers~ the
peripheral nonuniformity of the steam flow parameters after the last atage
is reduced, which prnmotes an increase in the operating reliahility of the
blades; in addition, in tE~e exhaust lines it is possihle to recover abouC
30 percent of the output energy of the steam from the last stage. The
exhaust in two directions permit a decrease in overall ditnensions of the -
line and depth of the pipe bundle of the condenser at the same apeeds.
24
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~~ou u~~r~tnt, us~? ONLY
On the bc~c~i~ of th~ primary ~rructur~~l degigng c~dupt~d for th~ K-50U-60/]500
tu~bine, e turbine of rhe K-1dd0=6~/1SCltl type m~~de uh at the hi$I~-pr~~eurc
~yii~,a~r, tt~e mQdiurn-pr~~sure cyli~lder ~nd three ]dw-pr~ygurc rylind~r~ hn~
b~pn de~ign~d ~nd m~nuf~~tured by che pl~nt. All nf th~ Gylind~r~ df elii~
turbin~ er~ made twn-flnw ~nd th~ir tl~rnugt~-flow ~ert..~n~ are ~n~ldgou~
ea the flas~ ~~ctiot~s af the cdrrepponding Comp~rtmente of the K-500~6n/1SOn
eue~iin~.
A version of the turbine witi~out the medium=~r~g~ur~ Cylindpr hgg al~n
been d~veln~~d Cgp~ ~igure G). 'The turbin~ ig m~dp in dcr.c~rd:~:~Ge with thp -
following layd~t: high-pregsur~ cylinder plus three 1ow-preggur~z cylinderg.
Th~ diamerer of the pipe~ ~~eding the eteam to the 1nw-preg$?~re cylinder
i~ 12UU mm in~te~d of 2d00 mn in the verginn stith the medium-prpg~ure
cylittder. ~v~n with c~ide plncement nf tt~e condenger~ thig mak~~ it pns~ibl.e
td f~ed the ste~m to the low-pr~~~ure cylind~r through th~ ldwer part ~f the
hnusing. In tt~e givhn ver~inn nf th~ structurnl d~~i~n, the r~pair c~nd
maintengnce conditiong havr b~en improved while ret~ining the bagic ~d-
vgnt~ges of the turbin~s with eide ~xhau~t (r~lative compactn~~e ~nd rech-
nulo~icnl nature of the housi.ngs of the low-preggure cylind~r, th~ religbility
of the ~~li~nmenc, high nerodyngmic characteristica nf thc exhnuet line).
Desi~n developnentg ~rp being warked on far the individual c~ssembli~e ~f
the low-sp~ed turbines: the last stages and the low-pressur~ cylindera which
will permit further inereaye in unit power.
~ r,
t-r} ~ 4.'~ r~ -
~(,-~'r~ f`~.,~ ~r ~ ~ . ,
3,~ ~ l,~ jj~ r. ( ~ ~ ~ : ~
. l ~ ! _ ~ ~ly+ �Y
_ ~ ~rr~+ �
' ~
: i ~ 't ` _ -
r. '
" ; ~K ~ .
( . ` _ -
- - - 1
Figure 4. One thousand megawatt turbine operaCing at 1500 rpm without ~
~r,edium-pressure cylinder wiCh side condensers.
Turbine Exhaust
The size of the exhaust arEn is determined by che average diameter Dave and
the length of the rotor blade of the l~st stage. The ~elation of the~e two
parameters is the most important characteristic which to a great extent
determines the strUCtural design of the low-pressure part of the turbine.
In the lasc 20 years n trend has been observed toward an increase in the
exhaust areas caused by an increase in length of the active part of the blades
25
FOtt O~FICIAL USE ONLY
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APPROVED FOR RELEASE: 2007/02/49: CIA-RDP82-44850R000100064430-1
,
FAR OF~YCIAL US~ ONLY
a~ th~ 1~~t ~eeB~g df rh~ turBine~ mhe lengthg di th~g~ b1~dh~ nrp b60,
74U, 7~A, g52, 960 ~nd~lni~~g~umghlade with~~ngaetiv~igeCeion 1200imm21ong
Cnng~~~~ n� the CPSU, a t
is in ehe efleckoue ~ee6~)~
Wher building th~ last~~gtofQeae~dynemieg~~ndyatrteagth~ m~nufacturingct~chno~
n~ct~d with ehe probl 8
ingy and m~tellurgy.
Lnw~rin~ the turbine ~nw~r 1~ad~ ~to a gignifirane chong~ i.n th~ volumeeric
eonswaptinn of the warking,medium at th~ ~xit from th~ rnCOr of the last
gtgge~ It algd change~ on variation of th~ pre~surp in the eonden~er.
The v~rigbility of the flow rate ig conn~aeed with th~ variationg of th~
fnllowing: rhe thermal gradient p~r stagQ; th~ degree of regctivity and thp
re~ctivity gradient with respece to radiuggft~/~oflgQhuently,iwithethegvariatione
v~locity, cn is the eot~l flow velociey), q
of th~ mggnitude and dtrectionto~fr~diu~xit velocity and also the nature of
its distributinn with resp~ct
With a decr~ase tn the flow rgtp, the indicated peCUli~ririe~ 1egd, if
~ppcial measures are not take, to ~ fase decrease in Chp degre~ of reertivity
in the roor zone and, as a consequen~e, ro the appe~rnnce nf neg~Civ~ values
nf it, a~ a result of which increased energy lossee are obgerved in thia
zone, compounding the losgearoot$andion~thefbackiedgesaofethegprofilesthe
flow both on the rim at th
The last stage is also charactarized by a signifi:ant gnglc of rise of Che
outgide meridional rim. This fact can lead to additional losgea connected
with flow $round the profiles over oblique aurfaces in the layer of variable
thiekn~ss and with certain other fectors, as a reault of which separation
of the f low fram the outaide meridional bQUndary and the edge of the profile
take~ place easily. The growth of the slope angles of the meridional rims
and the M numbers (where M is the Machient~of'the degree off reactivityawith
leads to significant growth of the grad
respect to radius differing significantly from that calculated without
consideration of these factors.
The ~numerated deficiencies are to one degree or another ~erdeficienciesf
the stages manufactured previously (before the 197~'s).
connected with the op$ignificanttdegreethetexplainedrbyetheerandomiflow8
and at idle can to a g
processes which have already been mentioned.
The Khar'kov Turbine Building Plant imeni S. M. Kirov hegan the design of
the last two stages several years ago, one o~ which with a length of the
rotor blade of 1030 mm was designed for a num6er of 3400-rpm turbinea, in-
cluding the turbines of the nuclear power plants, and the other, with a
for the 1500-rpm
length of the active part of the rotor blade of 1450 mm,
turbines installed at thfoiutuYbineswoperating nhorganic fuelexcThee the
possibility of using it
26
FOR OFFICIAL USE ONLY
i
. . ~ .ti . . . r~
_ _:a .,....W.,. . r
APPROVED FOR RELEASE: 2007/02/09: CIA-RDP82-00850R000100060030-1

APPROVED FOR RELEASE: 2007/02/49: CIA-RDP82-44850R000100064430-1
~
E'Uk oCt~~ rc.1 AL USL tlNLY
pritt~i~ler~ permitttiig ug to obtain Itnprdved ch~~r~cteriatir~ wc~re u~~d in
the de~igng fvr the new ~egges. 'fhe ha~ic~ relntiong oE th~ genmetric
peramet~r~ ~nd rhe ~h~p~s of the gtructur~l el~ment~ en~uring np~r~ting
reli~billty w~re gelerted in gccordance with rhese prin~ip~~~. Tfi~ ~e~f~ct
oE the vnriuug parnm~ters on th~ CI1Cir1CC~Y~gC~Cg. Of the stnge wn~ ~~~~~d
in numerdus ~xperimenes.
At the pr~$~nt time vne of thesc ~tngeg ha~ undergone c~peruting tp~ting
for 25,000 hnurq; ttle other has gone tt~rdugh ~ CyC1@ of ~dmpr+~h~ngive ~t~die~
ns a result nf whiCh it was discovered that tt~~ principleg u~ed in eh~ deeign
~~n~ure more sf~ble operneinn in th~ p~rtinl regtmes end ntt incre~~e in
~~Efi~ienr.y nf the gtnge by 2.5 pcrcent by cnmp~rison with tt~e old de~igns.
'Che plant i~ con~inuing itK projccts aimed ~t ~renting new progpective
des~.gns fnr the l~st stnges.
~
Keduction df L~bor Consumpcic~n ~nd Metnl Consumption
One of the areas o~ imprnvempnt n~ the elem~nte of the turbineg with lnrge
unit power nnd improvement of the prnduction efficiency ig ra reducCinn of
the l~ybor consumptinn und metel con~umptinn. Until recen[ly the e[ructur~l
designs of some of the larg~ turbine asaemblies and partg were cr~nted
,,by.~stablished tradieional forms attd were not ~upported by the corresponding
.~strength c~lculations which frequently led to inefficient u~~ of the
mechttnical properties of the met~l gnd to the npplic~Cion of imperfect
structural forms. In realizing the problem of improving the productioc~
efficiency~ the designprs, the efficiency experts attd tt~e inventore at the
plant nre doing a great deal of work on improving the structural designs E
in the direction of reducing their muss and labor conaumption and nlso im-
proving other indexes. In particular, the assemblies of ttie compensntion
units, the reducers and the housings of the low-pressure cylinders have been
subjected to careful ~nalysis.
The strengnc ~alculations of the supports installed under the condenser
springs have made it p03~ible to ^�^a�~^^ ^~{^,hr�-r derign And signiEicantly
reduce their mass. The analysis and corresponding calculation of the hnusing
strength of the condenser have made it possihle Co change its design and
do away wiCh the heavy (from 10 to 30 tons depending on the type of turbine)
supporting frames welded to the bottom of the housing dn installation.
~ According to plan, the supporting frames were provided for transfer of forces _
from the 24 springs (6 at each corner of the condenser) to the bottom of
the condenser, and they also served as a base for assembly of the porCable
p.3rts of the condenser during installation, the analysis of the structural
design demonstrated that the application of the frames is not necessary,
and the transfer of forces from the springs to the tube panels of the con-
denser can be reslized ~hrough two beams welded to the hottom of the con-
denser. At tr,e support point of the springs the beams are made more rigid
by stiffening rtbs. The developed design with two longitudinal beams in-
stead of the previously used frames satisfies the strength conditions and
makes it possible to reduce the meCal consumption (from 9 to 29 tons) . and
the labor conswnption of each condenser.
27
FOR OFFICIAL USE ONLY
APPROVED FOR RELEASE: 2007/02/09: CIA-RDP82-00850R000100060030-1

APPROVED FOR RELEASE: 2007/02/49: CIA-RDP82-44850R000100064430-1
~dR dF~'ICIAL U5E~ f~NLY ~
TIt~ ~Bt~UGE~'g cdnn~Ct~ng ehe ldwpr halve~ af tli~ ~xl~augt lin~g d~ th~ hnu~ing~
df ~h~ l~w pr~~gur~ ~ylinder~ e~ the ~~c~d~nger~ ~ir~ ~nx ~tru~eur~s mede of
~heer rdiled produce~ 16 mm thick wich ov~xall dimpn~inn~ of ~ppr~ximately
7x~ m~eer~ n heighe fr~m 2 to 5 m~tera, depending nn thp eyp~ and eize of
thp turbin~. 'Ch~ inieial ~tructural d~~ign of ehe reducere provided for
tnking th~ ~tmogpherir pre~~ur~ fereps by th~ ingide ribbing ef the we11d
and thp ingt~llation nf a thr~e-dim~ngiongl ~ystem nf supporting r~d~ mad~
oC raund r~11~d preductg 45 mm in diamet~r. Th~ redu~erg of two ad~acene
Gylind~rs nr~ Cdnn~~t~d by twn byp~~seg from eh~ conditinn of eh~ pd~sibiiity
~f di~Gnnn~eting on~ nf rhe condens~rg fnr Cleaning~ Th~ unh~l~nc~d f~rc~
~ ~ppe~~ring ag g r~sult of Cttig from th~ ntmdsphpric presgur~ an ~ach re~ducer
is n~uernlized ~g follows: openings arp cut in the wgllg uf the reducer
oppdqite to the bypesges which gre ~qual with reap~ct ro dimen~idng to th~
cros~-geceion of rh~ byp~sse~. The ~upporting pleteg ingtnlled ingide the
rpducer dpposie~ ehe op~ning~ t;~ ehe bypa~seg gre eonn~et~d eo th~ wn11 a~ong
th~ outlinE of the 1en~ romppneatnti~. 'The hearing plat~g nf the nd~acenr
twd r~ducere ~re conneceed through thp byp~~~ by the ~pgtinl
sysrem of rodg.
The p~culinrieies of the structurgl degign nf thpse reducere cnn slsn inClude
the fa~t that each reducer, from Che condirinn of trunspdrting it by rail,
is split inro two p~rts which are welded togethpr on installntinn. 'Che
deficiencies of th~ dpsign of the tnve~tigated redu~prg ean include the
following: lgrge metal conaumption and labor congumptian c~uaed by the pre-
sence of th~ three-dimensidnal rod system for taking the acmospheric presgure
and neutrc~lizing the imbalanced forcea; the necessity .for welding a large
number of rods of the two halves of the reduCer under installation conditiona;
additiongl consumptien of from 2 to S tons of shaped rolled products (channela
No 2b) for adding rigidity to the parts of the reducer during Cransportation
of them; worsening of the aerodynamic qualities of the reducers as a result
of camplicating them with the rod system; increasing the transport expendi-
tures.
The new developed "panel" gCructural design of the reducera (Figure 5)
permi[s elimination of the en~erated deficiences of thia unit. A newly
designed reducer is made up of four wall panels one ribbed on the inside
with channels 7. The reducer i~ transported hy individual panels welded
to each other on installaCion. The correspondence of the geometric dimensions
of the reducer 2 to the drawings and enaurance of theae dimensions on in-
stallation is achieved by marking the reducer at the plant. For this purpose,
on each panel small flanges are provided which are matched and drilled out
on assembly with the flanges of the ad3acent panel. On the horizontal
plane in the middle of the reducer under installation conditions a number
of tubular hraces 8 are welded on which, jointly with the stiffening ribs
of the panels, take the :tmospheric pressure. The tApping lines are fastened
to these braces. In connection with thQ transportation of the reducers in
individual panels, there is no necessity for trans~port stiffeners. The
absence of the three-dimensional system of rods in the new design permits
improvement of the aerodynamic qualities of the reducers. The unequalized
28
.
FOR OFFICIAL USE ONL'_'
APPROVED FOR RELEASE: 2007/02/09: CIA-RDP82-00850R000100060030-1

APPROVED FOR RELEASE: 2007/02/49: CIA-RDP82-44850R000100064430-1
FUIt (~~~ICIAL U~~ ONLY
fnrc~~ af th~ r~ducers. nr~ Cqken by th~ rigi~f hx~~~~ G 1nae~1l~d b~tw~~n
eh~ w~t~r Chamb~r~ 5~f rh~ cdndengerg. qnd th~ Cr~ngvpr~h pin~ n~ ehc ~ix~d
poinrg o~ th~ l~w-pr~ssur~ cylind~r~
.r nll'`t~~ j ~
~ ~ J ~ . ~ t
t ~ ~ ~ ~
~
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