Steam boilers. Powerful steam boilers Krasny Kotelshchik How they work at TKZ Krasny Kotelshchik

15.03.2020

I continue to talk about the most advanced power engineering enterprises in our country. Today we are visiting the leader of the domestic boiler industry at the Taganrog boiler plant Krasny Kotelshchik, which is part of the Power Machines company. By the way, over 60% of all power plants in Russia and the CIS are equipped with TKZ boiler equipment, and more than 80% with heat exchange equipment. In addition, the company's products operate in more than 60 countries around the world! By the way, this year, on September 22, 2016, the plant turned 120 years old. So there are more than enough reasons to talk about it! So go ahead.

The plant was founded in 1896 by the Russian-Belgian society and was called the Boiler Plant Albert Nev, Wild and Co. And it was built in less than six months. The following evidence has survived. “... On Sunday, September 22, 1896, the grand opening of the Albert Neuve, Vilde and Co. boiler plant took place. In his greeting at the solemn opening of the plant, the mayor notes that only on October 2, 1895, the decision of the Duma on the alienation of the land for the plant took place, and only a few days ago it was received Highest Resolution for the alienation of this land, we have not yet had time to conclude a deed of sale, and the plant is already ready. It was built by 500 Russian workers and completed in just 120 working days. Further, the mayor indicated that both the building and the workers in it were all Russians, there would be no more than 20 foreigners.

In those years, various riveted structures were made on it: railway bridges, mechanisms for oil industry, equipment for mines and blast furnaces, steam boilers. Then, on an area of 16 hectares in six shops for 12-14 hours per shift, from one and a half hundred to one thousand two hundred adult workers and adolescents worked. Various boilers were produced: steamboat, locomotive, Filda, Tishbein, Ferbern, Shukhov-type units. Of the modern equipment at that time were boilers "Fitzner", "Gamper", "Garbe-Kestner", Lancashire. Their productivity was only 2-3 tons of steam per hour. Nevertheless, the total share of boiler building in the plant's output was not large, only 30-40%.

On March 15, 1918, the Taganrog Boiler Plant was nationalized. As a result (and the German occupiers helped) from 1922 to 1925, he was on conservation. In 1925, the name was changed to the Krasny Kotelshchik State Plant named after Comrade Smirnov (Vladimir Stepanovich Smirnov - participant civil war, Bolshevik underground worker. He directly participated in the battles against the junkers and took Active participation in an armed uprising at the boiler plant in January 1918, but was captured by the junkers and shot at the gates of the plant). In 1932, the plant again started producing boiler equipment, and in 1934 the USSR completely abandoned the purchase of drums for boilers abroad. Moreover, in 1934-1935, one of the most important launches for the pre-war history of the enterprise took place - the launch of the CSB - a shop for welded drums, called "golden". Since that time, boilermakers have been able to refuse to purchase imported drums for boilers. So "Krasny Kotelshchik" became the main supplier of drums for all boiler plants in the country.

In 1942, during the war, the boiler production was relocated to Podolsk (now JSC ZiO-Podolsk), and part was dismantled and disguised in Taganrog. Many workers went to the front, and those who remained made shells of aerial bombs, parts and components of sea underwater mines, hand grenades, etc. But already on December 31, 1943, a resolution of the State Defense Committee on the restoration of the Taganrog Krasny Kotelshchik plant was adopted, which indicated that the GOKO considers the restoration of the plant to be the paramount military and economic task of the People's Commissariat of Heavy Machinery, the People's Commissariat of Construction and the Rostov Party Organization.

5. Monument to Anton Chekhov on the territory of the plant. The fact is that Anton Pavlovich comes from Taganrog

And now, after the war, our plant is back on horseback. The team of the design department of KTZ developed the first large boilers TP-230 in the USSR. The units produced in Taganrog were the basis on the basis of which the country's post-war energy industry developed over the course of a decade. Boilers manufactured and shipped 377 boilers to the power plants, their total capacity was 65% of the total power capacity of thermal power plants commissioned in those years. Since 1948, the plant began to send its products for export: to Albania, Bulgaria, Hungary, Vietnam, China, Mongolia, Poland, Romania, etc. The year 1959 was distinguished by the fact that TKZ received an order for heat exchangers for the Beloyarsk NPP, this was the first task from nuclear scientists.

And then other records followed. In 1962, Europe's largest giant boiler was designed with a capacity of 2500 tons of steam per hour for a turbine with a capacity of 800 MW, and in 1978 the most powerful and only steam generator in Europe with a capacity of 3950 tons of steam per hour was manufactured to operate with a turbine of 1200 MW. The power unit was delivered to the Kostroma State District Power Plant. It was called simply - the giant boiler. The height of the boiler is 67 meters, higher than a twenty-story building. The total length of the steam generator pipes is 800 kilometers. It took 650 railway platforms to ship it.

Since 2005, the plant has become part of the EMAlliance holding, but new story plant actually began in February 2012 after joining the Power Machines company. This made it possible to combine competencies and act as an integrated supplier of power equipment on the market.

9. The production facilities of the enterprise are located on a plot of 108 hectares, even getting into the first workshop, we can immediately feel what a colossus it is. But this is only the beginning of our acquaintance.

Krasny Kotelshchik's product line includes fossil fuel boilers, waste heat boilers for CCGT units, heat exchangers and auxiliary equipment.

Now the plant is actively working on projects for: Long Phu-1 TPP (Vietnam, supply of two pulverized coal boilers with a steam capacity of 1908 t / h each for two power units of TPP with a total capacity of 1200 MW), Bar TPP (India, supply of three steam boilers TPP-660 with a steam capacity of 2225 t/h each for three TPP power units with a capacity of 660 MW each), Belarusian NPP (manufacturing and supply of feed water deaerators, heaters for high and low pressure for power units No. 1 and No. 2), Sakhalinskaya GRES-2 (RusHydro Group, supply of two steam boilers with a capacity of 230 t / h of the E-230-13.8-560KT type, including auxiliary boiler equipment), Nizhnekamsk CHPP (Tatneft, reconstruction of 4 boiler units TGME-464 with the transfer of petroleum coke to combustion of fuel, installation of electrostatic precipitators, nitrogen purification, construction of a dust preparation workshop, design and survey work, commissioning) and SIBUR-Kstovo LLC (design, manufacture and delivery of a boiler unit with a capacity of 100 t/h of the E-100-11.8-535G type (with auxiliary boiler equipment) designed to operate on methane-hydrogen fraction (main fuel) and natural gas (reserve fuel). 100 t/h steam with parameters: pressure - 11.8 MPa, temperature - 535°C).

Concerning production process, then it includes four main areas: blank production, production of metal structures and fittings for pipelines, production of heating surfaces and production of hull equipment. All this allows TKZ to produce up to 4 GW of boiler equipment per year. If you count in tons, then this is about 15 tons finished products in year. Next year, most likely, there will be twice as many, which is what we want.

16. This is the future loophole where the burner will be inserted.

18. And this is what the containers in which the components of the boilers are sent look like

20. Collector manufacturing area

22. Recently, the machine-tool building series was strengthened with such a Center for processing collectors. It is capable of creating and processing collectors up to 8 meters long.

23. Again, the scale speaks for itself.

26. Painting and packaging of products is underway at this site. AT green color painted at the request of the client, all this stuff is sent to Long Phu Thermal Power Plant (Vietnam)

27. And these silvery collectors will go to India to the TPP "Bar".

28. And this is another building and a burner area

32. What else exactly will I remember the plant for, that the workers here are not at all afraid of photographers, they don’t immediately run away from their workplace at the sight of a camera, but on the contrary, they ask for an encore :).

33. Great luck, so in the conversation it turned out that a whole dynasty works in this workshop - the Chezhichenko family (Irina Nikolaevna and Alexander Ivanovich and their son Evgeny).

Steam boilers for power units for supercritical steam parameters from 300 to 1200 MW and steam production from 900 to 3,950 tons of steam per hour
Boilers for burning various types of biomass (wood chips, straw pellets, husks) of various steam outputs

steam boilers

The Taganrog Boiler Plant "Krasny Kotelshchik", being a traditionally recognized leader in the production of boiler units for the electric power industry, pays special attention to the reliability, efficiency and durability of the manufactured equipment. The enterprise has all the necessary competencies in the creation of power steam boilers, drum and once-through, with a capacity of 50 to 3,950 tons of steam per hour at an operating pressure of up to 28 MPa and more, to operate on all types of energy fuel (anthracite, brown, black and lean coals , coke, blast furnace and natural gas, oil, fuel oil, etc.). The development of steam boilers is carried out in the engineering departments of the company, which have extensive and successful experience in development and research.

The production capacity of Krasny Kotelshchik allows the production of up to 4 GW of boiler equipment per year. Over the past few decades, TKZ has been a leading supplier of once-through boilers for power units 1200, 800, 600, 300 MW for supercritical steam pressure (SKP) for powerful thermal power plants in Russia and the world. According to the main indicators of reliability and efficiency, these boilers correspond to the modern level of foreign boiler building of leading companies, which is confirmed by many years of experience in their operation. Taganrog Boiler Building Plant "Krasny Kotelshchik" is one of the world leaders in total production of SKD boilers for 1200, 800, 600 and 300 MW power units.

Steam boilers for power units for subcritical steam parameters up to 660 MW and steam production from 50 to 2000 tons of steam per hour

I continue to talk about the most advanced power engineering enterprises in our country. Today we are visiting the leader of the domestic boiler industry - at the Taganrog Boiler Plant "Krasny Kotelshchik", which is part of the Power Machines company. By the way, over 60% of all power plants in Russia and the CIS are equipped with TKZ boiler equipment, and more than 80% with heat exchange equipment. In addition, the company's products operate in more than 60 countries around the world! By the way, this year, on September 22, 2016, the plant turned 120 years old. So there are more than enough reasons to talk about it! So go ahead.

The plant was founded in 1896 by the Russian-Belgian society and was called the Boiler Plant Albert Nev, Wild and Co. And it was built in less than six months. The following evidence has survived. “... On Sunday, September 22, 1896, the grand opening of the Albert Neuve, Vilde and Co. boiler plant took place. In his greeting at the solemn opening of the plant, the mayor notes that only on October 2, 1895, the decision of the Duma on the alienation of the land for the plant took place, the Highest permission for the alienation of this land was received just the other day, we had not yet managed to conclude a deed of sale, and the plant is already ready. It was built by 500 Russian workers and completed in just 120 working days. Further, the mayor indicated that both the building and the workers in it were all Russians, there would be no more than 20 foreigners.

In those years, the company produced various riveted structures: railway bridges, mechanisms for the oil industry, equipment for mines and blast furnaces, steam boilers. Then, on an area of 16 hectares in six shops for 12-14 hours per shift, from one and a half hundred to one thousand two hundred adult workers and adolescents worked. Various boilers were produced: steamboat, locomotive, Filda, Tishbein, Ferbern, Shukhov-type units. Of the modern equipment at that time were boilers "Fitzner", "Gamper", "Garbe-Kestner", Lancashire. Their productivity was only 2-3 tons of steam per hour. Nevertheless, the total share of boiler building in the plant's output was not large, only 30-40%.

In 1932, the plant again started manufacturing boiler equipment. Moreover, in 1934-1935, one of the most important launches for the pre-war history of the enterprise took place - the launch of the CSB - a shop for welded drums, called "golden". Since that time, boilermakers have been able to refuse to purchase imported drums for boilers. So "Krasny Kotelshchik" became the main supplier of drums for all boiler plants in the country.

5. Monument to Anton Chekhov on the territory of the plant. The fact is that Anton Pavlovich comes from Taganrog

And now, after the war, our plant is back on horseback. The team of the design department of TKZ developed the first large boilers TP-230 in the USSR. The units produced in Taganrog were the basis on the basis of which the country's post-war energy industry developed over the course of a decade. Boilers manufactured and shipped 377 boilers to the power plants, their total capacity was 65% of the total power capacity of thermal power plants commissioned in those years. Since 1948, the plant began to send products for export: to Albania, Bulgaria, Hungary, Vietnam, China, Mongolia, Poland, Romania, etc. The year 1959 was distinguished by the fact that TKZ received an order for heat exchangers for the Beloyarsk NPP, this was the first task from nuclear scientists.

And then other records followed. In 1962, Europe's largest giant boiler was designed with a capacity of 2500 tons of steam per hour for a turbine with a capacity of 800 MW, and in 1978 the most powerful and only steam generator in Europe with a capacity of 3950 tons of steam per hour was manufactured to operate with a turbine of 1200 MW. The equipment was delivered to the Kostroma State District Power Plant. It was called simply - the giant boiler. The height of the boiler is 67 meters, which is higher than a twenty-story building. The total length of the steam generator pipes is 800 kilometers. It took 650 railway platforms to ship it.

In 2005, the plant became part of the EMAlliance holding, but the new history of the plant really began in February 2012 after joining the Power Machines Group of Companies. This made it possible to combine the competencies of the Group's enterprises, and Power Machines to act as an integrated supplier of power equipment in the market.

Krasny Kotelshchik's product line includes fossil fuel boilers, waste heat boilers for CCGT units, heat exchangers and auxiliary equipment.

Now the plant is actively working on projects for: Long Phu-1 TPP (Vietnam, supply of two pulverized coal boilers with a steam capacity of 1908 t / h each for two power units of TPP with a total capacity of 1200 MW), Barh TPP (India, supply of three steam boilers TPP-660 with a steam capacity of 2225 t/h each for three TPP power units with a capacity of 660 MW each), Belarusian NPP (manufacture and supply of feed water deaerators, high and low pressure heaters for power units No. 1 and No. 2), Sakhalinskaya GRES-2 (Group RusHydro, supply of two steam boilers with a capacity of 230 t/h of the E-230-13.8-560KT type, including auxiliary boiler equipment), Nizhnekamsk CHPP-2 (Tatneft, reconstruction of 4 boiler units TGME-464 , installation of electrostatic precipitators, nitrogen treatment, construction of a dust preparation workshop, design and survey work, commissioning) and SIBUR-Kstovo LLC (design, manufacture and supply of a boiler unit with a capacity of 100 t / h type E-100-11 ,8-535G (with auxiliary boiler equipment), designed to operate on methane-hydrogen fraction (main fuel) and natural gas (reserve fuel). The boiler is designed to produce 100 t/h of steam with parameters: pressure - 11.8 MPa, temperature - 535°C).

As for the production process, it includes four main areas: blank production, production of metal structures and pipeline fittings, production of heating surfaces and production of cabinet equipment. All this allows TKZ to produce boiler equipment with a total capacity of up to 4 GW. If you count in tons, then this is about 15 tons annually! But the task is not just to produce, but first to design science-intensive equipment.

16. This is the future loophole where the burner will be inserted.

18. And this is what the containers in which the components of the boilers are sent look like

20. Collector manufacturing area

22. Recently, the machine-tool building series was strengthened with such a center for processing collectors. It is capable of handling collectors up to 8 meters long.

23. And again, the scale speaks for itself.

26. Painting and packaging of products is underway at this site. Painted green at the request of the client, all this is sent to the TPP Long Phu-1 (Vietnam)

27. And these silver collectors will go to India to the Barh TPP.

28. And this is another building and a burner area

33. Great luck, so in the conversation it turned out that a whole dynasty works in this workshop: Irina Nikolaevna Chizhichenko, her son Evgeny and husband Alexander Alexandrovich Ivanov.

36. Workshop for the production of hull equipment. This workshop assembles high and low pressure heaters, high, medium and low pressure drums, evaporators, deaerators, separators, chemical water treatment filters, and condensing units.

37. Drums high pressure. The one closer to us is intended for the Novo-Bogoslovskaya CHPP

39. Like in a submarine production shop :)

40. And this drum will go to the Sakhalinskaya GRES-2, where I REALLY want to go, yes, this is a hint :)...

47. Future deaerator tank for the Belarusian nuclear power plant. Its diameter is 3.8 meters, the total weight is over 200 tons, and the length is 36 meters.

Over the past few decades, OAO TKZ Krasny Kotelshchik has been the main supplier of once-through boilers for power units 1200; 800; 300 MW for supercritical steam pressure (SKP) for powerful thermal power plants in Russia and the world.

What boilers are currently in operation

Earlier we already wrote about the development of TKZ.

To date, the following have been issued with the TKZ brand:

1 boiler with a capacity of 3950 t/h for a power unit of 1200 MW;
26 boilers with a capacity of 2650 t/h for power units of 800 MW for a total capacity of 20800 MW;
161 boilers with a capacity of 1000 t/h for power units of 250-300 MW.

All boilers are capable of operating in a wide range of loads at supercritical and subcritical pressures. A significant part of the technical solutions for TKZ boiler equipment is protected by a number of domestic inventions and patents.

How they work at TKZ Krasny Kotelshchik

The high technical level of boiler designs is ensured by:

participation of design departments in testing and adjustment of boiler units and their components, in the study of equipment failures directly at power plants;
hydraulic, aerodynamic and strength tests on factory stands of full-scale samples of critical equipment elements;
aerodynamic studies on physical models of the furnace, gas ducts and heating surfaces of the boiler with measurements of the gas velocity and pressure fields to determine the optimal design characteristics and layout;
three-dimensional geometric modeling of pipe systems, screens, frame and boiler as a whole;
multivariate calculations on computers (mathematical modeling) of complex mechanical and thermal-hydraulic systems as a whole using modern calculation methods.

TKZ boilers are characterized by simplicity of design, sophistication and reliability of technical solutions:

execution of the combustion chamber and gas ducts of the boiler from all-welded gas-tight panels;
the use of U-shaped and T-shaped layout of heating surfaces;
application of multi-purpose gas recirculation;
use of regenerative rotary air heaters of various diameters with corrosion-resistant packing.

Read also: Cleaning the boiler from scale, corrosion protection and repair of the boiler

From reconstruction to modernization

Works on the reconstruction and modernization of once-through boilers TKZ previously delivered to TPPs can be divided into three main areas:

reconstruction based on the results of primary operation, the need for which arises when power plants use non-design fuels;
restoration of working capacity (renewal of heating surfaces), which, as a rule, is combined with the introduction of environmental measures;
modernization of boilers that have worked out their resource. In a number of cases, it turns out to be more expedient to carry out modernization at a new, higher technical level with the possibility of preserving the foundations and frames of boilers than installing new equipment.

Export of boilers

One of the central issues in the development of new models of power equipment is to ensure the minimum toxicity of their emissions. The environmental measures developed and implemented on new and modernized boilers make it possible in most cases to ensure the current regulatory indicators. OJSC TKZ “Krasny Kotelshchik” is constantly working on the creation of boiler equipment for export. Today, once-through boilers SKD with a steam capacity of 1000 t/h are successfully operated in Iran (TPP "Ramin"), in China (TPP "Nanjing" and "Yingkou").

A certain prospect for the development of once-through boilers SKD is the transition to higher levels of parameters (P=300 kgf/cm 2 , Tpe=600°C and P=350 kgf/cm 2 , Tpe=650°C) and the use of double overheating in order to increase efficiency of power units.

Taking into account more than 40 years of experience in the market of SKD boilers, OJSC TKZ can carry out the development and complete delivery of equipment for supercritical pressure boiler units of any capacity using any fuel.

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