Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
GAS TURBO
TECHNOLOGY
ISSUE,
2009
CONTENTS
Publisher: Alexander Gorshkov
Editor-in-Chief: Jim Roberts
Editorial Board: Yuriy Anurov
(Energomash Corporation)
Meherwan P. Boyce
Operation Experience
GTU-50 MW gas turbine package experience
at Kazanskaya TETs-1 heat and power plant
Oleg Bryndin
(Saturn Gas Turbines)
Viktor Chepkin
(Saturn)
Vladimir Lupandin
(Magellan Aerospace
Corporation)
Gurgen Olkhovskiy
(All Russian Thermal
Engineering Institute)
Alexander Shaykhutdinov
New Developments
New design of a multi-case turbine compressor
with a gas turbine drive
12
16
(Gazprom)
Discussion club
What mechanical drive gas turbine engines
are necessary for the Ukrainian pipeline network?
24
Analysis
The quality of gas treatment
at compressor stations
28
34
Operation Experience
Dry Gas Dynamic Seals And Buffer Gas Treatment:
The Commissioning Experience
At Ural Gas Compression Packages
40
44
OPERATION
EXPERIENCE
Photo.
GTE-25/NK
external gas
turbine
package
at
Kazanskaya
TETs-1
heat and
power plant
Issue 4, 2009
1
2
3
4
5
6
7
8
9
10
11
12
13
Issue 4, 2009
TURBOnews
The equipment assembly of the constructed package at Tumenskaya TETs-1 heat and power plant began
The investment project realised by Fortum (Fortum department in Russia) provides
for the installation of the new package with all necessary systems at the site of the
disassembled equipment in the existing main building.
Combined cycle package #2 rated at 190/220 MW is comprised of V64.3A gas turbine
produced by Ansaldo Energia with the electric power of 68.5 MW, E-500-13.8-560 GN
boiler (model TGE-435-A/PGU) produced by Krasny kotelschik, T-130/160-12.8 steam
turbine produced by Leningrad Metal Plant and TZFP-160-2MUZ turbine generator
produced by Elektrosila.
The site for the package was prepared, the frame of the waste heat boiler heating
surface was assembled, the gas turbine and the generator were produced, tested and
supplied, and the equipment for the steam turbine (electric generator and steam turbine
with the auxiliary equipment) was supplied. The package transformers produced by
ABB were manufactured and tested; the transformers will be supplied in August 2009.
The foundation for the steam turbine was prepared; the works on the construction of
the gas turbine foundation are finished. The project is agreed with the system operator
and network structures.
The turnkey construction of the combined cycle package is carried out by KvartsNew technologies. The general project of the construction was prepared by
VNIPIEnergoprom.
The operation experience of the first package built and commissioned in 2003 was
considered at the equipment manufacture for package #2.
Due to the project realisation the electric power will be increased by 190 MW
and the heat power by 225 Gcal; the economic and ecological characteristics of
the plant will be improved. The electric power production will be increased from
434 to 1715 million kWh annually; the economic efficiency due to the reduction of the
specific fuel flow will be over 150 million rubles annually.
The commissioning of the second package planned for April 2010 will provide the
balance of the electric power production and consumption in the south of Tumen
region, the necessary heat generating facilities for the new house construction.
The construction of PGU-235 combined cycle package began at Syzranskaya TETs heat and power plant of Volzhskaya TGK
The initial construction works were completed on July 10.
The last pile was driven, then the manufacturing building will be
constructed and the fixed structures for the new turbines and
generators will be assembled.
The general contractor is Samara production and repair
company. 25% of the planned works have already been performed.
The new package of Syzranskaya TETs heat and power plant
will be equipped with the advanced equipment produced in
France, Czech Republic and Slovenia by General Electric, Siemens
and Istorenergo group. The reconstruction project named as
Volzhsky agat provides for the construction of the combined
cycle packages based on two PG6111 gas turbines produced by
GE Energy with the electric power of 80 MW each and SST-600
steam turbine rated at 65 MW produced by Siemens. The electric
generators are included in the supply of the main equipment.
The efficiency of the new package will be 52%. The combined
cycle package will include the waste heat boilers produced by
Istorenergo, booster compressors produced by Energaz, the
a u t o m a t i c c o n t ro l s y s t e m p ro d u c e d b y G E , t h re e
TDTs-125000/110-UKhL1 modular transformers.
Due to the realisation of the construction project the outdated
turbines will be removed from operation and the installed power
will be increased on over 52% from 255 to 392 MW considering
the removal of the old package. The power and economic
efficiency of Syzranskaya GRES powerplant will be considerably
increased: the specific flow of the reference fuel will be decreased
on over 22% for the electric power production, and on over 6%
for the heat power production.
The commissioning of the combined cycle package is
planned for the end of 2011. The cost of the project realisation
is about 9 billion rubles. The estimated payback period is about
13 years.
The delivery of the gas turbine packages from the manufacturing plant was first made by
water and then using two heavy weight coupled carriers
HTTP://WWW.GTT.RU/EN
NEW DEVELOPMENTS
New design
of a multi-case turbine compressor
with a gas turbine drive
Vladimir Panenko, Vladimir Danileyko, Yury Zinchenko, Victor Timofeev,
Vasiliy Kholod Sumy Frunze NPO
In recent years Sumy Frunze NPO along with the traditionally supplied gas compression
packages performed several orders to develop the compressor equipment for oil and
petrochemical industry. The equipment featuring high pressure ratio and final pressure
of the compressed gas required the development of the multi-case compressors with a
step-up gear, the application of non-traditional approaches to the design and calculation
and also the development of the new compressor cases.
ccording to Surgutneftegaz
specifications Sumy Frunze NPO in
2007 designed TKA-Ts-16/037-14.2
package to compress the casing head gas.
The modular automatic packages were
designed around NK-16ST gas turbine
engines (figure 1) to use at Talakanskoye
field compressor station. The reference
data for the centrifugal compressor
designing is given in Table 1; the oil gas
composition is given in Table 2.
The method when a multicase
compressor is divided into sections was
used to define the design scheme of
the centrifugal compressor. The section
quantity and parameters were calculated at
the specified pressure distribution. The
centrifugal compressor includes 3 cases
(Table 3): 193GTs1-270/3.6-16M26 low
Issue 4, 2009
0.36
14.40
Initial temperature, K
303
1.37
313
Components
Methane, CH4
Ethane, C2H6
Propane, C3H8
i-butane, i-C4H10
n-butane, n-C4H10
n-pentane, n-C5H12
Nitrogen, N2
Carbon dioxide, CO2
Other gases
Table 2
Volume concentration
0.7558
0.1404
0.0609
0.0076
0.0027
0.0024
0.0122
0.0012
0.0168
HTTP://WWW.GTT.RU/EN
HTTP://WWW.GTT.RU/EN
Table 3
Low
Medium
High
pressure case pressure case pressure case
Capacity adjusted to the temperature
of 293 K (+20 C) and the pressure
of 0.101 MPa (1.033 atm), m3/sec
(million m3/day)
Capacity to the inlet conditions,
m3/sec (m3/min)
Initial pressure, design, MPa (kgf/cm2)
Final pressure, design, MPa (kgf/cm2)
Pressure ratio
Inlet gas temperature, K
Compressor rotor rotational speed,
design, 1/sec (rpm)
Section power, MW
15.85 (1.37)
3.60
3.41
Figure 2. TKA-Ts-16/0.37-14.2
gas compression package
turbine unit: 1 power unit
based on NK-16ST gas turbine
engine; 2 step-up gear;
3 low pressure case;
4 medium pressure case;
5 high pressure case
Issue 4, 2009
Technical characteristics
of the step-up gear
Delivered power, design, kW
Drive shaft rotational speed, rpm
Driven shaft rotational speed, rpm
Speed increasing ratio
Table 4
16,000
5300
11,603
2.19 (81/37)
Issue 4, 2009
TURBOnews
Gosekspertiza approved
the feasibility study of PGU-410 combined cycle
package construction
at Srendeuralskaya GRES powerplant
The development of the feasibility
study of PGU-410 combined cycle
package construction was performed by
Ural power engineering center, a part
of Energostroyinvest-Holding. The
construction management of the
combined cycle package rated at 410 MW
at Sredneuralskaya powerplant to the
contract with OGK-5 is carried out by
Iberdrola. Ural power engineering
center is working on the adaptation of
the main drawings made by Iberdrola
engineers; the working documentation
for the booster compressor station and
coast pumping station.
The construction at the site is
carried out by EES Engineering center.
In accordance with the contractor
agreement made in January 2009 the
company shall provide the construction
of the foundations including the
foundations of the gas turbine, the steam
turbine, the waste heat boiler and the
Issue 4, 2009
T h e c o m p re s s o r d e ve l o p m e n t ,
production and tests were performed
according to the requirements of API
Standard 617 (Axial and Centrifugal
Compressors and Expander
compressors for Petroleum, Chemical and
Gas Industry Services), approved by
#ODC 0550-0010/1.2 Certificate issued by
S G S G ro u p ( S o c i e t e G e n e r a l e d e
Surveilance) on December 1, 2005. The
quality of development, production, repair,
installation and servicing is provided by the
Quality Management System Certificate
# 203218 to ISO 9001:2000 issued
by Bureau Veritas Quality International
on October 30, 2006. The centrifugal
compressor was manufactured, tested and
shipped in the first half of 2008.
The long experience on development,
m a n u f a c t u re a n d c o m m i s s i o n i n g ,
performing of complex compressor,
component and system tests at the test
benches of Sumy Frunze NPO provide
for the production of reliable, efficient
compressors convenient in operation.
The foundations
of the main
building
and the main
equipment
of the combined
cycle plant
are being built
at the construction
site
10
HTTP://WWW.GTT.RU/EN
TURBOnews
KES and SOYUZ made the turnkey contract for the construction of a combined cycle package at
Permskaya TETs-6 heat and power plant of TGK-9
The contract for designing, supply and construction of the power generating
facilities at Permskaya TETs-6 heat and power plant with the total cost over 3 billion
rubles was awarded to SOYUZ to the results of negotiations carried out in
B2B-Center.
The reconstruction of Permskaya TETs-6 heat and power plant is one of the
priority investment projects of KES Holding (Ural generation division) and the basic
for the development of Perm region power system. A new building will be built on
the territory of the plant where the combined cycle plant with the electric power of
120 MW will be installed. The package will include two SGT-800 gas turbines and
SST-300 steam turbine produced by Siemens. The contract on the equipment supply
was made between TGK-9 and Siemens at the end of 2007.
The gas turbines were produced by Siemens Industrial Turbomachinery AB in
Finspong (Sweden). The equipment supply is planned for July.
Due to the commissioning of the combined cycle package planned for the end
of 2010 the electric power of Permskaya TETs-6 heat and power plant will be
increased up to 180 MW, the heat power up to 240 Gcal/h. The additional heat
power supply can provide heat to over 50 thousand of flats.
HTTP://WWW.GTT.RU/EN
Issue 4, 2009
NEW DEVELOPMENTS
NK-16-20ST
engine replaceable external oil
filter and the electric starter
Issue 4, 2009
12
TURBOnews
REP Holding will supply 19 Ladoga GPA-32
gas compression packages for Gazprom
The companies signed the contract
for 14 billion 970 million rubles
(341,277 million) without VAT on June
30, 2009.
Ladoga GPA-32 is a station gas
compression package rated at 32 MW
developed on the basis of MS5002F Italian
gas turbine designed for any operating
conditions, with high efficiency (36%)
HTTP://WWW.GTT.RU/EN
NK-16-20ST engine
5428
7069.782
5465.917
20
4654
10.779
859.408
676.419
32.62
TURBOnews
The operating time of GTU-12PG gas turbine is 50,000 hours since the beginning
of operation at Fedorovskoye oil and gas condensate field
In July 2009 the operating time
of PS-90GP-1 leader engine included into
GTU-12PG gas turbine package
produced by Perm Engine Plant reached
50,000 hours since the operation
beginning at Fedorovskaya KS-42
compressor station of Surgutneftegaz
(Khanty-Mansijsk autonomous district).
After the first overhaul the operating
time of the engine is 26,500 hours at
the overhaul period of 25,000 hours
according to the specification.
P S - 9 0 G P - 1 l e a d e r e n g i n e wa s
supplied to Surgutneftegaz in June 2001,
it was overhauled in 2005. Now there
are 19 GTU-12PG gas turbine packages
operated at Surgutneftegaz; 6 packages
are used for the gas compression
package drive, 13 packages for gas
turbine powerplant drive. To provide
the uninterrupted operation of gas
compression packages and gas turbine
powerplants Surgutneftegaz purchased
four PS-90GP-1 backup engines.
14
HTTP://WWW.GTT.RU/EN
15
NEW DEVELOPMENTS
Issue 4, 2009
16
Figure 1. GTE-65 package model compressor. Measurement of the channel pressure and temperature at the inlet and outlet.
The strain measurement of the blades of 1-4 stages
Figure 2. Design and experimental characteristics of the first three stages at the full
open inlet guide vanes
Table 1
5440
184.4
1280
555
15.6
61.5/65.0
35.2
90/180
52
<25
Issue 4, 2009
Figure 3.
Results of the vibration stress
tests of the model compressor
blades of 1 and 2 stage
Photo 2.
Test model of the combustor
at the test bench of Leningrad
Metal Plant
Issue 4, 2009
18
Figure 4.
Radial temperature
distribution at the combustor
model outlet at full load:
calculation
experiment
maximum admissible
temperature
minimal admissible
temperature
Photo 3.
GTE-65 package blades with
instrumentation for tests
19
Issue 4, 2009
Examination of turbine
blade characteristics
Figure 5.
Design and experimental
efficiency of blade cooling:
leading edge;
center part of the profile;
trailing edge
Figure 6.
Fatigue test results
of compressor and turbine
blades
Conclusion
crack
after fatigue tests
Issue 4, 2009
References
1. Lebedev A.S., Varlamov I.S., Roslyakov
M.V. GTE-65 gas turbine package of the average
capacity class: design and production. Electric
power plants, #1, 2007, pp. 1922.
2. Lebedev A.S., Latypov G.G.,
Solomatnikov A.A., Nechkin B.V, Naryshkin
V.F. Selection of parameters, development and
model tests of compressor of GTE-65 package of
the average capacity class. Heavy engineering,
#1, 2007, pp. 26.
3. Lebedev A.S., Lesnyak O.B., Kravchenko
I.F., Gusev V.N. Development of low emission
combustor of GTE-65 package of the average
capacity class. Heavy engineering, #11, 2007,
pp. 1216.
4. Lebedev A.S., Sundukov Yu.M.,
Krivonosova V.V. High temperature turbine
cooled blades of GTE-65 package of the average
capacity class. Heat power engineering, #4,
2008.
5. Lebedev A.S., Simin N.O., Petrenya
Yu.K., Mikhailov V.E. GTE-65 package: tests
of the main components, application and
further development. Heat power engineering, #4,
2008.
6. Lebedev A.S., Ponomarev N.N. Test
benches for low emission combustor examination.
Gas Turbo Technology, #5 (40), 2005, p. 44.
TURBOnews
KS-7/2 compressor station will be reconstructed
at Fedorovskoye field of Surgutneftegaz
Sumy Frunze NPO will produce
three TKA-Ts-16/76-4.0 gas compression
packages each rated at 16 MW and the
equipment for the reconstruction of
KS-7/2 compressor station at Fedorovskoye
oil field (Tumen region). The capacity
of TKA-Ts-16/76-4.0 gas compression
packages is 360 m3/min. The drive is
NK-16ST converted aircraft gas turbine
engine produced by KMPO. The nominal
power is 16 MW, the pressure ratio is 10,
and the efficiency is 29%. The centrifugal
compressor produced by Sumy Frunze
NPO provides for the gas compression
from the nominal value of 0.39 MPa to the
outlet pressure of 7.5 MPa.
It is planned to finish the equipment
supply till August 31, 2009. Sumy NPO
specialists will perform the installation
supervision and the commissioning,
the training course in the equipment
operation. The contract cost is
18.9 million euros.
HTTP://WWW.GTT.RU/EN
Table 2
Specimens
T, C
20
800
Specification
20
800
767
757
735
680
833
803
830
735
Relative elongation, %
3.6
18.3
>3
>3
Relative contraction, %
7.9
23.1
TURBOnews
Two powerplants based on Capstone C65 small turbines were
commissioned in Kobyaisky district of the Republic of Sakha (Yakutia)
In the beginning of July 2009 the specialists of BPC Power
Systems performed precommissioning of two small powerplants
each rated at 195 kW in Tyaya and Chagda settlements of
Kobyaisky district, on July 22 the powerplants were commissioned.
The customer is Sakhaenergo, the subsidiary of Yakutskenergo.
The production of six Capstone C65 turbines each rated at
65 kW for two powerplants started last summer. At the end of
2008 the powerplants were transported to Yakutsk and then to
Kobyaisky district to the ice road where the packages were
assembled on the foundations and the external gas supply
systems were installed.
Capstone C65 engine consists of the generator with
the permanent magnet in the rotor and the electric inverter
instead of synchronous generator with the reduction gear typical
for the turbines, the small turbine rotor rotational speed increases from 45,000 to 96,000 rpm and has no connection with
the output voltage. Thus the turbine can operate in the range
from 0 to 100% of nominal power; the fuel flow is proportional
to the load.
Due to high automation level of the powerplant the remote
monitoring, inspection and control from the main center in
Yakutsk is possible. The pressure, temperature, load and other
parameters at the site are controlled by the operator.
The power supply project of Tyaya and Chagda settlements of
Kobyaisky district provides not only the electric power supply but
EMAliance and E4 Group, the general contractor of Nyaganskaya GRES powerplant construction, signed the contract on the supply of waste heat boilers
EMAliance will perform the
designing, production and supply of
t h re e wa s t e h e a t b o i l e r s f o r t h e
constructing Nyaganskaya GRES
powerplant (Fortum), inspect the assembly
and precommissioning, perform tests and
commission the equipment.
The contract cost is over 3 billion
rubles (68, 392 million).
Issue 4, 2009
22
Three GPA-16M-04 gas compression packages were commissioned at Purtazovskaya compressor station
T h re e m o re G PA - 1 6 M - 0 4 g a s
compression packages supplied by
Iskra-Turbogaz were commissioned at
Purtazovskaya-4 compressor station of
Gazprom transgaz Surgut. Each package is
equipped with GTU-16P gas turbine
drive (PMZ), 398-26-1LSM centrifugal
compressor (Compressor Complex) and
MSKU-5000 automatic control system
supplied by Sistema-Servis.
The general designer of the
construction is VNIPIgazdobycha, the
general contractor is Yamalgazinvest.
Issue 4, 2009
DISCUSSION CLUB
The International Power Summit and Power Forum concluded on May 23, 2008 in Kiev.
It was declared the Ukraine requested the help of the European Union in the
development of the joint energy policy including the reconstruction of the Ukrainian
pipeline network. As supposed, the volume of natural gas transit to Europe will remain
the same. The European commission will allocate 2.5 billion dollars in the autumn
of 2009.
he Ukrainian pipeline network is
the second one in Europe and one
of the largest in the world. Its total
length is 37.6 thousand km including 22.2
thousand km of the large diameter (up to
1420mm) main pipelines. The annual inlet
natural gas capacity is 290 billion m3; while
the outlet gas capacity is 175 billion m3.
The gas transportation network provides
the natural gas supply to the industrial
facilities and utilities of Ukraine, as well as
transit of the natural gas from Russian and
Central Asia to the Western and Eastern
Europe, the Balkans and Turkey. The
infrastructure of the Ukrainian gas
transportation network consists of 81
compressor stations equipped with 765 gas
compression packages with the total
operating power of 5.6 million kW. The gas
transportation network includes also
1600 gas distribution stations and 13
underground natural gas storages, 6 border
gas measuring stations and 89 gas filling
stations.
The stationary gas turbines, converted
aircraft and marine gas turbine engines,
electric drive units and internal combustion
engines are used to drive gas compression
packages. The mechanical drive gas
turbines prevail in the Ukrainian
network, they include 455 units with the
total power of 4.6 million kW that is over
Issue 4, 2009
24
25
The decommissioning
schedule of gas compression
packages equipped
with gas turbine drives
Issue 4, 2009
26
TURBOnews
The first in Russia TTK-110 turbine generator
with tubular case was delivered to the customer
NPO Saturn will continue the development of gas turbines and packages to equip the sea platforms,
gas turbine locomotives and high speed ferryboats
To the results of the tender held by the
Ministry of industry and trade of the
Russian Federation NPO Saturn received
the right to make the state contracts under
the federal special programme of the civil
marine engineering development till 2016.
The tender concerned the Development of
the marine gas turbine engine with the
service life up to 100 thousand hours rated
at 8 MW (based on the gas turbine engine
27
HTTP://WWW.GTT.RU/EN
Issue 4, 2009
ANALYSIS
Issue 4, 2009
28
Technical characteristics of dust collectors and filter separators operated more than 25 years
Unit
GP-199,
TsKBN
GP-144,
TsKBN
Type
Multicyclone
5-cyclone
1972
1975
1976
1976
1979
8.0
20
17.6
15
30
20
3075
Up to 75
4560
3045
Up to 75
80 120
80120
Year of manufacture
Peerless,
USA
CMP,
France
Table 1
GPR-138,
TsKBN
GP-584,
TsKBN
GP-585,
TsKBN
Filter separator
5-cyclone
Filter separator
1981
1981
pilot specimen pilot specimen
Weight, ton
13
22
20.4
28.7
30
54.5
60
0.5
0.5
0.3
0.7
0.7
0.8
1.0
Table 2
Installed, pcs.
~ 4000
~ 3500 (87.5%)
~ 500 (12.5%)
Defective, %
1,7
2
0
Table 3
1030
722 (70.1%)
308 (29.9%)
Table 4
Russian
companies
CIS countries
companies
Foreign
companies
197 (23.1)
456 (53.5)
200 (23.4)
18 (24.7)
43 (58.9)
12 (16.4)
9
20
3
8
10
11
Issue 4, 2009
Table 5
TsPU-7.5 (ZIOMAR)
TsPU-8.3 A (ZIOMAR)
GP 2101, GPR 2129 R (TsKBN) Dust collector with counterflow cyclones produced by TsKBN
Gas treatment units (TsKBN):
GP 1891.27
GP 1891.24
GP 1891.23
GP 1891.28
GP 1891.25
GP 1891.05
Cleaning unit
Pressure reduction unit
Measuring unit
Drying unit
Auxiliary unit
Capacity unit
PTG-15M (Gazstroydetal)
Conclusions:
1. The considerable part of gas
treatment facilities is outdated requiring
re c o n s t r u c t i o n , m o d e r n i s a t i o n o r
replacement;
2. The assessment of condition and
operating terms of gas treatment facilities
can be useful to prepare recommendations
for technical requirements, selection
of units for compressor stations and
Technical characteristics of modern dust collectors (design pressure is 7.35 MPa (75 kgf/cm2))
Table 6
TsPU-7.5 dust
Dust collector
GP 628 cyclone Dust collector for main gas Dust collector
collector (ZiO Podolsk) (OMNI Technologies)* dust collector pipeline compressor stations
(Ruspolmet)
Nominal capacity, million ncm/day
21
25
25
25
24.7
Liquid weight concentration
5000/80
5000/15
5000/750
5000/50
in gas at inlet/outlet, mg/m3:
Degree of gas cleaning
> 40 m 100%
> 40 m 100%
> 40 m 100%;
> 1 m 98.9%
from solid particles
2040 m
2040 m
> 40 m 100%
2040 m
> 3 m 99%
with the dimensions
98%
99%
0.15 mg/m3 maximum > 5 m 99.99%
Hydraulic resistance, MPa
0.033
0.05
0.045
0.035
0.03
(at nominal capacity)
Specific metal content,
881
1436
1152
1016
1660
kg/million ncm3/day
Erosion hazard 20
* 12 MPa project
Issue 4, 2009
30
HTTP://WWW.GTT.RU/EN
TURBOnews
Table 7
Dust separators
Filter separators
For particles
with the dimension
over 20 m 100%
For particles
with the dimension
over 10 m 100%
Outlet concentration
of mechanical impurities, mg/ncm
Up to 1 (for a short
period of time, 100 h/year
maximum, up to 3)
1 maximum
Outlet liquid
concentration, mg/ncm
1 maximum
0.03
0.03
Design hydraulic
pressure, MPa, maximum
Table 8
0.5
0.2
1.0
300-500
5 maximum
55
Not admitted
Issue 4, 2009
TURBOnews
ORMA-Gazprom meeting
The meeting of Gazprom, the
Department on gas transportation,
underground storage and use and ORMA
specialists was held at ORMA on
September 3. The meeting was devoted
to vane repair problems of GTK-10I,
GTK-25I, and PGT-10 industrial gas
turbines. The presentation of ORMALiburdi Turbine Service Limited joint
company was made during the first
meeting in July 2006. The present
meeting concerned the work results of
the company the development concept of
which is closely connected with the gas
transportation and repair facilities of
Gazprom.
The meeting was opened by Igor
Pustygin (Gazprom) presenting the
damage statistics of gas compression
package mechanical components. The
absence of the standard documentation,
failure of design specification preparation
and delivery terms, the absence of general
repairability criteria to assess the initial
condition and the allowed repair, the
absence of repair efficiency criteria were
specified among the problems of the
repair companies. It was noted that the
gas compression package repairability
is a priority for the gas transportation
companies, and Uralaviaspetstekhnologia
and Tribonika repair companies do not
always manage with the vane repair.
The meeting was continued by Alexey
Orberg, ORMA general director, reporting
about the technologies used for vane and
impeller repair using the powder
a)
metallurgical technique. Due to use of the
specified technologies the service life of
vanes can be increased up to 100,000 h;
the technique was demonstrated on GE
Frame 7EA package vanes. The repair
technologies were developed in the USA
and Canada by Liburdi Turbine Service
Limited thus GTK-10I, GTK-25I and
PGT-10 gas turbines of foreign production
were repaired first. The technology is
based on the powder metallurgical
technique. The intellectual property is
strictly limited: Liburdi supplies the
prepared powder and the heat treatment
technology for the specific order, ORMA
performs the specified process. Due to use
of the powder metallurgical technique the
material properties of the repaired part
can be kept. If necessary the repair
composition with the specified
c h a r a c t e r i s t i c s c a n b e p re p a re d
beforehand. The technology provides
the recovery of the mechanical properties
of vanes, the stability to the thermal
influence and the increase of the
overhaul period up to the service life of
the new parts (24,000 hours). It is possible
to perform over 3 repair cycles.
132 guide vanes of the first stage of
Frame 3 and Frame 5 turbines were
repaired using the powder metallurgical
technique in 2008-2009 for Gazprom and
Naftogaz of Ukraine gas transportation
companies. The longest operation period
of the repaired guide vanes over 8300
hours was in Gazprom transgaz Yyugorsk.
The fault detection after 8000 operation
b)
Gas turbine equipment of PGU-450 combined cycle package at Yuzhnaya TETs-22 heat and power plant was installed at the foundation
Under the turnkey construction contract of power package
#4 at Yuzhnaya TETs-22 heat and power plant of TGK-1 in SaintPetersburg the specialists of Technopromeksport assembled
GTE-160 gas turbines and TZFG(P)-160-2MU3 turbine generators
without a crane. The generators with air cooling were produced
by Power Machines.
The new technology developed by Russian designers allowed
the assembly without a heavy-duty travel crane installed inside
the main building. The reduction of construction material and
the volumes of construction works resulted in the cost saving.
The combined cycle package with the electric power
of 450 MW and the heat power of 350 Gcal/h includes two
PR-228/47-7.86/0.62-515/230 waste heat recovery boilers
(Podolsk Machine-Building Plant) and T-125/150-7.4
cogeneration steam turbine (Power Machines). The general
project was performed by Zarubezhenergoproekt.
The package is designed for the centralised heat and electric
power supply in Saint-Petersburg. Due to commissioning of the
combined cycle package the installed electric power of the heat
and power plant will increase up to 1250 MW; the heat power
up to 2600 Gcal/h.
32
HTTP://WWW.GTT.RU/EN
Issue 4, 2009
ECONOMICS
AND FINANCE
W CHP
se
OA
x=
=
;
sq
OA+OB W CHPse + Q CHP
Q CHP
sq
OB
.
y=
=
sq
OA+OB W CHPse + Q CHP
Hence:
The electricity cost price is
S CHP
=
e
xS CHP
W CHP
S CHP
se
se + Q CHP
sq
W CHP
yS CHP
Q CHP
S CHP
sq
se + Q CHP
sq
W CHP
W CHP
se
OA=
CHP electricity total
cost
O= Q CHP
sq CHP heat cost
S CHP
CHP total expenses,
OA = OB
(2)
By solving the system of (1) and (2)
equations, we find:
Issue 4, 2009
34
xi = 1;
x1
x2
xi
xn ,
P A= P A = P A= P A
A1 s1 A2 s 2 A i s i A n s n
i=1
S P ,
[A Pj s Aj ]
j=1
(3)
F CHP
,
k Fl
=
CHP
fPP + QCHP
fHB
W CHP
The CHP specific fuel consumption:
e
e
f CHP
= f PP
k Fl
CHP for electricity,
h
e
f HB = f PP k Fl
CHP for heat
(1 k Fl
)100%
CHP percentage fuel
CHP
saving
Or:
e
CHP
= W CHP
/F CHP
the CHP thermal
efficiency for electricity
h
CHP
= Q CHP
/F CHP
the CHP thermal
efficiency for heat
e
PP
the PP thermal efficiency,
e
e
f PP = 1/PP
HTTP://WWW.GTT.RU/EN
h
f HB
h
HB
the HB thermal efficiency,
e
= 1/HB
The fuel use efficiency is
e
h
CHP
CHP
1
Ef
Fl
.
k CHP = e + =
h
PP HB kCHP
Then
ext e
e
CHP = PP
k Ef
CHP,
ext h
h
CHP = HB k Ef
CHP
Issue 4, 2009
Q CHP
=
mh
Q kCHP, W CHP
=
me
W CHP
l ,
k=1
l=1
mh is the number of heat consumers, me is
the number of power consumers.
IV. Use of resources (R)
R
s R
k i = n Si i , s r ij = s k Ri r ij ,
[A j r j ]
j=1
R i is
s R
k = i=1
[s k Ri
i],
[A
c
]
i i
i=1
where c Si is the CO2 specific emissions
when manufacturing (delivering) the i
energy product; C S is the CO2 total
emissions by a station or system (S); A iS
is the amount of the i energy product
delivered, n is the number of i products
manufactured or delivered to consumers;
2
cNi is the normative specific emissions, k CO
S
is the effectiveness factor of energy
manufacture/supply from the viewpoint
of emission minimization.
VI. Environmental pollution
s V
ki
Issue 4, 2009
V i
= n V i , s ij = s k Vi ij ,
[A j N j ]
j=1
36
s V
k = [s k Vi
i=1
i],
TURBOnews
Iskra-Turbogaz supplied three
Ural GPA-10DKS-07 gas compression packages
The packages were supplied to the
booster compressor station of UKPG-5V
gas treatment plant at Urengoyskoye oil
and gas condensate field. The customer is
Gazprom dobycha Urengoy.
HTTP://WWW.GTT.RU/EN
TURBOnews
The tests of GTK-10 package startup system
were performed
38
HTTP://WWW.GTT.RU/EN
39
Issue 4, 2009
OPERATION
EXPERIENCE
Since 2003 Iskra-Turbogaz has collected the significant experience on the production,
assembly, commissioning and start-up of Ural gas compression packages with compressors
equipped with dry gas seals.
he application of dry gas seals is
the advanced and hightechnology
solution for compressor rotors seals.
Gradually the dry gas seals replace the
traditional oil seals. Due to the application
of dry gas seals the operation costs are
reduced, the reliability is increased, the oil
penetration to the compressor internals is
eliminated thus the service life of the
compressor equipment is increased and
the ecological parameters are improved.
Besides, the use of dry gas seals allows
installing the compressor internals with
various pressure ratio without updating
the sealing systems, thus simplifying the
modernisation.
At the same time the advanced and
complicated equipment as the dry gas seals
has some features to be considered during
the operation.
The operation principle of dry gas
seal is the provision of minimal sealant
flow through the clearance in the endseat
contact pair. Considering the absence
of friction in the given contact pair
and the related damage of surfaces and
heat production the regular servicing
as lubrication or coolant supply is not
required for the dry gas seals. At the
same time the sensitivity of the working
clearance with the value of 35 m to
the influence of liquid and abrasive
particles requires the special treatment
of buffer gas and dividing air. Thus
the operation reliability and service life of
Issue 4, 2009
40
Number
Ural GPA-16-04
Ural GPA-10PKhG-01
Ural GPA-10PKhG-01
Ural GPA-16-05
Ural GPA-16DKS-04
Ural GPA-10PKhG-01
Ural GPA-16-01
Ural GPA-16NK
Ural GPA-12-05
Ural GPA-16-03
Ural GPA-12-06
Ural GPA-16-02
Ural GPA-16DKS-07
Ural GPA-25DN
Ural GPA-16-04
Ural GPA-12-07
Ural GPA-12-07
Ural GPA-12-01
Ural GPA-16DKS-07
Ural GPA-16DKS-08
Ural GPA-12-06
Ural GPA-25
Ural GPA-16DKS-09
Ural GPA-10DKS-08
Ural GPA-10DKS-07
Ural GPA-16-07
6*
Ural GPA-16-06
4*
5*
109
96
Ural GPA-25
Total 2003-2009:
28
* these gas compression packages will be supplied till the end of 2009
HTTP://WWW.GTT.RU/EN
41
Issue 4, 2009
42
TURBOnews
Luzhskaya gas turbine heat and power plant was commissioned
The gas turbine heat and power plant
with the electric power of 36 MW was
commissioned on September 10 at
Luzhskoye highroad in Veliky Novgorod.
The gas turbine heat and power plant
was put into the electric network, the
current frequency was synchronised. The
powerplant consists of 4 GTE-009 packages
each rated at 9 MW. The pilot startup was
made in August 2009. After comprehensive
tests had been performed; the ecological
and sanitary examinations were carried out.
The project was developed and
realised by GT TETs Energo, a part of
Energomash. The project cost was about
43
OPERATION
EXPERIENCE
The results of gas turbine package air filtration system operation research are given
in the article. The gas turbine packages installed at the enterprises of the Moscow
integrated power company were used for the research. The following points were covered:
the comparative characteristics of the air filtration quality using various filter elements,
the relation of the ambient conditions with the initial dust content and the air filtration
system efficiency, the main reasons of the compressor flowpath contamination. The
necessity of the gas turbine package operation based on the actual state of the flowpath
contamination is noted.
he right choice, operation and
diagnostics of the complex air
filtration system provide for the
proper cleaning of the atmospheric air
supplied to the gas turbine package
flowpath. Therefore the cyclic air
preparation system can provide the high
reliability and efficiency of the package
operation or cause the unscheduled stops
and emergency situations.
The operation results and tests of
the complex air filtration systems at three
small heat and power plants of the Moscow
integrated power company are given in the
article:
n Lyublino-Mariyno plant #6 of YugoVostochny department #5 (Lyublino district
heat and power plant);
n Mariyno-Pechatniki plant #7 of YugoVostochny department #5 (Kurianovo
GTES-12 gas turbine powerplant);
n Plant #9 of Zapadny department #8
(Peredelkino GTES-12 gas turbine
powerplant).
The comparison of the filter element
efficiency is given. The disadvantages of
the complex air filtration systems and the
auxiliary equipment location detected at
various operation conditions are specified.
The tests of the filtration system
elements to define the functional
characteristics were performed by
Issue 4, 2009
44
b)
HTTP://WWW.GTT.RU/EN
Photo 3. FV1000000G
fine filter view from
the air supply side
45
Photo 4. Results
of air sampling at the tests
of gas turbine package complex
air filtration system, unit 1,
at Lyublino district heat and
power plant on 26.05.06:
a) sample 1 the air before
the complex air filtration
system;
b) sample 2 the air after filtration by the complex air filtration system
Issue 4, 2009
b)
Photo 5. Results
of air sampling at the tests of
gas turbine package complex
air filtration system, unit 2,
at Kurianovo GTES-12
powerplant on 23.06.06:
a) sample 1 the air before
the complex air filtration system;
b) sample 2 the air after
filtration at the first stage
(slot filter) of the complex air
filtration system;
c) sample 3 the air after
filtration at the second stage
(fine filter) of the complex air
filtration system
Issue 4, 2009
b)
)
46
c)
c)
HTTP://WWW.GTT.RU/EN
TURBOnews
Two GE 6FA gas turbines for the constructed Kurganskaya TETs-2 heat
and power plant were tested
The tests carried out at GE Energy in Belfort (France)
included the examination of the mechanical condition,
aerodynamic and thermodynamic characteristics and
vibrations at the turbine bearings. The turbines were
operated at full power without load for several hours, and
then the temperature between the turbine stages, the
compressor, bearings and oil temperature was measured.
The bearing and turbine shaft vibration was measured at
various operating stages.
The test results confirmed the conformance of the
turbine operating characteristics to the specified
parameters and the readiness of equipment for delivery
and operation.
Kurganskaya TETs-2 heat and power plant will consist
of two packages each rated at 111 MW. Each package will
include PG 6111A gas turbine with the electric power of 76
MW, SST-400 steam turbine rated at 35 MW produced by
Siemens and the waste heat boiler. The gas turbine
efficiency is 35% in simple cycle and over 54% in combined
cycle. The installed electric power of the heat and power
plant is 222 MW; the heat power is 250 Gcal/h.
GE 6FA gas turbine is designed around F class
technology. The operating time of such packages is over
2 million hours in 30 countries of the world. The 100th GE
6FA gas turbine will be installed at Kurganskaya TETs-2
heat and power plant; it will be the first package of this
type in Russia. It is planned to finish the turbine supply
to the construction site and start the assembly in
September-October 2009.
CTF 180/V mechanical cooling tower was produced
and tested at FANS in Glinsko (Czech Republic). The
tower is designed for the cooling of water used for the
plant equipment operation. The tower will be soon
delivered to the construction site.
Intertekhelektro-New generation, the owner of
Kurganskaya TETs-2 heat and power plant, will operate the
powerplant; the project is realised by PSG-International,
the EPC contractor, in cooperation with Intertekhelektro.
The commissioning of the combined cycle package
planned for 2010 will cover 40% of the power shortage
in Kurgan region, thus city and region social and economic
development will be encouraged.
The new gas turbine powerplant is located close to the district heat
power plant and will substitute the heat production at the district heat
power plant and also at Nagatino and Lenino-Dachnoye powerplants
47
Issue 4, 2009
TURBOnews
The equipment was supplied to the construction site of combined cycle package at Permskaya TETs-6 heat and power plant
KES-Holding constructs the building at the existing powerplant site to
install the new PGU-124 combined cycle package as part of Malakhit investment
project. The equipment produced by Siemens was supplied. The combined
cycle package will include two SGT-800 gas turbines with the electric power of
47 MW and the efficiency of 37.5% and SST-600 steam turbine. The equipment
was selected by Siemens considering the international standards (ISO, EN,
and IEC) and modernised in accordance with the Russian requirements.
The general designer is Institute Teploelektroproekt, Engineering Center EES
department. The specialists of Siemens and the Engineering center of Ural
power engineering participated in the design documentation development.
The project was approved by the State examination.
The main components of the combined cycle package turbines, generators and other equipment were supplied to Perm by water under the contract
of KES-Holding and Siemens held at the end of 2007. Siemens specialists will
carry out the tests and equipment startup, check the quality of the construction
works, and perform the training of TETs-6 heat and power plant specialists.
The general contractor of the construction is SOYUZ.
After the project realisation the powerplant electric power will increase
3 times, the heat power will be increased by 240 Gcal/h. The annual output of
the electric power will be about 1 billion kWh; the heat power output will be
about 2200 thousand Gcal a year. Due to the high efficiency of the new package
the annual emission of greenhouse gas will be decreased by 600 thousand tons.
Permskaya TETs-6 heat and power plant commissioned in 1942 is one of
the main power supplies in Perm providing the heat power to Sverdlovsky,
Leninsky and Motovilikhinsky districts and large industrial facilities.
Beside Malakhit KES-Holding is finishing Granat project in Perm region
(reconstruction of Permskaya TETs-13 heat and power plant) and carries out
the preliminary works on Ametist project (increasing Permskaya TETs-9 heat
and power plant capacity).
The first gas turbine package was supplied to Syzranskaya TETs heat and power plant
The first Frame 6FA (PG6111) gas turbine package produced by General
Electric with the electric power of 80 MW was supplied to Syzranskaya heat and
power plant construction site on October 11 (Volzhskaya TGK) to realise
Volzhsky agat investment project performed by KES-Holding.
PGU-325 combined cycle plant will include SST-600 steam turbine rated
at 65 MW produced by Siemens, waste heat recovery boilers produced by
Istorenergo, booster compressors produced by Energaz and the automatic
control system produced by GE.
The prime contractor is Samara Repair Company. The commissioning
of the combined cycle plant is planned for the end of 2011.
Under Diadema investment project KES-Holding ordered 9 turbines
produced by GE rated at 630 MW for the construction projects of new power
generating facilities at Syzranskaya heat and power plant, Novokuybyshevskaya
TETs-1 heat and power plant (3 Frame 6FA turbines), Igumnovskaya heat and
power plant (2 LM 6000 PD turbines) and Kirovskaya TETs-3 heat and power
plant (2 Frame 6FA turbines).
.
The
construction
site at
Syzranskaya
TETs heat
and power
plant
Issue 4, 2009
48
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