gas turbo technology feb 2011

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D I G I T A L

Publisher: Alexander Gorshkov

Editor-in-Chief: Jim Roberts

Editorial Board: Yuriy Anurov(Energomash Corporation)

Meherwan P. Boyce

(The Boyce Consultancy Group)Oleg Bryndin(Saturn Gas Turbines)

Viktor Chepkin(Saturn)

Vladimir Lupandin(Magellan Aerospace

Corporation)

Gurgen Olkhovskiy(All Russian Thermal

Engineering Institute)

Alexander Shaykhutdinov(Gazprom)

Senior Editor: Lyubov Rastorguyeva

Overseas

Manager: Kseniya TorochkovaMarina Stukota

News editor: Marina Malysheva

Designers: Olga LebedevaNatalya Repina

Federal Relation and Mass CommunicationSupervision Agency.

Registration Certificate PI #FS77-34887issued December 29, 2008.

Copyright 2007 Gas Turbo Technology JSC.All rights reserved.

Reproduction withouta written permission prohibited.

Editorial office: P.O.Box 55, Rybinsk,Yaroslavl region,152900, Russia

Tel. +7 (4855) 295235,295236

Fax +7 (4855) 295237

www.gtt.ru/en

[email protected]

CONTENTS

New Developments

Arlan GPA-16 modular gas compression package.The project realisation 2

Low Emission Technology

Influence of the gas turbine combustor flametube shape on the flow structure 10

Advanced ProjectsIskra-Turbogaz: projects realised in 2010 16

Specialised Information and Analytical Edition

G A S TU RBO

TECH NOLO GY

GAS TURBO

TECHNOLOGY 2ISSUE,

2011



Th e ad vanced developmen ts of science and engineering aimed tooptimise operating processes shall

be used by any company for efficientsolutions of production problems.

Th e en gine erin g prin ciples of Saturn-Gas turbines meet the specifiedre qu ire me nt : n ew t ec hn ol og ie s a nd

equipment are introduced that leads to thesatisfactory result.One of the company priority tasks is

meeting the customer requirements inthe development of high–technology equipment.

The outdated equipment of gastransportation system and the loadincrease to the system forecast by Gazprom were the factors contributed to Gazpromorders to supply the new equipment.Considering the specified facts muchattention is paid to the reconstruction andreequipment of the compressor stations.

It is obvious that modern gas compressorpackages produced in Russia shall be usedat compressor station reconstruction.

It should be noted that previousSaturn-Gas turbines did not produce thepackages rated from 16 MW and higher;thus there was an opportunity for thecompany to develop a new package usingthe advanced solutions, the gas compressorpackage design, production and operationexperience of other suppliers as well as theexperience of Gazprom operators, the new

requirements to gas compressor packagesand systems in standard information.

The development of Arlan GPA-16 gascompressor package ( photo 1) was carriedout within the long–term cooperation withGazprom.

Ufa-AviaGaz, UMPO took part in thepackage development together with Saturn-Gas turbines as well as in cooperation andunder control of Gazprom transgaz Yugorsk.

The first Arlan GPA-16 gas compressorpackage was assembled in December 2009.The commission consisting of Gazprom

G A S T U R B O T E C H N O L O G Y

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Arlan GPA-16 modular

gas compression package.

The project realisation

Robert Nabiullin, Alexey Yablokov — Saturn-Gas turbines

Alexey Prokopets, Vasily Nikitin, Sergey Andreev — Gazprom transgaz Yugorsk

The reconstruction of KTs-4 compressor shop at Lyalinskaya compressor station of

Urengoy – Tsentr 1 gas pipeline started at Nizhneturinskoye department. The assembly

works at the basic Arlan GPA-16 gas compressor package rated at 16 MW equipped with

AL-31ST gas turbine drive were finished at Lyalinskaya compressor station of Gazprom

transgaz Yugorsk.

NEW DEVELOPMENTS

Photo 1. Arlan GPA-16

gas compression package



representatives (Yamalgazinvest, Gazprom

tsentrremont, Gazprom transgaz Yugorsk)approved the package for supply assessingthe high production level and introducedtechnical solutions to Arlan design.

According to Gazprom decision thebasic Arlan GPA-16 gas compressor package will be installed at Lyalinskaya compressorstation of Nizhneturinskoye department(Gazprom transgaz Yugorsk); the station isunder reconstruction now.

T he ge ne ral co nt rac to r w il lvb e

Yugorskremstroygaz. Arlan GPA-16 gas compressor package was developed considering the possibilitiesof installation to the existing foundationsof GPA-Ts-16 gas compressor package.Thus the reconstruction cost can bereduced considerably in case of theexisting foundation approval.

S at ur n- Ga s t ur bi ne s ( th e pa ck ag esupplier) and Ufa-AviaGaz will disassemblethe outdated GPA-Ts-16 gas compressorpackages and assemble Arlan GPA-16

packages with turnkey commissioning.The design docume ntation was

developed by Sibneftetransproekt.

Arlan GPA-16 gas compressorpackage design features

As specified above the package designfeatures were determined in cooperation with Gazprom transgaz Yugorsk specialists.

A r l a n G PA - 1 6 g a s c o m p r e s s o rpackage is made of the transportedmodules considering the possibility of easy

assembling at the customer open site

( figure 1).

Drive

AL-31ST serial gas turbine engine(table 1, photo 2 ) developed by Lyulka-Saturn (produced by UMPO) is used asthe drive. The acceptance tests weresuccessfully carried out in 1996 atGazprom.

As seen from table 1 AL-31ST gas

turbine engine meets the requirementsspecified in the world and recommendedto use at Gazprom.

The electric start of the gas turbineengine instead of startup gas (or air)system was used for Arlan GPA-16 gasc o m p r e s s o r p a c k a g e . T h u s t h eextended system of startup gas includingthe gas pipelines and high pressure valves (including the equipment of

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Figure 1. Arlan GPA-16

gas compressor package

Photo 2. AL-31ST gas

turbine engine



Rostekhnadzor) is eliminated; the packageecological characteristics are improveddue to zero emission of technological gas.

Gas turbine

The section for gas turbine hasconvenient servicing areas due to the

absence of heat and sound enclosure. Theareas are located along the engine sides:along the gas generator with the width of 2000 mm; along the power turbine withthe minimal width of 820 mm (because of special protective enclosure preventing theaccess to the hot section).

In accordance with the modularprinciple the gas turbine section isdouble-staged. The fan is located at thesecond stage.

The gas turbine section ventilation isprovided by the axial fans with free airdischarge channel and noise suppressionin the air supply and discharge channels.

The air filters interchangeable with thefilters of TsN-70 centrifugal pump airfiltration system are installed in the airsupply channels.

The remote–control screens areprovided in the air supply and dischargechannels.

The sliding protective screens are

included into the engine section design toreduce the engine noise, provide the venti-lation along the engine and protect theequipment from the engine heat emission.

All sections are equipped with modernlocks.

The double–layer isolation of theengine section, the centrifugal compressor,the support systems, etc. (80 mm + 100 mm)made of sandwich panels is used to reducethe noise and decrease the heat losses.

Centrifugal compressor

A centrifugal compressor for installationcan be produced by Compressor Complex,REP-Holding, Kazankompressormash,Iskra, Sumy Frunze NPO, Rusturbomashor other companies.

The centrifugal compressor producedby Compressor Complex (table 2 ) is used in Arlan GPA-16 gas compressor packageassembled at Lyalinskaya compressor

station.The design features are oil bearings

and dry gas seals. The inlet duct is locatedfrom the left (from the engine side).

To simplify the centrifugal compressormaintenance the oil tank is eliminatedfrom the design; the oil supply to thecentrifugal compressor supports in case of emergency situations is provided by:

n Using new oil air cooler (the designprovides the oil supply to the air cooler in

the upper point and the discharge — at thebottom, thus the oil air cooler replaces thecompressor oil tank;

n Using the displacement pump as thepower pump maintaining the requiredpressure in the oil system for a long periodof time.

Centrifugal compressor section

Compared to similar GPA-Ts-16 gascompression package section produced

by Sumy Frunze NPO Arlan GPA-16 gascompressor package section is increasedin length to simplify the maintenance incase of operation with the compressorreplaceable bundle.

The section is double–staged. The sitesfor servicing the lifting devices, roof fansand other equipment are located onthe upper stage. To reduce the noise thecentrifugal compressor section holes aremade of three–layer plate glass.

To provide the operation of dry gasseals two air blowers in the centrifugalcompressor section are used in the package


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Volumetric capacity at 20 °C and 0.1013 MPa, million m3 /day 35

Compressor outlet gas pressure, abs., MPa 7.45

Pressure ratio 1.36

Compressor inlet gas pressure, abs., MPa 5.48Polytropic efficiency, % 85

Individual nominal parameters of centrifugal compressor replaceable bundle Table 2

AL-31ST Engines produced by other suppliers

(for comparison)

UGT16000 LM2000PA SGT-500

Nominal power, MW 16.8 17.2 17.9 17.4

Effective efficiency, % 37-0.5 32.5 36 32.8

Power turbine rotational speed, rpm 5300 5200 3600 3450

NOx emission, ppm 75 35 – 25

Basic parameters of AL-31ST engine (under ISO 2314) Table 1



design. In case of electric power loss thebackup line is provided for gas compressionpackage operation.

Air filtration system

The cyclone-type system with double–

stage air filtration is used. The multi–cyclone elements developed by Gazprom VNIIGAZ are used at the first stage; themodern highly efficient F8 fine filters areused at the second stage. The air filtrationsystem supplier is Samara-Aviagaz.

The air filtration system designprovides for four units — central, two sideand spacer. The installation and removalof replaceable filter elements can beperformed without using special tools andlifting devices.

The bypass valves protecting the enginecompressor inlet duct from the negativepressure are installed in the filtered airarea at the side section of the spacer. Thebypass valves are equipped with theelectric heating to prevent freezing. Theair filtration system is equipped with the weather hood eliminating the snowpenetration to the cyclone unit inlet.

It shall be noted that at high operatingtime of the packages the standard air

filtration system do not provide the properquality of filtration and freeze in winterperiod. It results in the early parameterdeterioration caused by gas-air ductcontamination and ice penetration to thecompressor flowpath — and even leads tothe early engine removal.

TsN-100 centrifugal pump air filtrationsystem (similar to TsN-70 centrifugal pumpair filtration system, figure 2 ) installedat Oktyabrskaya compressor station of Gazprom transgaz Yugorsk was examined

under conditions of change from negativeto positive temperatures and showed goodresults in air filtration and resistance tofreezing.

Exhaust system

The internal part of the exhaust systemincluding the exhaust gas duct and noisesilencer as well as the exhaust stack aremade of the corrosion-resistant steel to

provide the long–term operation.The design of the exhaust ductcompensator was optimised in cooperation

with Gazprom transgaz Yugorsk. To prevent

the gas generator rotor windmilling theexhaust system is equipped with the louverscreen to shut the exhaust duct.

The waste heat recovery generator canbe installed optionally in the exhaust duct.

Electric system

The electric system includes the powerpanels, the package power equipmentcontrol panels, the local control board

as well as the gas turbine engine startupsystem. The system is vented using thebuilt–in fan.

Low-voltage package

According to Gazprom requirementsthe low–voltage package for new gascompressor packages shall be designedaround the moving modules ( photo 3 ).

The design of the low-voltage packagesproduced to GE license based on moving

modules allows repairing the moduleor replacement without power–off andlow–voltage package switch–off;vthus

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Figure 2. TsN-70 centrifugal

pump air filtration system

Photo 3. Low-voltage package

sections with moving modules



increasing the reliability and improvingthe servicing with the possibility of defectelimination without equipment shutdown.

The supplier of Arlan GPA-16 packagelow–voltage package is ChETA; the supplier was approved by Gazprom.

The automatic control system includes the

necessary equipment supplied by Sistema-Complex. It shall be noted Arlan GPA-16gas compressor package is equipped withthe large number of instrumentation andoperating mechanisms. Thus Arlan GPA-16gas compressor package automatic controlsystem supply scope is extended.

The electric system and the automaticcontrol system have the same platformto simplify the maintenance. The systemsare electrically heated. The heater powerfor each system is 5 kW.

ROXTEC cable systems (with rubberseals) with the possibility of other diameterc ab le r ep la ce me nt ( mu lt i– di am et ertechnology) are used in the electric system,gas turbine and the automatic controlsystem. The cable systems in the gasturbine are the explosion–proof.

The oil air coolers (the gas turbine engineand the centrifugal pump) are located inthe superstructure not requiring separate

supports (and the foundations as well).T h e o i l a i r c o o l e r s u p p l i e r i sGazkholodtekhnika.

T h e a u t o m a t i c f i r e c o n t ro l , a i rc o nt am in at io n c on tr o l a n d f ir eextinguishing system supply scope isextended: the upper level equipment

(the alarm and control panel support, theoperator work station, the equipment of digital lines, etc.) is supplied with the firstgas compressor package together withthe standard supply scope including thepackage fire controller, fire detectors andsignals, gas analysers, cables and fireextinguishing modules ( photo 4 ), pipelines,etc.

The project of the automatic firecontrol, air contamination control and fireextinguishing system was developed by

Spetspozhengineering (Moscow) andapproved by Gazprom.

The video monitoring system and thesecurity system (integrated to the automaticfire control, air contamination control andfire extinguishing system) was includedinto the design for the first time to providethe security and eliminate the personnelpresence in the sections. The systemsi n c lu d e t h e cam e r as ( 8 x Wat c hX9800A3M43R2 with fire detectors),

the server, the video display with theinformation storage period of 30 days), two video monitors (the one monitor is alarmproviding the signal and picture from any video camera if the movement signal isdetected). The video monitoring systemsare required by the package specification.

The package features the integratedTPM-02S turbine washing system ( photo 5 )to simplify the package servicing inoperation. The supplier is Turbotect –Saint-Petersburg. TPM-02S turbine washing

system is located in the support systemunit.

Fuel gas preparation system

The fuel gas preparation system isrequired by the package specification. Thesystem provides the fuel gas heating,drying and compression. The fuel gas issupplied to the gas regulator inlet includedto MP-75 unit. The gas is cleaned by the

filter separators to eliminate the penetrationof condensate and moisture. Thus the fuelgas shop system and the compressor station


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Photo 4. Fire extinguishing

system gas modules are located

in the support system unit



piping is eliminated reducing theconstruction cost. The increased filter areaprovides the long-term operation.

The gas-oil heat exchanger with theintermediate safety cavity preventing thegas and oil mixing at emergency situationsis included to the package design to

provide the specified temperature valuesof the fuel gas supplied to the gas turbineand to eliminate the condensate at gasthrottling.

The application of the gas-oil heatexchanger allows recovering the heated oilheat, eliminating the additional powersupply to heat the fuel gas and reducingthe power supplied by the engine oil aircooler.

It shall be noted the application of thegas–oil heat exchanger is the advanced

technical solution of Gazprom accordingto STO 2-3.5-138-2007 (section 11).

Non-contact torque meter

The gas turbine and the centrifugalpump are connected by the transmissioncovered by the casing from the centrifugalpump side passing through the fire wall.

The transmission design provides forthe balance of heat expansions and

changes during the operation (up to 3 mm).The transmission can be operated duringthe whole operating period withoutoverhauls.

Gazprom transgaz Yugorsk specialistsinsisted on equipping Arlan GPA-16 gascompressor package with the non–contacttorque meter to measure the torque at thetransmission and calculate the packagepower and efficiency at operation. It isnecessary to confirm the gas compressorpackage parameters during the acceptance

and monitor the values during theoperation.

It shall be noted the non–contacttorque meter to equip Arlan GPA-16 gascompressor package features the high–temperature design (150 °C). The

additional cooling units (as well as theadditional electric power supply) are not

required to provide the torque meter areacooling in the package.

The reconstruction of Lyalinskayacompressor station is carried out in2 stages. The first stage includes theadjustment and system tests of one gascompression package. After carrying outthe preliminary and acceptance tests andapproving the package operating capability the contractors will start the secondre con st ru ct ion s ta ge i nc lu di ng t he

d isasse mbl y of f our G PA- Ts-1 6 gascompression packages with the outdatedservice life and the assembly of three ArlanGPA-16 gas compression packages. Thusfive GPA-Ts-16 gas compression packages will be replaced by four Arlan GPA-16 gascompression packages.

The instal lation of similar gascompression packages is planned atNizhneturinskaya compressor station of the same department; two compressorshops with 12 GT-750-6 packages will be

replaced by one shop consisting of four Arlan GPA-16 gas compressor packages.The power produced by one shop will beenough for two gas pipelines — SRTO(Northern districts of Tyumen region)-Uraland Nadym-Punga 3.

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Photo 5. TPM-02S turbine

washing system



TURBO news

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GTE-160 gas turbines produced by Power machines are part of PGU-450combined cycle plant. Their testing was finished on December 14, 2010.The work s at th e power pl an t

construction site have moved toa continuous start cycle.Gas turbine testing at no load with

the shift to the maximum rotation

speed (3000 rpm) is the first stage of the set of precommissioning worksbefore the operation. Temperatureand vibration parameters at turbineoperation, functioning of safety

systems and automation complex arecontrolled.The combined cycle plant has the

electric output of 450 MW and the

heat capacity of 350 Gcal, it includestwo Pr-228/47-7,86/0,62-515/230steam heat recovery systems producedby Podolsk machine building plantand T-125/150-7,4 heat extraction

steam turbine produced by Powermachines. Zarubezhenergoproyektmade the general project.

T h e n e x t k e y s t a g e o f preoperational testing will be thegenerator testing, trial hook up to thenetwork, blow down of heat recovery systems and gas turbine testing atno-load. After that the power plant will have complex testing that willconfirm its readiness for operation.

At the same time the assemblage

of combined cycle plant is getting toits end. The main units of fuel and water supply systems have beenassembled and tested. Heat insulation works are also to end soon. Thea ut oma ti c c on tro l s ys te ms areadjusted.

The power plant will providecentralised heat and electricity supply of St. Petersburg consumers. After thecombined cycle plant is commissioned

the heat and power plant installedcapacity will increase up to 1250 MW,the heat capacity up to 2600 Gcal/h.

In summer 2011 GRES powerplant management plansto sign the contract. It is planned the general contractor will start the works at the construction site in summer.

In July 2009 the project shareholders OGK-1 and

TNK-BP introduced the changes to the configuration of the third package of Niznevartovskaya GRES powerplantto construct two power packages each rated at 400 MW instead of one power package rated at 800 MW. Taking intoconsideration the complicated investment situation thecommissioning of the power facilities by stages is optimal.The construction finishing of package 3.1 is planned forautumn 2013, package 3.2 – for the end of 2015.

Institute Teploelektroproekt, Engineering Center EESdepartment performed the engineering investigations andthe design documentation to be approved by the statecommission.

The accordance with the specification the projectdesign provides for the installation of two double–shaft

combined cycle packages with the nominal electric powerof 400 MW each. It is planned to use the equipmentproduced by General Electric Energy – MS9351 (FA)gas turbine rated at 270 MW with the generator and the

steam condensing turbine rated at 140 MW with thegenerator.

The gas turbine supply is planned for autumn 2011,the steam turbine — for 2012.

At present time the installed power of the first stageof Niznevartovskaya GRES powerplant is 1600 MW; thepowerplant includes two existing combined cycle packageseach rated at 800 MW. The new power packageconstruction necessity is determined by the increase of theelectric power demand due to the development andexpansion of Nizhnevartovsk. Due to the commissioningof two power packages with the total capacity of 800 MW

the electric power supplied to the customers of Tyumenregion will be increased.

Preparation to T-125/150-7,4 steam turbine testing

Precommissioning testing started at the new package of Yuzhnaya heat and power plant of TGK-1 generating company

The general contractor of the third package construction at Nizhnevartovskaya GRES powerplant (OGK-1) is selected



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At present the main building, the combined cycleplant primary and auxiliary equipment are assembled atthe construction site. Two LM-6000PD SPRINT gas turbinesrated at 45 MW each produced by General Electric are

mounted, electric cables and control and automationsystem cables are laid and connected, the powerplant mainequipment is precommissioned. At the same time theterritory of the future PGU-115 MW combined cycle plantis improved.

After the works are finished the heat capacity of theboiler plant will be 721.8 Gcal/h and the electric output will be 115 MW. The new powerplant will cover the heatdemands of the whole Severno-Zapadny district, overbuiltPobeda and Yugo-Zapadny microdistricts of Kursk city,and also will do the reserve function of heat supply in thecity central part.

The station reconstruction was started in 2008. Thetotal investment sum into the project will be over 5 billionroubles, the station commissioning is planned for 2011.

The investment project is called PGU-115 MW combined cycle plant construction at the boiler plant of Severo-Zapadny district in Kursk. It is a part of the largeinvestment programme of the Kvadra company on the

power equipment renewal that includes the constructionof 1092 MW of new facilities before 2015 in the context of signed agreements on energy provision. PGU-52 MW combined cycle plant at Eletskaya heat and power plant(Lipetsk region) and PGU-115 MW combined cycle plantat Voronezhskaya heat and power plant (Voronezh region)are already commissioned.

PGU-115 main building

Precommissioning of PGU-115 combined cycle plant equipment is held at the boiler plant of Severo-Zapadny district in Kursk

Fortum commissioned combined cycle package #2rated at 231 MW at Tyumenskaya TETs-1 heat and powerplant. It is the first finished project of the company investment programme.

The combined cycle package includes the followingequipment: V64.3A gas turbine package produced by Ansaldo Energia, E-500-13.8-560 GN (model TGE-435- A/PGU) boiler produced by Krasny kotelschik, T-130/160-12.8 steam turbine package with TZFP-160-2MU3 generatorproduced by Power Machines. The new power package isinstalled instead of the disassembled equipment in the

main building.The project is realised to increase the reliability of the

power system in Tyumen region and improve the technicalparameters of the powerplant. The EPC-contractor isKvarts–New Technologies that is part of Kvarts.

Tyumenskaya TETs-1 heat and power plant is used torealise several investment projects of Fortum in the West-Siberian region. By 2014 it is planned to commission twomore power packages each rated at 225 MW. The totalcapacity of the powerplant will be 1150 MW.

According to the design procedure in the Kyoto

Protocol the greenhouse gas emission at TyumenskayaTETs-1 heat and power plant will be reduced by 444 tonsannually.

The combined cycle package was commissioned

at Tyumenskaya TETs-1 heat and power plant

The main building of the combined cycle package at

Tyumenskaya TETs-1 heat and power plant

The combined cycle package engine room



The important development stage of the burner within the multi–burnercombustor is the carrying out

of tests at the single–burner bench. Tomaintain the thermal stress the benchflame tube cross section area shall be equal

to the combustor flame tube squaredivided into the number of burners.Though the flame attachment to the flametube walls is possible in this case due to thesignificant increase of the flame openingangle compared to the natural conditions.It will result in the damage of thecombustion area structure as well as thelocal overheating of the flame tube walls.

The flame attachment can be eliminatedthrough the increase of the flame tube

cross section area though it will result inthe decrease of the thermal stress. Thus it isnecessary to eliminate the flame attachment without increasing the flame tube crosssection area. It is proposed to make theflame tube for the single-burner bench with square cross section. To maintain thethermal stress the total square will be equalto the round section square. The present work shall confirm through the experimentand design the efficiency of the flame tubesquare cross section application.

T h e d e s i g n a n d e x p e r i m e n t a linvestigation of the cold air spinned flowoutlet the burners in the flame tubesimulators with various round and squarecross sections was performed. GTE-65 gasturbine low emission annular combustor[1] burner was used for the investigation.

The burner basic characteristics arepresented in the article [2]. Solid WorksFlow Simulation 2009 software was usedf or c al cu la ti on s. T he e xp er im en ta linvestigations were performed at thespecial bench with flow visualisation; the

flame tube simulator walls were made of transparent material. The flame attachment was detected to the change of the flameopening angle outlet the burner. Thespecific flow rate outlet the burner atdesign and experiment was the sameλ = 0.25.

The calculations were made for the tubes with round and square section (table 1).The length of each tube is 700 mm. Theexternal diameter of the burner outlet

section is 49 mm. The calculation results were presented as the flow axial velocity fields in the flame tube simulatorlongitudinal sections; as an example the velocity profiles are given in figure 1.

The results of flow calculations in theflame tube simulator with round sectionshowed that the flame opening angle waspractically the same (31°) at the decrease of the tube diameter from 300 mm to 230 mm.

T h e f l a me op e n i n g a n g l e wassignificantly increased up to 61° at the tube

diameter decrease up to 225 mm. Thefurther tube diameter decrease had noinfluence on the flame angle; the flameangle was equal to 61–63°. The section of 225 mm in diameter and the square of 39,760 mm2 wherein the flame angleincreased significantly was taken as critical.It is shown in figure 1 where the profilesin the tubes with subcritical and criticalsections are presented. The given profilesshow the flame angle increase in the

cri tical sect ion and caused flameattachment to the flame tube simulator wall.


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Influence of the gas turbine

combustor flame tube shape

on the flow structure

Alexander Vedischev, Lev Danilets, Boris Khryakov – Power Machines

LOW EMISSION

TECHNOLOGY

1 2 3 4 5 6

Circle diameter, mm 200 210 220 225 230 300Square side length, mm 133 140 145 150 – –

Cross section characteristics Table 1



The similar calculations were madefor the tubes with square section. It wasdetermined the critical section is the

section with the square side of 140 mm andthe total square of 19,600 mm2. It can beseen the critical square section is 2 timesless than the critical round section.

To check the design model reliability the calculation results in the tube with thediameter of 230 mm were verified throughthe experimental results concerning thedetermination of the flow velocity andangle to the burner outlet section height.The experimental results were received at

the flow traversing during the cold blowingof the tested burner [2]. The design andexperimental parameter dependencesfrom the burner outlet section relativeradius are presented in figure 2 . Comparingthe specified curves it can be seen thedesign values are close to the experimental values.

T h u s t h e c a r r i e d o u t d e s i g ninvestigations detected the critical crosssection of the flame tube simulator andthe considerable reduction of the section

value at change from the round section tothe square section.

To check the results the experimentalinvestigations were carried out ( figure 3 );the investigations concerned the cold air visualised flow outlet the burner in theflame tube simulators with various roundand square cross sections.

The air was supplied to the burner withthe pressure up to 115 kPa, the temperatureup to 40 °C; the air flow was 0.2 kg/s. The

air was discharged to the atmosphere.The flame tube simulator walls weremade of transparent material to perform

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Figure 1. Axial velocity profiles in the tubes with subcritical (a) and critical (b) sections

Figure 2. Comparison of design and experimental radial profiles of the flow

relative velocity (v) and the flame opening angle ( ϕ) in the burner outlet section

Figure 3. Scheme of the experimental bench

а) b)



the flow video record inside the tube( photo 1).

The flow was visualised using thespecially designed measuring device. Thecompressor was used to prepare thesand-chalk mixture and supply the mixtureto the basic air. The special attention waspaid to the selection of the background,lighting quality, mixture concentrationand record direction. The flame openingangle was determined graphically to the

received video ( photo 1).The tests were carried out at seventubes with round section and five tubes with square sections (table 2 ); the tests werestarted with the tubes with round sectionand carried out from larger sections to thesmaller sections.

At the diameter of 180 mm the flameopening angle was increased rapidly up to640 and remained unchanged at furtherdiameter decrease. The flame openingangle increase and the flame attachment

to the tube walls at change to the criticalsection are seen in photo 2 . Thus the tubec ri ti ca l s ec ti on w as e xp er im en ta ll y confirmed; the tube diameter of 180 mm was practically the same as the designdiameter (225 mm).

The tubes with square section weret es te d c on si de ri ng t he p er fo rm edcalculations and the round tube test results.The maximum tube section diameter wasdetermined based on the square valuehigher than the critical round section(25,446 mm2) and the design critical

square section (19,600 mm2

). During thetests it was determined the flame openingangle in all tested square tubes remains thesame (32°). Thus there is no critical sectionin the investigated section area.

The minimal section square of thetested tubes was 16,900 mm2 that is 34%less than the critical section of tubes withround section (25,446 mm2). Thus it wasshowed through the experiment anddesign that the critical section of the flametube with square section is far less than the

critical section of the flame tube withround section.

The received data allow providing theflowing scheme of the flame attachment. Itcan be seen from the design profile of axial velocity presented in figure 4a the reverseflows appear close to the tube walls. Thereverse flows are formed due to the pressuredifference between areas A and B. Thereverse flows cover the wide area in thetubes with subcritical section ( figure 4a )

providing the pressure maintenance inarea A to determine the reference flameangle (32°).

Approaching to the critical section thearea of reverse flows narrows decreasingthe feeding of area A. Upon achieving thecritical section the pressure in area A decreases rapidly and the flame openingangle increases (64°) resulting in the flameattachment to the tube walls ( figure 4b ). It isconfirmed by the video received duringthe experiment ( photo 2 ) and the axial

velocity design profiles ( figure 4 ). Thefurther cross section square decrease hasno influence on the flame opening angledue to the flow coverage of area B feeding.

The difference of critical sections forthe tubes with round or square sections can


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Photo 1. Visualised flow inside

the flame tube simulator

1 2 3 4 5 6 7 8 9

Circle diameter, mm – – 169 180 191 203 225 230 360

Square side length, mm 130 140 150 160 170 – – – –

Section square S, mm2 16,900 19,600 22,365 25,446 28,726 32,205 39,760 41,526 101,785

Tube section characteristics Table 2



be explained by the influence of the

reverse flows. The section outlines of thesame square with the flow section are givenin figure 5 . It can be seen the squaresection (a) has larger angular areas for thereverse flows than the round section (b).It provides for the presence of the complexreverse flow areas in the square section andas a result the smaller values of the criticalsquare section compared to the roundsection.

Conclusions

1. The flame attachment to the flametube walls outlet the burner upon achievingthe critical cross section was provedthrough the design and experiment.

2. The critical section of the flame tube with square cross section is significantly lessthan the critical section of the tube withthe round cross section.

3. The application of the flame tubes with square cross section at the single–burner bench can be considered as the

efficient method of the flame attachmentelimination.

References 1. Lebedev A.S., Lesnyak O.B., Kravchenko

I.F., Gusev V.N. Development of the low emission combustor for GTE-65 gas turbine package of average capacity//Heavy engineering, #11,2007. p. 12.

2. Vedischev A.F., Danilets L.A., Kozlov D.A., Ponomarev N.N., Snyatkov G.L. Bench

tests of GTE-65 gas turbine package combustor burner//Gas Turbo Technology, #5, 2010. p. 22.

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13H T T P : / / W W W . G T T . R U / E N

Photo 2. Photos of the flow in the tubes with subcritical (a) and critical (b) section

Figure 4. Axial velocity design profiles in the tubes with subcritical (a) and critical (b) sections

Figure 5. Cross section outlines

of the flame tube with the same square

а) ∅230 мм

b) ∅225 мм

а) b)



TURBO news

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The construction of Energy technology center was held by GE in

rather short period of time. It issituated in Rosva technology park180 km away from Moscow. Thestrategic agreement on the facility construction was signed in March2009 between GE and Kalugaregion government, Kaluga regiondevelopment corporation and Kalugaadministration. The construction work started in August 2009. Theopening ceremony of the new centertook place on November 8, 2010.

John Krenicki, GE vice chairman,the president and the main executivedirector of GE Energy Infrastructureand Ron Pollett, the president andthe main executive director of GE inRussia and CIS, Anatoly Artamonov,Kaluga region governor, officialrepresentatives of Russian governmentand USA embassy.

The facility is one of the twelve GEtechnological centers in the world.

The center will expand the company opportunities inside Russia foroffering its solutions and services.The center offers new work placesand opportunities for education, itprovides service and maintenance of

modern power equipment that isinstalled in Russia and CIS. By theend of 2010 GE was to have about 300specialists as its personnel thus itsignificantly expanded its activity inthe country.

The multi–stage Center of Energy technology with the area of 7800 m2 isa two-floor office building (1200 m2)and a modern workshop with four

departments for GE equipment testingand repair.The two first stages of the facility

are moderate–size repair sections 1and 2 for small component repair.The first stage of the Center is aimed

at repair and service of fuel nozzles of heavy-duty gas turbines such as 6B,6FA, 9FA. The second stage includesthe repair of combustion systemcomponents such as covers, flametubes and transition sections.

In the future the Center willincrease production capacity tosupport the growing GE presence atthe Russian energy market. The

further stages will have two highsections for routine maintenance andtotal overhaul of large equipment.The third stage will include gas turbinerotor repair with two cranes with thecarrying capacity of 100 t and partstore location. The fourth stageinvolves the repair of GE Jenbachergas piston engines.

The production site can besignificantly expanded in the future.

The Center stands to the principles

of energy efficiency and responsibility for environment preservation so it isequipped with modern systems of airfiltration, heat reflection windowsand water-saving technology.

The opening of Kaluga Center of energy technology is the next step of strategy of GE Energy businesslocalisation in Russia that is aimed atproviding a full access to engineering–technical and operation company

resources for customers in Russia andthe CIS. The company investmentinto the project is $ 50 million.

GE opened the Energy technology center in

Kaluga region

The first stage of the Energy technology Center

Equipment for repair and maintenance of gas turbine fuel nozzles



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EGSI-S-430/850 WA booster compressor unit

ENERPROJECT SA gas booster compressors of EGSI-S-430/850 WA series are assembled at the booster pumpstation of I-Pimskoye field. The units are packaged and

will be operated as part of oil and gas producing complexin the constant operation mode.

Booster compressors are designed for casing head gascompression supplied from the booster pump stationand its further supply to the transporting pipeline up tothe compressor station of Lyantorskoye field.

The works on transportation and field supervision were carried out by ENERGAZ specialists (Moscow).The company engineers will hold precommissioning works and provide booster compressor unit maintenanceduring operation.

Compressor packages produced by ENERPROJECT SA

are assembled at I-Pimskoye oil field

The construction site of PGU-90 combined cycle plant isprepared. By the end of the year it must be 90% ready for newequipment delivery. The works that include the disassembly of the

turbine package #1 foundation and boilers #1, 2, 3 are to befinished in the first quarter of 2011. The new technology was usedin the turbine foundation disassembly. It was previously used by Ural power engineers, solid foundations were cut with extra–hardcables. After the disassembly finish 550 tons of metal constructions were carried out of the boiler room by the middle of December.

The optimal arrangement of the combined cycle plant is twogas turbines, two heat recovery systems and a steam turbine. It isdefined that the boiler equipment will be installed on the placeof the disassembled boilers; the gas turbines will be placed in aseparate package behind the main building. The constructionof the additional building will start this year. The steam turbine

will be installed in the compartment of the demounted turbinepackage #2. The design and working documentation isdeveloped by E4-SibKOTES. The documentation is examinedby the State.

On the results of the held tender General Electric will bethe gas turbine supplier. GE is supposed to complete the orderin about a year. The approximate price of the equipment is 1.8billion roubles. The project budget is over 4.7 billion roubles.

The new power package commissioning is planned for2012. The commissioning will be the first stage of TETs-3 heatand power plant reconstruction, it will increase the electric

capacity of the powerplant by 90 MW, the heat capacity by 59 Gcal/h and improve operational economy.

TGK-11 generating company has started the construction

of combined cycle plant at Omskaya TETs-3 heat and power plant

It is planned to startup the first stage of Yakutskaya GRES-2 powerplant

in 2014

The increase of the electric power demand in Central Yakutia, the possibilities of new industrial object constructionas well as the characteristics of the existing power generatingfacilities made the problem of Yakutskaya GRES-2 powerplantconstruction actual. The project realised by RAO ES Vostok

is included to the Programme of Social and economicdevelopment of the Far East and Baikal region.

The installed electric capacity of the new powerplant willbe 297.5 MW and the heat capacity — 368 Gcal/h. It is plannedto equip the powerplant with seven LM-6000 gas turbinepackages each rated at 42.5 MW produced by GeneralElectric each value at 1 billion rubles. The agreement on theequipment supply was signed in September.

The powerplant construction is planned in 2 stages. Thefirst stage (170 MW) is planned to startup in the first quarterof 2014; the second (127.5 MW) — in 2016. It is planned to

finish the designing and state approval in September 2011.The preliminary cost of the project realisation is estimatedat 27 billion rubles.

Sumy NPO will supply gas turbine power packages

for Surgutneftegaz

Sumy Frunze NPO signed several contracts withSurgutneftegaz on the supply of gas turbine powerpackages and waste heat recovery systems. Theequipment will be installed at Vachimskoye and Vostochno-Surgutskoye oil and gas fields.

Using the gas turbine power packages with the totalpower of 72 MW Surgutneftegaz plans to supply therequired electric power to the fields. Due to thecommissioning of the waste heat recovery systems theadditional heat power will be supplied for own needs.

The company engineering departments started thepreparation of the reference data required for thedevelopment of construction documents. The supply isplanned for the end of 2011.

Sumy Frunze NPO and Surgutneftegaz have beenthe partners for a long period of time. The specialists

of Sumy Frunze NPO took part in the works at Severo-Labatyuganskoye (the second stage), Fedorovskoye andTalakanskoye fields operated by Surgutneftegaz.



Eighteen of them are equipped withthe compressors developed andproduced by NPO Iskra. Five

GPA-25DU-01 Ural units have 588-51-1LSUcompressors with dry gas dynamic sealings

produced by Compressor Complex (SaintPetersburg). These were the first five of the units for booster compressor stationsof gas fields for Bovanenkovskoye oil andgas condensate deposit (1 GP-2 moduleo f t he b oost er co mpres sor s tat io n).GTU-25NU80.10 gas turbine units areused as drives in the packages, the gasturbines are based on DU-80 marineengines produced by Zorya-Mashproyekt.The packages are equipped with the

control system produced by Sistema-Complex, SVO-400MR01 ventilation andheating system developed and produced by Promtekh. Five more of such units but withNTs-25DKS/120 compressors produced by NPO Iskra are to be delivered in the firstquarter of 2011.

DG-90L2.1 marine engines producedby Zorya-Mashproyekt are installed at twoGPA-16DG Ural gas compression packages.They were supplied for the reconstructionof the 4th compressor room at KS-13

Urdoma compressor station by the order of Gazprom tsentrremont. These are the firstof Ural packages where this enginemodification is used. To join the engine with NTs-16M-01 Ural dry compressor a

special transmission was produced by ourcompany, it was developed specially for thisunit by Aviadvigatel together with NPOIskra.

Two GPA-16M-10 Ural gas compressionunits were produced for Gazprom EasternGas Program, in particular for the headcompressor station of one of its priority objects Sakhalin – Khabarovsk – Vladivostokgas-main pipeline. The environmentalspecifications of the region are taken into

consideration the gas compression unitsare designed for higher seismic resistanceof 9 points on MSK-64 scale, the previously produced Ural units were designed for 7points.

Besides, Gazprom has a programmeo n a p p l ic a t io n o f e n er g y– s a v i n gtechnology and equipment in thecompany to reduce fuel and energy consumption for auxiliary needs till 2020. According to this programme GMT-100-01gas–oil heat–exchanger developed by


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Iskra-Turbogaz:

projects realised in 2010

Mikhail Yunitsky – Iskra-Turbogaz

Iskra-Turbogaz produced 23 Ural gas compression units rated at 16 and 25 MW

in individual packages in 2010.

ADVANCED PROJECTS

Photo 1, 2, 3. Delivery of GPA-16M-10 Ural compressors # 1, 3 for the main compressor station at Sakhalin-Khabarovsk-Vladivostok

gas transportation system



Gazkholodtekhnika was applied for thefirst time in GPA-16M-10 gas compressionpackage.

The heat-exchanger is designed forcooling oil in engine bearings of thepackage and simultaneous heating of fuel and start-up gas. Air oil cooling units

were traditionally used to reduce the oiltemperature at the compressor station.

Application of gas–oil heat-exchangershas a number of advantages:

n smaller overall sizen energy–saving — utilised heat from

lubricating oil is used to heat fuel gas(when the heat in the air oil cooling unitis emitted into the atmosphere) thateliminates burning additional gas forauxiliary needs (heating fuel and start–upgas)

n reduction of electricity consumptionthat is specially important for energy–deficient regions

n it eliminates the need of usinga fuel gas treatment unit as part of a gascompression package.

Application of gas–oil heat–exchangerleads to significant simplification andincrease of reliability of fuel and start–upgas treatment system and reduction of energy consumption for auxiliary needs.

GPA-16M-10 gas compression packagesare equipped with the control systemsb ase d o n MS KU -5 00 0-0 1 pro du ce dby NPF Sistema–Servis and SVO-400MP0 ventilation and heating systems.

C om pl et el y d ry c o mp re ss or sNTs-16DKS/100 Ural were developed andproduced by NPO Iskra for GPA-16M-10g as c om pre ss io n p ac ka ge s. T he secompressors delivery was the company’sfirst experience of delivering equipmentby air. Two compressors with the weight of

50 tons each were delivered to Sakhalin by An-124-100 Ruslan airplane. NPO Iskradeveloped and produced special fixingnecessary for transportation of compressorsaboard the airplane. Volga-Dnepr Aviationcompany provided the delivery.

Nine gas compression units weres u p p l i e d t o B a b a y e v s k a y a a n d Yelizavetinskaya compressor station in 2009for Nord Stream pipeline. Additionally nine 16 MW gas compression packages

were delivered last year — four GPA-16M-08packages for Pikalevskaya compressorstation and five GPA-16M-09 packages for

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Compressor station, operator Number

GPA-16-03 Ural Vuktyl compressor station, Gazprom transgaz Ukhta 2

GPA-10DKS-04K-Ural DKS-3 booster compressor station UKPG-14, 15gas treatment units, Gazprom dobycha Orenburg 3

GPA-16-04 Ural Purtazovskaya compressor station, third stage,Gazprom transgaz Surgut 6

GPA-10PKhG-01 Ural Sovkhoznaya underground gas storage,Gazprom dobycha Orenburg 6

GPA-10PKhG-01 Ural Kanchurinskaya underground gas storage,Gazprom transgaz Ufa 6

GPA-16M-01 Ural Shatrovskaya compressor station,Gazprom transgaz Yekaterinburg 2

GPA-16-05 Ural Gornozavodskaya compressor station,Gazprom transgaz Chaikovsky 3

GPA-16DKS-04 Ural Yamsoveiskaya booster compressor station,Gazprom dobycha Nadym 2

GPA-10PKhG-01 Ural Yelshanskaya underground gas storage,Gazprom transgaz Saratov 4

GPA-16NK Ural Volokolamskaya compressor station,Gazprom transgaz Moscow 2

GPA-12-05 Ural Volokolamskaya compressor station,Gazprom transgaz Moscow 2

GPA-16M-03 Ural Kamensk-Shakhtinskaya compressor station,Gazprom transgaz Moscow 5

GPA-12-06 Ural Mikun compressor station, Gazprom transgaz Ukhta 2

GPA-16M-02 Ural Sokovka compressor station, Gazprom transgaz Samara 1

GPA-16DKS-07 Ural Yubileynaya booster compressor station,the second stage, Gazprom dobycha Nadym 5

GPA-25DN Ural Tayezhnaya compressor station, Gazprom transgaz Yugorsk 6

GPA-16M-04 Ural Purtazovskaya compressor station, fourth stage,Gazprom transgaz Surgut 7

GPA-12-07 Ural Voskresenskaya compressor station,Gazprom transgaz Moscow 3

GPA-12-07 Ural Tuma compressor station, Gazprom transgaz Moscow 2

GPA-12M-01 Ural Myshkino compressor station, Gazprom transgaz Ukhta 1GPA-12-06 Ural Gryazovets compressor station, Gazprom transgaz Ukhta 2

GPA-16DKS-07 Ural Yamsoveiskaya booster compressor station, second stage,Gazprom dobycha Nadym 6

GPA-16DKS-08 Ural Zapadno-Tarkosalinskaya booster compressor station,Gazprom dobycha Noyabrsk 4

GPA-25M Ural Zapolyarnaya compressor station, Gazprom transgaz Surgut 2

GPA-16DKS-09 Ural A booster compressor station at Yuzhno-Russkoye oiland gas field, Severneftegazprom 4

GPA-10DKS-08 Ural Priobskaya compressor station, Rosneft 3

GPA-10DKS-07 Ural A booster compressor at UKPG-5V gas treatment unitsat Urengoiskoye oil and gas condensate field,

Gazprom dobycha Urengoy 3

GPA-16M-07 Ural Baidaratskaya compressor stat ion, Gazprom dobycha Nadym 6

GPA-16M-06 Ural Yelizavetiskaya compressor station,Gazprom transgaz Saint Petersburg 4

GPA-25 Ural Babaevskaya compressor station, Gazprom transgaz Ukhta 5

GPA-25DU-01 Ural A booster compressor station, module 1 GP-2at Bovanenkovskoye oil and gas condensate field,

Gazprom dobycha Nadym 5

GPA-16DG Ural Compressor room 4, KS-13 Urdoma compressor stat ion,Gazprom transgaz Ukhta 2

GPA-16M-10 Ural The main compressor stationat Sakhalin-Khabarovsk-Vladivostok

gas transportation system, Gazprom transgaz Tomsk 2

GPA-16M-08 Ural Pikalevskaya compressor station,Gazprom transgaz Saint Petersburg 4

GPA-16M-09 Ural Sheksninskaya compressor stat ion, Gazprom transgaz Ukhta 5

GPA-25M-02 Ural Yarynskaya compressor station, Gazprom transgaz Ukhta 5

Total in 2003-10 132

ГПА серии «Урал», поставленные ООО «Искра-Турбогаз»



S h ek sn in sk ay a c om pr es so r s ta ti on .Unlike last year packages equipped withcompressors produced by MHI (Japan)and by Iskra and MHI together, the newpackages are equipped with NTs-16M/120compressors developed and produced by Iskra. Russian compressors have lower

price and higher technical parameters.The units are equipped with Sistema–Complex control system, John Crane —Iskra dry sealings, VNIIEM magneticbearing systems, fuel and buffer gastreatment systems and anti–surge regulating valves produced by Mokveld.

Iskra-Turbogaz also continued thesupply of units to compressor stations onBovanenkovo-Ukhta gas-main pipelinesystem, the first of compressor stations —

Baidaratskaya — was equipped with six16 MW GPA-16M-07 Ural gas compression

packages last year. Five GPA-25M-02 Uralgas compression packages were deliveredto Yarynskaya compressor station in 2010.They are equipped with NTs-25M/120Ural compressors, Sistema–Complexcontrol systems.

This year Iskra-Turbogaz will continue

to supply Ural gas compression packagesto compressor stations of the mostimportant for Gazprom compressorstations at Nord Stream (the second stageso f Ye l iz av et i ns k ay a, B ab ay e vs k ay a ,P ik a l ev sk ay a a nd S h ek sn in sk ay acompressor stations) and Bovanenkovo —U kh t a ( Ga ga ra ts ka y a, U si ns ka y, Vorkutinskaya compre ssor station)pipelines. Altogether the company plansproductions of 44 Ural gas compression

packages rated at 10, 16 and 25 MW in2011.


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Photo 4, 5.

Assemblage of GPA-16M-10

Ural gas compression

packages # 1, 2

at for the main compressor

station at Sakhalin-

Khabarovsk-Vladivostok gas transportation system

TURBO news The integrated team of the specialists from Karat RSK,

ORGRES, ABB — power and automated systems, Saturn —Gas turbines, RETEMP together with the operationalpersonnel held experimental-adjustment works for the firsttime at Peredelkino heat and power plant of the branch #8

Zapadny of MOEK (Moscow power company).The scope of work included— an autonomous development of generating and

heat equipment from the ground up operating with thediesel generator in case of emergency switch–off of externalelectricity supply;

— providing auxiliary needs with GTA-6RM gas turbinepackages and power plant operation recovery in case of emergency shut–off.

The time of development of the gas turbine at the dieselpowerplant from the ground up with creating a local network

from gas turbine generator was about 1 hour, the furtherburning of the water-heating boiler operated on gas and fueloil took one more hour. At the emergency shut–off from the

external network the powerplant will provide from 700 kW to2.5 MW of electricity for auxiliary needs depending on theamount of operating equipment and the season. The volumeof the designed capacity produced by the powerplantovercomes auxiliary needs and transmits the excess electrici-

ty into the city network. At the autonomous mode of diesel and gas turbine

powerplant operation the frequency of the autonomousnetwork is supported by frequency regulators of diesel or gasturbine powerplants, so the generation is carried not on thetarget power but on the factual one. RETEMP supplied andcustomised 0.4 and 6.3 kW variable-frequency drivedeveloped by Allen-Bradley (Canada). The automatedcontrol system of mechanic and electrical equipment wasdeveloped and supplied by ABB Automation.

At present the adjustment work on the system of automatic

excitation of gas turbine generators is finished as well asmodernisation of the electric system of the heat and powerplant.

Heat and power plant upgrading with gas turbines



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LM2500+G4 turbine produced by General Electric wasproduced in Houston (USA) and delivered to Kaluzhskayaheat and power plant to realise Kvadra investment projecton the construction of gas turbine package rated at

30 MW. The automatic process control system panels werealso supplied to the powerplant with the gas turbine. It isplanned to adjust the automatic process control system tillthe end of January 2011; then the commissioning works will start.

The new power complex at Kaluzhskaya heat andpower plant will include the gas turbine, heat recovery steam generator produced by BZKO and EGSI-S-600/1000-150/1000 WA fuel gas booster compressorstation produced by Enerproject.

The precommissioning is carried out at Kaluzhskayaheat and power plant now; the main pipelines were laid

(steam, gas and water). The areas of the relay board andthe main building were finished; the automatic processcontrol system is adjusted.

The project of GTU-30 MW gas turbine packageconstruction at Kaluzhskaya heat and power plant is thepart of Kvadra investment programme realised under theagreements of power supply. All works are carried out

according to the schedule. The project cost is 1.7 billionrubles. Under the investment programme Kvadrd plans toconstruct the power generating facilities with the totalinstalled power of 1092 MW.

The gas turbine was assembled at Kaluzhskaya heat and power plant

The general view of the main building at Kaluzhskaya heat and

power plant

TURBO news



TURBO news

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The power package constructionis being finished. The construction w o r k s w e r e f i n i s h e d . T h ecommissioning and startup began.

The third cooling tower and thepower transmission supports werebuilt at the modernised site of ORU-220 kV open switchgear. Twopower transformers and the complexair filtration system were built close to

the main building. The gas treatmentstation and the second exhaust stack were constructed. The constructionof external engineering lines is beingfinished. The HRSG availability is100%, the availability of the gas andsteam turbines is 99%.

The construction and assembly of the mechanical equipment is being

finished; the electric equipment of the automatic process control systemand the instrumentation is assembled.The commissioning and startup works are carried out at the basicequipment as well — the HRSG is washed, the gas turbine automaticcontrol system is adjusted, the boostercompressor station and gas treatmentstation are started-up, switchgear

0.4 kV and 6 kV are adjusted. The works at the construction site arec ar ri ed ou t d ay–a nd –n ig ht . T heobject availability is 90%.

The combined cycle packageincludes GTE160 gas turbine andtwo turbine generators rated at 160and 70 MW produced by LMZand Elektrosila included to Power

Machines, T-50/70-6.8/0.12 steamturbine produced by Kaluga Turbine Works, P-134 waste heat boilerproduced and supplied by ZiO-Podolsk – IK ZIOMAR.

T he c on st ru ct io n g en er alcontractor is Intertekhelektro.

The commissioning of the newpackage with the electric power of 225.5 MW and the heat power of

122 Gcal is planned for the first half of 2011. Due to the commissioning of the new power generating facilities atChelyabinskaya TETs-3 heat andpower plant the reliability of theelectric power supply to the dwellingareas and industrial enterprises willbe increased, the heat load of the newheat suppliers will be provided.

To reconstruct Mikun compressor station (KomiRepublic) DG-90 engine rated at 16 MW was delivered toIskra-Aviagaz order. The equipment is supplied under thereconstruction programme of Gazprom gas pipeline

objects to replace the gas compressor package drives with the terminated service life. The similar engine will besupplied to reconstruct Sindor compressor station.

Under the programme of the Ukrainian compressorst at ion reconst ruct ion th e purch asing of Zory a-Mashproekt equipment was included to the investmentplans of Ukrtransgaz in 2011.

The gas turbine drives for the packages each rated at16 MW will be supplied for three compressor stations:

An an iev, Alek sa ndr ov ka an d Bil ch e- Volytsy a theequipment shipment is planned for the fourth quarter of 2011.

The equipment produced by Zorya-Mashproekt will be

used instead of the foreign outdated engines and theengines with the terminated service life rated at 10 MW. Itis planned to use the reconstruction scheme providing theinstallation of the packages with higher capacity reducingthe engine number in the compressor shop.

Due to the application of Zorya-Mashproekt engines with the efficiency up to 34% in simple cycle the fuel gasconsumption at the specified compressor stations will bereduced on 21–27%.

The commissioning and startup began at the third package of Chelyabinskaya TETs-3 heat and power plant

Zorya-Mashproekt reconstructs the gas turbine powerplants in Russia and Ukraine

The new power package at Chelyabinskaya TETs-3 heat

and power plant

The complex air filtration system at Chelyabinskaya TETs-3 heat

and power plant



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The power supply project of Liebherr maintenance and supply complex was finished

The new power supply center of the maintenance and supply complexlocated in Odintsovo district of Moscow region was approved by Rostekhnadzor and put into commercial operation. BPC Power Systemsperformed the turnkey construction as the general contractor.

The independent power supply center operates in trigeneration mode.The basic equipment includes 14 Capstone C65 microturbines

each rated at 65 kW, 14 Capstone waste heat recovery generators, Broadrefrigerator and 2 peak hot water boilers. The total electric power of theobject is 910 kW, the heat power — 1820 kW, the installed cooling capacity is 800 kW. The natural gas is used as the fuel.

The decision on the construction of the independent power supply center was made by Liebherr-Russland (Liebherr subsidiary, the worldmanufacturer of construction engineering and refrigerating equipment)due to the necessity of reliable and efficient power supply of the objectsinvolved into the new maintenance and supply complex occupying thearea of over 8 ha including the maintenance shop, spare parts store,

Liebherr refrigerating and cooling equipment warehouse, the trainingcenter, the construction engineering test facility and the large office.

It is planned the payback period will be about 3 years.The project feature is the irregular daily power consumption. The peal

day loads increase the power consumption during the night hours inseveral times. Capstone microturbines provide the uninterrupted electricpower supply of all the complex objects maintaining the optimal fuel flow.

At present time the powerplant operates in standard mode providingthe reliable and uninterrupted electric and heat power supply as well asthe complex cooling.

The test startups of the gas turbine within PGU-420 combined cycle package

were carried out at TETs-26 heat and power plant

The test startups of the gas turbine within power package #8 of PGU-420combined cycle package were successfully carried out at Mosenergo TETs-26heat and power plant.

The combustion system in the gas turbine and the automatic synchronisationsystem in the generator were adjusted. During the tests the control and regulationsystems at operation in transient modes were adjusted; the compliance of theturbine vibration condition with the specification requirements was confirmed.

The next stage is the gas turbine load increase up to 60-80 MW to perform

the steam line blowing and the preparation for the commissioning works at thesteam turbine. Then the operation of PGU-420 combined cycle package at fullload will be possible.

KA26-1 combined cycle power package includes GT-26 gas turbine withthe nominal power of 288.3 MW, the steam turbine (135.7 MW) and theturbine generators for both turbines produced and supplied by Alstom. Thehorizontal-type P-133 HRSG was produced by ZiO-Podolsk to Alstomengineering adjusted to the Russian production capabilities. The generalcontractors of PGU-420 combined cycle package construction at TETs-26 heatand power plant are Alstom and EMAliance.

The works on heat insulation are finished at the construction site now:

the heat insulation was applied to the gas turbine casing and auxiliary pipelines;the temporary heat insulation was applied to the pipelines used for the steamblowing.

FosAgro AG will construct the gas turbine

powerplant rated at 32 MW

FosAgro plans to commission then e w i n t e g r a t e d c o m p l e x a tCherepovetsky Azot (Vologda region,Cherepovets) in 2012. The complex will be used for the productionof carbamide with the capacity of 500 thousand tons and the gasturbine powerplant rated at 32 MW.

The total cost of realisation will beover 250 million dollars.

The commissioning of the new gasturbine powerplant will allow coveringthe company electric power demand;the new fertiliser shop will coverthe steam demand improving thecompany power efficiency parameters.

It is planned the powerplant willinclude LM2500+GA gas turbineproduced by GE Energy. Enerproject

E GS I- S- 10 0/ 70 0 WA b oo st ercompressor station will be suppliedby ENERGAZ.

Capstone C65 microturbines

The microturbines are arranged at the first floor

of the independent power supply center



TURBO news

D i g i t a l i s s u e 2 , 2 0 1 124

H T T P : / / W W W . G T T . R U / E N

ENERGAZ specialists finished the commissioning of Enerproject EGSI-S-150/1400 WA compressor packages at the constructed PGU-110 combinedcycle package of Astrakhanskaya GRES powerplant. The booster compressorpackages are designed for fuel gas supply to LM 6000PD turbines produced by General Electric.

The installed electric power of the powerplant will be 110 MW; the heatpower – 65 Gcal/h. The reliability of the electric power supply of dwelling areasand industrial facilities will be increased providing the conditions of Astrakhan

infrastructure development. To the specialist opinion the combined cyclepackage meets the requirements of ecologists.The construction customer is TGK-8 (LUKOIL).

The construction of two combined cycle packages for Surgutskaya

GRES-2 powerplant is continued

The washing of waste heat recovery boilers at theconstructed power packages of Surgutskaya GRES-2 power-plant (OGK-4 department) was finished. The washing of waste

heat recovery generators is the last preliminary stage beforecommissioning.

The alkaline solution was used to remove thecontaminations appeared during the assembly.

The inspection carried out after washing confirmed thepower packages are ready for further stages of commissioning:the blowing of the waste heat recovery generators and startingup of 9FA gas turbines produced by GE Energy.

The construction of new power packages designed aroundPGU-400 combined cycle package (package #7 and 8) is car-ried out within the realisation of OGK-4 and E.ON investmentprogramme.

The combined cycle packages are constructed separately from GRES powerplant engine room. The construction iscarried out by the international consortium headed by GEand Gama.

E.ON international concern and its daughtercompany OGK-4 generating company officially commissioned PGU-400 combined cycle plant at

Shaturskaya GRES heat and power plant (Moscowregion).

It is the first E.ON project realised in Russia as partof the company investment programme.

The construction of PGU-400 combined cycleplant was started in the second quarter of 2008, thecomplex power package testing took place in thebeginning of October, 2010. The project primecontractor is General Electric and Gama consortium.

This single shaft power package is the first inRussia to have the most powerful F class gas turbineMS9001FA (9FA). The combined cycle power plant has

the highest efficiency of 56% among all powerpackages operated nowadays in Russian heatgeneration.

The new power plant has significantly lower CO2

emission per a unit of generated electricity incomparison to less efficient packages that will reducecarbon dioxide emission by the end of 2012 by over1 million tons and nitrogen oxides 6 times.

High efficiency and ecological properties of PGU-400 combined cycle plant made this project thefirst Russian one approved by UN as a Joint

Implementation Project as part of the Kyoto agreement.In the context of the investment programme reali-sation E.ON and OGK-4 are finishing the constructionof three combined cycle packages at two company branches (Surgutskaya GRES-2 and Yaivinskaya GRES)they are also to use the Kyoto protocol mechanisms.Their commissioning is planned for 2011.

The investment programme of E.ON and OGK-4tot al l y r ated at 2. 3vb il l ion euros involve scommissioning of 2400 MW of new facilities in Russiabefore 2014.

The commissioning of two combined cycle packages

for Surgutskaya GRES-2 powerplant is planned for 2011

EGSI-S-150/1400 WA

booster compressor package

E.ON and OGK-4 commissioned a new power package rated

at 400 MW at Shaturskaya heat and power plant

ENERPROJECT compressor packages were commissioned at Astrakhanskaya GRES powerplant



D i g i t a l i s s u e 2 , 2 0 1 125H T T P : / / W W W . G T T . R U / E N

Precommissioning of the second unit of Kaliningradskaya TETs-2 heat

and power plant is finished

The general contractor for the construction of the secondunit of Kaliningradskaya TETs-2 heat and power plant is VOTechnopromexport. It finished the precommissioning work and is

ready for a complex 72-hour equipment testing. At present the company specialists prepared all technological

operations at the power package and prepared its equipment forcomplex testing.

The second power package at Kaliningradskaya TETs-2 heat andpower plant is based on a combined cycle package that includes twoGTE-160 gas turbines and T-150-7,7 steam turbine with generatorsproduced by LMZ (Power Machines), P-96 heat recovery systemsproduced by ZIO-Podolsk.

The contract on the construction of the powerplant was signed inDecember 2008 as a result of VO Technopromexport winning inthe open one-stage tender. According to the contract agreement

the company erects the main building and auxiliary facilities,equipment supply and assemblage, commissioning, personneltraining and powerplant commissioning. Due to the agreement the work was finished on December 22, 2010.

In 2005 VO Technopromexport was the technical consultant atthe construction of the first power package at KaliningradskayaTETs-2 heat and power plant.

It is expected that the presence of two operating units willcompletely solve the problem of power supply in Kaliningrad regionfor the nearest few years.

Alexander Inozemtsev, the Managing Directorand the General Constructor of Perm constructionBureau held a video press–conference inDecember 2010 close to the 71st anniversary of

the company.Last year Aviadvigatel had important events:

the end of assembly and beginning of testing of PD-14 gas generator — demonstrator for theadvanced aviation engines and gas turbines, 10million operating hours of Perm gas turbinesdeveloped by Perm construction bureau atRussian industrial objects.

The total amount of produced industrial gasturbines with different capacity was over 560. Asthe General Constructor noted that 10 millionoperating hours show their reliability and active

operation.In 2010 Aviadvigatel introduced a new kind of

service — repair and maintenance at LUKOIL — West Siberia power generating facilities. Thisservice provides a life-time warranty of theequipment. The payment will be effected due tothe time gas turbine is operated. The manufacturer will provide a full 100% service, including capitaloverhaul, eliminate all detected flaws thatinevitably appear during gas turbine operation.

Alexander Inozemtsev told about the

programme on development of PD-14 aviationengine on the base of an advanced unified gasgenerator, about its main advantages andprospects, applied technology and designsolutions. The total volume of financing will be 70billion roubles, 35 billion will be from the statebudget and the same amount from non–budgetsources. According to the business plan that isfulfilled according to the established dates theassemblage of PD-14 engine-demonstrator isplanned for April, 2010 and the completion of works on the new engine development is planned

till 2015.

Sumy Frunze NPO delivered the products ordered by Gazprom to reconstruct two booster compressor stations of Medvezhye gas condensate field.

To reconstruct DKS-6 booster compressor station Sumy Frunze NPO produced the modernised gas compressorpackages. The packages are equipped with gas turbines each

rated at 8 MW. The package design features the individualprotection cover to simplify the adjustment and furtheroperation. The fuel gas treatment and compression system

was also supplied to DKS-6 booster compressor station. Thesystem is packaged; it provides the natural gas compressionfrom 9 to 26 atm.

Sumy Frunze NPO produced also the centrifugalcompressors and package equipment to reconstructGPA-Ts-16 gas compressor packages operated at DKS-9

booster compressor station for a long period of time.It is planned to start-up DKS-6 and DKS-9 boostercompressor stations in the present year.

Aviadvigatel summed up the year results

The gas compressor packages for DKS-6 and DKS-9 booster compressor stations of Medvezhye gas condensate field were supplied

gas turbo technology feb 2011

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