gas turbo technology march 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

Analytical Review

Modernisation of Ukrainegas transportation system:the problems of new gas compressorpackage development 2

Heat Protection

Development and comparative analysisof design solutions concerning the efficiencyof the turbine vane cooling quality 8

Low Emission Technology

The mathematic simulationof low emission combustors at developmentand adjustment 16

Specialised Information and Analytical Edition

G A S TU RBO

TECH NOLO GY

GAS TURBO

TECHNOLOGY 3ISSUE,

2011



The Ukrainian gas transportationsystem has been developed forover 50 years, it requires serious

modernisation at present time estimatedfrom 6 to 16 billion dollars. The greatestcost will be used for modernisation andconstruction of compressor stations,mainly to replace over 200 outdated gascompressor packages, for updating of gas pipeline linear sections and gasunderground storages.

The approach to use the foreignequipment to modernise the Ukrainiangas transportation system will form thedependence from the foreign manufacturerbecause the spare part purchasing as well asthe servicing and maintenance will requireserious cost practically equal to the cost of the basic equipment.

The Ukraine is among six leadingcountries in the world performingthe complete cycle of designing andmanufacturing of gas turbines rated

from 1.5 to 110 MW. The followingcompanies are included to theinfrastructure of the Ukrainian gasturbine compressor manufacturing: Zorya-Mashproekt (Nikolaev), Ivchenko-Progress(Zaporozhye), Turboatom (Kharkov),Sumy Frunze NPO, etc. Thus the priority task is the attraction of the Ukrainianengine-building companies to theprogramme of the Ukrainian gastransportation system modernisation.

Gas compressor packages designedaround gas turbines equipped with thecentrifugal compressors (with the capacity

over 82% in the Ukrainian gastransportation system, with the capacity upto 87% in the Russian system) are used totransport gas to main gas pipelines with thediameter 700…1420 mm in Ukraine andother CIS countries. More than 50–yearoperating experience of gas compressorpackages designed around gas turbinesoperated at main gas pipelines confirmedthe high efficiency and reliability inoperation.

One of the most important problems of the Ukrainian gas transportation systemmodernisation is the development of thereliable gas turbine drive to equip the gascompressor package with high operatinglife (up to 150 thousand hours). Thedetailed analysis presented in the Conceptof gas compressor package modernisation[1, 2] shows it is efficient to use the gasturbine engines with combined or simplecycle with further cycle sophistication forthe Ukrainian gas transportation system.

The highly efficient advanced industrialgas turbine engines are developed basedon the Concept at present time: thecombined cycle GTD-16R rated at 16 MW with the efficiency of 40.3% (Zorya-Mashproekt) and the simple cycle AI-312rated at 12 MW with the efficiency of 38% (Ivchenko-Progress). The specifieddevelopments are carried out at theexpense of the company internal funds without state support. The detailed list of

the priority scientific projects for theUkrainian gas turbine compressormanufacturing was made by the

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

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Modernisation of Ukraine

gas transportation system:

the problems of new gas

compressor package development

Dmitry Kostenko — VNIPITransGAZ;

Vyacheslav Romanov — Sumy Frunze NPO;

Artem Khalatov — Institute of engineering thermal physics of National Academy

of Sciences of the Ukraine

ANALYTICAL REVIEW



Figure. Specific weight

and overall characteristics

of gas turbine engines,

gas piston engines

and gas compressor packages

— GPA-Ts-6.3

gas compressor package;

— Deutz

(gas piston engine);

— Jenbacher


— Ivchenko-Progress

(gas turbine engine);

— DR-12

(gas engine compressor);

— Wartsila (gas piston engine);

— JMS 620GS – NLS


— Zorya-Mashproekt

(gas turbine engine)

Commission on industrial gas turbines andelectric drives by the Department of powerengineering physical-technical problems of the National Academy of Sciences of Ukraine [2].

The piston gas compressor packagesdriven by the combustion engines and the

integrated engine compressors are used inthe Ukraine mainly at pipeline branches with the diameter of 700 mm maximum as well as at underground gas storages wherethe high compression is required. Eachpiston gas compressor package is ratedat 3 MW maximum (10GK, MK8, 10GKN);the total power of piston gas compressorpackages installed at the Ukrainian gastransportation system is less than 3%.

The piston gas compressor packages were widely used at the early stage of

the Ukrainian gas transportation systemdevelopment; the experience shows theapplication of the specified packages is notefficient at main gas pipelines at the powerover 3 MW. The non-failure operating timeis 10…15 times less than the non-failureoperating time of gas turbine compressor;the lubrication oil flow is high(0.25–0.33 g/kWh; the cost of maintenance and repair is also high. Thespecific weight characteristics of the gas

piston engines are 25…40 times worse thenthe specified characteristics of the gasturbine engines and packages ( figure ). Thespecific weight characteristics of a gasturbine engine are 0.25–1.0 kg/kW of the installed power; the specifiedcharacteristics of a gas piston engine are8–25 kg/kW. The overall characteristicsof the gas turbine engine are also better.For gas turbine engine the characteristicsare (0.1–0.25)•10–2 m3/kW; as for thecombustion engines the characteristics are

(0.02–0.06)•10–1 m3/kW. The piston gascompressor packages are widely used in theUSA mainly at the high pressure gaspipelines of small diameter; the power varies from 1 to 5 MW.

The question is raised in several works with the reference to the USA experienceon the application of combustion enginesto drive the natural gas compressors atmain gas pipelines. The high efficiency (over 40%) and long service life (up to 200

thousand hours) are mentioned. It can beseen from the table the gas transportationsystems of the USA and the Ukraine differ.

The average capacity of gas turbinecompressor packages at the Ukrainian gastransportation systems is 9.85 MW (2.6 timeshigher than in the USA (3.78 MW)). The

following conclusions can be made usingthe table. There are many piston gascompressor packages with the averagecapacity of 1.285 MW in the gastransportation system of the USA (5400).The small capacity of gas turbine and gaspiston compressor packages within the gastransportation system of the USA is providedby the fact that the gas transportation systemconsists of gas pipelines of small diameterand the distribution network, while the gas

transit prevails over consumption withinthe Ukrainian gas transportation system.The analysis of the world market

development shows [3] the total order of the gas piston engine in the world forthe mechanical drive was 6851 engines in2007–2008; 6688 engines were with thecapacity of 0.5–2.0 MW and only 154 engines were within the range of 2.0–3.5 MW. It isinteresting to note that 4825 engines ratedfrom 0.5–2.0 MW (70.4%) were ordered inthe North America where the gas pipelines

of the small diameter are widely usedcompared to the West Europe countries where only 930 engines were ordered. Thusit is not correct to justify the applicationof the combustion engines at thecompressor stations within the Ukrainiangas transportation system by the experienceobtained in the USA.

The analysis performed in the work [4]shows that the combined operation of thegas compressor package and the gas

pipeline are more important than the driveefficiency. At station conditions there is thenon-linear connection between the gas

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flow through the gas pipeline and thecompressor pressure ratio. If thecharacteristics of the gas turbine drive andthe gas pipeline are compared it can beseen the operating characteristics arepractically the same. For that reason the gasturbine drive operates within the wide

range of the gas flow through the gaspipeline at optimal conditions. At the sametime piston gas compressor packagesdriven from the combustion enginesoperate at conditions far from optimalcharacterised by constant flow at pressureratio change. The average efficiency of thesystem «gas pipeline — combustion enginedrive» is about 79%, as for the «gaspipeline — gas turbine drive» systemefficiency it is 85–88% [4].

158 electric driven gas compressor

packages with the total capacity of 820 MW (14.6% of the total capacity of gas

compressor packages installed atcompressor stations within the Ukrainiangas transportation system) are installed within the Ukrainian gas transportationsystem. Though only 7–10 gas compressorpackages are operated used for 15–18%.The electric driven gas compressor packages

rated at 3–7 MW are used in France wherethe large quantity of the electric power isproduced at nuclear powerplants. Thoughthere are no main gas pipelines within thegas transportation system of France; thesystem consists of short gas pipelines of small diameter connected to the united gastransportation system. As follows from thetable the number of the electric drivengas compressor packages in the USA isinsignificant; the specified packages areinstalled in the regions with severe

ecological requirements (noise, NOx andCOx emission) making about 1% of thetotal gas compression packages.

At the existing price ratio for thenatural gas and the electric power thelarge-scale application of the electricdriven gas compression packages in theUkraine can be justified only if the fuel gasprice is 450 dollars for 1000 m3 [5, 6]. Theproduction of the electric motors rated at12, 16 and 25 MW with the adjustable

speed produced by the foreign companies(Siemens AG, ABB, Transresch, etc.) shallbe mastered for the wide application of theelectric driven gas compressor packages within the Ukrainian gas transportationsystem. For the reliable operation of theelectric driven gas compressor packagesthe electric power supply of the firstcategory is required (using twoindependent power supplies) complicatingsignificantly the package operatingconditions. It shall be remembered the

system efficiency (heat and powerpowerplant — power line — compressorstation — electric driven gas compressorpackage) is only 26–27%. Thus theapplication of the electric power can benon–efficient from the point of view of fullutilisation of the fuel chemical power. Thepayback period to transfer the Ukrainiangas transportation system for applicationof the electric driven gas compressorpackages is about 10 years.

The electric driven gas compressorpackages with the adjustable speed can beused at the compressor stations of the


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Gas transportation Gas transportation

system (the USA) system (the Ukraine)

Total length 300,000 miles 36,000 km

Transportation volume, billion m3 /year 540 194*

Fuel gas flow, billion m3 /year 15.8 4.53*

% of the transportation volume 2.92 2.34Number of compressor stations 1200 73

Compressor station average capacity, billion m3 /day 1.233 7.3

Capacity of the largest

compressor stations, billion m3 /day 124 295.5

Total capacity (N) of gas compressor packages, MW 12,353.3 5660

Piston gas compressor packages

Number of piston gas compressor packages 5400** 144

Average capacity, MW 1.285 1.263

Total capacity, MW 6939 182

Gas turbinesNumber, units 1000 469

Number of compressor stations

with gas turbine compressor packages, units 473 69

Total capacity, MW 5292 4620

Average capacity, MW 3.78 9.85

Gas turbine power range, MW 1.34-26.5 6.3-25

Electric drive

Total power (N), MW 122.3 828

Number of gas compressor packages

with electric drive, units no data 160

Comparative characteristics of gas transportation systems of the USA and the Ukraine

* — Average for 2006-2007 ** — 2/3 of piston gas compressor packages were installed before 1970



Ukrainian main gas pipelines in theregions with the excess electric powerproduction. In particular the applicationof the electric drives is efficient at Kiev – West of Ukraine gas pipeline (Berdichev,Krasilov, Ternopol, Rogatin compressorstations) [7]. At present time Sumy Frunze

NPO develops GPA-Ts-12.5R electricdriven gas compressor package with theadjustable speed rated at 12.5 MW. It is thefirst oil–free electric driven gas compressorpackage equipped with magnetic bearingsof the electric motor and compressor anddry gas seals of the compressor rotor andfrequency control.

The hydrodynamic control using theadjustable hydraulic couples and hydraulictransformers is the alternative to thefrequency control of the electric driven gas

compressor package. The advantages of the hydrodynamic control can be seen forthe drives rated over 700 kW. The basicadvantages are: low cost, high reliability,simple operation, small required area.Concerning the efficiency the frequency control and hydrodynamic control aresimilar though the application of theclimate control is necessary for thefrequency control. Voith hydraulic clutches(Germany) were used by Gazprom (Russia)

at two STD-12500 packages installed atCheboksarskaya KS-22 compressor stationsproviding the reduction of the electricpower consumption by 15.5 billion kWhannually.

The modern compressors for theUkrainian gas transportation system shallbe designed for the pressure of 5.6-7.5-9.8-12-15-21 MPa, the pressure ratio of 1.25-1.35-1.5-1.7-2.2-3-5; the design shallmeet API 617 standard requirements. Thecompressor design shall include the

magnetic bearings with digital control as well as tandem dry gas seals.

The modern gas compressor packagesare preferable to install in the individualbuildings without the wall between the gasturbine engine and gas compressors. Forthe compressor stations of undergroundgas storages where the pressure ratio is varied within the wide range at the modesof gas injection and bleeding it is requiredto develop the centrifugal compressors

with parallel–serial operation. The specifieddevelopment can be made by Sumy FrunzeNPO. The development of small capacity

booster compressors is necessary for theproduction of low-pressure gas fields andproviding the fuel gas to the gas turbinepowerplants. The piston, centrifugaland screw compressors can be used. Thecentrifugal and screw compressors arepreferable. DGK-30 centrifugal compressor

is developed at Ivchenko-Progress atpresent time. Due to the absence of thestate support the development is slow.

The attention of the Ukrainiangovernment to the problems of gas turbinecompressor manufacturing is very important because it remains competitiveat the world market. The absenceof the state support can result in the lossof the industry leading position,significant reduction of the workplacesand decrease of contributions to the

county budget.

References 1. Gailloreto G. Mechanical Drive Order

Survey//Diesel & Gas Turbine Worldwide.December 2008. pp. 20-23.

2. Brun K., Kurz R. Pipeline compression: recipes vs. centrifugals//Turbomachinery International. September/October 2008. p. 34.

3. Paton B.E., Khalatov A.A. Industrial gas turbines engines for the Ukrainian gas

t ranspor ta t ion sys t em//Zerkalo Nede l y.#26 (705). 12.07.2008.4. Paton B.E., Khalatov A.A., Kostenko

D.A., Pismenny O.S., etc. Industrial gas turbine engines for the Ukrainian gas transportation system: the current state and the problems of d ev el op me nt // Po we r e ng in ee ri ng a nd electrification. #7, 2008. pp. 20-22.

5 . P a t o n B . E . , K h a l a t o v A . A . ,Kostenko D.A., Pismenny A.S., etc. The Concept (project) of the state scientific-technical programme of the advanced industrial gas

turbine engine development for gas industry and power engineering//Messenger of the National Academy of Science of the Ukraine. #4, 2008. pp. 3-9.

6. Khalatov A.A. , Kostenko D.A.,Parapheinik V.P., Botsula A.L., Bileka B.D.,Pismenny A.S. Compressor stations of the Ukrainian gas transportation system: Concept of gas compressor package drive modernization.Kiev, 2009. 52 p.

7. Paton B.E., Khalatov A.A. Will the gas

turbines help overcoming the Ukrainian power system problems?//Zerkalo Nedely. #47 (726).12.127.2008.

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TURBO news

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The unit on gas treatment fort ra nspor ta ti on , K Ts -1 a nd K Ts -2p ow er p ac ka ge s, p ro du ct io n–operating unit, machinery and repair

shops and other facilities are builtat the compressor station now. Gascompression packages produced by

Rolls-Royce are mounted: six units with Trent 60 DLE gas turbine drivesrated at 52 MW and two units withRB211 DLE gas turbine drives rated at

27 MW. The construction of bypassline for gas supply to Nord Stream gaspipeline is close to its finish.

T h e p r e p a r a t o r y wo r k s o f Stroygazconsult ing subdivis ionand contractors started in the thirdquarter of 2009, construction and

assemblage works — in January 2010.The place where the compressorstation is built has difficult geologicalengineering conditions. One of themost complicated parts of theconstruction was piled foundationbuilding of the gas compressionpackages.

Portovaya compressor station willprovide gas transportation for thedistance of about 1200 km in NordStream pipeline. The compressor

station total capacity is 366 MW,operating pressure is 220 atm, thereare no compressor stations similar toit in Europe.

The introduction of the firstline compressor facilities is plannedfor 2011, the capacity is to beincreased up to 366 MW by the endof 2012.

Gazprom invest Zapad is theproject owner, Stroygazconsulting is

the prime contractor.Portovaya compressor station construction

The third power package can be built

at Noyabrskaya combined cycle powerplant

The necessity of Noyabrskaya CCPP enlargement iscaused by a permanent electricity shortage in Tarko-Salye –Noyabrsk service area. Now the group of companiesIntertechelectro – New Generation is studying the possibility of building the third power package with maximum usageof the existing site and gas and electricity supply. The

engineering infrastructure of the station enables installationof the package with the capacity up to 110 MW.

Noyabrskaya CCPP was commissioned on November 19,2010. The installed electric capacity of the powerplant is122.6 MW, heat capacity is 95 Gcal/h. Two combined cyclepackages based on PG 6581 gas turbines rated at 42 MW produced by GE Energy are installed in the main building.The powerplant was constructed by Intertechelectro – NewGeneration group of companies.

The powerplant commissioning eliminated the powershortage partly at Noyabrsk service area and met the growing

demand for electricity and capacity of oil and gas companiesof the region, as well as reliable and uninterrupted heat andpower supply of Noyabrsk consumers.

Commissioning works at Vnukovo gas turbine powerplant

Gas turbine powerplant main equipment consistsof two SGT-800 gas turbines produced by Siemens with KUV-60/150 (P-129) heat recovery systemsproduced by IK ZIOMAR and two KV-G-81,4-150N(P-130) main hot-water boiler produced by IK ZIOMAR, they were permitted for application by Rostekhnadzor, passed complex testing and are in

operation.The construction prime contractor is Promstroy,

a branch of Mospromstroy, Karat RSK is the maintesting and commissioning company.

At present the stage of gas turbine cold set–up isbeing finished: on February 18, 2011 the gas turbinerotor speed reached 1320 rpm driven by an electricstarter that corresponds to the rotation speed of gas-air duct ventilation.

The works are fulfilled by Karat RSK specialiststogether with MOEK operating personnel under the

supervision of Siemens experts. The «hot» adjustmentof gas turbine units is planned in the nearest future at Vnukovo gas turbine powerplant.

Foundation construction and the main technological equipment assemblage is finished at Portovaya compressor station



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Operational and acceptancetesting of CORVET-2500 equipmentset were held in January 2011 as partof production equipment prototypeof CORVET-2500 gas turbine powerpackage. It is produced by MPPEnergotekhnika in Saratov.

CORVET-2500 power package isinstalled at auxiliary powerplant

site of Novo-Pelymskaya compressors t a t i on cl o se t o t wo e xi s t i n gPAES-2500 transportable automatedpower plants. The compressor stationbelongs to Gazprom transgaz Yugorsk.

The power package is connectedto 6/10 kV open distribution deviceof auxiliary power plant. The fuel gasis supplied via a new gas pipeline.

CORVET-2500 equipment set isdeveloped according to the technicaltask issued by Gazprom transgaz

Yugorsk in July 2009 and approved by Gazprom.

The main differences betweenCORVET-2500 and PAES-2500 powerpackages:

— exhaust gases discharge in safedirection

— heat and sound insulatedstructures

— b ui lt –i n a ut om at ed f ire –extinguishing and gas control system

— the power package distantcontrol from the operator’s workingplace

— the human factor influence isexcluded at all stages and modes of work — the operation doesn’t requirethe constant presence of the personnelin the gas turbine powerplant rooms.

Hol di ng ca pi ta l ove rh aul of PAES-2500 powerplants with the useof CORVET-2500 includes thepossibility of using main equipment

of PAES-2500 for its remaining life.It meets modern requirements of R oste kh na dz or, G az na d zo r a ndGazprom to gas turbine powerplantsand is economical.

Prior to the acceptance testingC OR VE T- 25 00 p owe r p ac ka ge

successfully passed a full cycle of s ta rt –u p a nd c om mi ss io ni ng ,preliminary and operational testing(pilot operation lasted from August 2,2010 till January 16, 2011). Duringthe pilot operation CORVET-2500 gasturbine power package workedsteadily with continuous load in therange of 1.1 – 2.3 MW and with

short–term load in the range of 100 kW – 2.52 MW.During the acceptance testing the

reliable work of the power package inall load modes from 80 kW to 2.5 MW including load rise of 700 kW andload drop to 2000 kW.

CORVET-2500 gas turbine power package

Power Machines signed a number of contracts for thesupply of equipment to Kirovskaya TETs-3 and IzhevskayaTETs-1 (TGK-5), Vladimirskaya TETs-2 (TGK-6),Permskaya TETs-9 and Novobogoslovskaya TETs (TGK-9)

heat and power plants. New power packages will be built aspart of KES-Holding investment programme. The equip-ment producer was chosen according to the result of thecompetitive purchase, the total cost of contracts is over 5.5billion roubles (without VAT).

Each set consists of GTE-160 gas turbine, 180 MW gen-erator and its excitation system, gas turbine control systemand air filtration system.

According to the contracts Power Machines will provide supervision, the customer’s personnel training, par-

ticipation in individual testing as well as complex approvaland guarantee testing. The equipment supply will start inthe third quarter of this year and will be finished in thethird quarter of 2012.

GTE-160 turbines allow a planned transfer from steamto combined cycle due to sequential scheme of gas turbineintroduction into the existing part of the heat and powerplant. The project of this type will be realized at PermskayaTETs-9 heat and power plant. The investment projects atKirovskaya TETs-3, Izhevskaya TETs-1, VladimirskayaTETs-2 and Novobogoslovskaya TETs heat and power plantinclude the installation of new PGU-230T units with theelectric capacity of 220-230 MW at the existing power-plants.

Power Machines will supply the equipment for five heat and power plants of KES-Holding

New life of PAES-2500



The vane suction surface is thearea where the reliable cooling isdifficult to provide. The profile

of modern gas turbine vanes is curved; the

gas flow at the suction surface is increased(up to 400 m/s) in the area of the highestcurve; the pressure difference between thecooling air and the gas flow also increases.The specified factors influences negatively on the film cooling efficiency of thesuction surface. Finally it can result inthe overheating and irreversible suctionsurface deformation.

The main problem of the suctionsurface cooling is the difficulty of film

formation in the specified area dueto the high gas flow (about 400 m/s) as well as the high pressure differencebetween the cooling air and the gas flow(over 10 kg/cm2). The length of thesuction surface and impossibility to makeperforation at the suction surface outletthe nose are also negative factors. The vanefront cavity was divided into two cavities

( figure 1): the high pressure cavity (on thepressure surface) and the low pressurecavity (on the suction surface). Due to thedivision the optimal outlet parameters

as well as the film on the suction andpressure surface were provided. Besidesthe investigation concerning theapplication of perforation in the lastrow on the suction surface wasperformed.

The investigated perforation rowconsisted of 42 holes with the diameterof 0.65 mm, arranged to the angle of 300staggered to the suction surface profile.Three variants of the holes were

investigated — round, cone and radial( figure 2 ).To carry out CFD 3D viscosity

analysis the 3D calculation procedurebased on Navier-Stokes mean equationsolution using the finite volumes withimplicit integration algorithm within ANSYS CFX 12.1 software was used.

The turbulence model is SST; thecalculation scheme is High Resolution; theinitial time increment is 10–5 s.

The comparative assessment of the

film efficiency at various perforation( figure 3 , 4 ) variants was performed usingthe following formula:

Θ =Tgas – T wall , (1)Tgas – Tair

whereTgas — total gas temperature at the NGV

inlet;Tair — cooling air total temperature at

the deflector inlet;T wall — total temperature in the wall

layer in the selected section at the distanceof x/D from the perforation holes, where xis the distance between the section and the


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Development and comparative

analysis of design solutions

concerning the efficiency

of the turbine vane cooling quality

Stanislav Sendurev, Alexey Tikhonov – Aviadvigatel

HEAT PROTECTION

Figure 1. Vane with modified

design:

1 — vane body;

2 — deflector;

3 — high pressure cavity;

4 — low pressure cavity



perforation row and D is the perforationhole diameter.

Due to the shaped holes the air flowthrough the perforation is increased by 7%compared to the round holes, thoughthe film efficiency on the shaped holes is30–35% higher than the efficiency on the

round holes.The detailed analysis of the shaped

hole application using various geometry parameters at flat plates was carried out( figure 5 ).

The analysis was carried out using the3D calculation procedure based on Navier-Stokes mean equation solution using thefinite volumes with implicit integrationalgorithm (ANSYS CFX 12.1 software). It was determined the application of theshaped holes results in the increase of the

film cooling efficiency up to 30% at theaverage compared to the round holes atthe same cooling air flow ( figure 6 ).

It was also shown that the coolingefficiency of radial and cone holes ispractically the same at proper geometry parameters. The radial holes are 10–15%more efficient than the cone holes at thedistance up to 30d at the same cooling airflow ( figure 6 ), though the specified holes

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Figure 2.

Scheme of hole

arrangement:

a) round holes

b) cone holes;

c) radial holes

a) b)

a) b)

с)

Figure 3. Diagram of the film efficiency distribution

Figure 4. Distribution of the film efficiency to the vane suction surface: a) round holes, b) cone holes, c) radial holes

Figure 5. Cone (left) and radial (right) perforation holes

c)



are more complicated in manufacturing. Among the investigated hole variants theoptimal cooling efficiency was at radialholes with the depth of 5 or 6d (dependingon the thickness of the vane wall) and thehole outlet angle of 15°.

It was determined that depending on

the hole geometry the vortex flowcan appear in the hole expanding areachanging the cooling air flow andinfluencing considerably on the platecooling efficiency both positively andnegatively ( figure 7 ).

The vortex flow formation alsodepends probably on the outlet parameters,i.e. the shaped holes cannot be usedat any mode. If the engine operatingmode is changed the cooling efficiency atapplication of the shaped holes can be

increased or decreased compared to theround holes. It is efficient to adjust thehole parameters to Red Line operatingmode because it is the critical mode to thetemperature (the engine operates atmaximum mode under severe conditionsat the end of the service life).

It shall be noted the possibility of theshaped hole application is limited by the vane wall thickness, i.e. it is impossible touse the holes with high depth if the vane

wall is thin (≤ 1 mm).The radial holes of the most optimalconfiguration among the investigated variants concerning the design of the lastperforation row were assessed at thesuction surface of the turbine vane of thefirst stage. It was detected that compared tothe round holes the film cooling efficiency increased by 13% at the average ( figure 8 )and the film temperature decreased by 80 °C at the average at the distance up to 30perforation hole diameters (about 17 mm,

figure 9 ). At the distance over 30 perforation

hole diameters the cooling efficiency at thesame cooling air flow doesn’t differ eitherusing radial or round holes.

The conclusion was also made that tosolve the problems of film cooling efficiency using the mathematical simulation thehigh–digital grid of the wall area isrequired. The carried out investigationshowed that to get Y+ parameter

(dimensionless speed near the wall) valueof 2 maximum it is necessary that theheight of the first mesh in the prismatic


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Figure 6. Distribution of the adjusted film cooling efficiency to the flat plate

for radial, cone and round holes

Figure 8. Dependence of the vane suction surface film cooling efficiency from

the distance to the last perforation row

Figure 7. Examples of positive and negative influence using the shaped holes



layer shall be 0.005 mm maximum and thenumber of layers shall be 8 minimum at the

total height of the wall area of 0.1 mm.One of the problems to be solved for

introduction of the shaped holes is theapplication of heat protection coating. Dueto the application of the heat protectioncoating the vane temperature can bedecreased considerably: the maximumtemperature can be reduced by 100…130 °C; the average temperature — by 50…70 °C ( figure 10 ).

Though it shall be noted that among

the negative factors of the heat protectioncoating influence only the decrease of perforation hole square is considered

(10% of the hole square filling wasconsidered in the calculations). It can be

applied for the leading edge and thepressure surface, where the cooling airoutlet angles are large. As for the perforationrows located at the vane suction surface, where the cooling air outlet angles aresmall, the application of the heat protectioncoating can result in the significantdecrease of the film cooling due to theincrease of the cooling air outlet angles.The pictures of the cooling air outletfrom clean holes and the holes with heat

protection coating on the flat plate arepresented in figure 11. The simplest variant of the perforation hole filling was

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11H T T P : / / W W W . G T T . R U / E N

Figure 9. Distribution

of the total temperature

to the vane suction surface:

a) round holes,

b) radial holes

Figure 10. Temperature field

in the midsection of the turbine

vane of the first stage with heat

protection coating (left) and without heat protection

coating (right)

a) b)



simulated in the calculations: the heatprotection coating was applied evenly nearthe perforation holes changing the cooling

air outlet angle but not penetrating intothe holes (the square of perforation holes was not changed). The thickness of theheat protection coating is 0.2 mm. Thusthe heat protection coating forms the stageat the perforation hole outlet.

The distribution of the film coolingefficiency for the row of clean holes andthe row of holes with heat protectioncoating is presented in figure 12 .

It can be seen that the efficiency of

the film cooling for the holes with heatprotection coating is 5-15% less at theaverage to the plate length.

The calculations at flat platesconsidering the heat exchange betweenthe air and the heat protection coating,between the heat protection coatingand the plate were made. According to thecalculation results the application of heatprotection coating increased the platetemperature by 10–15 °C at the average at

the distance up to 20 mm from theperforation hole row. At the distance over20 mm the temperature of plate with heat

protection coating is by 5 °C higher at theaverage than the temperature of plate without heat protection coating. Thus theconclusion can be made that the applicationof heat protection coating to the vanesuction surface decreasing the square of perforation holes and increasing thecooling air outlet angle can result in theincrease of the suction surface temperature.To eliminate the negative influence of heat protection coating application it is

recommended to perform the lasertreatment of the perforation holes afterapplying the heat protection coating or themachining of the filled holes.

It is planned to make the combinedgas-dynamic and thermal calculation of theturbine vane of the first stage with theapplied heat protection coating andshaped perforation holes to get morereliable assessment of the vane thermalstate.


D i g i t a l i s s u e 3 , 2 0 1 112

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Figure 11. Cooling air outlet

from clean holes (right)

and holes with heat protection

coating (left) on the flat plate

Figure 12. Efficiency

of the plate film cooling

with heat protection coating and without heat protection

coating



TURBO news

NG-Energo finishes the works on the general contractorcontract concerning the construction, assembly andcommissioning of the gas turbine powerplant rated at20 MW for Ust-Tegusskoye field.

The gas turbine powerplant is the power complexincluding the gas turbine powerplant building, the fuel gaspreparation system, gas separators, condensate tanks, fuelgas receivers, air compressor station, flare system, emergency DES-1600 kW diesel power station, the draining system,sewage system, floodlight towers, lightning rod, etc. Theconstruction site is about 30,000 square meters. The basicequipment includes four Taurus 60 gas turbine packageseach rated at 5.7 MW produced by Solar Turbines.

The casing head gas separated from the oil at thecentral collecting station will be used as the fuel. The owngas turbine powerplant will allow using up to 95% of the

produced casing head gas.The finishing construction stage started in December

2010: the commissioning of the electrical andmanufacturing equipment as well the gas turbine andcompressor equipment carried out by Solar and Toromontspecialists is finishing. The first two turbines werestarted–up. The parallel operation, synchronisation andload division of GTU #1 and GTU #2 gas turbine packages

is adjusted. The turbines were load-tested; the loadincrease was 3.5 MW. The equipment operated in standardmode in accordance with specification. At the end of December the first turbines were put into commercial

operation. The construction of the powerplant secondstage is planned. The equipment purchase is discussed.The construction is planned immediately aftercommissioning of the powerplant first stage.

The gas turbine powerplant will cover the electricpower demand of Urnenskoye and Ust-Tegusskoye fields(East hub of Uvat project) as well as contribute to theproblem of the casing head gas recovery. At present timethe electric power for the remote fields is produced by local diesel powerplants.

NG-Energo put into commercial operation the gas turbine powerplant for TNK-Uvat

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TURBO news

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The first hot start is one of the most important stagesof start–up and commissioning works. Then steam pipes

will be cleaned with steam blowing with turbine generatoroperating at no load. After that the power package will be synchronized with the power system, all systems’operability will be tested and adjusted at partial andnominal loads. The final stage will be the complex testingthat will confirm the readiness of the power package tooperation.

Surgutskaya GRES-2, the branch of OGK-4 issimultaneously building two PGU-400 combined cyclepackages (#7 and #8) on the base of 9FA gas turbinesproduced by GE Energy. The commissioning of new powerpackages is planned for 2011. The construction is held by

the international consortium headed by GE and Gama. A single shaft combined cycle power package rated

at 400 MW based on SGT5-4000F gas turbine (V94.3A)produced by Siemens AG is being built at Yaivinskayastate district power plant. The combined cycle powerplant will be commissioned in the third quarter of 2011.

The construction is held by ENKA Insaat ve Sanayi A.S.

(Turkey).The construction of new packages is held as part of the

large-scale investment programme of OGK-4 and E.ONinternational concern, that is the main share-holder of thecompany. All the constructed objects are at the stage of hotstart-up and commissioning.

Aviadvigatel will supply Ural-4000 gas

turbine powerplant to Ilichevskoye field

Aviadvigatel and Trading houseLUKOIL signed an agreement for thesupply of a gas turbine powerplantrated at 4 MW in February 2011. Thepowerplant will operate on casinghead gas at Ilchevskoye oil and gasfield (Kungur town) belonging toLUKOIL-Perm.

According to the contract Aviadvigatel specialists will provideequipment delivery, installationsupervision, assemblage inside the

blocks, start–up and commissioning works and the customer’s personneltraining. Automatic fire–extinguishingsystem and two booster compressors will be supplied together with the gasturbine power plant.

The production and supply of Ural-4000 gas turbine power plant tothe site are planned for November this year. The commissioning is plannedfor March 2012. Trading house

LUKOIL plans to order three similargas turbine power plants for the samedeposit in the following three years.

ENERGAZ will supply equipment for Syzranskaya heat and power plant

EGSI-S-350/1600 WA gas booster compressor produced by ENERPROJECT

was delivered to the powerplant construction site at Syzranskaya heat andpower plant (Volzhskaya TGK). The modular booster compressor unit will beused for natural gas compression to the pressure of 3.4 MW and further supply to the gas turbine.

In 2010 two similar units were supplied to the heat and power plant as wellas a fuel gas treatment unit used for cleaning and metering the compressedpipeline gas.

I n s t a l l a t i o ns u p e r v i s i o n a n dcommissioning of thesupplied equipmenta s w e l l a s f i e l d

ma int en ance wil l b eh e l d b y E NER GA Zspecialists.

PGU-235 combinedcycle plant includes twoFrame 6FA (PG6111)gas turbines producedby General Electric w i t h t h e e l e c t r i ccapacity of 80 MW.P o w e r p l a n t

c om mi ss i o ni n g i splanned for the fourthquarter of 2011.

New power packages at Surgutskaya GRES-2

Booster compressor station unloading

The first hot start of the constructed combined cycle power

packages took place at Surgutskaya GRES-2 and Yaivinskaya state

district power plants



D i g i t a l i s s u e 3 , 2 0 1 115

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Two EGSI-S-400/1200-130/1200 WA double-stage compressors of fuel gas produced by ENERPROJECT will be supplied to the constructed

4th power package of Yuzhno-Sakhalinskaya TETs-1 heat andp o w e r p l a n t ( a b r a n c h o f Sakhalinenergo).

The units have a peculiar feature:the gas is compressed in two stages,that is after compression at the firststage the gas is passed to the secondstage without intermediate cooling.It provides stable operation of ENERPROJECT compressor station

in the whole range of suction pressurechanges. This in its turn guaranteesreliability of fuel gas treatment in

productivity and pressure as well aschemical composition and purity.

The compressors will supply fuelgas to three General Electric gas

turbines rated at 46.6 MW. The volumetric capacity of the boosterc o m p r e s s o r s t a t i o n w i l l b e4 2 , 9 0 0 m 3/ h . E a c h b o o s t e r

compressor station will be modular. A similar ENERPROJECT booster

compressor station is effectively operated as part of new PGU-115combined cycle plant at Kvadra heatand power plant in Voronezh.

E qu ip me nt d el iv er y, f ie lds u p e r v i s i o n , s t a r t – u p a n dcommissioning works as well asbooster compressor stations in theoperation process will be provided by

engineers of ENERGAZ (Russia) thatis part of Swiss industrial holdingENERPROJECT group.

ENERPROJECT double-stage booster

compressors

ENERPROJECT booster combustor station will provide uninterrupted fuel supply for the new power package

of Yuzhno-Sakhalinskaya TETs-1 heat and power plant

The specialists of Engineering —project center New generation issuedthe design documentation on thepowerplant main building to the

customer. Installation drawings of the main and auxiliary equipment were prepared and passed as well asarchitectural, constructional andt ech nol ogica l co nc ept s o n t hemai n, a uxilia ry build ings a ndconstructions. The following works were finished: preparation of themain electrical scheme, the drawingsof the electrical–technical parts of the main and auxiliary equipments e c o n d a r y c o n t r o l w i r i n g o f

protective equipment system andemergency control schemes, controlsystems.

Now IPTs-NG specialists holddesigner supervision of progress of w o r k s o n p o w e r p a c k a g emodernization.

Powerplant #5 reconstructionincludes the modernisation of thesteam package rated at 300 MW in thecombined cycle unit with the exhaust

discharge of GT 13E2 Alstom gast u r b i n e r a t e d a t 1 6 0 M W t o300 MW steam boiler unit. The main

c on tr ac to r f or c on st ru ct io n–assemblage works on competitivebase is Teploenergostroymontazh,that provides simultaneous supply of all necessary budgeted andconsumable materials. Teploenergo-

montazh is the contractor for the works on K-300-240 steam turbineunit produced by LMZ.

The powerplant rating afterthe modernization will be 431 MW.The new equipment commissioning will significantly increase the share of the powerplant at power generationmarket of the Republic of Armenia

and electricity supplies to nearby countries. The powerplant owner is ArmRosgazprom.

Razdanskaya heat and power plant

IPTs-NG finished the work on the modernization project of the powerplant # 5 at Razdanskaya heat and power plant



The mathematic simulation of combustor operation is widely used now. Due to the mathematic

simulation the influence of design andoperating factors on the combustor basic

characteristics can be investigated, theimprovement methods can be developedthus decreasing the volume of theexperimental researches. The mathematicsimulation is the advanced method thoughthe calculations are complicated and

the considered assumptions are specifiedduring the experimental data collection.

However the absence of the basicinformation concerning the operatingprocess the application of the received

experimental data during themanufacturing results in the increase of the volume and periods of adjustment works.

FlowVision software designed forsimulation of 3-D liquid and gas flows intechnical and natural objects as well forflow visualisation using the computergraphics is applied in the All-RussianThermal Engineering Institute.

The simulated flows include the

stationary and non–stationary, compressed,low–compressed and non–compressedliquid and gas flows. The use of variousturbulence models and adaptive analysisgrid allows simulating the complicatedliquid flows including the spinned flows,the combustion flows and the flows withfree surface.

FlowVision software is based on thefinite-volume method of hydrodynamicsequation solution with the application of square adaptive grid with local mesh. The

subgrid configuration definition is used toadjust the curved configuration withincreased accuracy. The application of thespecified technology allows importing theconfiguration from CAD systems andchanging the information with the finite-element analysis.

One of the main problems during thedevelopment of advanced gas turbinepackages is the designing of low emissioncombustors. The strict requirements

specified to the combustor designinginclude the fuel combustion intensification,reduction of toxics formation at design


D i g i t a l i s s u e 3 , 2 0 1 116

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The mathematic simulation

of low emission combustors

at development and adjustment

Ludmila Bulysova, Vasiliy Vasiliev, Mikhail Gutnik, Mikhail Gutnik,

Anatoly Tumanovsky – All-Russian Thermal Engineering Institute

LOW EMISSION

TECHNOLOGY

Figure 1. The longitudinal section of low emission combustor

Figure 2. The longitudinal section of annular mixing area (one of the variants)

Figure 3. The concentration field in the longitudinal section

of mixing area channel



and transient modes, formation of optimaltemperature field at the combustor outletand cooling of the flame tube and gascollector walls. Thus the scope of works onthe development of new-design combus-tors and adjustment of the operatingprocesses was significantly increased.

The principle of air-fuel mixturecombustion at the engine operating loadsfrom 50 to 100% is used in most low emis-sion combustors. Thus the low emissioncombustor head ( figure 1) is divided in twoareas: the pilot area where the principle of fuel diffusion combustion is used and themixing area fired from the pilot area wherethe air-fuel mixture is prepared to supply to the low emission combustor. Thehomogenous mixture is combusted for theengine operating load from 50 to 100%.

Due to the application of such fuelcombustion scheme NOx emission is lowbecause the mixture combustion tempera-ture is 1300…1500 °C maximum.

The numerical simulation was usedto solve the problem of efficient blendingof fuel and air to get the homogenousmixture.

The low emission combustor mixingarea consisting of the annular channel,spinning device and the fuel supply pipes is

presented in figure 2 .The air is supplied to the annularchannel; the fuel is supplied through theholes in the fuel supply pipes. Thenumerical analysis of the spinning deviceand fuel supply pipes relative position was carried out. The mixing degree wasestimated in the section at the combustorhead mixing area to the mean squaredeviation value of methane concentrationto the flow and square of the investigatedsection:

∫ s

( f –—

f k)2 • ρ • V n •dS.σ =√ ∫

s

ρ • V n •dS

The calculation results of three variantsare presented in table 1. The methaneconcentration fields in the investigatedsection and methane concentrationmean square deviation values designedto the flow and to the square are also

given. Variants 1 and 3 with the pipe arrangedbefore the spinning device were the best

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17H T T P : / / W W W . G T T . R U / E N

Table 1

Table 2



concerning the air-fuel mixture mixing.The values of methane concentrationmean square deviation in both variants are

similar. Though analysing the methaneconcentration fields it can be seen thebasic difference in variant 1 is axial, in variant 2 — radial. The arrangement of thefuel supply pipes relative to spinningdevice of variant 1 shall be consideredfor the further low emission combustoradjustment.

The methane concentration fieldin the air to the height of the preliminary mixing area channel was determined at

the next stage. The numerical investigationresults of the hole arrangement at thefuel supply pipes are presented in table 2 .The methane concentration fields in theinvestigated section at the head mixingarea outlet and methane concentrationmean square deviation values designed tothe flow are also given.

Variant 6 with the correspondingarrangement of the holes at the fuelsupply pipes was selected as the best

variant after carrying out the numericalinvestigations.

The length of the preliminary mixingarea was also defined using themathematical simulation. The channelpresented in figure 3 was selected forinvestigation. The methane concentrationmean square deviation value wasinvestigated in the channel cross sectionsstarting from the spinning device withthe pitch of 0.5 the mixing area annular

channel section.The dependence of methane meansquare deviation value from the mixingarea length is presented in figure 4 . Thedependence was calculated as a result of numerical experiment used to determinethe channel length values efficient forproper mixing.


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Figure 4. Dependence of the air-fuel

mixture mixing degree from the mixing

channel length

Figure 5. Dependence of mean square deviation value

of methane concentration in the investigated section from NO x

emission value at combustor gas collector outlet

0.12

0.1

0.08

0.06

0.04

0.02

0

mixing degree

number of annular channel sections, n2 4 6

0.12

0.1

0.08

0.06

0.04

0.02

0

mixing degree

number of annular channel sections, n2 4 6

Figure 6. Design area section (a);

flow field in the longitudinal section (b);

temperature field in the longitudinal section (c)

received at the calculation of gas turbine nominal mode with 5% of fuel supply to the pilot area

b) a)

c)



The quality of the air-fuel mixturesupplied to the combustion area influencessignificantly NOx concentration.

The dependence of methaneconcentration mean square deviation value in the investigated section of thedesign model from NOx emission values

received during the experimentalresearches of the same variants at the lowpressure test bench of the All-RussianThermal Engineering Institute ispresented in figure 5 .

The expected NOx emission can beassessed to the specified dependenceknowing the design value in the givensection at low emission combustoroperation at the load close to the engineload of 100% considering the basic fuel(over 90% of the total) is supplied to the

mixing area. Another example of the numerical

simulation application is the formationof the required temperature field at thecombustor gas collector outlet using themixer holes at the low emission combustorflame tube.

The design area section for theinvestigation of mixer hole arrangementand the flow and temperature fields inthe longitudinal section received at the

calculation of the gas turbine nominalmode with 5% of fuel supply to the pilotarea are given in figure 6 .

Five variants of mixer hole arrangement were considered; two variants are presentedin figure 7 .

The results of numerical investigationsof temperature fields in the section at thecombustor gas collector outlet dependingon the value, number and arrangement of the mixer holes are presented in table 3 .The temperature difference calculated to

the formula

Q вых =(Tmax out. – Tin)

(Tmidl out. – Tinl.).

is also given. Variant 5 was tested at the All-Russian

Thermal Engineering Institute testbench. The temperature field values atthe outlet received via the design andexperiment are given in figure 8 . Thetemperature field was measured in the gas

collector outlet section using 20 thermalcouples located in 5 rows each of 4 thermalcouples.

The field comparison shows the

reliability of data received via the designand possibility of investigation andadjustment of temperature fields at thecombustor outlet using the mathematicalsimulation.

At the initial stage of development andadjustment the combustors are tested atthe atmospheric pressure test bench. Thesimulation of the operating process ismade to the volume air flow, combustorinlet temperature and excess air factor

(i.e. all parameters as during the engineoperation except the combustor inletpressure). The influence of the operating

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19H T T P : / / W W W . G T T . R U / E N

Mixer hole number and diameter

V

a r i a n t

n = 6; d = 16 mm

n = 2; d = 18 mm;n = 2; d = 22 mm

n = 2; d = 20 mm;n = 2; d = 25 mm

n = 2; d = 18 mmand n = 1; d = 21.5 mm;

n = 2; d = 22 mm

and n = 1; d = 17.5 mm

n = 4; d = 20 mm

Temperature field designedusing FlowVision software

Temperaturedifference

Өout.

1.3

1.29

1.234

1.23

1.13

Figure 7. Low emission combustor mixer hole arrangement

Table 3

а) b)



pressure on the processes is very importantto assess for the further low emissioncombustor adjustment. The application of the numerical simulation contributes tothe problem solving.

The design investigation results of

recirculation area characteristics and NOxconcentration for the low emissioncombustor with the operating parameterscorresponding to 100% of the engineload at various operating pressures for two variants of fuel distribution between thecentral – pilot area and the mixing area aregiven in table 4 :

— 5% of fuel to the central area,— 30% to the central area.The results of flow field, temperature

field and non-combusted fuel field

calculation are presented in figure 9 . Thecalculations were made in the low emissioncombustor longitudinal section at theoperation under the atmospheric anddesign pressure.

The carried out numerical investigationsconfirmed that the reverse flow area isreduced at change of the low emissioncombustor operation from atmospheric tothe working pressure (though the combus-tion product weight in the areas does not

change significantly); the length of fuelcombustion field is decreased considerably,NOx concentration is increased. The presentdata are necessary for further analysis of the flame stability and control at thecombustion of lean homogenous mixtures,the assessment of the flame tube walltemperature, the development of designsolutions to reduce NOx concentration atoperating modes and CO concentration attransient modes.

The numerical simulation examples

specified above show the reliability of assessment concerning the processes of leanair–fuel mixture mixing and combustion as well as the efficiency of the numericalsimulation application for the optimisation


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Figure 8.

Temperature field values

at the combustor gas collector

outlet:

a) received via the design

experiment;

b) received via the numerical investigations

Bfuel cent. /Bfuel total, % P, kPa L max , mm Hmax , mm Mrecirc., % NO x , ppm

30 111 175 80 3.1 26.2

5 111 172 84 7.78 1

30 849 155 70 2.87 40.85 849 150 4 9.46 7

Table 4

b)

а)



of the design parameters, reduction of the volumes, periods and cost for the combus-tor adjustment.

Symbols and abbreviations Q out., % — temperature difference

coefficient at the gas collector outlet;

NOx, ppm — nitrogen oxide emission;Taver. out., °C — average temperature at

the gas collector outlet;Mrecirc., % — maximum gas mass,

involved into the recirculation;Hmax, mm — maximum height of

reverse flow area;Lmax, mm — maximum length of reverse

flow area;F — mean square difference calculated

to the square at the mixing area outlet;Bfuel cent. — fuel supplied through the

diffusion channel relative to the total fuelsupplied to the combustor.

References 1. Matthias Kern Chair of Combustion

Technology, Engler-Bunte-Institute University of Karlsruhe (TN)

Paris Fokaides, Peter Habisreuther, Nikolaos Zarzalis Chair of Combustion Technology,Engler-Bunte-Institute University of Karlsruhe

2 - D O M A I N - 1 - S T E P - K I N E T I K

TURBULENT REACTION MODEL FOR THE SIMULATION OF A LIFTED SWIRL FLAME. Proceedings of ASME Turbo Expo 2009: Power for Land, Sea and Air GT 2009 June 8-12, 2009, Orlando, Florida, USA.

2. Gutnik M.N., Vasiliev V.D., Bulysova L.A. Design and experimental investigations of low emission combustor for gas turbine packages//Abstracts of the scientific seminar The low emission combustors for gas turbine packages: development experience, problems and outlooks. Moscow, CIAM – All-Russian Thermal

Engineering Institute, 2004. pp. 36-37.3. Gutnik M.N., Tumanovsky A.G. The

possibilities of high temperature low emission combustor development for stationary gas turbine

packages//Gas Turbo Technology, #6(21),

2002. pp. 38-40.4. Khristich V.A., Tumanovsky A.G. Gas

turbine engines and the environment protection.Kiev, Tekhnika, 1983.

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21H T T P : / / W W W . G T T . R U / E N

Figure 9. Flow field (a); temperature field (b); fuel combustion field (c)

in the low emission combustor longitudinal section

100%

Ne

P =

8 4 9

k P а

P =

1 1 1

k P а

P =

8 4 9

k P а

P =

1 1 1

k P а

P =

8 4 9

k P а

P =

1 1 1

k P а

30% of fuel

to the central nozzle

5% of fuel

to the central nozzle

b)

а)

c)



TURBO news

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I n a m o n t h a f t e r V OTe ch no pro me xp or t ( th at i s t heprime contractor of the construction)s uc ce ss fu ll y f in is he d c om pl ex

72–hour testing of the new powerpackage, ceremonial equipmentcommissioning took place on April 8,2011. The new power package with the electric capacity of 450 MW and the heat capacity of 350 Gcal/hcorresponds to modern internationaltechnical and ecological standardsand will operate with the efficiency of 51%. Main technical–economicparameters of the power packagecompletely meet the ones stated

i n t he t ec hn ic al –a nd –e co no mi cassessment of the project andcontract documents.

The main equipment of thecombined cycle powerplant includestwo GTE-160 gas turbines andT -1 25 /1 50 -7 ,4 s te am t ur bi neproduced by Power Machines, twoP r - 2 2 8 / 4 7 - 7 , 8 6 / 0 , 6 2 - 5 1 5 / 2 3 0produced by Podolsky machine–building plant. The general project

is developed by Zarubezhenergo-project.

T h e t e c h n o l o g y o f g a st ur bi ne a ss em b la ge w it ho utapplication of cranes was usedfor the first time in Russia. It reducedthe amount of construction material

a n d w o r k s a t m a i n b u i l d i n gerection.

VO Technop ro mex po rt heldthe development of technical–and–economic assessment of PGU-450powerplant construction at YuzhnayaTETs-22 heat and power plant,

detailed engineering, construction works, equipment supply andassemblage, precommissioning worksand personnel training in propertime. A bit over three and a half yearspassed since contract signing.

The construction of the newpower package at Yuzhnaya TETs-22heat and power plant is one of thepriority projects of TGK-1 territorialgenerating company investmentprog r a mme t ha t wa s re a l i se d

with the support of the controllingsh a reh o ld e r of t h e c ompa ny,G a zp r om e ne r go h ol d in g ( 1 00 %affiliate of Gazprom).

T h e n e w p o w e r p a c k a g ecommissioning solves the pressingproblem of electricity shortage inSt.Petersburg and Leningrad region,increases the reliability and expandsheat supply in the city southernregions, it covers energy demands

f o r t h e d e ve l o p m e n t o f t h eindustrial–commercial complex of the ringway.

The main building of the new power package

Combined cycle plant machine room

PGU-450 combined cycle plant at Yuzhnaya TETs-22 heat and power plant (TGK-1) was commissioned



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Intertekhelektro is continuingconstruction of a combined cycleplant at Vologodskaya heat and powerplant. Territorial generating company

# 2 is the construction owner. Wall panels and roofing are

installed at the main building of thecombined cycle plant. The roof is alsomounted on the electrotechnicalbuilding as well as its floors andceilings. The gas turbine foundationis finished, the heat recovery systemfoundation is built. The works onb ui ld in g f ou nd at io ns fo r o ut erfacilities of the powerplant started.These are a gas treatment unit, a

drummed oil storage, a coolingtower. The powerplant mains areconstructed on the site. GP 50/10

br idge cr an e is prepared forassemblage. Gas and steam turbines w i t h g e n e r a t o r s , g a s b oo s t e rcompressors, block transformers,

a cooling tower have been deliveredto the construction site. The heatrecovery system is to be delivered in April 2011.

The combined cycle plant for Vologodskaya heat and power plant will consist of PG 6111FA gasturbine rated at 75 MW producedby General Electric, a 35 MW steamturbine produced by Kaluga turbineplant and a heat recovery systemproduced by Austrian Energy &

Environment.The powerplant commissioning is

planned for 2012.The main building of the constructed

combined cycle plant

110 MW combined cycle plant is built at Vologodskaya heat and power plant

Tutaevskaya PGU, an 100% affiliate, was established on April 11, 2011 to realize the project.

The prime contractor for the combined cycle plantconstruction is Saturn – Gas turbines. It will accomplish

design, equipment supply, construction, assemblage andadjustment. The combined cycle plant will include fourgas turbines single rated at 8 MW (Saturn – Gas turbines),a heat-recovery boiler (Energomash (Belgorod) – BZEM),two steam turbines (Kaluga turbine plant), two turbinegenerators (Electrotyazhmash-Privod).

The project is realised as state-private partnership.Tutaevskaya combined cycle plant construction cost is1.7 billion roubles, 25% of them will be invested by Yaroslavlgenerating company and 75 % will be obtained as credits.

Combined cycle plant commissioning is planned for2012.

Tutaevskaya plant commissioning will reduce the energy deficiency of Yaroslavl region by 4.8 %. The electricity generation will be increased by 390 million kW•h a year which is 5% of the regional consumption. Besides, the

energy capacity reserve will be created for the developmentof industrial park at the existing site of Tutaevsky motorplant.

Tutaevskaya combined cycle plant is a pilot project in oneof six federal projects in the sphere of energy efficiency —Complex small power generation. It is realised as part of subprogramme «The efficiency increase of fuel and energy complex of Yaroslavl region on base of cogenerationpower industry development» which is part of a regionalprogramme on energy-saving and energy-efficiency increase of Yaroslavl region for 2008-2012 with the per-spective till 2020.

Yaroslavl generating company will build PGU-TES-52 combined cycle plant in Tutaev (Yaroslavl region)

Future combined

cycle plant sketch



TURBO news

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Iskra-Turbogaz plans to start the commissioning

at Gryazovets compressor station

Iskra-Turbogaz was the tender winner to carry out thecommissioning of GPA-12-06 gas compressor packages #3, 4.The agreements with the customer — Gazprom tsentrremont —are made.

The packages were produced in 2007 and supplied in 2008.

The gas compressor packages include gas turbines designedaround PS-90GP-1 engine produced by Perm Engine Plantand NTs 12S/56 compressors produced by Iskra.

The company became a winnerof the open contest held by TGK-11for reconstruction and supply of themain equipment for the realization

of the project «PGU-90 combinedcycle plant construction for OmskayaTETs-3». The expected total costof the project will be over 2 billionroubles.

A c c o r d i n g t o t h e c o n t e s tconditions of the project EMAlyans will supply the power island of thepackage including two gas turbinessingle rated at 31.14 MW minimum

produced by GE Energy, two dual–circuit heat recovery systems produced with Nooter/Eriksen license and asteam turbine with electric capacity of

25.1 MW in condensation mode.I n J a n u a r y t h e d e s i g n

d oc um en t a t i on f or P GU -9 0combined cycle plant construction was passed to the state expertise. Themain contractors are ISKOM andOmskenergoremont, the branches of TGK-11. They started construction–assembly works on the second stageof preparing the construction site.

Gas turbine units will be placed in thenew building behind the main one.

The expected time of the workend is the second quarter of 2012.

It is supposed that commissioningof PGU-90 will influence positively onthe technical–economic parametersof the powerplant. The new powerunit efficiency will be 51%. Thespecific costs plan to be limited from360 to 240 g/kW•h. It will influences ig ni fi ca nt ly o n t he e le ct ri ci ty production cost. Emission will be alsoreduced.

EMAlyans will supply main equipment for Omskaya TETs-3 powerplant

Two Frame 6FA gas turbines with the installed capac-ity of 80 MW each produced by General Electric success-fully passed factory test in France and were shipped toRussia.

The turbine supply is expected in the second quarter

of 2011.KES-Holding investment project in Berezniki

includes commissioning of a combined cycle plant total-ly rated at 230 MW consisting of two gas and two steamturbines. The project realisation goals are: heat and elec-tricity production efficiency increase, reduction of harm-ful influence on the environment, reduction of electric-ity deficiency in Solikams-Bereznikovsky electric centerand replacement of outdated generating equipment.The project value is estimated at 10 billion roubles.

As part of cooperation with KES General Electric

will provide the equipment technical support, practicaltraining of Russian personnel, operational testing of turbines at the new powerplant commissioning.

Iskra-Turbogaz will supply gas compression packages for

Kanchurinsko-Musikhinskiy underground gas storage complex

The company received an order for the supply of oneGPA-10PKhG-01 Ural gas compression package inDecember 2011. The customer is Gazprom transgaz Ufa.

GPA-10PKhG-01 unit will include GTU-10P gasturbine produced by PMZ (supplied by Iskra-Avigaz)and NTs-10PKhG Ural centrifugal compressor devel-oped and produced by NPO Iskra.

Previously six GPA-10PKhG-01 Ural gas compression

packages were produced and supplied to Kanchurinsko-Musikhinskiy underground gas storage complex.

Alstom will supply equipment for Molzhaninovka combined cycle plant

The company signed a contract with Russian company Resad to supply GT13E2 gas turbine for the first stageof construction of Molzhaninovka powerplant nearby Moscow, its commissioning is planned by December 2012. It will be the first project in Russia with application of GT13E2.The total number of Alstom GT13E2 gas turbines on the world market is 144 units.

The project is realized as part of the investment contract with Moscow government for providing electricity and heat

to municipal housing in perspective development of Molzhaninovskiy district (Moscow) and Planernaya industrialzone with specialised productional area of Prom City Moscow-North. The project is financed by VneshekonombankDevelopment Bank.

Stroytransgaz was chosen as the general contractor of thefirst stage of powerplant construction according to theresults of the contest held in 2009. The company mustprovide the construction, including design, material andequipment supply, assemblage, precommissioning andcommissioning of the main and auxiliary equipment. But in July 2010 the contract was cancelled. Now the companies

hold legal proceedings.

The equipment supply started to Bereznikovskaya combined

cycle plant



D i g i t a l i s s u e 3 , 2 0 1 1H T T P : / / W W W . G T T . R U / E N

Two Ural GPA-16M-10 gas compressor

packages are assembled for Sakhalin-Khabarovsk-

Vladivostok gas pipeline compressor station

Iskra-Turbogaz, the supplier and manufacturerof Ural GPA-16M-10 gas compressor packages,

performs the package assembly at the maincompressor station of Sakhalin-Khabarovsk- Vladivostok gas pipeline.

The package designer is Iskra; Iskra alsodeveloped and produced NTs16DKS/100 Uralcompressors used in the packages.

The packages are equipped with GTU-16P gasturbines, the control systems designed aroundMSKU-5000-01 (Sistema-Servis), GMT-100-01gas–oil heat exchangers (Gazkholodtekhnika).

The reconstruction of Lyalinskaya compressor station

is continued

The first Arlan GPA-16 gas compressor package was commissioned and started under thereconstruction of compressor shop #4 atL y a l i n s k a y a c o mp r e ss o r s t a t i o n o f Nizhneturinskoye department (Gazprom transgaz Yugorsk).

The package rated at 16 MW produced by Saturn-Gas turbines was designed around AL-31ST gas turbine drive produced by UMPO.

Iskra-Turbogaz will be the contractor to carry out the

commissioning works at Urdoma compressor station

Iskra-Turbogaz will perform the commissioningof GPA-16DG gas compressor packages #1, 2. Thecontract details are determined with the customer.

Two GPA-16DG gas compressor packages areproduced for Urdoma compressor station in 2010.The packages consist of DG-90L2.1 engine (Zorya-Mashproekt) and NTs-16M compressors (Iskra). Itis planned to start the gas compressor packageassembly in February 2011.

The customer is Gazprom tsentrremont.

Ural NTs16DKS/100 compressor

gas turbo technology march 2011

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