most efficient ccpp in russia

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Special Project ReportSpecial Project Report

Russia’s frst power plant to be built on the basis o a turnkey EPC contract bya non-Russian company is nearing completion in the capital city o Moscow. The €300 million ($378 million) advanced combined-cycle cogenerationacility, ofcially titled Mosenergo Moscow TPP-26 Unit 8, will also be the mostefcient in the country. Here in a special report, PEi describes the plant andlooks at the role o Alstom, whose unique partnership with local power groupEnergomachinostroitelny Alliance (EM Alliance), represents the frst major

contribution by a oreign company to Russia’s growing demand or heatand power.



Special Project Report

I

t would be no exaggeration to suggest that on the outskirts o metro-politan Moscow, Europe’s biggest city, a new chapter is being writtenin the development o the power industry o one o the continent’s most

inscrutable and ercely nationalistic countries. The Great Bear has brokenwith tradition and, or the rst time, opened its market to intervention bya major global company to produce a combined heat and power (CHP)plant that could set a new benchmark or Russia’s power industry with itseciency o 59 per cent – the highest eciency o any combined-cyclepower plant (CCPP) in Russia. Its commissioning will be a powerul spur tothe development o similar projects not only in Moscow but also in otherregions o Russia and the Commonwealth o Independent States (CIS) coun-tries as a whole.

CHP is rmly established in Russia’s power culture. Historically, it haswidely used cogeneration plants to set up regional district heating in its cit-ies. But the new Unit 8 at TPP-26 takes existing technology to an entirely new

plane. Importantly, the unique partnership means that Russian industry hasthe opportunity to participate rom access to new technology, since much othe key equipment to be used in the construction o the new generation plantis being manuactured by local suppliers. Similarly, the execution o detailedengineering o some elements o the plant by Russian design organiza-tions will prepare the ground or urther co-operation. On Alstom’s part,

the venture represents an opportunity to adapt its regular working practicesto an entirely new market. Alstom is working closely with its client, partnerand other stakeholders to meet the ambitious target o delivering the plantwithin the contractual timescale, to budget and, most importantly, to thequality expected.

The plant is being built or Mosenergo, the biggest utility provider in the

Moscow region and a company devoted to developing electric power in themetropolitan region and central Russia, by a consortium comprising Alstomand local partner EM Alliance under a turnkey engineering, procurement andconstruction (EPC) contract. It is based on Alstom’s KA26 combined-cyclepower plant in a multi-shat, one-on-one conguration (KA26-1) and usesthe company’s unique ‘Plant Integrator’ approach, drawing on its expertize

Who’s Who at tPP-26

Client: Mosenergo

Country/Region:

Russia/City o MoscowBid date: September 2006Project Award: 31/10/2006Contract Signing: 15/12/2006Notice to Proceed: January 2007Partner (external): EM Alliance

The cutaway schematic clearly shows both the generation block and the district heating system o the high-eciency TPP-26 CHP plant




as an EPC contractor and original equipment manuacturer (OEM). Theplant will deliver 420 MW o electric power and up to 265 MWth odistrict heating, bringing the maximum overall eciency o the plant to morethan 85 per cent in terms o uel utilization. Moreover, Alstom’s design givesthe plant the fexibility to perorm in various operating modes, a actor thatwill enable the client to reduce gas usage by some 30 per cent comparedwith existing plants in Russia.

The TPP-26 project orms part o Mosenergo’s programme to developMoscow’s power network to meet the ast-growing demand or powerand heat in the capital’s populous metropolitan district o Vostriakovsky. Itwill be the eighth unit o a 1410 MW generating power plant operatedby Mosenergo at the site. Alstom is responsible or all the engineering,

procurement, construction and commissioning o the new unit, including thesingle KA26-1 multi-shat combined-cycle unit, control systems, electricalrooms and transormer units, the steam extraction system or the districtheating element o the contract and gas uel plant (gas preparation centre,booster systems and diesel generators).

Alstom says its ‘Plant Integrator’ approach creates more value or thecustomer by optimizing investment costs, integrating operating andmaintenance costs and reducing lead times to produce electricity asterwhile improving uel eciency over the plant’s lie cycle, and overall plantreliability. It points to being one o the ew OEMs in the market able to oerall the major power generation technologies in-house; this, it says, enablesit to bring together the knowledge and expertise o the ‘architect-engineer’,

or EPC contractor with those o an OEM, integrating all o the installedcomponents into a ully optimized plant.Alstom believes that, with this approach, it has the appropriate

capabilities, the required skills and credentials to contribute signicantly topower expansion and replacement capacity needs in precisely the waycurrently being undertaken in Moscow. Moreover, it believes its approach ishighly conducive to meeting the increasing demand globally or EPC turnkeysolutions, as is particularly the case in the liberalized European market.This comprehensive approach to turnkey EPC includes perormance andschedule guarantees, warranties and assurances encompassing the entirescope o the plant, rather than being limited to individual components orpackages. In this way, says Alstom, end-user risk is signicantly reduced.

Moscow TPP-26 Unit 8 uses Alstom’s proven and mature combined-cycletechnology based on the advanced class GT26 gas turbine, with more thantwo million operating hours operating experience. The ull line-up includes a

three-casing, double-fow, low-pressure steam turbine, air-cooled generators,a water-cooled condenser and a three-stage re-heat, horizontal type heatrecovery steam generator (HRSG). The unit’s control system is based onAlstom’s ALSPA P320 technology.

Mosenergo – the client

The last 18 months have seen major changes at Mosenergo. In April 2007,the majority o the stock o the company was acquired by Gazprom, theRussian natural gas giant, which now holds a 53.47 per cent stake inMosenergo. Gazprom, which itsel is a major stockholder in a number olarge Russian power generation companies, including OGK-2, OGK-6 andTGK-1 (Lenenergo), has thus strengthened its position in the country’s power

generation sector.Today, Mosenergo has a total installed capacity o 11.1 GW rom17 power plants, representing some 8 per cent o all thermal generationcapacity in Russia. Almost all o these plants are based on cogeneration anduelled by natural gas. District heating in Moscow is on a scale unequalledanywhere else in the world.

A steady growth in gross domestic product (GDP) in recent years, risingto an average o 8.9 per cent, has led to a situation where the Russianpower market is developing rapidly, but the power sector has suered badlyover many decades rom under investment. Existing power plants are ageing– typically more than 20 years old with uel eciencies o less than 38 percent. Installed capacity has languished around the 215 GW level, leadingto a general shortage in power generation. To put it simply, electricity supply

will not meet the demand in the coming years. To counter this position, Russiaplans to invest $118 billion in new plant to 2012, representing an increaseo 20 GW o new gas red capacity.

Mosenergo has a large programme o its own or the development andtechnical upgrading o the Moscow’s power network by 2010. It plansto commission more than 2400 MW o capacity by constructing newcogeneration units, as well as modernizing and re-engineering existinginstallations at a number o its power plants.

Acknowledging that the continuing development o Moscow’s gridis impossible without urther reinorcement o central power supplies,Mosenergo has set itsel a demanding improvement strategy. It includes,over the next ten years, eliminating current capacity deciencies in the

Moscow region and doubling the installed capacity o its power stations,based on contemporary technologies. And, signicantly, ‘contemporary’is the key. Mosenergo has stated that it wants to sweep aside theineciencies o the past and invest in only the latest technologies oeringreal economic advantages.

F

D

B

A

C

E

A. Turbine hall

B. HRSGC. Transformer

D. Forced draft cooling tower

E. Tank

F. Administration building/

control room & warehouse




alstoM Ka26 technology

In winning the TPP-26 project, Alstom says it was able to oer the mosteective combined-cycle power plant technology in its class virtuallyo-the-shel. The designer, manuacturer and supplier is providing the keyequipment rom a single source. Answering one o the key project driverso the Unit 8 contract, the company says that a huge reduction in gasconsumption in the rst year o operation alone translates into a massive$55 million (based on 2011 expected gas prices) saving.

The solution adopted at TPP-26 comes ater the recognition o the act thatutilities, independent power producers and merchant power generators aceunprecedented change – deregulation and tougher competition, shitingconsumption trends and more stringent emissions legislation. Alstom has

developed a range o turbines – the GT24 and GT26 in particular – thatrise to these challenges. They also need to ensure reliability o supply yetreduce the cost per kWh o producing electricity. Raising eciency remainsa constant challenge. And nally the fexibility to uel gas composition needsto be addressed in times o the global transport o uel gas.

Alstom has integrated its heavy-duty GT26 gas turbines into an optimizedsingle-shat or multi-shat combined-cycle generating block – the KA26Reerence Plants. In the mid-1990s, Alstom introduced two similar sequentialcombustion gas turbines, the GT24 or the 60 Hz market and the GT26or the 50 Hz market. Since their launch in 1995, these advanced classGT24/GT26 units have demonstrated this technology platorm oerssignicant advantages to the plant operator – superior operating fexibility,

low emissions, high part-load eciency and world class levels o reliabilitybeing amongst them.

These benets are brought about by utilizing the concept o sequentialcombustion, a principle introduced as early as 1948 as a means oincreasing eciency at low turbine inlet temperature levels. Sequentialcombustion, the re-heat principle or gas turbines, had already been

applied to earlier (at that time Brown Boveri) units, but using twoside-mounted silo combustors.

In the case o TPP-26, the GT26 combustion system is based on thewell-proven Alstom combustion concept using the EV (EnVironmental) burnerin an annular combustor ollowed by the SEV (Sequential EnVironmental)burner in the second combustion stage. This dry, low NOx EV burner hasa long operating history and is used across the whole range o Alstom

gas turbines. By integrating the concept o a dry, low-NOx EV burner andsequential combustion into a single-shat engine, the GT24/GT26 designis able to achieve a high power density in a compact unit with a smallootprint.

The sequential combustion system, or reheat cycle concept, is a keytechnology behind the GT26. Compressed air is heated in the rst stage

The onsite erection o the GT26 gas turbine, which oers a high power density in a compact design

Division of labour

Alstom says it knew rom the outset the importance o teaming up witha strong local partner to build Unit 8, a groundbreaking venture byany standard, being the rst time a major European developer has leda project o such a magnitude in Russia. Consequently, the division oresponsibilities was set out at an early stage.

Alstom’s activities can be split between its two commercial units, Al-stom Russia, a locally deployed resource o EPC expertize employingsome 50 engineers and support sta, and Alstom (Switzerland). Theirindividual roles are outlined as ollows:

The Alstom Russia unit acts as the consortium leader and includesAlstom’s ‘Plant Business’ department. One o the key activities o the divi-sion is what Alstom calls the ‘Russication’ o its activities – that is, assim-ilating the specic eatures required to construct power stations suitedto the Russian market environment. Its duties include assigning technicalsupervisors or installation works. It is also responsible or the supplyo the heat recovery system o the new plant – the HRSG, designedand manuactured according to Russian specications and regulations.Interestingly,it is showing the most dynamic development o all o AlstomRussia’s divisions, and the current goal is or urther signicant growth.

Alstom (Switzerland) is responsible or the conceptual engineering,including all the basic engineering o the plant, (but also encompasses

the detailed engineering or the gas and steam turbine). The parentcompany also undertakes the assignment o technical consultants andoversees the engineering package associated with the basic engineer-ing o the HRSG.

Crucially, Alstom (Switzerland) is responsible or the supply o all thekey equipment, as laid out in the ‘Plant Integrator’ concept promotedby the company. This includes the supply o the GT26 gas turbine andsteam turbine, each with a generator (including auxiliary systems), andthe ALSPA control system.

For its own part, EM Alliance provides some detailed engineeringworks on areas not covered by Alstom. Its responsibilities also includethe execution o all civil works and associated plant erection, and pre-commissioning and commission (together with Alstom).

Other areas o responsibility include such items as the procurement othe cooling tower and cooling water pumps, and the supply o electri-cal equipment, such as step-up transormer, auxiliary transormer andswitchboards.




EV combustion chamber by adding around 50 per cent o the total uel (atbaseload). Ater this, the combustion gas expands through the single stage,high-pressure (HP) turbine, which reduces the pressure by approximatelya actor o two. The remaining uel is then added in the second stageSEV combustion chamber, where the combustion gas is heated a secondtime to the maximum turbine inlet temperature and nally expanded in theour-stage low-pressure (LP) turbine.

TPP-26 Unit 8 will burn either natural gas or, as a back-up, liquid uel.With a rated output o 288.3 MW at an ambient temperature o 15 ºC andISO conditions, the gas turbine will have an exhaust gas fow rate o 616kg/s, leaving the turbine at a temperature o 616 ºC. At that point it willenter a three-pressure re-heat, horizontal type HRSG. From there the steam

enters the three casing steam turbine.Alstom says the concept gives the new generation o turbines the

commercial edge. In today’s dynamic power generation market environment,operational fexibility is a major consideration or customers and crucialor commercial success. Since their start in commercial operation, theKA24/KA26 combined-cycle power plants have enjoyed industry leadingoperational fexibility.

Alstom says this is due to a combination o a number o key advantagesoered by its advanced technology. These include: excellent start-upcharacteristics or hot, warm and cold starts; operational fexibility rom 100per cent down to 40 per cent combined-cycle power plant (CCPP) load andbelow; high part-load eciency and low NOx emissions down to 40 per

cent CCPP load and below; extremely low ‘parking load’ during o-peak

periods at about 20 per cent CCPP load; and, a very good uel fexibilitycapability with regard to varying natural gas compositions.

start-uP behaviour

The start-up behaviour o a power plant is determined both by the start-uptime and the reliability. Alstom says the start-up time o the KA26 combined-cycle power plant, like the KA24, is short in comparison to other gasturbines o a similar size. With the optimal plant concept it has been shownthat the combined-cycle baseload is reached within 50 minutes or a hotstart (i.e. ater about an eight hour shut-down). This short start-up time meansthe plant is able to supply power sooner and thereore earn money or itsowner. This ability is an important advantage in a market environment with

a volatile electricity price. It allows the operator to take opportunities withminimal time delay.

Secondly, Alstom’s monitoring o its KA24/KA26 feet has demonstrateda power plant start-up reliability o more than 95 per cent. This, says Alstom,is again important because a missed start can be extremely expensive interms o buying in the previously committed power. There may also be urtherbenets such as revenues rom non-spinning reserve payments.

The short start-up times and high start-up reliability thus have the abilityto boost revenue or customers, compared to CCPPs using othertechnologies. Depending on the individual plant economic model, theseconsiderations could represent millions o euros o additional operatingrevenues each year.

A simplied fow diagram o the TPP-26 combined-cycle CHP plant




high Part-loaD efficiency

High part-load eciency is important in achieving high operational fexibility.In low price periods, par t-load eciency is the crucial actor when it comesto fexibility and protability. It gives the operator the added option to decidewhether or not to continue to run the CCPP during the low price periodsby reducing the power output to a minimum without sacricing substantialeciency. This operational mode reduces the number o starts during theselow price periods, and thereore decreases the associated starting costs.

Additionally, the lietime consumption that is related to the number o startso the gas turbine can be controlled by reely choosing whether the gasturbine is shut-down during low price periods, or not. This oers an impor tantadvantage, which signicantly increases the fexibility in outage planning.

Furthermore, the high part-load eciency indirectly allows control o thecumulative emissions o the power plant, since a decrease in the number ostarts reduces the absolute emissions produced during start-up.

Moreover, Alstom says, the company has developed an operatingmode – the ‘low load operation concept’ – which is capable o maintainingall the required emission levels at loads lower than 25 per cent o theCCPP’s maximum, thus allowing the operator to ‘park’ the units during o-peak hours. This is much lower than has been seen in the CCPP market todate, and is again a eature arising rom the Alstom sequential combustiontechnology. Also, as an alternative to any daily ‘cycling’ mode, this eaturedoes not reduce hot gas path lietime, and urther increases plant fexibilityand its ability to cope with new operating regimes.

Plant in Detail

The generation block consists o one Alstom GT26 gas turbine and onesteam turbine arranged in a multi-shat conguration, each turbine providedwith its own air-cooled generator. In addition the block eatures one HRSG,one water-cooled condenser, two steam/water heat exchangers or districtheating, and the auxiliaries required to operate the plant.

It is anticipated that the plant will need to accommodate daily loadvariations in the range between 50-100 per cent relative active load.However, daily start-up and shut-down cycles are also envisaged, as isshort-term plant operation at gas turbine loads down to 30 per cent.District heat extraction will be possible between 30-100 per cent o

gas turbine load. The acility will be capable o operating at baseload withoutany restrictions in an ambient temperature range o -42 ºC to 37 ºC. Designambient conditions are: ambient temperature (-3.1 ºC); and ambient pressure(995 mbar); relative humidity (77 per cent).

The plant is designed to operate principally with natural gas and oil as theback-up uel. It complies with strict near-eld and ar-eld noise guaranteeswhich are considerable more onerous than the industry ‘norm’ and belowthose stipulated in the contract or the plant’s metropolitan location. Abnormaloperation modes such as equipment ailure or block trip, however, areexcluded rom these noise guarantees. Furthermore, steam turbine bypassoperation, plant start-up and shutdown, as well as peak load operation arealso excluded rom the near-eld noise guarantees.

Major coMPonents anD systeMs

g t

The GT26 type gas turbine consists o one common rotor or one HP turbinestage and our LP turbine stages and 22 compressor stages. Heat inputis perormed by two annular combustion chambers (EV & SEV burners),applying the sequential combustion principle. The HP turbine is locateddownstream o the EV burners and upstream o the SEV burners orrst expansion o the exhaust gas. The turbine inlet air is ltered in the airintake block.

The rotor is rigidly coupled to the generator shat. The airfow through the

gas turbine is controlled by the angular position o three variable guide vane(VGV) rows, placed in ront o the rst three compressor blades rows. Duringpart-load above the 25 per cent gas turbine load, the turbine controllermaintains the exhaust gas temperature at the maximum part-load temperatureby opening the VGV and increasing uel injection to both combustors.

For cooling and sealing purposes, air is drawn o the compressor at anumber o stages. Two airfows are partly cooled external to the gas turbineby a ‘once through cooler’, which is connected to the water steam cycle,producing additional steam and thus power through the steam turbine.An anti-icing and air pre-warming system based on a heat exchanger isprovided in order to preheat the air during icing conditions, enabling the

normal operation o the gas turbine.

sm tThe Alstom STF30C steam turbine consists o one reheat type

single fow HP chamber, one single fow IP (intermediatepressure) chamber and one double fow LP chamber.The turbines are rigidly coupled. HP live steam enters the

HP turbine through a single valve block, consisting o onestop and one control valve, and is expanded to re-heat

pressure. The cold re-heat steam is mixed with the IP steam,generated in the HRSG, and re-heated. The LP steam enters

the IP turbine exhaust through a one stop and one control valve,where it is mixed with the IP steam beore entering the LP turbine. The outletsteam o the LP turbine is discharged to the water-cooled condenser.

The IP steam turbine is equipped with extractions or district heatingoperation. Steam or the district heater DH1 is drawn o rom the IP exhaust.District heater DH2 receives steam rom the IP steam turbine at an intermediatestage. During pure condensing mode, a minimum amount o steam is fowingthrough the last stages o the IP turbine in order to prevent ventilation, anddischarged into an intermediate state o the LP steam turbine.




gAn Alstom TOPAIR type generator is driven by one gas turbine at19 kV rated terminal voltage, while the steam generator drives a TOPAIRat 15 kV. The generators have a two-pole, three-phase synchronous typeo air-cooled design. The hot air is re-cooled in heat exchangers locatedin the generator housing. The heat is transerred into cooling water andrejected to atmosphere through a remote cooling system.

The gas turbine-generator is equipped with a static requency converteror starting the generator as a synchronous motor. During start-up, the startingenergy is provided – via redundant connection rom the station servicetransormers – by the high voltage (HV) grid across the generator step-upunit transormer. Starting without a power supply rom the HV grid is not

possible.

h r sm g

A single, horizontal type HRSG, triple pressure re-heat unit operates innatural circulation mode or the LP, IP and HP systems. Heat dischargedrom the gas turbine as hot exhaust gas serves as the heat source to

produce superheated HP, IP and re-heat steam and superheatedLP steam.

The HP/IP eedwater pumps eed the HRSG, which the LP eedwateris extracted downstream o the second row o IP/LP economizers. Theeedwater fows are pre-heated in the respective economizers and admittedvia control valves into the HP, IP and LP drums. Saturated steam is generatedat the HP, IP and LP evaporator.

The HP steam is led to the multi-stage HP super-heater, the IP steam to the IPsuper-heater and subsequently to the re-heater. The LP steam is super-heatedalso. At the outlet o the HRSG, the HP and re-heat steam are attemperatedwith eedwater extracted rom the HP economizer eedwater line and IPeconomizer section.

A blow down tank collects the drains o the HRSG and the drains o thesteam turbine external steam system, which are located near the HRSG.Ater separation, steam is discharged to atmosphere and condensate isdischarged to the wastewater system.

The onsite erection o the GT26 gas turbine, which oers a high power density in a compact design



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M sm sm

The main steam system consists o the HP steam line, the cold re-heat steamline, the IP steam line and the LP steam line. The HP steam line transers theHP steam produced in the HRSG to the HP section o the steam turbine.The HP steam is expanded in the steam turbine and released into the coldre-heat steam line. When the steam turbine is not in operation, the HPbypass guides the HP steam into the cold re-heat steam line. The cold re-heat steam line transers the cold re-heat steam back to the HRSG, where itis re-heated and mixed with the IP steam.

Steam is taken rom the cold re-heat steam line or the supply o the airremoval system and the gland steam system. It also supplies the auxiliarysteam header with steam and acts as a secondary supply o the hightemperature cogeneration heater.

cd smThis is a horizontally arranged two-pass condenser, cooled directly usingwater rom the cooling tower. Non-condensable gases on the steam sideare extracted at a dened point o every tube bundle with the lowest pres-sure – the so-called ‘air coolers’.

D h sm

The district heaters (DHs) consist o surace heat exchangers. District heatingwater enters the inlet water box o the rst heater, fows through the tubesand leaves the heater via the outlet water box; then it passes through thesecond district heater in much the same way. Condensing heater DH2is ed with steam turbine extraction steam, while the condensate rom it

drains into DH1 through an expansion device. The condensing andsub-cooling heater DH1 is ed with cascade condensate rom DH2, steamturbine extraction steam and with hot eedwater rom the HRSG. The hotwater rom the HRSG drains into the heater through its expansion device.Cooled condensate rom the heater DH1 leaves the heater via the heatercondensate extraction pumps, o which there are our.

f g spp sm

Fuel gas is delivered to the plant by a pipeline. Because o the highvariability in supply pressure and quality o the eed gas, it has to be treatedor conditioned beore it can be ed to the gas turbine uel gas blocks.The uel gas enters the plant via the main gas inlet valve and passes theredundant gas scrubber units. Separated condensate is collected in a skidand returned to the client systems. A redundant uel gas compressor systemincreases the gas pressure according to the needs o the gas turbine. In thisway, gas pressure is controlled by a dedicated system o recirculation.

im & c (i&c)

The I&C system permits the sae running and supervision o the whole CHP

plant. Alstom’s scope o work covers the control and monitoring o the gasturbines, water and steam cycle, HRSG, steam turbine, all the auxiliaries,and steam turbine generator, including the electrical equipment.

oPeration MoDes

These are loosely divided into ‘Condensing Mode’ and ‘District Heating’modes. Both are considered in the plant automation and are designed tobe selectable by the plant operator through a human machine interacemodule.

cd Md

In this operating mode the exhaust steam rom the HP steam turbine is

re-heated in the HRSG and directed into the IP steam turbine, passing acrossover line into the LP steam turbine, and nally condensed. In this mode,the steam extraction control and check valves are closed, hot circulatedeedwater is returned to the eedwater tank, the DH water control valve isclosed and the DH condensate pumps are out o operation. The load o thepower plant is controlled according to the grid requirements (i.e. electricload/requency).

D h Md

In this operational mode the steam turbine is in operation and on equalor higher than minimum DH load, the steam extraction control and checkvalves are open, hot circulated eedwater is being ed into the DH1,the DH water control valve is open and the DH condensate pumps are

in operation.District heating network operators will determine the water fow and

heater outlet temperature in accordance with the required heat load.The DH fow controller will throttle the DH water control fap accordingto requirements.

alstoM’s russian couP

As one o the ew OEM manuacturers in today’s market that has all themajor power generation technologies in-house, Alstom believes its oray intothis little know European market marks a signicant coup or the company.

As the power industry continues down the path to liberalization,competition or new and burgeoning power markets are bound to attract

intense competition. Being the rst to win over customers in markets suchas Russia, which has traditionally kept itsel to itsel, is without doubt abreakthrough.

Having the skills set in-house, with the ability to transer technologies topower-hungry nations at the European Union’s back door, would seem to bea good place to start.

Consruction o the single, horizontal-type HRSG

most efficient ccpp in russia

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