Specialised

Information
and Analytical
GAS TURBO
Edition TECHNOLOGY
Issue 1, 2007

Contents
From the Publisher New Developments
Dear Reader!
2 32 New Aviadvigatel
gas turbine unit for
the power industry
Gas Industry
A strategic view Technology Adoption
4 of the development
of the Russian gas 36 Conversion
of the aircraft gas
transport system turbine engine
Advanced Projects into a drive
for industrial application

10 The PGU-450T operated

at Kaliningradskaya TETs-2
heat and power plant
Alternative Fuel
EU project HEGSA:
Equipment Selection 40 High efficient gas
turbine with syngas
Basic approaches
16 to meeting the growing
energy needs
application
Exhibitions & Conferences
in Moscow Exhibitions &
Cycle Designs 46 conferences 2007
Graz cycle – a highly
22 efficient oxy-fuel cycle
for CO2 capture

Publisher: Alexander Gorshkov Senior Editor: Lyubov Rastorguyeva Editorial office:

Editor-in-Chief: Jim Roberts Overseas Manager: Evgeniy Kruzhkov 148 Lenin Ave., office 115,
Editorial Board: Rybinsk, Yaroslavl region,152903, Russia
Designers: Olga Lebedeva
Yuriy Anurov (Energomash Corporation) Tel. +7 (4855) 210041, 211363
Svetlana Larionova
Meherwan P. Boyce (The Boyce Consultancy Group) Fax +7 (4855)210777
Oleg Bryndin (Saturn-Gas Turbines) www.gtt.ru
Registered by Russian Federation press committee.
Viktor Chepkin (Saturn) Registration certificate # 018636 issued info@gtt.ru
Vladimir Lupandin (Magellan Aerospace Corporation) on March 26, 1999.
Gurgen Olkhovskiy (All-Russian Thermal Engineering Copyright 2007 Gas Turbo Technology JSC.
Institute) All rights reserved. Reproduction without a written
Alexander Shaykhutdinov (Gazprom) permission prohibited.
GAS TURBO TECHNOLOGY
FROM THE PUBLISHER
Dear Reader!
Y
ou have the first international issue
of Gas Turbo Technology magazine
in your hands.
The magazine has been published
for 8 years in Russian, and distributed
in CIS countries, but the decision to enter
the international market was influenced
by reforms in the Russian power industry,
in the oil and gas complex, and in housing
and public utilities, as well as by the active
developments in the gas turbine industry
of Russia and Ukraine.
It might seem strange that we are trying
to enter this information space where
there are such well known and respected
magazines as Gas Turbine World, Diesel &
Gas Turbine Worldwide, Turbomachinery,
etc., all of which give professional coverage
to international gas turbine issues.
Nevertheless, a review of the information
in those magazines, and in the data
handbooks, led us to the conclusion that
they do not fully cover the Russian
and Ukrainian powerplant engineering
industry, which started conversion
of aircraft and marine engines 10 to 15
years ago, and is now increasingly visible
on the international market. Meanwhile
the Russian domestic market already has
over 100 gas turbine models for power
generation and mechanical drive. CIS
powerplant engineering is entering the
market with a full range of equipment
and provides up to 10 competing products
in certain power ranges. Most of these
products may not be competitive in
the traditional markets for international
corporations from the USA, Japan, and
EU countries, but Russian industry can
offer equipment which is acceptable in
developing countries.
Another interesting opportunity
for research by our publication lies in
the markets for energy equipment — the
power industry, the oil and gas production
and transmission industries, the housing
and utilities infrastructure. We will analyse
the changing situation in these branches,
both at the legislative level and in terms
of business restructuring — mergers,
acquisitions, cooperation agreements and
2
Issue 1, 2007
diversification. Growth in its investment
potential is opening huge opportunities
for the power engineering industry. We
are constantly monitoring the gas turbine
market and sense that revolutionary
changes are round the corner.
So the magazine isn’t going to compete
with existing publications, but we hope will
broaden the readers’ horizons in this field.
It is well known that Russian engineers
were often leaders in applied science.
Outstanding scientists such as Lomonosov,
Mendeleyev, Tsiolkovsky and Sikorsky,
Korolyev, Sakharov, were designers by
profession. Even the youth magazines on
engineering, technology and radio which
were published in Soviet times were
always thoroughly studied by specialists
in countries where innovations were
the source for economic growth. Many
ideas from Russian inventors were
patented and commercialised in Japan,
the USA and other countries. Today
Russian enterprises have generally fallen
behind in techniques, automation and
production management but they are still
creating features, and finding solutions,
which become the basis for further gas
turbine development. We constantly
monitor new developments and will
present the major results in this English
language magazine. Our reviews will
typically cover new casting technologies,
electrochemical processing, coatings,
ceramic components, and revolutionary
nanotechnologies. We will also describe
thermal cycles suitable for the Russian
climate which have been developed by
the Russian Academy of Science.
Special attention will be devoted
to analysis of the gas turbine market,
to the legal framework of the power
industry, to housing and utilities
infrastructure, and to the oil and gas
industries. We will dwell on the issues
of power project financing, risks and
insurance.
The key annual event over our 8 years
has been the publication of the Gas
Turbo Equipment Catalogue. We see it as
a comprehensive information source
HTTP://WWW.GTT.RU

which helps the buyer to understand
who’s who in the Russian powerplant
engineering market and helps
the manufacturer to estimate his market
share. That is why besides the traditional
chapters of typical handbooks which
provide the basic gas turbine technical
parameters, we also cover the characteristics
of energy consumers, auxiliary systems
and complete units. That adds up to 17
chapters including tabulated technical
data. The reference section offers about
thirty gas turbine cycles with their energy
balance together with additional
formulae further extending the volume
of information presented in the tables.
We regularly present market reviews
and information on commissioned
projects and contract signings. We note
a significant annual growth of orders
(2006 orders were 45% higher than 2005)
for gas turbines in the CIS market.
The main growth is due to large–scale
power generation. This year the Catalogue
has been significantly expanded, as we
present detailed descriptions of most
of the powerplant in the CIS market.
Diagrams depicting the influence
of operating conditions on the parameters
of each unit have been included in the new
chapter. Estimation of gas turbine exhaust
heat, and its dependence on air
t e m p e r a t u re , a s s i s t s t h e a n a l y s i s
of application of a particular drive in
a combined cycle installation or
in delivering the necessary parameters
of process steam. A general description
covers the scope of manufacture,
the possibilities for future modernisation,
acceptable fuels, environmental
HTTP://WWW.GTT.RU
performance, and the suitability for
producing different kinds of energy
(electricity, heat, compressed air, cold).
Another chapter evaluates the companies’
experience in the CIS, each model being
provided with a reference list. The main
criteria of product experience are its fleet
leader and total operational experience.
We identify the year of commissioning
of gas turbines at specific sites, together
with time in service.
The Catalogue is becoming a tool for
preliminary equipment selection. We
hope that this information source will be
interesting and useful to the English
speaking reader and that the publication
will enhance your knowledge in this field.
In our turn we would like to invite
interested readers into interactive
communication — you may ask questions,
express your opinion and offer comments.
We will contact specialists on the matters
of interest and report our feedback on
the issues. Information can be a more
valuable commodity than cash. It is
a long–held truth that «Knowledge is
power».
We can only make this information
source effective and of the highest quality
by joint effort, and here we’d like to thank
our colleagues who invested their time
and effort in creating the first issue of
the magazine the way you see it:
Editorial Board Members: Jim Roberts,
Editor-in-Chief (Warwickblue Strategies),
Vladimir Lupandin (Magellan Aerospace
Corporation), Dr. Meherwan P. Boyce
(The Boyce Consultancy Group).
Alexander Gorshkov
3
GAS TURBO TECHNOLOGY
TURBOnews
General Electric supplied
equipment for a gas turbine
power plant built in Dashoguz
(Turkmenistan)
Erection of the simple-cycle
power plant with total output
of 254.2 MW began in March,
2006. According to the contract,
construction is being carried
out by General Electric (USA)
in cooperation with Chalyk Energy
(Turkey). In February 2006, this
alliance commissioned the similar
gas turbine power plant near
Ashkhabad.
Two 9E gas turbine units rated
at 157.1 MW will be installed
at Dashoguz power plant. Gas
turbine units of this model are
recognised to be reliable and
cost-effective. The world’s first 9E
gas turbine unit was manufactured
in 1978. 390 units are now
in service and their total
accumulated operating experience
is over 16 million hours. 9E gas
turbine units have a typical General
Electric assembly: a 17-stage axial
compressor with compression
ratio 12.6, a 14-chamber cannular
combustor and a 3-stage power
turbine.
Construction of the power
plant, valued at 120 million dollars,
is scheduled to be complete by
October 2007. It will generate
2,226,792 kW-hr of electricity
a year.
Currently, electricit y to
the Dashoguz region is supplied
by the Maryiskaya state district
power plant and Seydinsk TETs
heat and power plant, located
in the south-east of the country.
The installed capacity of the 6
power plants operating
in Turkmenistan is approximately
3311.4 MW. In 2005 production
of electricity in the country
reached 12.8 billion kW-hr. That
is 7% higher than the level of
the previous year. Approximately
1.3 billions kW-hr were exported
to Turkey, Iran and Afghanistan.
GAS TURBO TECHNOLOGY
GAS TURBO TECHNOLOGY
GAS INDUSTRY
Fig. 1. Reduction
of the gas transport system
technically possible pipeline
capacity from NPTR,
relative to design capacity,
within the period
of 1991-2004
Issue 1, 2007
A strategic view
of the development of the Russian
gas transport system
Alexander Ananenkov – Gazprom
Gas transport system condition
T
he period from 1991 to 2000 was
the first stage for establishing new
economic conditions in the country.
It was distinguished by a significant
reduction of gas consumption, and
therefore of transportation volumes. This
fact resulted in cancelled construction
of new main gas pipelines, as well as
a reduction in reconstruction and overhaul
of the operational gas transport facilities.
Actual financing for reconstruction
and repair works was not more than
25–30% of that required for complete
restoration of the gas transport system
design capacity, against a background
of continuing natural deterioration of
the production facilities.
This resulted in a gradual reduction
of the technically possible pipeline
capacity (TPPC), which is the principal
characteristic of the system production
capacity (fig. 1). Whereas in 1991 the
difference between the design production
capacity and the system’s actual TPPC was
24 billion m3/year (4%), by 2002 it had
reached 59.6 billion m3/year (10%),
4
the equivalent of de-commissioning two
typical domestic gas main pipelines with
capacity of 30 billion m3/year.
In addition to the reduction in gas
transport system production capacity,
underfinancing led to underachievement
of the required effort on overhaul and
reconstruction of the gas transportation
facilities which were considered necessary
for industrial safety improvement, and
for the technical re-equipment of auxiliary
s y s t e m s ( i n c l u d i n g p o we r s u p p l y,
automation, monitoring, etc.)
Consequently during the period
1991–2000 the total length of gas
pipeline runs with restricted working
pressure was increased from 8,100
to 22,800 km, and the annual number
of failures due to stress–corrosion grew
from 1 to 14.
Underfinancing of the necessary
activities, and postponement of unfinished
reconstruction tasks caused an avalanche
of growth in the volumes of reconstruction
and major overhauls. As a result
the required annual reconstruction effort
within the period from 2002 to 2006
increased six or sevenfold in comparison
with the period from 1991 to 1995.
The subsequent period of 2002–2004
was marked by increased gas consumption
in the country, and correspondingly by
growth in gas transmission volumes and
in 2004 the load on the operating gas
transport system reached the limit
of technically possible pipeline capacity.
Thus, the Russian gas transport system
entered a new stage of its development:
■ with the operating system reaching
its ultimate load;
■ with reduced production capacity
(by approximately 10%) relative to
the design capacity;
HTTP://WWW.GTT.RU

■ with the need to carry out
a considerable scope of work on
reconstruction and major overhauls, both
accumulated during the previous periods
and also connected with the continuing
natural deterioration of the gas transport
facilities.
Resource base and anticipated
loading of the gas transport system
The Russian Federation Government
approved the formal «Energy Strategy
of Russia for the period until 2020»
in August 2003. The document determines
the basic purposes, tasks and priorities
for gas industry development. The Energy
Strategy considers the decreasing
production regime at the main Gazprom
deposits in the Nadym–Pur–Tazovskiy
region (NPTR) (fig. 2). This production
decrease needs to be compensated
by the creation of a new gas production
centre on the Yamal peninsula and its
adjacent offshore area. In addition, the
growth of gas extraction by independent
producers must be taken into account,
as well as the development of new gas
producing regions in Eastern Siberia and
in the Far East.
The Yamal peninsula and the offshore
area of the northern seas will have strategic
priority among the gas producing
regions for the long term. Gas supply
from Yamal should start from 2011
(15 billion m3/year). By 2020 it will
have grown to 135 billion m3/year. It is
expected that during the same period,
supplies into the gas transport system from
NPTR will be reduced by approximately
100 billion m3/year.
Such a serious change in the ratio
between gas production at Yamal
and NPTR fundamentally changes
the features of loading on the gas transport
system.
In 2004 all the three main gas transport
systems of the united gas supply system
were fully loaded, i.e. to the level of the
technically possible pipeline capacity.
During the period prior to
introduction of the Yamal gas transport
system, small gas deposits are expected
to be developed by Gazprom and
independent producers in NPTR, by which
HTTP://WWW.GTT.RU
GAS TURBO TECHNOLOGY
gas supply into the system will be Fig. 2. Forecast of gas
increased by 45–50 billions m3/year. For production in Russia
this purpose reconstruction and major
repairs be required for gas transfer units,
as well as the commissioning of new
facilities in the Northern gas transmission
system.
During the period from 2011 to 2015
the first branch will be commissioned, and
the construction of the Yamal gas transport
system will continue, whereas the North
European gas main pipeline will reach its
design capacity. Due to the continuing
decline in gas production at the old gas
fields of NPTR and the growing gas
extraction at Yamal, the load on the South
(Surgut) gas transport system will be
reduced.
By 2020 the load on the main parts
of the basic Yamburg and Urengoy systems
(Urengoy–Nadym, Urengoy–Pravaya
Khetta, the link pipe Urengoy–Yamburg,
Yamburg–Pravaya Khetta) will also be
reduced.
By 2030 the only part of the gas
transport system loaded to its technically
possible pipeline capacity level will be that
to the East of Yamal–Ukhta–Cheboksary–
Pochinki–Petrovsk–Frolovo pipeline.
Practically all the remainder of the gas
transport system will be underused.
Thus, the tendency to replace gas from
the old fields of the Nadym–Pur–Tazovskiy
region (Yamburg, Urengoy, Medvezhye)
by Yamal gas will inevitably result in
the gas transport system being divided
into «loaded» and «underused» parts,
being governed by different strategies
of optimal control over the development
and functioning of the production
facilities.
5
Issue 1, 2007
GAS TURBO TECHNOLOGY
Principles of optimum development
and gas transport system operation
The principles of optimum develop-
ment and production facility operation
in the «loaded» and «underused» parts
of the gas transport system are different
(see the table).
For the «loaded» parts of the gas
transport system, the optimality criterion
for development and operation is
the economically feasible increase in
the technically possible pipeline capacity.
For «underused» parts of the gas
transport system, the optimality criterion
for development and operation is the
economically feasible reduction in
operating costs.
The methods for guaranteeing optimal
development and operation of the
«loaded» parts include all the main types
of investment activity in the field of gas
transmission: construction of new gas
mains and gas transport units,
reconstruction of operating gas pipelines,
and to a certain degree, complete overhaul
of gas pipelines.
B a s i c a l l y t wo m e t h o d s o f n e w
construction are possible:
a) gas transmission system expansion for
gas intake from the newly developing gas
producing areas (for example, from Yamal);
b) the construction of a new gas
pipeline instead of reconstruction of the
one in service, if it proves to be more cost-
effective.
An important tool for optimization
of the «loaded» gas transport system
development and operation is
reconstruction of gas main pipelines
with restricted TPPC (i.e. elimination of
«bottlenecks»).
Principles of gas transport system optimum development and operation
Degree of loading «Loaded» gas transport system
Optimization The economically feasible increase of gas transport
criterion system technically possible pipeline capacity
Methods 1. Construction of new gas mains and gas transport units
of guaranteeing 2. Reconstruction of operating gas mains
gas transport 3. Complete overhaul of pipeline runs
system optimum 4. Distribution of pipeline runs for «tight spot»
development elimination
and functioning 5. Construction of loopings and connection pipes to make
repair and diagnostic works possible without reducing
the planned gas supplies
6
Issue 1, 2007
A specific approach to expansion of
the «loaded» gas transport system pipeline
runs is the erection of loopings and
cross–connections, in order to make
complex maintenance and diagnostic
works possible without reducing the
planned gas delivery. A special gas main
may be built to increase the technically
possible pipeline capacity of the system
during repair operations.
The basic challenges to improving
the development and operating efficiency
of «underused» gas transport systems are
the forced underutilization of the installed
production facilities, which leads to their
partial shutdown and inefficient operation
when the gas pipelines run under partial
load conditions.
The tendency for gradual unloading
of parts of the gas transport system
while increasing the Yamal gas supply and
reducing gas production from the main
NPTR gas fields (Medvezhye, Urengoy,
Yamburg) will in the long run result in full
loading and extremely intensive use of
the Central and North–East zones of
the unified gas supply system, but partial
load in the remainder, including
the Southern system. The degree of load
reduction will be increased as Yamal gas
production grows. This problem brings
a considerable threat of deterioration to
the technical and economic performance
of the Gazprom gas transport complex as
a whole.
The possible ways of improving gas
transmission technical and economic
performance in the unloaded part of
the gas transport system are:
a) closure of surplus gas transport
facilities not required in the future. Most
probably, the elimination of entire lines
«Underused» gas transport system
The economically feasible operational cost reduction
of the gas transport system
1. Elimination of surplus gas transport facilities
not required in the future
2. Conservation of temporarily unused units
3. Reconstruction of gas pipelines to reduce operational
costs, including transition to energy-saving technology
4. Reconstruction of gas mains with modification
to their function, including conversion into distribution
gas pipelines
HTTP://WWW.GTT.RU

will be possible only at underused
multiline systems (removal of one or two
surplus lines along with their compressor
units). Elimination of single-line gas mains,
as a rule, is impossible, since the pipelines
serve also for gas distribution.
The economic efficiency of gas
pipeline closure is doubtful — estimates
have indicated a very high level of closure
expenses;
b) mothballing of temporarily unused
units to reduce operational expenses;
c) reconstruction of underused gas
pipelines, ensuring their optimal operation
and the reduction of operational expenses
under reduced load (reduction in
the number of gas–compressor units,
c o m p re s s o r h a l l s , a p p l i c a t i o n o f
interchangeable working parts, etc.);
d) reconstruction of gas pipelines with
transition to energy saving low pressure
technology of gas transmission;
e) reconstruction of gas pipelines with
modification of their function, including
conversion into distribution gas pipelines.
In certain cases gas pipeline production
capacity under-utilization can be caused
by a lack of active underground storage
capacity (fig. 3). At the same time, the gas
transmission seasonal variation is regulated
by the gas pipelines themselves, which are
loaded to the extreme during the winter
period, but only partially in summer.
Additional gas which could be pumped
during the summer season therefore
remains undeveloped. So, with a practically
full winter loading of the Central system,
for the rest of time there is an excess
of technically possible pipeline capacity,
which could enable the transport
of 10 billion m 3 additionally during
3 summer months.
The solution to this problem depends
on appropriate underground storage
management.
Thus, the determining role in
establishing the principles for optimum
development and operation of the gas
transport system is played by the loading
rate. As a result, whatever the gas transport
system load, the optimum development
and operation should be based on
a systematic approach, including the
optimal interaction between a new or
an existing gas main with other units of
the unified gas supply system.
HTTP://WWW.GTT.RU
GAS TURBO TECHNOLOGY
Fig. 3. Central system gas
transport pipeline capacity
under-utilization due to lack
of underground gas storage
active capacity, 2004
Period Under-utilization of capacity,
billions m3/per.
Year 24.3
Winter 5.1
Off-season 9.3
Summer 10.0
Gas transport system development
due to establishment of a new gas
production region
The Russian Federation Energy
Strategy for the period to 2020 provides
for the establishment of two new gas
production regions: one is the Yamal
peninsula and the adjoining shelves of the
Arctic seas; the other is Eastern Siberia
and the Far East, including the offshore
shelf of the Far East.
Due to the continuing depletion of the
main fields in Western Siberia, the industry
is facing active gas resource development
on the Yamal peninsula. Transmission
of the Yamal gas will require by 2030
the construction of a heavy duty gas
transport system with capacity over
300 billion m3/year. The severe
environmental conditions of the Yamal
peninsula and the adjoining territories,
and the remoteness of the gas production
areas from the districts of gas distribution
and consumption, will result in extremely
high transportation costs for Yamal gas.
It is known that in the complex
cost structure of gas production and
7
Issue 1, 2007
GAS TURBO TECHNOLOGY
Fig. 4. The scheme transmission, gas transport is the most
of the natural expensive. Because of this, the efficiency
gas transmission of the Yamal project as a whole will
from Eastern Siberia depend to a considerable extent upon
and the Far East the efficiency of the gas transmission
technology which is applied. This indicates
a need to employ primarily new resource–
saving gas transportation technology and
simultaneously to require its maximum
implementation in the Yamal gas transport
system.
Already Gazprom has basically
completed the preliminary design for the
initial Yamal development (with extraction
of 178 billions m3/year). The primary
conclusions in terms of gas transmission
are as follows: erection of three gas trans-
port lines, 1 420 mm in diameter, with an
internally smooth wall lining for the
increased operating pressure of 11.8 MPa
in the Yamal (Bovanenkovo) — Ukhta
branch, 1074 km in length. There will
be 10 compressor stations; their total
capacity will be 3165 MW. A 2–line system
will be erected with an operating pressure
of 9.8 MPa in the Ukhta–Gryazovets
branch.
8
Issue 1, 2007
The suggested technology will allow
a reduction of capital investments by
26%, of metal requirement by 13%,
in operational expenses by 14%, and in gas
transmission costs by 15%.
The preliminary design analysis of gas
transmission technology options for
the other parts of the Yamal gas transport
system (Ukhta–Gryazovets, Gryazovets–
Torzhok, and Ukhta–Cheboksary) also
corroborates the efficiency of gas
transmission under the higher pressure.
The choice of particular design parameters
for these branches will depend upon the
scheme of anticipated gas flows.
A new system of gas pipelines from
the Yamal peninsula, created on the basis
of highly efficient gas transmission
technology and gas pumping equipment,
should become the core of the unified
gas supply system, in which would be
concentrated the most progressive and
advanced technical and technological
solutions.
Eastern Siberia and the Far East,
including the offshore area near Sakhalin
Island, will become a fairly large gas
HTTP://WWW.GTT.RU

production area in 2010–2020 (fig. 4).
The development of gas production
and creation of the gas transport
system in these regions will promote their
socio–economic development and the
expansion of gas export to China, Japan,
and Korea.
In Eastern Siberia and the Far East
there is a considerable resource base.
The basic fields offering large scale gas
production are the Kovykta gas condensate
field (Irkutsk region), the Chayanda oil
and gas condensate field (Republic of
Sakha–Yakutia) and the fields of the
Sakhalin Island offshore area.
Within the framework of the developed
«Programme for creation of the unified
system of gas production, transmission and
supply in Eastern Siberia and the Far East,
considering possible export to Chinese
and other country markets in the Asia
Pacific region», three basic variants of gas
resource development in these eastern
regions of the Russian Federation are
considered.
As a result of technical and economic
assessment of the specified variants,
the benefits of the so–called «East»
variant were established, according
to which gas production at the Kovykta
gas condensate field, during a period
of constant withdrawal of volumes of
up to 37.3 billion m3/year, will
allow the provision of gas supplies
to consumers in the Irkutsk region,
Krasnoyarsk Territory, and the Kemerovo
region of up to 13 billion m3/year and
the supply of gas to the unified system
of up to 35 billion m3/year (including
gas supplied from fields in the Krasnoyarsk
region).
To transmit the planned volumes
of gas it will be necessary to construct gas
TURBOnews
One more SGT-300
commissioned at Hasireysk field
Siemens commissioned the third SGT-300
Tempest gas turbine powerplant at this oil field
in Yamal-Nenets autonomous region.
The SGT-300 packaged units, rated
at 7.9 MW, were supplied to the Hasireysk field
HTTP://WWW.GTT.RU
transport mains 1,420 mm in diameter, at
a pressure of 9.8 MPa, and with a length of
1,673 km, with a total installed compressor
station capacity of 750 MW, together with
about 1,200 km of gas pipelines of smaller
diameter.
Gas production in the offshore
area of Sakhalin Island of up to
56.2 billion m3/year (by 2030) will enable
the supply of 17.2 billion m3/year
of gas to consumers in the Sakhalin
region, Khabarovsk and Primorsk
Territories, and the export of up to
25 billion m3/year of gas to China, Japan
and Korea.
Gas transport pipeline construction
will also be required to transport gas from
the Sakhalin sea shelf fields to the city
of Vladivostok. This pipeline will have
a diameter of 1,420 mm; an operating
pressure of 9.8 MPa, and its length will be
1,205 km. The construction of other gas
transport pipelines with a diameter of
1,220 mm and length of 410 km is also
specified.
The new regions of anticipated gas
extraction will play an important role
in the development of the Russian gas
industry. There is no alternative to
development of Yamal for compensating
the reduction in gas production at the
existing fields of the Nadym–Pur–Tazovskiy
region and for providing a stable supply for
the European part of the country.
The gas transport systems in Eastern
Siberia and the Far East are intended
primarily for the supply to local consumers
and for export to the Asia Pacific
countries.The erection of a gas transport
pipeline that would connect the gas
transport system of Eastern Siberia with the
unified gas supply system is currently
under consideration.
(Severnayaneft) as part of the existing
powerplant modernisation program.
General designer for the power plant was
the ILF company (Denmark). TechnoServ
(Moscow) was prime contractor. Energotech
(Moscow) manufactured and supplied
equipment including gas and water treatment
systems, switchgear and an automatic control
system.
The second stage of modernisation will be
completed by commissioning a fourth SGT-300
unit which is already assembled and packaged.
9
GAS TURBO TECHNOLOGY
TURBOnews
GTES-12 gas turbine powerplant
installed in Peredelkino
The Energy-Saving Agency
(Moscow) was plant customer,
and has accepted the cogeneration
gas turbine powerplant after its
successful complex testing. In
addition to 12 MW of the electrical
capacity, Peredelkino (Moscow)
district heating system receives
a thermal output of 24 Gcal/h.
The project was worth 130 million
roubles (about $4.9 million).
Two NPO Saturn GTA-6RM
power generation units with
KUV-11.9/150 waste heat boilers
were installed at the powerplant.
The boilers were designed by
ZIOMAR, a part of EMAlliance
Holding.
Each power generation unit
uses a Privod TK-6-2RU3 turbine
generator. The engines are
equipped with acoustic and
thermal enclosures and
powerplant emissions meet
the environmental regulations.
Similar cogeneration plants,
each rated at 12 MW, are
in operation in Penyagino,
Kuryanovo and Zelenograd.
The GTA-6RM power unit
is one of the best in its class on
its technical and economic
parameters.
By its results in 2005,
the GTA-6RM unit became a prize
winner in the «Production for
industrial and technical purposes»
nomination of the «100 best
Russian products» competition
receiving «Pride of the Country»
status.
Last year Saturn established
a new subsidiary company Saturn
Gas Turbines which will manufac-
ture industrial gas turbine generat-
ing units.
All four power generating units are located
in a quick-build facility equipped with all neces-
sary auxiliary systems.
Fuel for the unit will be associated
gas with high hydrogen sulphide content.
The fifth SGT-300 unit, which is still under
construction, will operate on diesel oil (with
the possibility of conversion to casing
head gas).
By the end of 2007 the total output
of the Hasireysk booster pumping station’s
power centre will be around 32 MW.
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GAS TURBO TECHNOLOGY

ADVANCED PROJECTS
The PGU-450T operated
at Kaliningradskaya TETs-2
heat and power plant
Vladimir Gribin – Moscow Power Engineering Institute
Alexander Gorshkov – Gas Turbo Technology

The pilot project for the combined cycle power unit construction at Kaliningradskaya
plant is a result of a balanced partnership of the State, RAO UES and leading power
engineering companies. The decision to erect a new power plant was made in 1990,
its basic construction phase lasted from 2003 to 2005, and the plant proved to be not only
a considerable contribution into the power security of the Kaliningrad region, the Russian
Federation European enclave, but also an additional stimulus for regional development
through its enhanced attraction of investment.

Photo 1. Kaliningradskay
TETs-2 heat and power plant
I
ndustrial production growth in the
Kaliningrad region reached 25% over
the last five years. Because of this
growth, the construction of RAO UES’
Kaliningradskaya TETs-2 (the first heavy–
duty combined cycle power unit based on
the LMZ GTE-160 Engine) was included in
the Federal special programme for
Kaliningrad regional development planned
through to 2010 and also in the «Energy–
efficient Economics» Federal special
programme. Construction was delayed
because of the strong dependence on
foreign equipment for heavy duty combined
cycle power projects, which basically
resulted from he absence of investment
in domestic state–of–the–art power
generation gas turbine development.
However, the need for development of
regional power production became more
pressing, because after decommissioning
of Ignalinskaya AES atomic power plant in
Lithuania, which was the basic source of
electric power in the region, as demanded
by the European Union, power supply
p ro b l e m s i n e v i t a b l y a ro s e i n t h e
Kaliningrad region. In 2004, when total
power demand was 3.6 billion kW/h,
domestic production of electric power was
only 235 million kWh a year, approximate-
ly 6.5% of the required volume. The
demand for thermal power was also grow-
ing. Kaliningrad, a city with a population
around half a million people, is still heated
rather inefficiently by hundreds of small
boiler–houses.
A 2003 decree modifying the budget
financing practice for high priority civil
Research and Advanced Development
facilitated the construction and
commissioning of the first Russian 450 MW
combined cycle power unit. A new tool
of State support, named, Innovation
Projects of State Importance (called
«mega–projects»), was introduced on the
initiative of Andrey Fursenko , who at that

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 GAS TURBO TECHNOLOGY

time was Head of Russia's Industry and

Science Ministry. To receive State financial
support a project at this level had
to comply with the following standards:
making a considerable contribution to
national economic development, having
shared financing by the State and private
business and offering short payback
on the invested funds.
The new approach to the selection of
mega–projects which obtained substantial
financial support from the State budget
involved:
■ official participation of large private
business and scientific community leaders
in appraisal and selection of the promising
innovative projects;
■ restriction of the State’s rights to use
the project results exclusively for the field
of State interest defined in the government
contract for project execution;
■ separation of the workscopes
financed from the budget and none–budget
funds (with the budget share not exceeding
50%) in the government contract for project
execution;
■ obliging the project contractors
to provide a fivefold multiple of the sales
volume to the budget funds invested in the
project.
The winners of the first innovation
project tender were two Russian companies:
Power Machines and Saturn. They
proposed a project important to advancing
the domestic economy and named
«Development and manufacturing of high
efficiency combined cycle power units with
capacity over 200 MW», with a budgetary
financing share of about 450 million
rubles. It should also be noted that
Russia's Industry and Science Ministry
was in charge of the project from the mid-
dle of 2004.
In accordance with the tender
conditions, a number of tasks important
to domestic power engineering were to be
achieved during project execution:
■ creation of objective reasons,
including economic justifications, for
increasing electric power production from
gas turbines;
■ resolving the challenge of import
substitution in the field of heavy duty
power generation gas turbines;
■ modernization of the scientific and
technical base of domestic power turbine
GTE-160 gas turbine unit
Capacity (on natural gas) , MW 158.9
Capacity (on diesel oil) , MW 155.5
Turbine inlet temperature, °C 1060
Outlet temperature, °C 537
NOx emissions, ppm (O2 = 15%) 25
Weight, t 257
Exterior heat recovery steam generator of horizontal type
HP/LP steam production capacity, t/h 242.3/51.6
HP/LP steam pressure, kgf/cm2 83.3/6.9
HP/LP steam temperature, °C 520/217
Heat supply from water-to-water heat exchanger, Gcal/h 9.9
Gas flow, kg/sec 532.9
Inlet gas temperature, °C 538
Feed-water temperature, °C 164
Total weight, t 2580
T-150-7,7 steam turbine unit
Capacity, MW 160
Direct steam flow per HP/LP steam, t/h 472.2/95.9
HP/LP steam pressure, kgf/cm2 77.6/6.8
HP/LP steam temperature, °C 521/211
Turbine weight without a condenser, auxiliary equipment
and duct system, t 400
TFG-160-2U3 and TFP-160-2U3 turbogenerators
Active/total output, MW 160/200
Voltage, kV 15.75
Efficiency, % 98.54
Rotation speed, rpm 3000
TFG/TFP weight, t 238/262
engineering to increase its competitive
ability and develop export capacity.
In line with the framework
of the project workscope, in carrying
out the PGU-450 combined cycle
primary equipment development and man-
ufacture, Power Machines, committed to
raise the share of Russian production
in the licensed GTE-160 project from 70%
to 95%.
In addition, Power Machines were
required to undertake GTE-160 gas turbine
manufacture, assembly, testing and
commissioning, and operating procedures.
The workscope also included demonstration
of the technological processes for
manufacturing of the most stressed
assemblies (flame tubes, turbine blades
and disks) of the gas turbine as well as
development, production and rigging
of the gas turbine with special

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GAS TURBO TECHNOLOGY
Photo 2. The plant mnemonic
diagram
Photo 3. The horizontal
heat recovery steam generator
is installed externally
Issue 1, 2007
instrumentation for measurement of
vibration level and the thermal condition
of rotor components. To minimize technical
risks during completion of the gas turbine,
a set of backup measures were developed
to supplement the existing design
documentation, in order to provide low
NOx emissions, the ability to withstand
high axial load and dynamic excitation,
and to test them autonomously at the tand.
Recognizing that the steam power
component of a generating set is specifically
designed to match the type of gas turbine,
it was essential to design the steam turbine
unit for the specific parameters optimized
for each cycle scheme. In addition,
the steam turbine was designed with due
consideration of some specific features
12
of operation within a combined cycle,
such as: throttle regulation of the steam
distribution, flow increase throughout the
turbine when operating in condensing
mode, increased wetness in the low
pressure section and a high requirement
for turbine flexibility.
To provide high efficiency and
reliability of the power generation unit,
especially in low flow mode, it was
necessary to validate the steam turbine
sections with advanced blade profiles on
specialised test stands.
Kaliningradskaya TETs-2 power plant
was to be the pilot project for introduction
of the new equipment.
The cycle design
of Kaliningradskaya TETs-2
The cycle design of Kaliningradskaya
TETs’ first module was developed
in accordance with the Technical Design
Assignment, the design data of the primary
equipment developers and with due
consideration of the technical solutions
in the cycle design approved in the techni-
cal and economic assessment.
Each module of the PGU-450 combined
cycle unit consists of two Power Machines
GTE-160 gas turbines, two Podolsk
Engineering Works P-96 heat recovery
steam generators, and a Power Machines
T-150-7.7 heat extraction steam turbine.
Primary components completing the
entire cycle operation are (photo 2):
■ condensate circuit;
■ deaerator and HP and LP feed
circuits;
■ HP and LP main steam pipelines;
■ steam pipelines for the module
auxiliaries;
■ connections to the auxiliaries’ mani-
folds;
■ feedwater heating installation;
■ feedwater deaerator.
The power generation cycle design is
based on a two unit principle.
The cycle design provides the
possibility for the module to continue
operating in the case of a sudden shut-
down of the steam turbine, with HP and LP
steam supply from the heat recovery steam
generator flowing to the turbine
condenser through a pressure reducing
desuperheating station.
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The feedwater deaerator consists of
a DP-1000 deaeration vessel with
a throughput of 1 000 t/h.
Condensate pumps transport the full
flow condensate into the condensate gas
heater of the heat recovery steam generator
through the steam turbine gland seal
system steam condenser and a low pressure
heater. Following the condensate gas
heater the condensate is fed into the
deaerator.
Each heat recovery steam generator
design includes a condensate gas heater
recirculation line with the installed water
heat exchanger cooled by the returning
system water.
Kaliningradskaya TETs-2
primary equipment specification
The GTE-160 is a stationary single shaft
unit consisting of a 16–stage compressor,
two external vertical silo combustors,
each having eight combined burners, and
a 4–stage axial turbine. It is designed
to drive the Elektrosila TFG-160-2U3
turbogenerator and discharges combustion
products into the Podolsk Engineering
Works P-96 heat recovery steam generator.
Primary fuel for the unit is natural gas
with diesel oil as back up. To reduce NOx
emissions water is injected into the
combustor during operation on diesel oil.
The horizontal, dual pressure, drum
type heat recovery steam generator has
natural circulation, gradual evaporation
and is designed for operation with variable
HP steam pressure over a load range from
50 to 100% without regulation of the steam
temperature.
A T-150-7.7 heat extraction steam
turbine is designed as the drive for
the TFG-160-2UZ turbogenerator and for
supplying steam to the boiler plant to heat
the system water. It is a single shaft dual
cylinder unit consisting of a single flow HP
cylinder and a double flow LP cylinder.
Grid valves are installed in the LP cylinder
for thermal load regulation and their
complete closure provides minimum
steam flow into the condenser.
TFG and TFP turbogenerators have
similar windings and magnetic circuits and
differ from each other only in the position
of connections. The connections are
upwards for the gas turbine and for
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GAS TURBO TECHNOLOGY
the steam turbine they are downwards.
The generators are equipped with static
thyristor self–excitation systems. A thyristor
starting device allows generator operation
in motor mode for the gas turbine rotor
acceleration during starts. Lubrication
of the generator bearings is provided by
the combined turbine and generator
lubrication system.
Basic specifications of the equipment
components are shown in the table above.
Design features of Kaliningradskaya
TETs-2 equipment
Teploenergoproekt Institute (Moscow,
Russia) is general designer for the PGU-450
combined cycle cogeneration unit. The
unit designed for Kaliningradskaya TETs-2
power plant has the following functional
and technological differences from the
prototype located at North West Power
Plant (St. Petersburg, Russia):
■ horizontal heat recovery steam
generator installed externally photo 3 (the
prototype has a vertical forced circulation
heat recovery steam generator located
in the turbine hall);
■ the units differ in guarantee rates
and requirements for combined heating
and electrical loads due to the difference
i n e n v i ro n m e n t a l c o n d i t i o n s a n d
demand for heat extraction load during
autumn and winter periods (heat deficit
periods);
Technical and economic parameters of Kaliningradskaya TETs-2
power generation unit
Fuel usage average annual coefficient, % 76
Thermal efficiency (gross), % 51
Auxiliary power consumption, % 2.22
Average annual specific consumption of the equivalent fuel*
for the electric power output, g/kw•h 181.5
Average annual specific consumption of the equivalent fuel*
for the thermal power output, kg/Gcal 155.0
Calculative tariff rates for electric power, rub/kw_h ($/kW•h)**
Calculative tariff rates for thermal power, rub/Gcal ($/Gcal)** 1.10 (0.042)
(when the fuel gas price is 45 $ per 1000 m3) 337 (12.91)
Annual production output in natural values.
Electric power from bus-lines, in millions kW*h 2792.8
Thermal power from manifolds, in thousands GJ 6956.3
Payback period from the moment of commissioning, years 4.5
* 1 kg of equivalent fuel is 7000 Kcal
** $1 is 26.1491 rubles (March 15, 2007 rate)
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GAS TURBO TECHNOLOGY
Photo 4. The rotor equipment
is mounted on vibration
absorbing supports
Issue 1, 2007
■ due to the difference in ground
geology, the turbine equipment differs
from the prototype in being mounted
on vibration absorbing supports photo 4
with a corresponding rise of the baselines
and modifications to the pipeline layout;
■ a state–of–the–art automatic control
system based on TELEPERM–XP is used
instead of the TELEPERM–ME of
the prototype;
■ to increase combined cycle flexibility,
working parts were modified;
■ GTE-160 gas turbine units were used
at Kaliningradskaya TETs-2 power plant
instead of the Siemens V94.2 units used
in the prototype.
The gas turbine was manufactured
in LMZ under the license obtained by
Power Machines for production and
marketing of GTE-160 gas turbine units.
The functional and technological
differences from the prototype V94.2
include:
■ correction of the basic documenta-
tion to recognize use of Russian construc-
tional materials, standardized parts and
assemblies, technical
requirements for the basic technological
operations to be carryied out in line with
existing norms;
■ introduction of technological
processes suited to the available manufac-
turing equipment and high manufacturing
quality assurance;
■ design modifications for individual
assemblies (an exhaust diffuser for the
PGU-450 combined cycle unit and a thrust
bearing for the PGU-230 combined cycle
unit) to ensure compatibility with other
equipment of the combined cycle unit.
14
Environmental protection
A high level of environmental safety
for the Kaliningradskaya TETs-2 power
plant is a requirement of both Russian and
European rules. Combined cycle technology
provides optimal use of the combusted fuel
energy and a reduction of emissions. The
level of NOx emissions is 25 ppm, which
is five times lower than the maximum
allowable concentration level established
for already existing power generation
plants.
To minimize interference with regional
water resources, the process water supply
uses a recirculation scheme at the cooling
towers.
Sewage treatment facilities with
the possibility of a biological second stage
treatment were installed for utility
wastewater purification. Their throughput
is 200 m3/24 hours. Unpolluted waste
and rain water will be channeled to two
treatment facilities with a throughput
of 1,728 m3/24 hours. Purification
of wastewater polluted with oil products
from the plant site will be carried out at
treatment facilities with a throughput of
2,400 m3/24 hours.
Operational testing
Thermal testing of the combined cycle
unit was carried out by specialists from
the ORGRES company in two basic
operational modes: as a semi–unit (1 gas
turbine unit + 1 heat recovery steam
generator + the steam turbine) and as a
complete unit (2 gas turbine units + 2 heat
recovery steam generators + the steam
turbine). A standard automatic process
control system was used, and steam flow
sensors and feedwater flows in the HP and
LP loops were additionally calibrated. The
combined cycle capacity was varied over
the range from 35 to 100% of the nominal
value of 450 MW. The testing was intended
to determine the two basic parameters
of combined cycle operational economy:
gross efficiency and specific consumption
of equivalent fuel.
Te s t r e s u l t s h a v e s h o w n t h a t
the technical and economic parameters
of the GTE-160 gas turbines and T-150
steam turbine comply with the designed
values. However, the steam turbine
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designed output (151.4 MW) was not
obtained because of steam–production
undercapacity from the heat recovery
steam generator high pressure loop,
and that had a negative effect on
the economic parameters of the entire
PGU-450 combined cycle unit. The heat
recovery steam generator efficiency
obtained during operation in nominal
mode was 6–6.5% lower than the
manufacturers’ parameters.
The unit gross efficiency obtained
during operation close to nominal load
was 50.1% and the specific consumption
of equivalent fuel for the electrical power
output was about 250 g/kw•h. To increase
the high pressure loop steam flow to
the nominal value, it is necessary to modify
the heat recovery steam generator.
Conclusions
Tasks achieved in line with the frame-
work of project execution, and the first
results obtained during Kaliningradskaya
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GAS TURBO TECHNOLOGY
power plant operation allow the following
conclusions to be drawn:
1. The Power Machines «Development
and manufacturing of high efficiency
combined cycle power units with capacity
over 200 MW» innovation project can
be considered as one of the successful
e x a m p l e s o f p a r t n e r s h i p b e t we e n
the State and private business in such
a science-intensive and hi–tech industry
branch as power engineering. The validity
o f t h e a p p ro a c h e s d e ve l o p e d f o r
the task assignments, supervision of their
achievement, and inspection of the results,
together with the possibility that
mega–projects offer an efficient approach
for solving problems in the country’s
economical development, have been
validated in practice.
2. The possibility and prospects for
introduction of heavy duty combined cycle
cogeneration units, constructed on the
basis of the LMZ (a branch of Power
Machines) heavy duty GTE-160 gas turbine
have been confirmed.
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Issue 1, 2007
GAS TURBO TECHNOLOGY

EQUIPMENT
SELECTION Basic approaches
to meeting the growing energy
needs in Moscow
Nikolay Kalyuzhny – Moscow energy directorate
Mikhail Trusov, Vladimir Alexandrov – TEPENGINEERING
Alexander Gorshkov – Gas Turbo Technology

During the last decade the gas turbine market has shown growth in order volumes from
the power and gas industries. This trend has led to Russian and foreign equipment
manufacturers’ interest in this potentially large market.
The competitive advantages of foreign equipment, its higher reliability and fuel efficiency,
are tempered by its high price (including higher maintenance costs). The customer has
a complicated task in making a competent choice of suppliers, construction and design
companies, but above all in selecting the equipment.
Classifying the basic approaches to equipment selection and forming a model for decision-
making, we offer a new chapter «Equipment Selection». Design companies, consumers,
economists, analysts, engineers and ecologists will all introduce basic requirements
for power equipment. This chapter will help potential customers to understand selection
criteria and will become a real tool for the manufacturers’ marketing specialists.
The chapter starts with an article depicting the approaches of the Moscow energy
directorate and design companies to selection of equipment for Russia’s power deficient
capital.

D
uring the last few years Moscow has
experienced energy demand
growth of 4–5% per a year, as
a result of the substantial increase
of housing and municipal construction.
At the same time the level and pace
of power network and substation
construction and modernization, as well as
generating facility commissioning, have
significantly reduced at the Mosenergo
cogeneration facilities.
Analysis of the daily load curve
during the autumn and winter periods,
characterised by the maximum load, shows
that the power shortage during the whole
day is 1,500 to 2,000 MW in Moscow.
Meanwhile the transmission and
distribution mains are operating at their
technical capability limits.
The Moscow Energy Plant Design
Institute (Mosenergoproyekt) created
Photo 1. GTES-12 gas turbine power plant at Zelenograd district heat plant a Project for correction of the Energy

16
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 GAS TURBO TECHNOLOGY

Programme for Moscow’s regional

development to 2010. According to the
Project the electrical demand will reach
18.5 to 21.8 GW by 2010, depending on the
growth rate. The power consumption is
forecasted to be increased by 3.9 million
kW till 2010. Fig. 1 shows that the
Mosenergo system has been inadequate
from 2001 and will remain so in the future.
The analysis of the existing heat supply
system condition showed that there was
no available heat capacity at most
Mosenergo cogeneration plants, while
Mosteploenergo also had insufficient heat
reserve (18%). The capital’s heat and
energy supply scheme to 2020, designed
by the Moscow General Plan Development
Institute, confirmed the further growth
of energy consumption. Heat consumption
is predicted to increase by 9.8 thousand
Gcal/hour.
The Moscow city department
for fuel and energy facilities, along with
TEPENGINEERING, prepared a plan
for generating facility commissioning
in Moscow to 2010 to cover the predicted
heat and electricity load increase in
the city. The plan is based on the estimated
electricity and heat demand for 2005, 2010 environmental aspects, and location Fig. 1. The balance
and 2020 related to specific consumers, requirements for different technical solu- of the Moscow region electric
and assumes use of the existing city tions to the construction and modernisa- capacity from 1995 to 2010:
infrastructure. tion of energy facilities. — high rate of power
In solving the challenges of increasing The conclusion of the major research capacity growth;
energy project efficiency in Moscow, there work, carried out by specialists from various — average rate of power
are good reasons to attract investments departments, was a recommendation for capacity growth;
through long term contracts to buy energy extensive application of combined cycle — low rate of power capacity
from new facilities which are included and cogeneration power plants, as is now growth;
in the plan for generating capacity traditional for most developed countries. — load (factual);
introductions in Moscow. This makes Numerous proposals from suppliers — load (forecasted);
investment projects more attractive and of high technology power equipment make — installed capacity
reduces the risks related to selling energy. the task of selecting the optimal equipment (factual);
The construction of new generating rather complicated, and expert bodies and — installed capacity
facilities is planned on the sites of existing scientific and technical councils are (forecasted)
district heating plant, gas distribution formed to evaluate the different offers.
stations, Mosvodokanal (water treatment Generally speaking the primary task is
system) sites and Moscow enterprises. to assess the requirements by relying on
Construction of new gas turbine the operational peculiarities for a typical
cogeneration plant is planned in new customer. The wide range of parameters
districts which cannot be connected demands classification of the basic technical
to the existing heat and power sources. and economic indices and an integrated
Taking into consideration the negative approach to equipment selection.
aspects of the new power supply for Scientific and technical councils, and
Moscow consumers, the city government open competitions, have become routine,
developed a strategy to meet the growing and systematize the main approaches to
regional energy demand. It carried out equipment selection in order to reduce
comprehensive analysis of the efficiency, the risk of inefficient solutions.

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GAS TURBO TECHNOLOGY
Fig. 2. The forecast
of the electricity price changes
at the wholesale energy market:
— the forecast
of the electricity prices 1;
— the forecast
of the electricity prices 2
Fig. 3. Gas price changes:
— at the competitive
market;
— average;
— at the regulated market
Issue 1, 2007
Considering the approaches which
were applied for the first power projects
which were implemented as part of the
Moscow generating facility development
programme, the following points were
analysed and considered while creating the
plan for generating facility commissioning:
■ the energy and heat demand in a
particular district
■ the possibility to set up a buffer zone
■ the possibility of transferring
the existing loads from decommissioned
equipment to another heat supply source
during the reconstruction periods
■ the technical capacity for electric
transmission
■ the potential gas supply
■ the possibility of providing heat load
on the gas turbines, especially in summer,
to increase the equipment operational
efficiency
While selecting the sites for building
additional gas turbine units at district
heating plants, the first analysis considered
the existing heat consumption and forecast
development of district infrastructure
i n c l u d i n g re s i d e n t i a l a n d u t i l i t y
construction, heat consuming enterprises,
etc. The determining factor was the space
18
available for gas turbine power plant
construction and the technical possibility
of providing additional generating capacity
with the fuel gas supply and the heat and
power transmission capacity.
The long range power demands were
also evaluated, together with the possibility
of meeting them at the existing sites with
minimal additions. The highest economic
performance and the shortest payback
period are achieved with the equipment
in full time operation in the basic heat
extraction mode throughout the year, and
this is possible in principle if the plant
thermal production covers the district
needs for hot water or there is a facility
consuming heat all year round.
The following urban features were also
taken into account: the high building
density and the worsening environment
in Moscow, so that one of the main
requirements for newly constructed energy
facilities is compliance with noise and
emission limits. Other factors being
equal (without special measures on
NOx reduction) high efficiency, high
temperature, gas turbines have worse eco-
logical characteristics. This in particular
brings a conflict between two most
important criteria — economic efficiency
and environmental safety. The fact that the
overall fuel efficiency of a gas turbine unit
with heat extraction makes the generation
efficiency less significant was also
considered, and therefore gas turbine
plants designed around third generation
aircraft engines were preferred for the first
projects.
Aircraft engine building construction
is a rapidly developing industry in Russia,
with a huge scientific and technical
resource, and during the last 5 to 10 years
it has been the leading supplier of gas
turbine power plants. All the drives were
designed around aircraft gas generator
prototypes during this period. These units
differ fundamentally from traditional
stationary power units, being highly
efficient, with small weight and dimen-
sions as well as challenges in providing the
required reliability and operational life.
Lightweight aircraft designs need
complete conversion to ensure operability
in a wide range of modes. Lower turbine
inlet temperature improves the service life
of gas turbine hot end components which
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are the critical elements in this respect.
The reduction in economic efficiency is
compensated by the possibility of exhaust
gas utilisation.
Engines with a by–pass ratio of 2 to 4
are used in civil and military transport
aviation, which limits the output of
engines converted without significant
changes. The majority of aeroderivative
gas turbine engines are rated between 4
and 16 MW and only five manufacturers
compete in the 16 MW class. In choosing
a supplier, the power plant references
and operational experience are the key
considerations at present. Gas turbine
development is rather time consuming.
Success depends on the correct technical
solutions in conversion (the original
aircraft engines have impressive reference
lists as a rule) as well as understanding the
physics of the process taking place under
the different operating conditions of the
gas turbine. In selecting the equipment
supplier, the experts inspected operating
installations and analysed their operating
experience. The main evaluation criteria
were equipment reliability parameters
such as availability rate and Mean Time
Between Failures. Various operational
modes were considered in the analysis.
The next most significant parameters
in evaluation of different gas turbine
implementation potential were
the economic ones: payback period, the
specific cost per kW of installed capacity,
the net cost per kWh of electricity. Despite
the appreciable difference in capital cost
in favour of third generation gas turbines,
and in fuel cost in favour of fourth
generation gas turbines, the economic
analysis of the different equipment shows
similar payback periods, which is the result
of unreasonably low anticipated gas, heat
and electricity tariffs.
In dynamically developing countries
where the prices for energy, heat and gas
are controlled by the market and depend
first of all on supply and demand,
competition drives the manufacturers into
constant improvements to their equipment.
The Moscow regional power system
development is planned on the basis of
a strategy of steadily increasing rates for
power and heat, in order to bring them
to the economically realistic prices which
can deliver the necessary level of investment
HTTP://WWW.GTT.RU
into the development of generating
facilities. The increasing attraction
of projects from an investment viewpoint
must be balanced by realistic consideration
of the possibility that consumers can pay
for the energy supplies.
The forecasts for energy and gas price
growth in Moscow are shown in Fig. 2
and 3. The balance between them
influences the economic characteristics
of projects with different power equipment
and thus their attraction as an investment.
The changes of tariff policy in the regions
greatly influences the selection of technical
solutions for generation.
The first stage in the generating
facility commissioning programme was
the construction of small capacity gas
turbine power plants.
TEPENGINEERING, along with the
Teploelektroproyekt institute, carried out
the pre-project expert evaluation of gas
turbine selection for Mosteploenergo
district heating plant.
This study included analysis of the sites
for gas turbine installation, the available
space, the existing and forecast heat and
electricity loads, the plant auxiliary loads,
the possibility for exporting electricity into
the Mosenergo network and a number of
technical aspects of generating equipment
implementation.
An analysis was also made of Russian
gas turbines, reference lists, the heat and
power rating of the gas turbines, the layout
solutions, and the economic benefits
of different variants of gas turbine power
plant construction.
The department for the Moscow fuel
and energy system held a scientific and
technical council in 2003, in which experts
from different companies participated,
including the Teploelektroproyekt
institute, Mosteploenergo, Mosenergo,
the Moscow agency for energy saving
(now Moscow energy directorate),
the Department of science and industrial
policy, the Regional energy committee,
Mosgorenergonadzor and Gostekhnadzor,
as well as a number of design, construction
and scientific companies. The issues of gas
turbine selection for Mosteploenergo
district heating plant were discussed.
The Expert evaluation of gas turbine
selection for Mosteploenergo district
heating plant also included evaluation
19
GAS TURBO TECHNOLOGY
TURBOnews
Two DGA-5000
turbine expanders will be
commissioned at Mosenergo
TETs-23 heat and power plant
Turbine expanders from
Energy Company (Krivoy Rog) will
be installed at the plant’s gas
pressure reducing station and will
substitute for throttling devices.
The DGA-5000 turbine expander is
designed for the gas main pipeline
pressure of 1.2-0.6 MPa. As
the gas passes through the
turbine, its excess pressure is
reduced to 0.12–0.07 MPa and it
becomes cooler, requiring a gas
heater to be installed at
the outlet. The gas flow will be
579,000 nm3/hour.
Both units use Privod
T-6-2ZU3.1 turbine generators
rated at 5 MW. The generators
were manufactured on very short
leadtime and delivered to the heat
and power plant (the contract was
signed in June, 2006). A reduction
gear with transmission ratio
of 3.2 is installed to reduce the
rotational speed to the 3000 rpm
input of the turbine generator.
The first unit was installed,
and construction of the second
unit completed, in 2006.
The turbine expander
installation is an energy-saving
technology with significant
potential. Its introduction in
the capital’s power plants is part
of the Moscow Power Grid
development and re-equipment
programme, developed by experts,
Moscow government, Mosenergo
and the Russian Academy of
Sciences. About 100 similar power
generating units are planned to be
supplied for Mosenergo needs
in 2007-2012. Other RAO UES
subsidiary companies are also
interested in application of
DGA-6000 turbine expander units.
Wholesale Generation Company
OGK-4 placed an order for delivery
of 6 turbine expanders for
Surgutskaya GRES-2 state district
power plant in 2007.
Issue 1, 2007
GAS TURBO TECHNOLOGY
Photo 2. GTES-12 gas turbine
power plant at Peredelkino
district heat plant
Issue 1, 2007
of the economic benefits of two variants
o f p l a n t re c o n s t r u c t i o n w i t h t h e
Aviadvigatel 4 MW gas turbine or the
Saturn 6 MW gas turbine, as well as the
analysis of two variants of heat distribution
covering forecast loads and also meeting
the existing plant loads.
Mosteploenergo requirements for the
gas turbine are typical for installation at
new build or modernised district heating
plant.
The department for the fuel and energy
system defined the main objective
for introduction of the gas turbine to be
meeting the plant auxiliary loads of 7
to 9 MW, with export of surplus capacity
to the Mosenergo network.
Comparing the variants showed that
installation of two Saturn (Rybinsk) 6 MW
gas turbine units was the more appropriate
and this was taken into account in
the subsequent project documentation
development.
Starting in 2003, TEPENGINEERING
developed the project and engineering
documentation of Moscow plant recon-
struction (Kuryanovo, Penyagino,
Peredelkino, Zelenograd RTS-3) on the
instruction of the Moscow agency on ener-
gy saving (now Moscow energy direc-
torate). The cogeneration plants are
equipped with GTA-6 gas turbine units
in all of the projects. The Kuryanovo and
Penyagino plants were commissioned
in 2005, whilst the Zelenograd plant
(photo 1) and the Peredelkino plant
(photo 2) were commissioned in 2006.
20
Preparing documentation, gaining
approvals, and design supervision were
carried out by the specialists in line
with existing standards and technical
specifications, to exacting quality
requirements and on schedule. One of the
conditions for successful solution of
the assigned tasks was the correct choice
of equipment for modernization.
A significant factor in choosing the
main equipment supplier is a guaranteed
lead time, as any delays in heat and power
plant commissioning, especially in new
districts, bring disruption in delivery
of municipal or industrial facilities as
well as extending the payback period.
Factory-assembled equipment is preferred
for the same reason.
Main equipment manufacturers are
judged by the degree of development
of their maintenance systems, their
equipment serviceability, and their
running experience together with
planned and unplanned maintenance
downtimes.
A complex approach is used to optimise
the customer’s maintenance costs. It is well
known that the equipment maintenance
costs for different foreign manufacturers
vary greatly. As a rule this is the result
of their different business models. It is
important for the decision on equipment
purchase to be based on fair and open
business, so that the customer-supplier
relationship becomes a long term
partnership and the business is mutually
beneficial.
The legal framework for a long term
and profitable generation business is one
of the necessary and essential conditions
for independent generating companies
to appear. One of the significant factors
of investment attractiveness is the legal
framework that regulates connection to the
network, sales, environmental issues, tax
burdens, etc.
That’s why equipment manufacturers
need to maintain constant monitoring
of the economic and political trends
in regional development. To make
a powerplant engineering business stable
and progressive, the enterprises should
have technical and technological strategies
based on effective marketing, thoughtful
analysis and a reliable forecast of demand
in a constantly changing market.
HTTP://WWW.GTT.RU
TURBOnews
Lidskaya TETs heat and power plant (Belarus)
began construction of a new combined-cycle
gas turbine power plant
The state owned enterprise
BelNIPIenergoprom is the general designer of
the heat and power plant modernization.
Lidskaya TETs heat and power plant cycle
scheme, according to the project, will be based
on cross connections, i.e. a steam manifold,
connecting the steam from several power
boilers, will be installed downstream of a steam
boiler at the GTES gas turbine power plant.
The primary component of the plant is
a Kuznetsov Samara GTE-25/NK-830E gas
turbine unit rated at 25 MW, designed around
the NK-37 gas turbine engine. Its assigned life is
100,000 operating hours, with a time to first
overhaul of 25,000 hours.
At present, there are three gas turbine units
with NK-37 engines in operation – one at
Bezymyanskaya TETs heating and power plant
and two at Kazanskaya TETs-1. Their total accu-
mulated operating time is over 30,000 hours.
On the 29th of September last year the state
owned enterprise Grodnoenergo signed a contract
with Kuznetsov Samara for the equipment to be
delivered to Lidskaya TETs heat and power plant.
State testing of the first domestically
produced gas turbine for Russian Navy
was carried out at Saturn
On November 25, 2006 the State
Commission signed the acceptance certificate
for the M75RU marine gas turbine engine at
Saturn. The engine’s maximum output
is 7000 hp. This event confirms that the first
fourth generation Russian marine gas turbine
has completed assembly and testing. A whole
range of engines for the Navy, the Frontier
Troops, and for civil vessels will be designed
around it. Saturn has become one of the
companies which can design and produce the
marine gas turbines independently.
State testing of marine gas turbines
has therefore been carried out in our country for
the first time. A state commission under the
chairmanship of Captain Mikhail Alexandrov
worked at Saturn during the month. Testing of
the pre-production models of the M75RU gas
turbine did not show up any problems, and the
engine was accepted by the state commission
and recommended for installation in Russian
Navy vessels.
Modern systems incorporated into this
gas turbine have also been designed, supplied
and tested. Systems manufactured by
Saint Petersburg companies include the
Sheksna-07 multiprocessor local control
system (manufactured by Avrora), the
SVD 70/75 vibration monitoring system
(Technicheskiye Systemy & Technology),
and the engine start system (TsNII SET).
An interactive electronic control system
designed by Istok Company considerably
facilitates operation.
HTTP://WWW.GTT.RU
A tender for delivery of a heat recovery steam
generator will be held in the near future.
The NK-37 engine is derived from the
NK-321 aeroengine and uses 60% of its compo-
nents. Its weight, together with its mounting
frame, is 9150 kg, its nominal power rating
25 MW, compression ratio 23.1 and its efficien-
cy reaches 36.4 %.
Turbine inlet temperature is 1454 K and
the exhaust temperature 730 K. Power shaft
rotation speed is 3000 rpm, mass flow
101.5 kg/s, and the fuel consumption at nominal
conditions is 5253 kg/h.
Heat recovered from the NK-37 turbine, at
approximately 35 Gcal/h or 30 MW of heat
power, will be used in the new 40 MW steam
turbine. The steam will be supplied at a pressure
of 4 MPa.
The primary fuel for Lidskaya TETs heat and
power plant is natural gas, delivered via the
Vilnius–Ivatsevichi gas pipeline. A booster com-
pressor station will increase the gas pressure to
4.4 MPa and the gas will be supplied to the NK-
37 fuel-metering equipment. The booster equip-
ment and automatic control system will also be
supplied by Kuznetsov Samara.
Delivery of all the equipment is to be com-
plete by June 2007.
M75RU marine gas turbine at the test stand
Saturn is planning to submit another marine
gas turbine, the 14000 hp M70FRU, for testing in
2008. Besides the M75RU and M70FRU projects,
Saturn and Zorya-Mashproekt are collaborating
in construction of the Russian M90FR marine gas
turbine, rated at 27500 hp.
Saturn will be granted investments to build
Russian marine gas turbines in accordance with
the federal programme “Defence Industry devel-
opment for 2007-2010 and for the period to
2015”. The vice-chairman of the state commis-
sion, Colonel Sergey Shchetinkin, reported that
the special equipment had been purchased at the
expense of the Defence Department, with deliv-
ery scheduled for 2007. A multipurpose test
stand for marine engines and power generation
units will be constructed at the main Saturn pro-
duction facility. The Federal Industrial Agency
has already approved its design assignment.
21
Solar Turbines signs supply contract
with LukoilNizhnevolzhskNeft
Its scope includes delivery of four power
generation packages consisting of Taurus 60
gas turbine generators. Three Taurus 70 gas
turbines will drive Dresser-Rand compressors.
The equipment will be installed on the new
Caspian shelf drilling platform at the Korchagin
field.
The nominal power rating of each
generation package is 5.2 MW, and the
electrical efficiency is 30.4%. They will be
operated in cogeneration cycle with a thermal
capacity of 9.6 MW. The power generation units
will supply electricity to the low pressure
compressor station, platform drilling equip-
ment, and the entire station infrastructure.
The nominal power rating of the Taurus 70
is 7.69 MW, and the efficiency 34.8%. The com-
pressor units will be used for gas transmission
to the Makhachkala-Astrakhan gas pipeline and
for the platform process needs.
The primary fuel will be associated gas,
and changeover to diesel oil will also be
possible.
The first stage construction
of Severnaya GTU-TETs
gas turbine heat
and power plant (Moscow)
is underway
The first stage of the plant is based on
a Pratt & Whitney Power Systems SWIFTPAC
FT8 gas turbine power unit with total electrical
output of 60 MW.
The SWIFTPAC FT8 is a twin-engine unit.
Two FT8 gas turbines, with nominal power
rating of 27.4 MW each, drive a single turbine
generator from opposite ends, and the turbine
generator can be operated either with two
engines or with one in half load mode.
The plant’s first stage is equipped with
two heat recovery steam generators, each
with a thermal capacity of 30 Gcal/hour and
two PTVM peak heating boilers each rated
at 60 Gcal/hour). Dorogobuzhkotlomash will
manufacture the heat recovery steam
generators and the water heating boilers. Sventa
will supply the required fuel gas booster
compressors, which are manufactured by
Enerproject (Switzerland).
After the first stage commissioning, further
expansion of the GTU-TETs plant is planned.
Another SWIFTPAC FT8 gas turbine with heat
recovery steam generators will be installed,
which will raise the total electrical output up to
120 MW and the thermal capacity to 240
Gcal/hour.
The GTU-TETs turnkey construction is
being undertaken by DKM-Engineering. The
plant will supply the capital’s new northern dis-
trict with energy and heat.
Issue 1, 2007
GAS TURBO TECHNOLOGY
CYCLE DESINGS
Graz cycle – a highly efficient
oxy-fuel cycle for CO2 capture
Herbert Jericha, Wolfgang Sanz – Institute for Thermal Turbomachinery
and Machine Dynamics,
Graz University of Technology
Introduction
I
n the last two years global warming,
environmental change and destruction
of natural resources like water and
forest reserves have reached exasperating
speed. Very little doubt is about the effect
a n d t h e e x t e n t o f a n t h ro p o l o g i c
contribution. Counter measures should
be put into effect quickly and in all realms
of human activity.
The reason — the worldwide ever rising
emission of noxious gases to atmosphere —
has been recognized since 1988 by
the 700 scientists who formulated the Call
of Action of the Toronto Conference.
Other events have followed and today
the Kyoto Goal is acknowledged by
the majority of governments around the
world. The combustion gas CO2 and very
effective also the biologically emitted
methane are the most important
contributors to atmospheric change and
global warming.
Only gas turbine technology offers
design and mode of operation that makes
CO2 retention possible in the short period
of time that may be available only
in the near future. Technology leaders
discuss three possibilities of CO2 capture
on grand scale:
1. Oxy–fuel systems with combustion
by pure oxygen only. After separation
of the combustion generated water by
proper condensation, the combustion
generated CO2 is retained, stored or used
for other technical applications.
2. Capture of CO2 from exhaust gases
by chemical means which appears up
to now to be costly, ineffective in use
of solvents and to lower air breathing gas
turbine efficiency.
3. Transformation of hydrocarbons
especially natural gas — with little or no
22
Issue 1, 2007
application of O2 — into a mixture of CO2
and H2 from which the heat engine or gas
turbine fuel H2 can be derived. CO2
is retained in the transformation process,
separation is intended to be effected by
solvents or by membranes, the second way
up to now with little success.
The Institute for Thermal
Turbomachinery and Machine Dynamics
at Graz University of Technology has been
active offering cycle and turbomachinery
design solutions since 1984. Ever since that
time the activities were directed to
advancement in gas turbine design
of highest efficiency with the additional
capability for capture and storage of CO2.
The Hydrogen–Oxygen Cycle with the
working fluid water and high temperature
steam had been proven to be very effective
in turbine and compressor sizing and
thermal efficiency. This was partly due to
the ample experience which had been
gained in German rocket engine design
and our theoretical combustion burner
and chamber studies. Besides
turbomachinery science had long before
gained experience in steam flow in its
oldest achievement — the large power high
temperature steam plant. So the change
in heat input from boiler evaporator and
superheat tubes to a combustion chamber
with a flame of 3,600° C from
stoichiometric combustion of H2 and O2
reduced by H2O input into the burner
flame was just one but important step. Also
forced by the thermodynamic properties
of steam a double loop cycle was required
anyway to hold the maximum steam
pressure at reasonable values. These
advantages were retained when turning
back to fossil fuels like natural gas or
oxygen blown coal gas. Thus the original
Graz Cycle was created and published first
at CIMAC Interlaken 1995. A direct
HTTP://WWW.GTT.RU

comparison of H2 to natural gas is given
in the paper to ASME Cogen Turbo Vienna
1995. Improvements and further
developments since then were presented
at several conferences. In the
following latest achievements of the Graz
Cycle system are presented with emphasis
on most modern design concepts well
in line with international gas turbine
development to higher efficiency and
operational reliability.
Graz Cycle configuration
The Graz Cycle is suited for all kinds
of fossil fuels. In this work thermodynamic
data are presented for a cycle fired with
methane, because it is the most likely fuel
to be used in a first demonstration plant.
Fig. 1 shows the principle flow scheme
of the S-Graz Cycle with the main cycle
data. Basically the Graz Cycle consists of a
high temperature cycle (compressors C1
and C2, combustion chamber, High
Temperature Turbine HTT, Heat Recovery
Steam Generator HRSG and High Pressure
Turbine HPT) and a low temperature cycle
(Low Pressure Turbine LPST, condenser
and compressors C3 and C4). The fuel
together with the nearly stoichiometric
mass flow of oxygen is fed to the
combustion chamber, which is operated at
a pressure of 40 bar. Steam as well as a
CO2/H2O mixture is supplied to cool the
burners and the liner.
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GAS TURBO TECHNOLOGY
A mixture of about 75.5% steam, 24% Fig. 1. Principle flow scheme
CO2, 0.4% O2 and 0.1% N2 (mass of the Graz Cycle power plant:
fractions) leaves the combustion chamber 1 — Low Pressure
at a mean temperature of 1400°C, a value Compressor (C1);
achieved by G and H class turbines 2 — High Pressure
nowadays. The fluid is expanded to Compressor (C2);
a pressure of 1.05 bar and 580°C in 3 — Combustion Chamber;
the HTT. Cooling is performed with steam 4, 5 — High Pressure Turbine
coming from the HPT at about 330°C (HPT);
(13.7% of the HTT inlet mass flow), 5 — High Temperature
increasing the steam content to 78.4% Turbine (HTT);
at the HTT exit. The hot exhaust gas is 6 — Turbine Generator;
cooled in the following HRSG to vaporize 7 — Four-flow Low Pressure
and superheat steam for the HPT; Steam Turbine (LPST);
the pinch point of the HRSG is 25°C at 8 — High Pressure Steam
the superheater exit. After the HRSG Turbine (HPST);
about 55% of the cycle mass flow is 9, 10 — Compressors
compressed using the main cycle (C3, C4);
compressors C1 and C2 with intercooler 11 — Heat Recovery Steam
and is fed to the combustion chamber with Generator (HRSG);
a maximum temperature of 600 °C. 12, 13 — Condensers/
The remaining mass flow which Evaporators (C/E1, C/E2);
contains the combustion generated CO2 14 — Condenser;
is fed to a condensation process in the 1 15 — Intercooler;
bar range in order to avoid the problems 16 — Water Pump;
of a working fluid condenser at vacuum. 17 — Deaerator
The heat content in the flow is still quite
high so re–evaporation and expansion
in a bottoming cycle is mandatory. For
proper re-evaporation two sections
of working fluid condensations are
provided, each following a compressor
stage with reasonable increase of flow
pressure resulting in a higher partial
condensation pressure of the water
23
Issue 1, 2007
GAS TURBO TECHNOLOGY

condensed and separated most of the water

Fig. 2. Heat – temperature content, the temperature of the working
diagram of the condensation/ fluid decreases strongly in the water pre-
evaporation process heaters of the bottoming cycle.
About three quarters of the
condensation cycle mass flow is evaporated
and superheated in the first condenser. It
is mixed with the steam of the second
condenser/evaporator unit providing
completely clean steam of 0.75 bar and
175°C at the LPST inlet. Expanding the
Graz Cycle content. The two compressor stages can steam to a condensation pressure of 0.021
Power Balance be regarded as pre-runners of the CO2 bar for a cooling water temperature of 8 °C
HTT power [MW] 617.9 delivery compressor and will be helpful (Northern Europe) provides about 72 MW
in cleaning the turbomachinery, piping power output. A four-flow design is
HPT power [MW] 49.9 and HRSG interior from air in preparation necessary to handle the high volume flow
LPT/LPST power [MW] 71.6 of a cold start. The heat exchangers are for a 400 MW Graz Cycle.
Total turbine well developed modern boiler elements Steam is extracted at a pressure
power PT [MW] 739.4 providing steam just below 1 bar for of 0.12 bar from the LPST and fed
the condensing steam turbine. to the deaerator. The expansion line is
C1 power [MW] 131.1 At the first pressure level of 1.27 bar to the major part in the dry steam region
C2 power [MW] 82.6 about 63% of the water content can be and crosses the Wilson line only before
C3 power [MW] 8.9 segregated, so that the power demand the last stage, so that only very fine droplets
of the second compression stage is in the outer last stage sections are formed.
C4 power [MW] 6.6 considerably reduced. It compresses up to A very high expansion efficiency hardly
Pump power [MW] 5.5 1.95 bar, which allows the segregation hindered by formation of humidity is to be
Total compression of further 25% of the contained water. expected.
power PC [MW] 234.7 Further cooling of the working fluid,
also for water preheating, leads to Graz Cycle power balance
Net shaft power [MW]
the separation of additional 11 %, so that
without mechanical
the water content of the CO2 stream The cycle arrangement of the Graz
losses 504.7
supplied at 1.9 bar for further compression Cycle offers several advantages: On one
Total heat input is below 1%. After segregation of the water hand, it allows heat input at very high
Qzu [MW] 758.6 stemming from the combustion process, temperature, whereas on the other hand
Thermal cycle the water flow is degassed in the deaerator expansion takes place to vacuum
efficiency [%] 66.52 with steam extracted after the HPT and conditions, so that a high thermal
fed to the HRSG for vaporization and efficiency according to Carnot can be
Electrical power
superheating. The steam is then delivered achieved. But only less than half of
output [MW]
to the HPT at 180 bar and 549 °C. After the steam in the cycle releases its heat of
incl. mechanical,
the expansion it is used to cool the burners vaporization by condensation. The major
electrical & auxiliary
loss 490.7
and the HTT stages. part is compressed in the gaseous phase
This two–step pre-compressed and so takes its high heat content back
Net electrical condensation counteracts the effect to the combustion chamber and thus
cycle efficiency [%] 64.68 of sinking H2O partial pressure due to contributing to the high efficiency
O2 generation & condensed water extraction from working in comparison to an air breathing gas
compression PO2 [MW] 74.7 fluid and thus allows a reasonably high turbine. The flow of working gas to
Efficiency considering constant reevaporation pressure of 0.75 bar the combustor is completed by steam
O2 supply [%] 54.83 for the bottoming steam cycle. Fig. 2 from the HRSG via the HPT flowing to
shows the heat — temperature diagram for the burners and to the HTT, supplying
CO2 compression this condensation/evaporation process. clean cooling medium to HTT blade
to 100 bar PCO2 [MW] 13.0
After the start of water condensation, cooling passages. The additional power
Net power the working fluid temperature decreases in the HPT is also reason for high cycle effi-
output [MW] 403.0 only slightly, leading to relatively small ciency.
Net efficiency mean temperature differences of 8 K Table 1 gives the turbomachinery sizes
in the first evaporator and 12 K in and the power balance of the Graz Cycle
ηnet [%] 53.12
the second evaporator. After having plant for 400 MW net power output. The

26
Issue 1, 2007 HTTP://WWW.GTT.RU

compression power is only about one third
of the total turbine power, which leads to a
thermal efficiency of about 66.5% or an
electrical net efficiency of about 64.65%.
If considering the efforts for oxygen
production and compression as well as the
efforts of CO2 compression to 100 bar for
liquefaction, the net efficiency further
reduces to 53.12%, a net efficiency higher
than that of most other CO2 capture
technologies if evaluated under the same
conditions.
Desing concept
for a very large Graz Cycle plant
of 400 MW net output
This power is derived from a 490 MW
turbo shaft configuration because of the
additional power demand of the air
separation unit and by the driving power
for the oxygen and CO2 compressors.
As an example of advanced
turbomachinery development the fast
running shaft 8,500 rpm is shown
in detailed design work together with mate-
rial selection, rotor stress values and rotor
dynamics.
In this design proposal intensive use
of steam cooling is made, not only for
blades, but for all rotors in the high–speed
high-temperature region. In that manner
a solid and simple rotor design forged
from one piece or welded from separate
disks can be used with no internal friction
between rotor disks as might be possible
in a rotor assembled from separate disks.
This type of rotor design provides for high
blade load carrying capability with
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GAS TURBO TECHNOLOGY
acceptable radial stress. The high
chromium ferritic steel which is in use
in steam turbine technology for a very
long time will have to be supplied by steel
makers in rotor drums of about 10 tons for
the high speed shaft. It has superior
qualities in high heat conduction and low
thermal expansion properties. The
relatively high speed selected for the free
compressor–turbine shaft has many
advantages. It provides for long blades
in the turbine stage and for high
flow efficiency and low tip clearance
loss even at low number of stages in the
compressors.
The main gas turbine components are
arranged on two shafts, the compression
shaft and the power shaft (see Fig. 3). The
compression shaft consists of the cycle
compressors C1 and C2, which are driven
by the first part of the high temperature
turbine HTT, the compressor turbine
HTTC. It runs free on its optimal speed of
8,500 rpm. This relatively high speed is
selected for reason of obtaining sufficient
blade length at outlet of C2 and to reduce
the number of stages in both compressors.
The second part of the HTT, the power
turbine HTTP, delivers the main output
to the generator. A further elongation
of the shaft is done by coupling
the four–flow LPST at the opposite side
of the generator. The two shafts are based
on the same spring foundation.
The intercooler between C1 and C2
is located on the fixed foundation. The
HPT can be coupled to the far end of the Fig. 3. Arrangement
LPST or can drive a separate generator of the main turbomachinery
which could facilitate a foreign heat input for a 400 MW Graz Cycle
in start. plant
27
Issue 1, 2007
GAS TURBO TECHNOLOGY
Fig. 4. C1 design with
an uncooled drum rotor
and an additional radial
stage from nickel alloy,
with radial diffuser and exit
scroll to intercooler
Issue 1, 2007
C1/C2 compressor design with intercooler:
The working fluid compressor C1 is
driven by the HTTC at 8,500 rpm. The high
speed poses a special problem for the first
stage of C1 which has yet been solved by
flow research and is now applied in many
aircraft jet engines and also stationary
compressor designs. The high tip Mach
number on the first stage should
not exceed the value of 1.4 for reasons
of shock formation. With the help of
a slight positive inlet swirl an inlet Mach
number of 1.36 is designed.
Compression at C1 starts at 106 °C
and reaches 442 °C at the outlet to
the intercooler. For reasons of rotor
dynamics the shafts of C1 and C2 are
separated with intermediate bearings
and a solid coupling. Due to the low inlet
temperature, cooling is not necessary.
This is possible by a combination of rotor
materials. So the first stage could be
supplied as a blisk of titanium alloy
a solution which is still investigated.
The first part with seven axial stages is
a ferritic steel drum, which reaches only
390 °C. This material can be highly stressed
without creep at temperatures below
400 °C. By the application of a final radial
wheel which has to be milled separately
from nickel alloy and which is mounted
to the main drum by elastic centering
completes the rotor construction of C1,
as shown in Fig. 4. The radial wheel with
a wide vaneless diffuser and scroll improves
the flow transfer to the intercooler.
The inlet temperature to C2 is
somewhat lowered by the intercooler
but still reaches 380 °C. During course
of compression the working fluid reaches
an outlet temperature of 580 °C, so that
from the second stage onwards cooling has
to be applied on the rotor surface of
28
the bladed annular flow channel. Seven
axial stages with a stepwise decrease
of blade length from 90 to 40 mm are
supported on a drum rotor with disk
extensions of constant diameter.
HTT compressor turbine (HTTC)
The same drum rotor either forged
in one piece or welded up from separated
disks carries not only the C2 but also the
compressor turbine HTTC. The HTTC was
designed alternatively as a two–stage
reaction turbine with 50% reaction at the
mean section or as a transonic one–stage
turbine. In this work the one–stage design
is presented (Fig. 5).
The authors’ institute has done
extensive development work for the design
of transonic turbine stages. Not only
several computer programs have been
developed for investigating three–
dimensional transonic flow, but a unique
test installation for transonic stages was
built where many effects of unsteady
viscous transonic flow were investigated.
A novel innovative cooling system has
also been developed and could be applied
here in order to save cooling medium,
high temperature material and cost of man
ufacture at the same time providing most
effective blade cooling at the blade leading
edge in transonic flow. The design
could follow the development path
of General Electric in providing thermal
barrier coating on the rotating blades since
these are free of the multitude of cooling
holes and are supplied only by low number
of slots creating cooling steam films
covering the whole surface.
The HTTC single-stage transonic
compressor turbine combined with a 50 Hz
power turbine would offer a design
solution with several advantages. These are
longer diffuser, lower outlet speed, lower
friction losses in the passage to the ribs
to the first nozzle of the power turbine.
The transonic stage has a mean radius
of 750 mm at a blade length of 120 mm.
The high radius leads to a small radius
difference from compressor turbine outlet
to power turbine inlet.
The high speed and power of this
turbine is made possible by ample steam
cooling. Rotor cooling steam is supplied
along the whole drum surface. It is fed into
a labyrinth seal in the inner range
of the combustion chamber allowing
HTTP://WWW.GTT.RU

the steam to flow to both sides. One flow
is directed backwards under the dump
diffuser into the outer surface of the C2
providing cooling steam as described
above. The main amount of cooling steam
flows along the rotor drum at the inner
radius of the combustor casing towards
the first disk of the HTTC.
The very-high flow temperature nozzles
are hollow with proper cooling passages
and are cooled by steam fed from
the casing outside in radial inwards
direction (red arrows). The steam is
collected in a chamber of the diaphragm
just opposite the first blade root. Via
nozzles, blowing in direction of rotor
speed, the cooling steam is then fed to
the lower part of the blade fir–tree root.
From there it flows along the serpentine
passages under pumping action of the
rotor wheel and is delivered to the blade
surface via laser drilled holes to form
the conventional cooling films at
the appropriate locations of the blade.
In terms of rotor dynamics the drum
rotor of C2 and HTTC will be designed
for the high stress considering the effect of
steam cooling on all surfaces. Stiff bearing
shaft extensions and solid double–lobe oil
bearings provide for high shaft and high
bearing stiffness in order to have all critical
speeds sufficiently high above running
speed.
HTT power turbine (HTTP)
A gas turbine system with two shafts at
highly different speed as it has to be built
here, requires an intermediate bearing
to be arranged right between the stages
of compressor turbine outlet and power
turbine inlet. The flow of gas transmitted
is at very high velocity, at temperatures
of 1 075 °C and at a pressure of 14 bar.
The power turbine is proposed with
a strong change of inner radius on a solid
shaft. This feature provides better flow
transfer from HTTC outlet, lower rotor
and blade stress in the high-temperature
region, high flow efficiency due to long
blades and efficient cooling and thrust
equalization at the outlet plane. Five stages
are necessary for a 50 Hz design of Fig. 5.
So the axial outlet speed should be kept
at medium value in order to reduce
the exhaust loss, to reduce axial diffuser
exit length and to facilitate the flow
transfer to the HRSG inlet. The design
HTTP://WWW.GTT.RU
GAS TURBO TECHNOLOGY
proposed provides last blade lengths
of 750 mm at 50 Hz at 1300 mm inner
radius. Rotor material should also be
ferritic steel heat-treated for high stress
and in the cooling passages shielded
by anti-corrosive layers.
The intermediate bearing casing in its
hot environment has to be insulated on its
outer surface in a mode of insulation
withstanding the friction of the hot outer
flow. The same holds true for the three
supporting ribs, which have to provide
ample inner space for transfer of oil,
cooling air and steam leakage outlet from
labyrinths on both shaft sides as well as
for monitoring equipment. At the same
time the bearing should be as short as
possible and the ribs should provide only
a minimum of flow resistance.
For thrust equalization a stepped
labyrinth on the exhaust side of the rotor
drum is proposed as shown in Fig. 5, which
is supplied with internal steam pressure
to provide for the necessary thrust
equalization. The steam supply feeds also
the cooling flow which is led along the
rotor drum surface under the root sealing
plates for the last and the penultimate
stage, whereas cooling flow to the first and
second stage is supplied via the hollow
nozzle blades to an inner diaphragm cavity
from which the inflow to the hollow rotor
blades is effected. Power turbine thrust
bearing is arranged outboard of casing in
vicinity of steam operated balance piston.
Part load and start-up
In part load the maximum gas turbine Fig. 5. Design
temperature can be lowered by reduction of transonic one-stage HTTC
of heat input. With the free running and 50 Hz HTTP
29
Issue 1, 2007
GAS TURBO TECHNOLOGY
TURBOnews
The first reconstructed compressor
unit is commissioned at Moskovo
KS-18A compressor station
The ceremonial commission-
ing was carried out on October 28,
2006 and was attended by Murtaza
Rachimov, the President of
Bashkortostan, Alexander
Ananenkov ,Vice-chairman of the
Gazprom Board of Directors, and
Bogdan Budzulyak, Head of
Gazprom’s Gas Transmission and
Utilization Department.
Before reconstruction of this
Urengoy-Novopskov gas pipeline
compressor hall, the existing GTK-
10-4 units were completely worn
out, failing to meet noise and tem-
perature regulations , unable to
deliver the designed output of 10
MW, and of very low efficieny (not
more than 22%) with correspond-
ingly increased fuel consumption.
When the GTK-10-4 unit was
operated for gas transmission, its
gas consumption was 130 million
m3 a year. After the commission-
ing of five GPA-16R gas compres-
sor units designed around AL-
31ST engines, the fuel gas con-
sumption almost halved with the
same pipeline throughput. And
that in its turn had a beneficial
effect on the environment.
The replacement of eight
GTK-10-4 units by five GPA-16R
gas compressor units, each rated
at 16 MW, emptied whole working
areas of the compressor halls
which previously had to be heated,
lighted and maintained. The emp-
tied areas of the buildings will be
closed.
The compressor station
reconstruction is continuing this
year, and the first gas compressor
unit installation has started in the
second compressor hall.
Issue 1, 2007
compressor shaft adjustment of flow
and temperature can be effected precisely
in operating IGVs and turbine valves
accordingly.
To keep the working fluid and the CO2
delivery line free of nitrogen in each cold
start careful scavenging of all internal
volumes in turbomachinery, HRSG and
piping has to be done. Since fuel and
oxygen input can be governed for each
burner quadruple ignition and safe
operation of flames is secured. See further
details of the start–up process in
the appendix.
In case of power loss a sudden closure
of oxygen and fuel valves should be
sufficient, since the large blades of C1
and C2 turn immediately to vintage
and are reducing quickly the working gas
flow into the combustion chamber. In case
still too large acceleration of the power
turbine shaft would occur well controlled
vacuum breaking could be activated as
well as a possibly arranged bypass flow
connection from the combustion chamber
to the working gas condenser.
Economic evaluation
A detailed economic evaluation was
performed resulting in increased costs of
electricity of a methane fired Graz Cycle
plant of 0.72 / c/kWhel compared to
a conventional combined cycle reference
plant. The mitigation costs are 21.0 $/ton
of CO2 avoided, if CO2 liquefaction
is considered. This value is clearly below
the threshold value of 30 $/ton showing
the economic potential of the Graz Cycle.
This result depends mainly on
the assumptions about additional
investment necessary for a Graz Cycle
plant, like the costs for the air separation
unit. Only considering its cost variation,
the mitigation costs vary between 21.0 and
27.9 $/ton CO2 for the methane fired
plant.
Conclusions
The Graz Cycle is an oxy-fuel power
cycle with the capability of retaining all
the combustion generated CO2 for further
use. In order to avoid the difficulties
of condensation of water out of a mixture
of steam and incondensable gases at
30
very low pressures, a modified cycle
configuration was presented with
condensation in the range of 1 bar.
It allows a separate bottoming steam
cycle with reasonably high pressures
and efficiencies, so that a high net
cycle efficiency above 53% can be
expected.
The output of the Graz Cycle plant
is raised from industrial size to 400 MW
net output. A design concept for this size
is presented with two shafts. A fast running
compression shaft of 8500 rpm is driven
by the compressor turbine HTTC, whereas
the power shaft comprises the power
turbine HPT and the LPST. In an
economical analysis the Graz Cycle power
plant is compared with a reference plant.
The resulting mitigation costs are in
the range of 20–30 $/ton CO2 avoided
depending on the costs of the ASU
and thus are below a threshold value
of 30 $/ton CO2 (assumed for future CO2
emission trading).
The authors have thus presented
a design solution for an oxy–fuel
CO2 retaining gas turbine system which
can by acceptance of international gas
turbine industry be put into operation
within a few years. The authors believe,
that this system is equal in thermodynamic
performance to any other proposal
in the field of CO2 reduction and is
superior in applying gas turbine experience
and research accumulated to our day.
The complete reference list to
the article is given at www.gtt.ru
web-site.
Referencez
1. Jericha H., 1985, «Efficient Steam
Cycles with Internal Combustion
of Hydrogen and Stoichiometric Oxygen
for Turbines and Piston Engines», CIMAC
Conference Paper, Oslo, Norway.
..
2. Jericha H., Sanz W., Woisetschlager J.,
Fesharaki, M., 1995, «CO2 — Retention
Capability of CH4/O2 – Fired Graz Cycle»,
CIMAC Conference Paper, Interlaken,
Switzerland.
3. Jericha H., Fesharaki M., 1995, «The
Graz Cycle — 1 500 °C Max Temperature
Potential H2 — O2 Fired CO2 Capture with
CH4 – O2 Firing», ASME. Paper 95. CTP-79,
ASME Cogen–Turbo Power Conference, Vienna,
Austria.
HTTP://WWW.GTT.RU

..
4. Jericha H., Gottlich E., 2002,
«Conceptual Design for an Industrial Prototype
Graz Cycle Power Plant», ASME Paper 2002-
GT-30118, ASME Turbo Expo 2002,
Amsterdam, The Netherlands.
..
5. Jericha H., Gottlich E., SanzW.,
Heitmeir F., 2003, «Design Optimisation of the
Graz Cycle Prototype Plant», ASME Paper 2003-
GT-38120, ASME Turbo Expo 2003, Atlanta,
USA, Journal of Engineering for Gas Turbines
and Power, Vol. 126, Oct. 2004, pp. 733—740.
..
6. Heitmeir F., Sanz W., Gottlich E.,
Jericha H., 2003, «The Graz Cycle — A Zero
Emission Power Plant of Highest Efficiency»,
XXXV Kraftwerkstechnisches Kolloquium,
Dresden, Germany.
7. Jericha H., Sanz W., Pieringer P.,
..
Gottlich E., Erroi P., 2004, «Konstruktion der
.. den Graz
ersten Stufe der HTT-Gasturbine fur
Cycle» (in German), VDI Berichte 1857, VDI
..
Tagung «Stationare Gasturbinen: Fortschritte
und Betriebserfahrungen», Leverkusen.
8. Sanz W., Jericha H., Moser M., Heitmeir F.,
2004, «Thermodynamic and Economic
Investigation of an Improved Graz Cycle Power
Plant for CO2 Capture», ASME Paper GT2004-
53722, ASME Turbo Expo 2004, Vienna,
Austria, Journal of Engineering for Gas Turbines
and Power, Vol. 127, Oct. 2005, pp. 765—772.
9. Sanz W., Jericha H., Luckel F., Heitmeir F.,
2005, «A further step Towards a Graz Cycle
Power Plant for CO2 Capture», ASME Paper
GT2005-68456, ASME Turbo Expo 2005,
Reno-Tahoe, USA.
..
10. Jericha H., Sanz W., Gottlich E., 2006,
«Design Concept for Large Output Graz Cycle
Gas Turbines», ASME Paper GT2006-90032,
ASME Turbo Expo 2006, Barcelona, Spain.
HTTP://WWW.GTT.RU
GAS TURBO TECHNOLOGY
11. Benvenuti E., 1997, «Design and Test of
a New Axial Compresssor for the Nuovo Pignone
Heavy-Duty Gas Turbine», Journal of
Engineering for Gas Turbines and Power, Vol.
119, 633—639.
12. Hennecke D.K., 1997, «Transsonik-
.. ..
Verdichter-Technologien fur stationare
Gasturbinen und Flugtriebwerke» (in German),
..
Festschrift zum Jubilaum 100 Jahre
Turbomaschinen TU-Darmstadt, published by
TU-Darmstadt, Darmstadt, Germany.
..
13. Gottlich E., Neumayer F., Pieringer P.,
..
Woisetschlager J., Sanz W., Heitmeir F., 2004,
«Investigation of Stator-Rotor Interaction in a
Transonic Turbine Stage Using Laser-Doppler-
Velocimetry and Pneumatic Probes», ASME
Journal of Turbomachinery, April 2004, 126:
297—305.
.. ..
14. Gottlich E., Woisetschlager J., Pieringer P.,
Hampel B., Heitmeir F., 2005, «Investigation of
vortex shedding and wake-wake interaction in a
transonic turbine stage using Laser-Velocimetry
and Particle-Image-velocimetry», ASME paper
GT2005-68579, ASME Turbo Expo 2005,
Reno-Tahoe, USA.
..
15. Gottlich E., Lang H., Sanz W.,
..
Woisetschlager J., 2002, «Experimental
Investigation of an Innovative Cooling System
(ICS) for High Temperature Transonic Turbine
Stages», ASME paper 2002-GT-30341,
Amsterdam, The Netherlands.
..
16. Gottlich E., Innocenti L., Vacca A.,
..
Sanz W., Woisetschlager J., Facchini B.,
Jericha H., Rossi E., 2004, «Measurement and
Simulation of a Transonic Innovative Cooling
System (ICS) for High-Temperature Transonic
Gas Turbine Stages», ASME Paper GT2004-
53712, ASME Turbo Expo 2004, Vienna.
31
Issue 1, 2007
GAS TURBO TECHNOLOGY
NEW DEVELOPMENTS
New Aviadvigatel gas turbine
unit for the power industry
Daniil Sulimov, Vladimir Sychev, Venyamin Belkanov – Aviadvigatel
The contract for manufacturing and delivery of the GTES-16PA gas turbine power plant
built around the PS-90EU-16A gas turbine engine, rated at 16MW was signed by the top
management of Perm Engine-Building Complex and Territorial Generation Company # 9
(Perm branch) in May, 2006.
T
he declared technical specifications
of the PS-90EU-16A engine (within
the GTE-16PA) testify significant
advantage of the new drive (Table 1)
in comparison with the PS-90GP-2 regular
engine (used in GTU-16PER).
The application of a power turbine
with the rotation speed 3,000 rpm (instead
of 5,300 rpm) is the main distinctive
feature of the new unit from the existing
GTU-16PER. The reduction of the rotation
speed makes it possible to eliminate
an expensive reduction gear and improve
the entire power plant’s reliability.
Basic design specifications of the power
turbines are given in Table 2.
The optimization of the power turbine’s
basic parameters
Such basic parameters of a free turbine
as diameter, gas path, number of stages,
and aerodynamic efficiency were optimized
to minimize the direct operational costs.
32
Issue 1, 2007
The operational costs include the free
turbine purchasing costs and financial
expenses during a certain (acceptable for
a customer as a pay-back time) period
of operation. The customer’s requirements
of a definite pay-back period allowed
an economically feasible design to be
implemented.
The optimal free turbine variant
for the particular application within
the GTE-16PA power plant was selected as
the integral part of the gas turbine engine
through the comparison of the direct
operational costs for each particular
variant.
Using one-dimensional modeling
of a free turbine, the attainable level of its
aerodynamic efficiency for the discrete
number of stages was determined from the
mean diameter. The flow path components
optimal for this particular variant were
selected. The number of blades, considering
their significant effect on the production
cost was defined to provide the Zweifel
aerodynamic load coefficient equal to 1.
The free turbine’s weight and its
production cost were calculated on
the ground of the selected flow path
components. The turbine variants were
compared within the engine system
according to their direct operational costs.
The number of free turbine stages was
defined taking into account variations
in efficiency, hot section components
and operational (fuel) costs.
Fig. 1 displays that the relative cost
is correspondingly increasing along with
the production cost if there are more stages.
The achieved efficiency is increasing in
the same way, as a result of reduction of
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 GAS TURBO TECHNOLOGY

the aerodynamic load on the stage.

GTU-16PER/GTE-16PA engine specifications
Operational costs (fuel expenses) are
(in ISO conditions) Table 1
reduced along with the efficiency increase.
However, the cumulative costs have GTU-16PER GTE-16PA
a certain limit when a power turbine has Nominal power at generator terminals, MW 16.4 16.3
4 stages. Efficiency at generator terminals, % 34.8 35.5
The calculations were based on Exhaust gas temperature, °C 495 481
the proper experience as well as other
Output shaft nominal rotation speed, rpm 5 300 3 000
companies’ experience (implemented
in the particular constructions). This Service life (base class of usage), h
– time between overhauls 25 000 25 000
experience made the calculations
– total 100 000 100 000
objective. In the final design, the
customer’s cumulative expenses were
reduced almost by 20% through the load
GTU-16PER/GTE-16PA power turbine specifications Table 2
increase on the stage and reduction of
the free turbine’s efficiency from the ST GTU-16PER free turbine ST GTE-16PA free turbine
maximum achievable value approximately Rotation speed, rpm 5300 3000 (3600)
by 1%. It was achieved through the Efficiency, % 93.5 92.4
reduction of the turbine’s production cost Number of stages 3 4
and its price by 26% (relative to the variant
Rotor’s weight, kg 650 655
with maximum efficiency).
External diameter, mm 1200 1800

Free turbine’s aerodynamic design

in the partial output modes, typical for
High aerodynamic efficiency of the base–load operation mode. With the
the new free turbine under a high load was constant rotation speed the modification
achieved with Aviadvigatel’s experience (reduction) of the load on a free turbine
in the low pressure and power turbine results in the attack angles increase
development as well as the application (deviation of the gas flow direction at
of multi–stage 3–D aerodynamic models the blade inlet from the designed value)
using Euler (excluding viscosity) at the inlet to the blade rows (fig. 3). The
and Navier–Stokes (including viscosity) negative attack angles appeared and they
equations. were the most significant at the turbine’s
Fig. 2 shows the comparison of last stages.
the GTE-16PA’s free turbine parameters Design of the free turbine’s blade rows
and those of the most state–of–the–art with a high resistance to the attack angles
Rolls–Royce low pressure turbines (LPT) modification includes the special blade
of the Trent family on a Smith plot. It’s row profiling with the additional control
apparent that the new free turbine has of the aerodynamic losses stability (as per
the parameters similar to the Rolls–Royce Navier–Stokes 2D/3D aerodynamic Fig. 1. Selecting a number
turbines, if we compare the flow curve models) along with high angle of the flow of stages in a free power
angle in the blades (approximately 105 at the inlet (fig. 4). turbine for power generation
degrees). Absence of the strict weight limi-
tation (typical for the aircraft units)
reduced, to some extent, dH/U2 load
coefficient through the enlargement of
the diameter and peripheral speed. The
outlet velocity value (typical for the
ground–based units) allowed the specific
shaft speed to be reduced. Generally,
the potential of a designed free turbine,
in terms of efficiency, is at the level of
the Trent family units.
The peculiar aerodynamic feature of
a designed free turbine is the ability
to provide the optimal efficiency value

33
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GAS TURBO TECHNOLOGY
Fig. 2. Aerodynamic
load on the stages
of a 4-stage ST GTE-16PA
power turbine in relation
to dH/U2 specific work
and Ca/U relative axial
speed in comparison with
Rolls-Royce Trent l
ow pressure turbine
family (Trent 800,
Trent 500, BR715)
on a Smith plot
Analytical characteristics of the new
turbine demonstrated a high level
of resistance to the negative attack angles
and the possibility to use it as the generator
drive producing 60 Hz current (with the
speed of rotation being 3 600 rpm);
in other words, to increase the rotation
speed by 20% without any considerable
reduction of efficiency. However, in such
a case, the efficiency reduction is practically
unavoidable in the modes of reduced
output (resulting in the additional increase
of the attack angles).
Power turbine’s design features
The proved design approaches were
applied to the turbine development
to reduce the amount of materials and
the free turbine’s weight. As a result,
the rotor’s weight appeared to be equal
to the weight of the GTU-16PER power
turbine’s rotor, despite the increase
of diameter and number of stages.
This resulted in significant unification
of transmissions, oil system, supports’ air
Fig. 3. The change of the gas flow direction at the free turbine Fig. 4. The free turbine blade
blade rows in midsection along with the free turbine capacity reduction performance optimisation in the design
(the constant rotation speed is 3 000 rpm)
34
Issue 1, 2007
pressurization system and free turbine’s
cooling system.
The volumes and quality of the
pressurized air cooling the transmission
bearings’ supports were improved
including its purification and cooling.
The quality of the transmission bearing’s
lubricant was also improved through
the usage of filter elements with fineness
up to 6 micron.
The specially designed control system
made the operational parameters of
the new gas turbine unit more attractive.
It allows the customer to take advantage
of using both the turbine expander (air
and gas) and hydraulic start–up systems
(developed at Aviadvigatel).
The engine’s weight and dimension
parameters allow its installation
i n t h e s t a n d a rd c o n s t r u c t i o n s o f
the packaged GTES-16P power plant.
Sound and heat enclosure (in case
of indoor installation) makes the gas
turbine power plant’s acoustic
characteristics meet all the sanitary regula-
tion requirements.
At present, the first engine has gone
through a number of special tests. The
engine’s gas generator has already passed
the first stage of equivalent-cycle testing
and started the second stage after the
technical condition inspection. The
second stage of testing is planned to be
completed this spring.
The power turbine as a part of
the entire engine has passed the first
special test which consisted of 7 throttle
characteristics. A large volume of testing
data was recorded. Testing results allow
a conclusion to be drawn about
HTTP://WWW.GTT.RU

the free turbine’s serviceability and its
correspondence to the designed
parameters. A number of modifications
were introduced into the free turbine’s
design based on these results. The
cooling system was modified to reduce the
heat emission into the station room, to
HTTP://WWW.GTT.RU
GAS TURBO TECHNOLOGY
Fig. 5. ST GTE-16PA
free turbine design:
1 — the transition duct
from the high pressure
turbine to the power
turbine;
2 — the free turbine rotor;
3 — the free turbine casing;
4 — the free turbine rear
support;
5 — the power turbine (front)
bearing support;
6 — the free turbine output
shaft;
7 — the heat-insulation;
8 — the outlet straightener
increase the fire safety level and optimize
the radial clearances to increase efficiency.
The axial load on the power turbine
rotor was modified as well. At present,
the free turbine is being prepared for
the repeated testing which is planned for
this summer.
35
Issue 1, 2007
GAS TURBO TECHNOLOGY
TECHNOLOGY
ADOPTION Conversion of the aircraft
gas turbine engine into a drive
for industrial application
Viktor Chepkin, Evgeniy Marchukov, Viktor Kuprik, Nikolay Bulychyev – Saturn
The article focuses on the experience of A. Lyulka Research and Development
Centre (Saturn) in the conversion of the AL-31F aircraft gas turbine engine of the fourth
generation into the AL-31ST engine for the industrial drive applications.
A
unique experience in introduction
of the scientific–technical
achievements of the military-
industrial complex into the gas industry
was obtained during the last years of the
20th century. An exceptional partnership
between the Defense Establishment and
Gazprom developed a new Industrial drive
by conversion of the AL-31ST engine.
The AL-31ST is a high efficiency aircraft
gas turbine unit and one of the world’s top
power units
The high-efficiency gas turbine drive
for gas compressor units on the basis of the
AL-31F aircraft gas turbine engine was
developed by A. Lyulka Center as seen
in Photo 1.
The AL-31ST gas turbine drive when
Photo 1. The AL-31ST converted to the new Industrial drive
gas turbine drive for gas compressors is rated at 16 MW.
36
Issue 1, 2007
The AL-31ST gas turbine drive was
developed on the base of the AL-31F
engine’s design scheme. To improve
reliability and parameters as well as to
reduce the adjustment period, minimal
modifications were introduced into
the AL-31ST’s design. The AL-31ST gas tur-
bine drive and the basic AL-31F engine are
60% identical.
The following components were
modified:
■ The LP compressor was redesigned
to reduce the air flow;
■ The combustion chamber (a flame
tube head, gas supply manifolds) was
converted to the gas fuel thus providing
the low emissions;
■ The LP compressor’s external
diameter was modified;
■ The support seals; the oil contact
seals were substituted by labyrinth seals;
■ The control system was replaced by
the Compressor Control Corporation
Series–4 electronic control system.
The gas turbine drive components
such as discs, shafts, bearings and
transmission (except for the gas generator
turbine’s support) were not modified.
The pilot engines operating experience
demonstrated insufficient reliability
of the gas generator turbine’s inter-shaft
bearing; this led to an upgrade which
included the introduction of the
individual support for the high pressure
turbine’s rotor.
A new Power turbine was designed and
entered commercial operation practically
without any adjustment. The Power
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 GAS TURBO TECHNOLOGY

Turbine speed was 5,300 rpm. For the first

AL-31ST technical specifications
time, the blades and nozzle vanes of the
power turbine and gas generator turbine Power turbine shaft output, MW 16.8
were manufactured with application Effective efficiency, % 37
of noncorrosive and heat resistant alloys
NOx emission, ppm 45
of Zn–Ni–Co family. The first model of the
AL-31ST gas turbine drive was assembled CO emission, ppm 80
in March of 1994 and delivered Assigned life, hours 75000
to A. Lyulka Centre’s test stand for Maintenance frequency, hours 3000
a performance test (Power, and Heat Rate), Maintenance time, hours 6
plus adjustments of its start–up and control
Power turbine rotation speed, rpm 5300
systems. One of the test stands
designed for the AL-31F base engine
testing was equipped for testing of
the AL-31ST engine, and has a Series–4
APCS control system and runs on gas fuel.
This gas turbine drive model is used as a
test bed for parameter improvements and
development of an alternative design low
emission combustion chamber to reduce
NOx emission to 25 ppm and below.
The second model of the AL-31ST gas
turbine drive was assembled in June of
1994, passed intensive testing on the test
stand and was delivered to Karpinskaya
compressor station (Tyumentransgaz)
in September of the same year for
experimental operation. In accordance
with the renovation project plan, the GPA
TS-16 gas compressor unit was equipped
with the AL-31ST gas turbine drive, which Fig. 1. Annual operating time of the GPA TS-16 gas compressor
replaced the NK-16ST gas turbine drive. unit number 45 with the AL-31ST engine at Karpinskaya compressor station
The lubrication system, starting gas system, during the adjustment period
fuel gas system and the control system
underwent minimum changes. The
preparatory works for the installation and
commissioning of the gas turbine drive was
carried out between September and
December of 1994. The experimental
operation began in January, 1995. During
the first operational period the engine
accumulated 1 175 hours. To provide
continuous operation of the GPA TS-16 gas
compressor unit, selected for the AL-31ST,
the Centre used two AL-31ST gas turbine
drives for the experimental operation. This
solution accelerated the AL-31ST
adjustment and supported a prompt
introduction of the new developments
improving parameters and reliability,
with their testing in the real operating
conditions. The diagnostic and
reconditioning center (located within
12 km of Karpinskaya compressor station)
founded on the base of Tyumentransgaz Fig. 2. Application of the AL-31ST gas turbine for power generation
(production and technical company) and mechanical drive

37
HTTP://WWW.GTT.RU Issue 1, 2007
GAS TURBO TECHNOLOGY
Photo 2. The AL-31ST
gas turbine drive outfitted
with an electric generator
for the gas compressor
auxiliaries
Photo 3.
Installation at Almaznaya
compressor station
Issue 1, 2007
was also useful for these purposes. The gas
turbine drive was partially disassembled at
the center; the condition of the design
components was thoroughly inspected.
The efforts on the gas turbine drive
adjustment period helped the AL-31ST
drive to pass the interdepartmental testing
and thus be recommended for the serial
production practically within a year after
the beginning of experimental operation.
The GPA TS-16 gas compressor unit,
running at the compressor station
(Tyumentransgaz) is used for the AL-31ST
gas turbine drive experimental–industrial
operation. Total accumulated operating
experience of the pilot gas turbine drive is
28,131 hours and the total operating time
(without repairs) of one power turbine
unit is 29,990 hours.
38
Fig. 1 depicts the annual operating
time of the compressor unit used for
the experimental operation of the AL-31ST
drive on the engine adjustment stage.
The diagram clearly demonstrates the fast
pace of the AL-31ST drive adjustment.
The defects were noted and eliminated
and the drive was improved during
the first year of operation. The
experimental–industrial operation of
the drive started in the second operating
year after the official testing had been
completed. The annual operating time was
6,300 hours in 1997 and 7,400 hours
in 1998 (the designed annual operating
time is 5600 hours). A large extent of work
on the drive’s design, maintainability
and parameter improvement as well as
reduction of the workforce needed was
carried out during the AL-31ST gas turbine
drive adjustment.
To improve maintainability, a special
packaging was developed and the gas
turbine drive with a «lower» accessory
gear box was manufactured enabling
the installation of the gas turbine drive
auxiliary generator, rated up to 90 kW
(Photo 2). To improve reliability and
efficiency, a reinforced external diameter
was introduced and the turbine’s support
oil extraction pump was re–located outside.
To reinforce a number of the gas turbine
drive components the material was
changed from titanium to steel.
The AL-31ST gas turbine drive can be
started up both by the gas starter (turbine
expander) and by the aircraft electric
motor. The starters’ installation areas are
similar. Their start–up algorithms do not
require modifications. A multimodule
combustion chamber with the double-zone
flame tube head (SFLE modification) was
designed to provide low emissions.
The level of NOx emission was reduced
below 45 ppm. This modified combustion
chamber is introduced into the commercial
gas turbine drives. The total operating
time of the engine with a low emission
combustion chamber is 10,000 hours.
No failures were registered during the gas
turbine drive operation. By the beginning
of 2007, there are eight AL-31ST gas
t u r b i n e d r i ve s w i t h l o w e m i s s i o n
combustion chambers and more than
30 drives with standard combustors in
operation.
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The AL-31ST gas turbine drive is
adapted to the control system designed
for gas compressor units by Russian and
foreign companies such as Sistema–Gaz,
System–Service and Woodward. The
AL-31ST gas turbine drive is widely applied
within the gas compressor units, designed
by different companies:
■ Sumy Frunze NPO (Sumy, Ukraine);
■ Nuovo–Pignone, GE PS Oil & Gas
(Florence, Italy);
■ UMPO (Ufa, Russia);
■ Zavod Kirov–Energomash
(St. Petersburg, Russia);
■ Iskra (Perm, Russia) (Fig. 2).
Gas compressor units with AL-31 ST
gas turbine drives are successfully
TURBOnews
ALSTOM wins the tender for turnkey supply
of a power generation unit to Mosenergo
TETs-26 heat and power plant
On October 31, 2007 ALSTOM together
with EM Alliance, was announced as winner
of the tender for a general contract for turnkey
construction of # 8 combined cycle power unit,
with an installed capacity of 420 MW. The tender
for this contract was held between the world’s
leading power generating equipment
manufacturers. Complex proposals were
submitted by such companies as Siemens
T26 gas turbine assembly
HTTP://WWW.GTT.RU
operated at the compressor stations
of Tyumentransgaz, Permtransgaz,
Bashtransgaz, Lentransgaz, Mostransgaz
and Severgazprom. The AL-31 ST gas
turbine drive is also used within the power
generating units, rated at 16–18 MW.
The pilot unit has been constructed
in Shaksha (Bashkiria). It’ll enter
the commercial operation in April, 2007.
Characteristics of the AL-31 ST gas
turbine drive completely match
the technical design assignment, approved
by Gazprom. The construction of such
a drive was possible through the extensive
scientific and technical experience
of A. Lyulka Centre and leading Russian
designers.
(with Power Machines), Mitsubishi (with
Technopromexport) and General Electric (with
Iberdrola Company, Spain).
The scope of work includes construction
of the main building with the turbine hall, heat
recovery steam generator delivery and erection,
together with exhaust stack and auxiliary
equipment, construction of the electrotechnical
facilities, package transformers, water supply
system and fuel gas equipment (the gas
treatment centre, booster compressors and
diesel generators).
ALSTOM will supply a state-of-the-art GT26
gas turbine unit with nominal power rating
of 288.3 MW. The gas turbine construction is
a typical ALSTOM assembly: a standard single
shaft rotor, welded from forged disks and rings
and mounted on two bearings, and an annular
combustion chamber with the traditional
EV-burners. ALSTOM experience has allowed
construction of a 22-stage compressor
(compression ratio is 30), and the engine also
has several design improvements relative to its
predecessors. Sequential combustion has been
introduced, and this provides high efficiency and
low emissions (the efficiency increase achieved
without an increase of turbine inlet temperature,
for prolonged engine life and reduced
emissions). After combustion of the air-fuel
mixture in the first annular combustion chamber
with its 24 EV burners, the hot gas feeds the first
single-stage high pressure turbine and then
passes through a diffuser into the second
annular combustion chamber (the SEV
chamber). In this second combustor the burning
process is similar to that in the EV chamber:
vortex formation, fuel injection, premixing and
vortex breakdown. The SEV chamber consists
of an annular arrangement of burners followed
by an annular combustion zone with convection
cooled walls. Every SEV burner has the
delta-shaped wings operating as ramps which
swirl combustion air into vortices. Finally,
the gas is expanded in the four-stage low
pressure turbine.
39
GAS TURBO TECHNOLOGY
29 GT26 gas turbine units are currently
operating worldwide, and ALSTOM has signed
contracts for construction of 14 more units by
2008.
The PGU-420 combined cycle unit
construction is being carried out at TETs-26 heat
and power plant as part of the Mosenergo
development and technical re-equipment
programme for elimination of the Moscow
region power shortage. The PGU-420 power
generating unit #8 at TETs-26 will be the most
up-to-date and efficient combined cycle unit in
Russia (its efficiency will be about 58%).
The total contract value is around 300
million euros, and commissioning is planned
for 2008.
The first construction stage of the power plant
for SINTEZ medical company is completed
The first stage is a GTES-5 gas turbine
powerplant, designed around two PAES-2500
gas turbine units consisting of Motor Sich
AI-20-DKN engines each rated at 2.5 MW.
Exhaust gas heat is recovered by two
Yzhtransenergo KUP-25 steamraising waste
heat boilers with total thermal capacity of
15.3 MW. The powerplant efficiency is 21.5%
in simple cycle, and 79% in cogeneration
mode.
The plant is peculiar in that, its generated
power is consumed by high capacity electric
motors. Their unit capacity is comparable to the
plant capacity, and startup of the first electric
motor, rated at 2 MW, caused some problems
with the plant’s operational stability. Resolution
of these problems prolonged the commissioning
period.
The second stage is a GTES-15 gas turbine
powerplant based on the Zorya-Mashproekt
UGT16000 engine, which is to be commissioned
by the end of 2007.
Construction of the powerplant is being
carried out by Malaya Energetika; its general
designer is Yzhtransenergo.
Issue 1, 2007
GAS TURBO TECHNOLOGY
ALTERNATIVE FUELS
EU project HEGSA:
High efficient gas turbine
with syngas application
Nadezhda Slavinskaya – Institute of Combustion Technology, Stuttgart, Germany
S
ustainability in energy supplies
requires improvements in overall
efficiency as well as fuel flexibility to
enable substitution of noble fuels (gas, oil)
through long–term available coal, lowgrade
fuels (waste) or CO2–neutral biomass. One
promising concept for realisation is the
IGCC (Integrated Gasification Combined
Cycle): Via gasification these feedstocks are
accessible for high–efficient gas turbine
cycles. IGCC is one of the most promising
advanced power generation technologies
using solid fossil fuels in a very effective
and environmentally friendly way. The
further development of this technology
supports European efforts to get more
independent of oil and natural gas. In
addition, the concept of IGCC supports
the following EU policy targets:
Reduction of greenhouse gas emissisions
to mitigate global warming: The application
of advanced, highly efficient gas turbine
technology in IGCC power plants leads to a
clear reduction of CO2 emissions which
contribute to global warming. Starting
from 45% net efficiency of current
technology an increase of 5%–points
is anticipated resulting in approx. 10%
reduction in CO2 emission. In addition,
the better understanding of the combustion
of H2 containing syngases forms the basis
for future concepts of CO2–free fossil–fuel
fired power plants.
Saving of primary energy: As
a consequence of the enhanced efficiency
primary energy sources will be saved.
Moreover, via the gasification process
refinery residues or even waste can
substitute the use of valuable coal reserves.
Increase the share of new and renewable
energy sources (RES): This can be realised
via co–gasification of biomass as it has been
already realised in the Buggenum IGCC
plant. Depending on the power output
40
Issue 1, 2007
also plants fired by only biomass are
feasible.
Security and diversification of energy
supply: As a conseqence of enhanced
efficiency and flexibility in terms of load
range and fuel the project contributes
to secure European energy supply.
Reduction of pollutents (NOx, SO2): Low
emissions of NO x and SO 2 are clear
advantages of the IGCC process. Whereas
the emission of SO2 can be effectively
reduced by desulphurisation before
combustion (pre–combustion), the
formation of thermal NO x can be
significantly avoided through the specific
combustor design.
The three large European IGCC power
plants in Buggenum/NL, Priolo/I and
Puertollano/E, which has been partly
funded by the EC, already demonstrate
commercial operation. The currently
commercially operating IGCC plants
(more than 1 GW installed) are equipped
with well proven gas turbines, but not with
the latest state–of–the–art gas turbine
technology. Thus, the efficiency level of
these plants is limited due to the
thermodynamic limits of the gas turbine
frames used. As there are more advanced
gas turbines of high reliability available
with a distinctly higher efficiency level (up
to 58 % in natural gas operation), it is
straightforward to introduce these engines
into the next generation IGCC plants.
The advanced performance of these newer
gas turbine frames has been achieved by
applying the necessary technology to allow
distinctly higher turbine inlet temperatures
or higher firing temperatures respectively.
Furthermore, the improved combustion
concept in the newer high firing
temperature gas turbines enables to keep
the NOx emissions level still below 25 ppm
with the option on further reduction.
HTTP://WWW.GTT.RU

A logical next development step is to
introduce the existing experience and
knowledge about syngas combustion into
the latest advanced gas turbine technology.
In order to enable the proper operation
and the demanded performance of the
syngas combustion system under
the advanced gas turbine conditions
(increased temperature and pressure)
further research and development
including basic research is necessary.
The project «High Efficient Gas turbine
with Syngas Application» (HEGSA) aimed
at the development of syngas combustion
systems for advanced high–temperature
gas turbines such as the Siemens
SGT5-4000F (previously named V94.3A)
with annular burner configuration.
In parallel, the burners for the silo-type
combustion systems of the E–class
machines (V94.x) used at the European
IGCC plants Buggenum operated by Nuon
Power, Puertollano (ELCOGAS) and
Priolo (ISAB) are to be improved in terms
of fuel flexibilty, combustion stability
and emissions. On European side the two
project members Siemens PG and Ansaldo
Energia are successful suppliers for syngas
fueled gas turbines. The project essentially
supports their efforts in improving existing
burner technology and developing
advanced burner technology applicable
in the most modern gas turbines.
The project methodology is based
on theoretical investigations, design work
as well as experimental tests. The project
brings together a well–balanced team of
manufacturers, power producers and R&D
institutes from three European countries.
Italian, Dutch and German scientists and
engineers are in close collaboration within
the HEGSA project.
AC Ansaldo Caldaie Spa
(Subcontractor)
AEN Ansaldo Energia Spa
DLR German Aerospace Center
Enel-P Enel Produzione S.p.A.
Nuon NV Nuon Energy Trade &
Wholesale
Siemens Siemens Aktiengesellschaft,
Project Coordinator
UT Universiteit Twente
The partners structure aims at
complementary expertise to a far extend:
Investigating the fundamentals of syngas
combustion — theoretically and through
HTTP://WWW.GTT.RU
generic tests — is combined with prototype
development and full-scale tests. The
definition of expedient boundary
conditions, which the designs are based
on, and the main project objectives are
additionally ensured by the competence of
the participating power producers, Enel
and Nuon. The latter one operates the first
European large IGCC plant in Buggenum.
Siemens PG and Ansaldo Energia supplied
the main parts for the power islands in
three large European IGCC plants,
particuarly the gas turbine, and thus, are
long experienced on this technology.
Scientific support is provided by the well
known research institutes, Universiteit
Twente and DLR, responsible for preparing
the fundamentals (CFD, thermo-acoustics,
syngas flame characterisation). Within
Framework Programme V — Energy,
Environment and Sustainable Development
(EESD) the project HEGSA focuses on the
target action «F: Clean Power Generation —
Gas Power Generation», thematic priority
5.1.3 More Energy Efficient Gas Turbines».
Project budget: 3.780 k€, project duration:
36 Months
The main objectives are:
■ Definition of typical boundary
conditions for burners applied for syngases
in advanced gas turbines. These boundary
conditions were determinated by Enel–P
and partly all participants on the study
of the hypothesis of natural gas suitability
with biomass syngas. The different syngas
mixers (8) were investigated as well.
Enel–P elaborated the assessment
of technical maturity of advanced hot gas
cleaning systems which are expected
to increase total plant efficiency and
improve operational behaviour. For reliable
operation of advanced combustion systems
a high-effective gas cleaning is essential.
In order to increase the total plant efficiency
this cleaning steps should be processed
at high temperature level. The assessment
of the technical maturity of such hot gas
cleaning systems was one objective of Enel
Produzione's (Enel–P) work. Within more
global plant concept evalutations the
impact of co–firing up to 50 % syngas from
biomass in a natural gas fired combined
cycle had been thermodynamically
analysed.
Contemporaneous combustion of
methane and syngas is a possible solution
41
GAS TURBO TECHNOLOGY
TURBOnews
Two TKA-Ts-16/76-4,0 gas
compressor units were
commissioned at Fedorovskaya
compressor station
(Surgutneftegas)
The TKA-Ts-16/76-4,0 gas
compressor unit manufactured
by Sumy Frunze has a capacity of
360 m3/min at the inlet flange. The
converted KMPO NK-16ST aircraft
gas turbine engine serves as t
he drive. Its capacity is 16 MW,
compression ratio is 10 and
efficiency is 29%. The Sumy
Frunze centrifugal compressor
pressurises gas from 0.39 MPa to
7.5 MPa at the outlet.
The Fedorovskaya packaged
compressor station is used for gas
transmission. TKA-Ts-16/76-4,0
gas compressor units have been
operated there from the third
quarter of 2006.
Surgutneftegas continues
to commission gas turbine power
plants
A number of gas turbine
power plants at the Zapadno-
Kamynskoye (GTES–24),
Muryaunskoye (GTES–24)
and Ukyavinskoye (GTES–36)
fields were put into commercial
operation one after another
following the commissioning of
GTES–24 gas turbine power plant
at the Konitlorskoye field.
All the gas turbine power
plants were assembled from
separate, functionally complete
power generating units, each rated
at 12 MW. The units were based
on the KMPO NK-16ST gas
turbine, with fuel-metering
equipment from Volchansk Power
Generating Units works, and a
Privod T-20-2U3 generator. Sumy
Frunze is the prime contractor
for construction and equipment
supply.
Another similar GTES–24 gas
turbine power plant will be
commissioned at the North-
Labatyuganskoye field at the end
of 2006. Contracts have been
signed for delivery of two
GTES–48 gas turbine power plants
(3x16 MW) to the Talakanskoye
field (commissioning is scheduled
for the fourth quarter of 2007) and
one GTES–36 gas turbine power
plant to the Rogozhnikovskoye
field (start-up is planned for the
third quarter of 2008).
Issue 1, 2007
GAS TURBO TECHNOLOGY
Geometrical options to use renewable sources in combined
for syngas feeding cycle plants. The suitability of natural gas
in advanced burner concept integration with syngas (from biomass
gasification) into existing large scale
combined cycles and in future IGCC has
been assessed by computerised simulation
of co–combustion of syngas from biomass
gasification in a natural gas fired combined
cycle power plant.
■ The foundamental data for flame
properties of syngas combustion (DLR and
the University Twente, UT). In order
to come to comparable test results and
integrated data sets both institutes made
use of the identical burner design. This
decision turned out as very effective. The
experimental burner and kinetic model
of syngas combustion were developed by
improving the theoretical background and
necessary simulation tools. Experiments
were performed to validate the analytical
results and to yield further insight into
syngas combustion. These were carried out
in the lab-scale syngas burner at pressures
of 1 and 2 bar and involved OH* chemilu-
minescence and OH planar laser–induced
fluorescence to characterise the flame's
structure and reaction zone, respectively.
Velocity measurements using particle
image velocimetry were conducted
to characterise the flame's flow field. These
experiments were followed by numerical
simulations using the model developed
within the project (DLR combustion
model). The combination of these three
42
Issue 1, 2007
main tasks allows CFD (in-house DLR
development solver) calculations designed
for syngas fuels under modern gas turbine
conditions and thereby a better optimisation
of syngas burners design in a pre-testing
phase.
■ Thermo-acoustic analysis of syngas
combustion systems based on a thermo-
acoustic syngas flame model (flame transfer
function for syngas flames) (UT). The goal
of UT’s work was the prediction of the ther-
mo–acoustic behaviour and stability
of syngas combustion. Specifically the
effect of the syngas composition, the air
inlet temperature and the operating
pressure on the flame transfer function
characteristics were of interest. For this
purpose, a combustion model linked
to a thermo–acoustic model that can
predict the behaviour of a non–premixed
turbulent syngas flame has been
developed. The model is a combination
of CFD, one-dimensional acoustics and
analytical modeling. A laboratory scale
test rig was built for the validation
of the combustion model and the thermo-
acoustic model. Here, the flame transfer
function has been measured for syngas
flames, fueled by various mixtures of CO,
H2 and CH4. A clear high frequency
damping effect of methane on the
thermo-acoustic behaviour and flame
transfer function has been measured. An
increase of the air inlet temperature shifts
the spectral behaviour of the flame transfer
function to a higher frequency range.
It shows that the flame transfer function
has an extremely complicated behaviour
that is difficult to predict. However, good
progress has been made in the accuracy
of the model.
■ Improved syngas burner for
silo–type combustion systems (Siemens
E–class): Variants of design. (Siemens,
AEN). In general, the design and
experimental work during first project
period yielded an enhanced knowledge
on syngas combustion and particularly on
the behaviour of different types of nozzles.
As concluded, the nozzle design used in
real machines needs to be specifically
adapted to the respective application
(targeted emissions, risk of deposits from
impurities, etc). The basic variants are
characterised by either applying
a segmented nozzle mouth (blockages)
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or an elongated nozzle with uniform and
unbroken shape (conus).
■ Advanced syngas burner for annular
combustion sytems (Siemens F–class):
Design specification, prototype. (Siemens,
AEN). Development of an novel advanced
syngas burner (low–NOx) to be used in
the current annular combustion chamber
configuration. The implementation of
the so–called two–passages–concept, which
means feeding syngas through an outer
main passage and additionally through
the natural gas diffusion passage (split up
to 80/20%) leads to increased flame
stability especially for low-LHV gases (3.5
to 4.5 MJ/kg). In accordance with the time
schedule the test campaign for
the improved silo-type burners has been
successfully finished within the first
18 project months. These comprised the
segmented as well as the conically shaped
nozzle types and were divided into a
screening and the optimisation phase.
The NOx formation was investigated
in relation to the swirl number, the impact
of the purging holes and the fuel split
between the two passages. In order to meet
low NOx emissions the fuel dilution
remains one of the most effective method,
which is more efficient when using H2O
instead of N2.
For the development of the advanced
syngas burner, a comprehensive concept
study had been done. All designs, which
are taken into consideration, are derivated
from the standard Siemens HR3 burner,
which is currently used for natural gas and
fuel oil in the F–class machines. They apply
the novel feeding concept through two
passages, too: the inlet which is normally
used for natural gas diffusion mode
combustion (= pilot) and one additional
concentrical line. Four different design
concepts have been developed and
evalutated by means of CFD in a first
phase. Velocity and pressure distribution
as well as the temperature fields have
been assessed resulting in two final
designs. These concepts mainly differ
in the geometrical arrangement of
the main syngas passage. One design is
characterised by supplying the main fuel
gas from the inner hub side, the other one
on injection from the outer cone side.
In both cases, due to the limited spatial
conditions of the existing gas turbine
HTTP://WWW.GTT.RU
arrangement and the limited cross–section
of the fuel gas passages, the syngas flux
is defined and minor dilution is possible
to not unacceptably increase the fuelside
pressure drop. These relatively rich
syngases in combination with the high
combustion temperature of the F–class
machines cannot be burnt any longer
in diffusion mode, but need premixing
the air and fuel in order to meet strict NOx
emissions requirements. For that the
main part of the syngas is fed into the com-
bustion air downstream the diagonal
swirler (premix). The optimal shape of
the injection zone to avoid flow separation
and flash–back was investigated in
a coldmixing study.
A concluding assessment considering
all relevant aspects such as flash–back
behaviour, potential NOx formation,
fuel flexibilty, manufacturing effort
and retrofitability led to the decision
to proceed with the outer injection
concept. This burner was finally
designed, manufactured as prototype and
tested at atmosheric (done at Ansaldo
Caldaie) and full pressure (at the DLR,
Cologne).
At least for a limited number of syngas
qualities base–load operation could be
achieved. The emission requirements for
NOx (< 25 ppmv) as well as CO (< 5 ppm)
could be met. DLN operation on natural
gas (secondary fuel) could be
demonstrated with similar performance as
with the standard hybrid burner hardware.
However, the major issue of this premix
burner is its flash-back risk on syngas
operation. Up to now, at least some minor
amount of diluents is required to lower
the reactivity. Nevertheless, the key factor
for future activities is to enhance
the flash-back resistance.
■ Full–scale combustion tests at
atmospheric pressure for both burner
types; in addition tests under pressurised
conditions for the advanced burner. (AEN,
Siemens).
Shortly the main results of HEGSA
project:
Measures for improving the existing
burner which is used in the silo–type
E–class machines have been developed and
proven in atmopheric fullscale tests.
The features are using more than one
passage for feeding the syngas and
43
GAS TURBO TECHNOLOGY
TURBOnews
The combined cycle unit enters
commercial operation at
Rizhskaya TETs-1 heat
and power plant
The primary equipment of the
unit consists of a Turbomach
TBM-RB211-Т gas turbogenerator
and a MARC 4 extraction steam
turbine manufactured by Blohm
and Voss. The gas turbine unit
consists of the Rolls-Royce
RB211-6761 aeroderivative gas
generator and RT-61 power
turbine, with an Allen Gears
reduction gear.
Total electrical capacity
is 48.1 MW, and thermal capacity
is 47.6 MW. The overall fuel
efficiency is 87%. The unit is
located in a rapid-build facility,
attached to the main building of
the combined heat and power
plant. The fuel is natural gas.
The station designer is
Teploelektroproyekt Institute
(Riga). The prime contractor and
primary equipment supplier is
Turbomach.
The first Sumy Frunze gas
compressor units with NK-36ST
engines will be installed
at Severgasprom
The scope of the contract
includes installation of three
S u m y F r u n z e N P O
GPA-Ts-25BD/76-1,44M gas
compressor units at Mikunskaya
compressor station and three at
Novogryazovetskaya station.
These stations are on the SRTO
(northern Tyumen region)-Torzhok
gas pipeline.
The equipment for
Mikunskaya compressor station
has already been dispatched, and
that for Novogryazovetskaya
station is in manufacture.
A Motorostroitel NK-36ST engine,
rated at 25 MW (efficiency 36%)
serves as the drive for the
GPA-Ts-25BD/76-1,44M gas
compressor unit. The throughput
of the Sumy Frunze 321GTs2-
560/53-76M supercharger, with
a polytropic efficiency of 86%,
is 1.9 million nm3/h. The units are
to enter commercial operation in
2007.
Issue 1, 2007
GAS TURBO TECHNOLOGY
applying nozzles types especially designed
for the respective fuel gas. Thereby, the
combustion stability is clearly increased
particularly for very poor syngases.
The concept for an advanced low–NOx
burner has been developed to be used
for future hightemperature syngas
applications in the F–class engines. It is
characterised again by two syngas passages
with injection of the main flow into
the diagonal swirler zone. The resulting
premixed flame is basis for low NOx
emissions. However, premix flames are
very sensible regarding flash–back. Here,
further development will focus on.
F ro m t h e re a s e a rc h i n s t i t u t e s ’
fundamental work valuable knowledge
about the combustion of H2 and CO
containing syngases has been gained
and the data basis could be significantly
extended. The computing tools as well as
the test rigs for the generic experiments
44
Issue 1, 2007
are now established and available for
further investigations. E.g. DLR’s lab scale
test rig developed for this project can
be used for investigating laminar and
turbulent flames to study the flame’s
structure and reaction-zone-temperature,
main species or OH, NOx profiles —
and flow field at atmospheric and elevated
pressure up to 40 bar by applying modern
laser diagnostic techniques.
In the context of CO2–free power
generation from fossil fuels future
applications focus on the study of
hydrogen–enriched fuel mixtures at
enhanced pressures, numerically and
experimentally. The phenomena of interest
are, for example, flame structure, auto
ignition behaviour, pollutant profiles of
species such as NOx and CO, and laminar
flame speed. Also for that the developed
reaction mechanisms and the tools are
the basis.
HTTP://WWW.GTT.RU
 TURBOnews GAS TURBO TECHNOLOGY

The second power generating unit was GTES-2.5 gas turbine power plant shipped
commissioned at Severo-Zapadnaya TETs to Nizhne-Shapshinsk field
heat and powerplant
The shipment from Saturn production facility
On November 29, 2006 Anatoly Chubays, took place in September, 2006 in accordance
the Chairman of RAO UES Management Board, with the Russneft contract signed the same year.
carried out the ceremonial start up of the second The general designer of the power plant is
the Giprong-Ecom Design Institute (Tyumen),
PGU-450T combined cycle unit. The nominal
and all the contractual work will be carried out
electrical power rating of the heat and power
by Saturn. Total operating time of the GTES-2.5
plant is now 900 MW. The PGU-450T combined
fleet had reached 48 thousand hours by the end
cycle unit is based on two Siemens V94.2 gas
of October, 2006.
turbines, two ZiO-Podolsk P-90 steam boilers, The packaged power plant is based on the
an LMZ T-150-7,7 steam turbine, and three Saturn DO49R gas turbine, with a nominal power
Elektrosila TZFG(P)-160-2MU3 air cooled The plant general view rating up to 2.85 MW. Its efficiency is 28.5%
turbine generators. (ISO), and its dual-fuel combustion chamber will
The gas and steam turbines were initially around 500 Gcal/h, raising the fuel efficiency run on diesel oil.
commissioned on November 23, 2006. The initial rate to 85%. Previously, the first plant had Connection to the Privod TK-2,5-2RUHL3
load on the power generating unit was 100 MW, functioned in condensation mode. generator is made via a reduction gear. The plant
and the 72-hour testing of the two gas turbines Technopromexport was prime contractor will be operated in simple cycle, without heat
was then carried out with the full electrical for the project and SevZapVNIPIEnergoprom recovery. Before shipping to the customer, all the
load. The heating main (from Severo-Zapadnaya the general designer. plant systems were tested on the Saturn test
TETs heat and power plant to Primorsk city Anatoly Chubays said that Severo- stand. The company’s experts will undertake
boilerhouse) was put into operation so that the Zapadnaya TETs heat and power plant had power plant erection, start-up and commissioning,
powerplant could function in heat extraction become the largest combined cycle power plant as well as the complex test schedule. The
mode and this allowed heat transmission of in Russia. GTES-2.5 plant commissioning is planned for the
first quarter of 2007.
Perm Motors has produced new gas turbines for Tomskgazprom
A contract for delivery of two P-96 heat recovery
The scope of the contract, signed in December 2005, includes delivery of two GTU–6PG gas steam generators for TETs -21 heat
turbine units to Tomskgazprom. The gas turbine units are incorporated into Iskra GPA-6DKS Ural gas and power plant (Moscow) has been signed
compressor units and will operate at the Myldzhinskoye gas-condensate field compressor station. Iskra
has worked in close cooperation with Aviadvigatel on these units. The station designer is In September, Mosenergo signed the contract
TyumenNIIgiprogas. with ZIOMAR for project design, manufacture
The GPA–6DKS Ural is the first gas compressor unit designed around the GTU–6PG gas turbine. and delivery of two P-96 heat recovery steam
Previously the Perm Motors drives rated at 6 MW have only been used in gas turbine generators for the PGU-450T power generating
generator units. The GTU–6PG gas turbine unit is derived from the D–30 aeroengine [third series]. unit, located at TETs-21 heat and power plant.
The packaged GPA–6DKS Ural unit has a capacity of 6 MW at 26.4% efficiency. Operating time The scope of the ZIOMAR contract includes
between overhauls is 25,000 hours; the engine life is 100,000 hours. All the equipment is currently supervision of installation, engineering setup,
ready for shipping to the customer, and the commissioning of both GPA–6DKS Ural units is planned for equipment commissioning and training or the
November 2007. customer’s operating personnel. The equipment
to be delivered is similar to the equipment
commissioned on the PGU-450T power generating
NK-16ST and NK-16-18ST (upgraded model) start system modernisation
unit at Kaliningradskaya TETs-2 heat and power
An STE-18ST electric starter with nominal position on the accessory gearbox of NK-16ST plant.
power rating of 65 kW was successfully tested and NK-16-18ST engines. The electric starter is
on an NK-16ST engine at the test stand of controlled by a BUS-18ST control unit which The waste heat boilers for Belgorodskaya TETs
Zelenodolsk Engineering Plant. The starter was transforms the three-phase AC voltage of 380 V heat and power plant are manufactured
designed by Elektroprivod under contract from and 50 Hz frequency into a three-phase AC
Everest-turboservis, and is intended as an voltage from 0 to 380V with a frequency range of
ZIOMAR signed a contract with BUSINESS
alternative to the pneumatic starter used for the 0 to 400 Hz. The control unit determines
ALLIANCE and TEK (Belgorod) for delivery of
engine motoring and starting, and which the starter’s operational readiness, sets its two KUV 35/150 waste heat boilers for the gas
exhausts gas into the atmosphere. With similar operating mode and initiation, defines its turbine powerplant which incorporates two
fitting dimensions and therefore being rotational speed, and generates a cutout signal. General Electric LM2500+ power generating
interchangeable, both the electric starter and the The maximum torque of the STE-18ST units. It is the second power project in Belgorod
pneumatic starter are mounted at the same electric starter is 539 n•m (55 kgf•m). using GE LM2500+ gas turbine generators (the
The motor also functions in intermittent first one was completed in 2005 at Luch GT-
periodic duty. During tests the electric starter TETs gas turbine heat and power plant).
worked in accordance with the NK-16ST and The thermal capacity of each KUV 35/150
NK-16-18ST engine starting scheme used at waste heat boiler will be 36.3 MW, with gas
Gazprom compressor units, and which involves temperatures at the boiler inlet and exhaust
a repeated sequence of three engine motoring being 505.2_C and 95_C respectively, and a
cycles followed by engine start. The maximum water flow of 454.7 t/hour. The boiler can oper-
starter casing temperature was 76_C. ate with the varying flows and temperatures of
The electric starter is certified to explosion the gas turbine exhausts which result from the
protection designation 1ExdIIBT3. The starter variations in ambient air temperature between
is therefore permitted to operate in explosion –35 °C and +38 °C, and the gas turbine load
hazard zones of both internal and external range of 50-100%. The maximum allowable
facilities. exhaust gas temperature is 550 °C.

45
HTTP://WWW.GTT.RU Issue 1, 2007
GAS TURBO TECHNOLOGY

Exhibitions & conferences 2007

Dates Venue Description Event Organizer
April 2-5 Syria SYRPOWER. Allied Expo
Damascus International Power & Electricity Exhibition www.syrpower.net/_index.html
April 3-5 China CIPPE. Beijing Zhenwei Exhibition
Peking International Petroleum & Petrochemical Technology Phone: + 86-10-58236588, +86-10-58236555
and Equipment Exhibition Fax: +86-10-58236567
E-mail: cippe@china-zhenwei.com.cn
www.cippe.com.cn
April 16-20 South Africa Africa Power & Electricity Congress & Exhibition. Terrapinn
Johannesburg International Power & Electricity Exhibition and Conference www.terrapinn.com/2007/powerza
April 4-6 Russia POWERTEK. International Exhibition dedicated ITE GROUP PLC
Moscow to Power Generation, Transmission and Distribution www.primexpo.ru
April 4-6 Kazakhstan Atyrau. Munai-Gas.kz – 2007. Expo.kz – International Exhibitions and Conferences
Atyrau The 2nd Caspian International Exhibition of Oil and Gas Phone: +7 (3122) 58-60-11
Fax: +7 (3122) 58-60-12
E-mail: atyrau@expo-kz.kz
www.expo-kz.kz
April 10-12 Russia NEFTEGAZEXPO. RESTEC Exhibition Company
St. Petersburg International Specialized Exhibition. Phone: (812) 320-63-63
Oil and gas exploration and development. Fax: (812) 320-80-90
Know-how technologies and equipment E-mail: main@restec.ru
www.restec.ru
April 10–12 Russia Fuel and Energy Complex of Russia – 2007. RESTEC Exhibition Company
St. Petersburg The 7th International Forum Phone: (812) 320-63-63
Fax: (812) 320-80-90
E-mail: main@restec.ru
www.restec.ru
April 18-20 France Turbine Forum 2007. Forum of Technology
Nice Effective Repair of Gas Turbine Components www.forumT.com
April 20-23 Iran IRAN OIL SHOW. Orient Exhibitions Ltd
Teheran International oil, gas and petrochemical exhibition www.iranoilshow.com
April 24-25 Russia Oil & Gas. Energo – 2007. APEKS
Ukhta Specialized Exhibition Phone: (383) 330-42-30, (383) 330-76-16
E-mail: apeks@nov.net
www.nsk.su/~apex
May 3-5 Kazakhstan Energy – 2007. ATAKENT-EXPO
Alma-Ata International Exhibition Phone: +7 (327) 258-25-35, +7 (327) 274-79-26
Fax: +7 (327) 258-29-59
E-mail: expo@netel.kz
www.exhibitions.kz
May 14-17 Canada ASME TURBO EXPO. Phone: +1 (404) 847-00-74
Montreal International Gas Turbine & Fax: +1 (404) 847-01-51
Aeroengine Technical Congress and Exposition E-mail: igtiexpo@asme.org
www.asmeconferences.org/TE07/index.cfm
May 15-17 Uzbekistan OGU. ITE Uzbekistan
Tashkent International Exhibition and Conference Phone: + 998 (71) 113-01-80
«Oil and Gas Uzbekistan» Fax: + 998 (71) 152-51-64
E-mail: management@ite-uzbekistan.uz
www.ite-uzbekistan.uz
May 16-19 Pakistan POGEE. Phone: (+92 21) 111 73-42-66
Karachi International Oil, Gas & Energy Exhibition & Conference Fax: (+92 21) 241-07-23
E-mail: info@pogee.com.pk
www.pogee.com.pk
May 23-25 Russia Oil & Gas. Energo – 2007. APEKS
Astrakhan Specialized Exhibition Phone: (383) 330-42-30, (383) 330-76-16
E-mail: apeks@nov.net
www.nsk.su/~apex
May 29-31 Russia Russia Power. PennWell Corporation
Moscow International Exhibition and Conference Phone: (495) 580-32-01
Fax: (495) 580-32-01
E-mail: svetlanas@pennwell.com
www.russia-power.ru
June 5-8 Russia RUS-GAZ-EXPO. FAREXPO
St. Petersburg International Specialized Exhibition of Natural Gas Industry Phone: (812) 718-35-37
and Technology for Gas Equipment www.farexpo.ru
June 5-7 Russia New in Energy-Saving Technologies – 2007. Maximum-Inform
Tver Specialized Exhibition dedicated Phone: (4822) 34-52-07, (4822) 49-08-09
to Energy-Saving Technologies E-mail: maxinform@tvcom.ru
www.maxinform.ru

46
Issue 1, 2007 HTTP://WWW.GTT.RU
 GAS TURBO TECHNOLOGY

Dates Venue Description Event Organizer

June 5-7 China EP. Phone: (852) 2516-33-42
Shanghai International Exhibition on Electric Power Equipment Fax: (852) 2516-50-24
and Technology Email: ebusiness@adsale.com.hk
www.adsale.com.hk
June 6-7 Czech Republic Energy Trading Central & Eastem Europe. www.energytradingcee.com
Prague International Power & Electricity Exhibition
June 5-8 Azerbaidjan Caspian Oil & Gas. Iteca Caspian
Baku International Caspian Oil and Gas Exhibition Phone: +994(12) 47-47-74
and Conference Incorporating Refining and Petrochemicals Fax: +994(12) 47-89-98
www.iteca.az
June 11-14 Poland ENERGIA. Poznan International Fair
Poznan International Power Industry Exhibition www.energia.mtp.pl/en
June 26-29 Russia MIOGE. ITE GROUP PLC
Moscow International Oil and Gas Exhibition www.mioge.com
June 26-28 Spain POWER-GEN Europe. www.powergeneurope.com
Madrid International Power Exhibition and Conference
Late June Russia LIV scientific-technical session on gas turbines Russian Academy of Sciences. Commission on gas turbines
St. Petersburg Phone: (495) 675-34-83
Fax: (495) 675-34-83
E-mail: vvg41@mail.ru, agt@vti.ru
September 4-6 Thailand POWER-GEN Asia. PennWell Corporation
Bangkok International Power Exhibition and Conference www.powergenasia.com
September 14-19 Ukraine XII International Congress of propulsion Engineering National Aerospace University «Kharkiv Aviation Institute»
Rybachye Phone: +38 (057) 719-05-40
Fax: +38 (057) 719-05-40
E-mail: aedlab@ic.kharkov.ua
www.khai.edu
September 20-22 Russia Oil & Gas. Energo – 2007. APEKS
Orenburg Specialized Interregional Exhibition Phone: (383) 330-42-30, (383) 330-76-16
E-mail: apeks@nov.net
www.nsk.su/~apex
September 26-29 Ukraine Fuel and Energy Complex of Ukraine: International Exhibition Centre
Kiev the Present and the Future. Phone: +38 (044) 201-11-57
International Forum Fax: +38 (044) 201-11-78
E-mail: nsilova@iec-expo.com.ua
www.tech-expo.com.ua
September 26-28 Russia Energy. Gasification. Energy-Saving 2007. RyazanVneshServis Exhibition Centre
Ryazan Interregional Specialized Exhibition Phone: (4912) 25-36-82
Fax: (4912) 28-95-33
E-mail: business@rvs.ryazan.ru
www.rvservice.ru
October 2-5 Kazakhstan KIOGE. Iteca
Alma-Ata Kazakhstan International Oil & Gas Exhibition Phone: + 7 (3272) 58-34-34
and Conference Fax: + 7 (3272) 58-34-44
E-mail: contact@iteca.kz
www.iteca.kz
October 9-10 Russia Oil & Gas. Energo – 2007. APEKS
Noyabrsk Specialized Exhibition Phone: (383) 330-42-30, (383) 330-76-16
E-mail: apeks@nov.net
www.nsk.su/~apex
October 23-26 Russia Ural Power – 2007. B ashkir Exhibition Company
Ufa International Specialized Exhibition Phone: (347) 253-38-00
Fax: (347) 253-14-33
E-mail: expo_05@mail.ru
www.vkbexpo.ru
October 31 - Indonesia OIL & GAS TECHNOLOGY. PT Pamerindo Buana Abadi
November 3 Djakarta International Oil and Gas Exhibition and Conference www.pamerindo.com/2007/ogti/ogi07exh.htm
November 6-9 Ukraine Oil & Gas. Energo – 2007. ACCO International
Kiev International Specialized Exhibition Phone: +38 (044) 458-46-21
Fax: +38 (044) 458-46-22
E-mail: acco@acco.kiev.ua
www.acco.ua
November 10-13 China ENERGY ASIA. Hannover Fairs China Ltd
Shanghai International Power & Electricity Exhibition www.energyasia.com.cn
November 11-15 Italy World Energy Congress. PennWell Corporation
Rome «Energy Future in an Interdependent World» www.pennwell.com, www.rome2007.it
December 2-7 Japan IGTC. Fax: +81-3-3365-03-87
Tokyo International Gas Turbine Congress E-mail: igtc@rainbow.dti.ne.jp
www.soc.nii.ac.jp/gtsj/igtc/IGTC07/index_e.html
December 7-9 India Energy Expo. Confederation of Indian Industry (CII)
Ahmadabad International Power Exhibition and Conference www.energyexpo.biz
December 11-13 USA POWER-GEN International. PennWell Corporation
New Orleans International Power Exhibition and Conference www.power-gen.com

47
HTTP://WWW.GTT.RU Issue 1, 2007
TURBOnews
72-hour testing of Siemens SGT-600 gas turbines was accomplished
at Ukhtinskaya compressor station

All three SGT-600 (GT10B) turbines met the guaranteed values for their
basic technical requirements. Vibration and temperatures were normal,
and the installation was free of faults. The SGT-600 turbines are components
of GPA-25 Baltika gas compressor units, whose nominal power rating per unit
is 25.4 MW, the fuel gas flow is 5,212 kg/hour, and efficiency 35.1% (ISO).
SGT-600 is an industrial gas turbine unit designed for severe operating
conditions. The two-shaft gas turbine has a 10-stage compressor (pressure
ratio is 14) with variable geometry in the first two stages, and the 2-stage
free power turbine has a rotational speed of 7,700 rpm. The unit is equipped
with two bleed valves for compressor surge prevention during starts and at Three GPA-25 Baltika gas compressor units at Ukhtinskaya
low loads. The rotor consists of disks joined by electron beam welding compressor station
into a single unit. The annular combustion chamber is a welded structure
of sheet metal, with 18 burners. The combustion chambers are manufactured units for Uzhnaya TETs heat and power plant (Lenenergo) and introduced
by the Metallist Plant (Samara). The combustor inner surface is covered a «Recon» Program to modernize the GTK-10 fleet which is now being
with a thermal barrier coating which reduces heat conduction and prolongs implemented (over 100 units have been repaired and reconstructed).
the service life. In accordance with the scope of the contracts for Ukhtinskaya
The packaged gas compressor units were manufactured in accordance and Vuktylskaya (a similar project for 3 gas compressor units) compressor
with the Gazprom - Siemens cooperation programme. Serial production stations, Siemens placed a considerable number of auxiliary equipment
of SGT-600 unit components was established by Demag Delaval Power orders (air filters, acoustic enclosures, ventilation systems, exhausts,
Nevskiy, the joint venture of Siemens and Nevskiy Zavod. The company was silencers, and fire fighting systems) on Russian manufacturers. A CCC
founded in 1994 and currently manufactures 18 types of gas turbine automatic process control system was installed at Ukhtinskaya compressor
components including compressor and turbine casings and diffusers, for station and the control system manufactured by System Service Company
the GT10 and GT35. It manufactured and supplied two GT8C gas turbine (Russia) was mounted at Vuktylskaya station.

The first MOBILEPAC gas turbine power plants will be installed in Moscow

The company Mobile GTES (founded by RAO UES of Russia) signed

a contract with Pratt & Whitney Power Systems for the delivery
of 10 MOBILEPAC gas turbine power plants to be installed in seven districts
of Moscow and its surrounding region. These mobile gas turbine power
plants are intended to supply the peak electric loads and can be easily
transported, in accordance with the electricity demand. Initially gas turbine
power plants will be installed in the Odintsovo, Krasnogorsk, Beskudnikovo,
Pavshino, Nachabino, Daryino and Sheremetyevo districts.
Pratt & Whitney Power Systems experts report that the gas turbine
power plants, each rated at 25 MW, will be delivered ready-to-operate
on monocoque trailers. They can be commissioned on the day of arrival
at the site, as long as the necessary location, fuel supply system,
Independent CHP provides electricity to motor show in Saint Petersburg and transformer substation for grid connection are prepared in advance.
Despite the relatively high production cost of a kilowatt-hour
The power plant operates in a local power grid system and is not of electricity, generated on liquid fuel, the value of such mobile power plants
connected to the Lenenergo electrical and heat networks. The prime is quite obvious. The additional output, generated during the peak demand
contractor for the project is Elektrosistemy (Saint Petersburg). The motor of the power system, will unload the transformer substations at the sites
show’s combined heat and power mini-plant is located in an independent where the gas turbine power plants are connected. It will prevent power
built-in facility with dimensions of 12m x 9.5m. equipment failures and improve power supply reliability.
The power plant consists of two Elliot TA–100 micro-turbine units, In case of a change of location, and at the customer's request, the
operating in parallel mode, and with integrated heat recovery systems power plants can operate on natural gas after a slight modification at the
(the unit power rating is 100 kW and heat output is up to 172 kW) together operating site.
with a Vitoplex 200 SX 2 hot-water boiler with a thermal capacity of 200 kW.
The boiler is intended to meet the thermal power demand during
the maximal estimated mode of heat consumption, and to provide
the heating load at the minimal electrical load on the CHP unit.
The maximum estimated electric load on the combined heat and power
mini-plant is 142 kW, with a heating load of 453.2 kW. The power plant was
tested for the equivalent electrical load in different operational modes,
including substantial load increases (up to 80% of the power rating)
and load drops. The integrated system of micro-turbine exhaust gas heat
recovery has also been tested. The heat recovery control system allows
a constant, predetermined temperature of the heating water to be
maintained, together with a permanent differential between the heating
and return water. The control system senses and transmits about 100
performance parameters of each micro-turbine to the monitor of the
operating personnel.

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Issue 1, 2007 HTTP://WWW.GTT.RU