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GAS TURBINES FOR POWER GENERATIONS AND GAS TURBINE POWER PLANTS



50 years for marine gas turbine manufacturing



The State Gas Turbine Research & Production Complex “Zorya-Mashproekt” since 2001 has combined with R&D production enterprise “Mashproekt” and mass production line “Zorya” one of the world leading manufacturer of gas turbine engines and gearboxes. Since 1954 more than 30 types of marine propulsion units have been delivered and proven on successful operation. The ships powered by propulsion units operate Navies of Ukraine, Russia, Bulgaria, Romania, Poland, Germany, India, Vietnam, China, USA, and other countries. In the middle of 60th “Zorya-Mashproekt” began conversion of naval production for civil application. Gas turbines designed for severe marine conditions possess high reliability, durability and compact design; they are economically attractive in comparison with industrial gas turbine engines. Application of “Zorya-Mashproekt” engines was performed parallel in two parallel directions for power generation and the gas pipeline industry. Spurt construction of transcontinental gas pipelines from European part of the former Soviet Union to Western Europe required a large number of gas pumping units fueled by natural gas. The first gas pumping unit of “Zorya-Mashproekt” GPA-10 of rated 10MW power was derived from marine gas turbine engine of M8 type. Near 500 of such gas pumping units have been delivered to gas pipelines. The leading engines have accumulated more than 100,000 firing hours with no overhaul and are still under operation. Later on other marine gas turbines were also powered gas pipeline industry. Nowadays gas turbine movers rated at 3, 6, 10, 15, 16 and 25MW are offered for application in gas pipeline industry. At present gas turbines manufactured by “Zorya-Mashproekt” are widely used to drive gas superchargers on gas pipelines of Russia, Ukraine, Kazakhstan and Belarus, at compressor stations in Iran, underground gas storage in Czech Republic. To meet customer's specific requirements concerning rotational speed “Zorya-Mashproekt” has its own gearbox manufacturing facility and got wide experience in the development variety of reduction gears.



2



35 years - industrial gas turbines manufacturing



In 1969 the first floating co-generating power plant “Severnoie Siyanie” ( “Northern Lights”) rated 24MW was equpped by “ZoryaMashproekt” gas turbines. Since then for more than 30 years several such power plants have provided heat and power in distant regions of Siberia and the Far East. In 70th mobile power trains were developed for power supply to constructed “Baikal-Amur” rail road, operating until now. In 90th third and the fourth generation gas turbines were introduced to the power market of CIS countries and abroad. At the beginning of 21 century, gas turbine engines energize more than 50 power plants from Turkmenistan in the East to Canada in the West. “Zorya Mashproekt” turbines operate in various climatic conditions from cold upper Arctic zones down to hot central Asian deserts. Present time “Zorya-Mashproekt” offers a wide choice of turbo generating sets and gas turbine plants ranged from 2.5 to 325MW of: -simple cycle plants; -cogeneration plants; -steam injection plants including “Aquarius” type units; -combined cycle plants; -cogeneration plants with distilling desalting units (DDU).



3



Gas Turbines For Power Generations



Power, MW



Efficiency, %



(D049)



о



о



Ambiet air temperature, С



Rated power, kW Efficiency, % 3



Fuel gas consumption, nm /kW .h



Ambiet air temperature, С



2850



Exhaust gas temperature, оC



28,5



Dimensions (L x W x H), m Weight, t



0,353



Exhaust gas mass flow, kg/sec



460 3,51х2,52х1,93 4,25



16,5



Features 1 2 3 4 5 6 7



1



2



3



4



- Рower flange - Gearbox - Electric starter - Compressor - Combustion chamber (CC) - Turbine - Frame



5



6



7 Gas turbine generating set UGT 2500



4



Gas Turbines For Power Generations UGT 6000, UGT 10000, UGT 15000, UGT 25000 Gas Turbine Design Features



56 1



2



7



3 4 Features 1 - Variable geometry inlet guide vane 2 - Low pressure compressor 3 - High pressure compressor 4 - Combustion chamber 5 - High pressure turbine 6 - Low pressure turbine 7 - Power turbine 8 - Auxiliary drive gearbox 9 - Electric starter 10 - Frame



8



10



9



Power, MW



Efficiency, %



(DV71)



2



о



о



Ambiet air temperature, С



Ambiet air temperature, С



Rated power, kW



6360



Exhaust gas temperature, оC



Efficiency, %



31,5



Dimensions (L x W x H), m



3



Fuel gas consumption, nm /kW .h Exhaust gas mass flow, kg/sec



0,319



Weight, t



30,5



5



428 4,6х1,8х1,8 4,5



Gas Turbines For Power Generations



Power, MW



Efficiency, %



(DN70)



о



о



Ambiet air temperature, С



Ambiet air temperature, С



Exhaust gas temperature, оC



10500



Rated power, kW



36,0



Efficiency, % 3



Fuel gas consumption, nm /kW .h



Dimensions (L x W x H), m



0,279



490 4,0х1,8х1,7 5



Weight, t



36,0



Exhaust gas mass flow, kg/sec



UGT 15000



Efficiency, %



Power, MW



(DB90)



18



о



о



Ambiet air temperature, С



Ambiet air temperature, С



Exhaust gas temperature, оC



17500



Rated power, kW



35



Efficiency, % 3



Fuel gas consumption, nm /kW .h Exhaust gas mass flow, kg/sec



Dimensions (L x W x H), m



0,287



Weight, t



72,2



6



414 4,7x2,1x2,2 9



Газотурбинные для привода Gasдвигатели Turbines For Power Generationsгенераторов UGT 16000



Power, MW



Efficiency, %



(DJ59)



о



о



Ambiet air temperature, С



Ambiet air temperature, С



Exhaust gas temperature, оC



15900



Rated power, kW



31,4



Efficiency, % 3



Fuel gas consumption, nm /kW .h Exhaust gas mass flow, kg/sec



Dimensions (L x W x H), m



0,324



Weight, t



96,0



UGT 25000



Power, MW



Efficiency, %



(DG80)



о



о



Ambiet air temperature, С



Ambiet air temperature, С



Exhaust gas temperature, оC



26200



Rated power, kW



36,3



Efficiency, % 3



Fuel gas consumption, nm /kW .h Exhaust gas mass flow, kg/sec



Dimensions (L x W x H), m



0,277



Weight, t



87,5



7



485 6,4х2,5х2,7 16



Gas Turbines For Power Generations



UGT 110000



Power, MW



Efficiency, %



(GTD110)



о



о



Ambiet air temperature, С



Exhaust gas temperature, оC



114500



Rated power, kW



36,0



Efficiency, % 3



Fuel gas consumption, nm /kW .h



Dimensions (L x W x H), m



0,279



Weight, t



365



Exhaust gas mass flow, kg/sec



1



Ambiet air temperature, С



2



3



4



Features 1 - Variable geometry inlet guide vane 2 - Compressor 3 - Combustion chamber 4 - Turbine 5 - Frame



8



5



Lub oil tank



Air inlet device



8



1



2



9 15



9



10



Gas turbine exhaust



11



Waste heat recovery boiler and contact condenser



12



7



3



Starting frequency converter



13



4



Generator



Gas turbine



5



6



14



Control system



“Zorya-Mashproekt” Complete Power Plants



Gas Turbine Power Plants “Zorya-Mashproekt” offers a wide choice of gas turbine based combined heat and power plants: -simple cycle plants; -cogeneration plants; -steam injection plants including “Aquarius” type units; -combined cycle plants; -cogeneration plants with distilling desalting units (DDU). Every type of plants has its own advantages for operation under certain conditions. What the Customer has to know for optimal selection of the plant type? All the plants can operate using liquid or gaseous fuel; they also have dual-fuel capability or can use alternative types of fuel (biofuel, gas oil etc.)



installed electric power. Steam injection plants can be produced as gas turbine based of non-covered (S1) and converted (S2) gas path versions. Such plants have advantages when used as power plants for industrial enterprises and as small regional power plants where maximum electric power is required and a source of fresh water is available. “Aquarius” type units also operate according to STIG cycle. They have a contact water condenser installed over the waste heat recovery boiler to return water condensed into the cycle. Their main application is implementation in regions suffering from fresh water shortage or in areas where are difficulties in treatment of boiler water large amounts. This type of units also has the ability to generate surplus of distilled water. At ambient air temperature the unit can increase the power of the electric power plant due to water injection at the engine inlet.



Simple cycle installations feature small dimensions, low weight, high maneuverability and fast start up; they can be used at mobile platforms. Such units have an advantage of being used as an emergency or peak power plants as well as stationary power plants in areas where cheep fuel is available and when a consumer needs only electric power.



Combined cycle power plants are designed for the highest possible effectiveness of power generation. Steam generated in waste heat recovery boiler is supplied to separate gas turbine. Electric power is the total power of gas turbine engine and a steam turbine. The plants are offered with two basic configurations: CC1 - one gas turbine with waste heat recovery boiler plus one steam turbine; CC2 - two gas turbines with two waste heat recovery boilers and one steam turbine operating for its own generator. The power plants have advantages when used as regional power stations and also as power stations for big industrial enterprises in areas with the high prices power resources.



Cogeneration plants are designed for simultaneous production of electric and heat power as steam or hot water. Electric power is directly related to the mechanical power of the gas turbine. As for heat it significantly varies in a wide range depending on the selected waste heat recovery configuration (steam or water type, or combined steam and water type, or use of supplemental firing). Such plants are most effective for manufacturing enterprises and public utilities with stable demand for electric power and heat as steam or hot water. Steam injection plants (STIG) utilizing steam injection into the gas turbine hot gas path are also designed for power generation. Steam produced in a waste heat recovery boiler is supplied to a gas turbine as additional working media. STIG type plants feature: -the most increase of electric power up to 90%; -cost effective low NOx, CO emission levels; -cost effective level of capitals $/kW



Cogeneration with distillationdesalinating plants are introduced for the countries with the fresh water shortage. Certain quantity of distillate when used for water injection to gas turbine inlet, allows providing nominal power output at high ambient temperatures.



10



Gas Turbine Power Plants Thermal Diagrams Steam-in-gas (stig)



Simple cycle Fuel



Exhaust gas



Exhaust gas



Feed water



Air Fuel



1 - Gas turbine. 2 - Generator.



Air



1 - Gas turbine. 2 - Generator. 3 - Waste heat recovery boiler. 4 - Feed water tank. 5 - Pump.



Co-generation



“Aquarius”



Exhaust gas



Exhaust gas Condensate



Feed water



Steam



Feed water Steam



Fuel Fuel



Steam-gas mix



Air



Air



1 - Gas turbine. 2 - Generator. 3 - Steam contact condenser. 4 - Steam condensate collector. 5 - Steam condensate cleaning unit. 6 - Feed water tank. 7 - Water cooler. 8 - Pump. 9 - Waste heat recovery boiler.



1 - Gas turbine. 2 - Generator. 3 - Waste heat recovery boiler. 4 - Feed water tank. 5 - Pump. 6 - Heat energy consumer.



Combined cycle CC1



Co-generation with sea water distillation 5 Exhaust gas



Exhaust gas



6 Feed water



Distilled water



Steam Sea water



Steam



Fuel



Feed water



Fuel



Air



Air



1 - Gas turbine. 2 - Generator. 3 - Distillation unit. 4 - Waste heat recovery boiler. 5 - Feed water tank. 6 - Pump.



1 - Gas turbine. 2 - Generator. 3 - Steam turbine. 4 - Waste heat recovery boiler. 5 - Condenser. 6 - Feed water pump. 7 - Pump.



11



Power Plants With UGT 2500



Cycle



Power, MW



Installation



Fuel consumption



Efficiency



Electr. T Therm. herm.



%



ВТU/kW.h



gas (m3 /h)



26,0



11975



1010



840



26,0



12411



1010



840



liquid (kg/h)



Simple



UGT 2500



2,5



Co-generation



UGT 2500C



2,5



Steam-in-gas STIG



UGT 2500S1



4,15



33,1



9614



1225



1020



“Aquarius”



UGT 2500S1A



4,0



33,1



9922



1225



1020



4,7



All data according to the ISO 3410



Gas turbine engine UGT 2500 is specially designed to drive the electric generators. The engine has an integrated gearbox and can be applied to generators with 50 and 60 Hz frequencies. According to the order from Canadian company “ORENDA Aerospace Corporation” such engine is adapted to work on biofuel (liquid wood) operates since 1995.



Gas turbine power plant UGT 2500C in Toronto, Canada.



Gas turbine power plant UGT 2500C in Rybinsk, Russia.



Gas turbine power plant UGT 2500C in Brno, Czechia.



12



Power Plants With UGT 6000



Cycle



Power, MW



Installation



% %



Electr. T Therm. herm. Эл. Simple



UGT 6000



6



Co-generation



UGT 6000C



6



Steam-in-gas STIG



UGT 6000S1



8



11.1



Fuel consumption



Efficiency



ВТU/kW.h



gas (m3 /h) газ (м3/ч)



liquid (kg/h)



31.5



10835



газ 2130



1790



73,2



11339



1990



1680



36.3



9402



2210



1860



UGT 6000 generating set



Co-genereting power plant UGT 6000C at Yablunevka refinery, Poltavskaya oblast, Ukraine



Co-generating power plant in Zapolyarie (Nother Russia) with 4 UGT 6000 gas turbines



Gas turbine engines of UGT 6000 type are in serial production since 1978 and have 6 modifications with different rotational speed and power take-off (from compressor side, from power turbine side and simultaneously from both sides). This class engines combine considerable specific power and high efficiency with reliable operation and simplicity in maintenance. More than 300 engines of UGT 6000 type are in operation all over the world. They are used at Naval ships of different classes and also as supercharges and electric generator drives of power stations.



13



5



Power Plants With UGT 10000



Cycle



Power, MW



Installation



%



Electr. T Therm. herm. Simple



UGT 10000



10,5



Co-generation



UGT 10000C



10,0



Steam-in-gas STIG



UGT 10000S2



“Aquarius” Combined



Fuel consumption



Efficiency



ВТU/kW.h



gas (m3 /h)



liquid (kg/h)



36



9481



2950



2460



85,6



9980



2960



2470



16,0



43



7937



3760



3140



UGT 10000S2A



15,7



42,2



8146



3760



3140



UGT 10000CC1 UGT 10000CC2



13,5 27,5



45,8 46,3



7452 7371



2980 5960



2500 4940



15,04



UGT 10000 engine has several modifications including flow path modification for STIG cycle which increases the engine power and reduces NOx emissions level to 25 ppm. UGT 10000S2A engine of “Aquarius” power plant was tested as electric generator drive at “Zorya”“Mashproekt” test facilities. The power plant “Aquarius-16K” with UGT 10000S2A engine was set into experimental and commercial operation in 2003 at Stavishchenskaya compressor station (Kiev region, Ukraine). UGT 10000S2A (DU70) Gas turbine engine



Exhaust Contact condenser



Waste heat recovery boiler



Condensate return Steam pipe Separator Air inlet device



Generator Gas turbine Thermal and sound insulating container



“Aquarius” installation layout



“Aquarius-16K” installation at Stavishchy compressor station



14



Power Plants With UGT 16000



Cycle



Installation



Power, MW



Efficiency



Therm. herm. Electr. T



%



ВТU/kW.h



Fuel consumption



gas (m3 /h)



liquid (kg/h)



Simple UGT 16000



16 300



Co-generation



UGT 16000C



14 500



Combined



UGT16000CC1



18 400



27, 04



Three UGT 16000C units at Kzyll-Orda, Kazakhstan



31,0



11010



5320



4430



79,9



4270



5260



4380



36,2



9430



5260



4280



Two UGT 16000C power units at Mozyr petroleum refinery, Belarus



Floating power station “Aurora borealis” with two UGT 16000C power units



Power station at Salekhard, Russia with one DC59 and two UGT 16000 gas turbines



UGT 16000 is the modernized engine of the 2nd generation. Still it remains popular among the Customers due to its high reliability, easy maintenance and optimal relation between price and quality. Some of the engines have accumulated 80-100 thousand hours without overhaul. Dual fuel version engine is able to switch over from gas to diesel fuel was implemented at Salekhard power station.



15



Power Plants With UGT 15000



Cycle Цикл



Installation Установка



Power, Мощность, MW МВт



Efficiency Эффективность



% %



Electr. Эл. T тепл. Therm. herm. Simple Co-generation Steam-in-gas STIG



UGT 15000



16.0



UGT 15000C



16.0



UGT 15000S2



ВТU/kW.h.h ВТU/kW



Fuel consumption Расход топлива 3 3 gas(м (m газ /ч)/h)



liquid (kg/h) жидкое (кг/ч)



33.5



9740



5020



4215



32.5



10490



4940



4150



25.0



42.0



8120



5960



5020



23,9



“Aquarius”



UGT 15000S2



25.0



42.0



8120



5960



5020



Combined



UGT 15000CC1



22.7



45.3



7530



4940



4150



UGT 15000CC2



45.8



45.9



7430



9880



8300



Assembling of UGT 15000 gas turbine engine



UGT 15000C power unit at Kostyukovichy cement works, Belarus



UGT 15000 in the container



“Aquarius” power station with UGT 15000S2 gas turbine at “Zorya-Mashproekt” testbed



Gas turbine engines of UGT 15000 type are in serial production since 1991. They are used at Navy ships, as gas supercharges drives and electric generators drives for power stations. The serial engine of DG90 modification with operation on natural gas reached NOx emissions level of 37.5 ppm and CO emissions level of 26 ppm. While operating on diesel fuel the decrease of NOx and CO emissions to 25 ppm is achieved by means of steam injection into combustion zone. GTRPC “Zorya-Mashproekt” manufactures and supplies container power stations with UGT 15000 engine.



16



5



Power Plants With UGT 25000



Cycle



Power, MW



Installation



Electr. T Therm. herm. Simple Co-generation Steam-in-gas STIG “Aquarius” Combined



Fuel consumption



Efficiency



%



ВТU/kW.h



gas (m3 /h)



liquid (kg/h)



35,0



9402



7330



6170



34.8



9807



7220



6060



30.8



40



8533



7720



6490



UGT 25000S2 UGT 25000S1



40.7



7974 8533



9570 7720



8020



30.8



42.8 40



UGT 25000S2



40.7



42.8



7974



9570



8020



UGT 25000CC1



34.7



47.5



7185



7220



6060



UGT 25000CC2



70.6



48.5



7037



14440



12120



UGT 25000



25



UGT 25000C



25



UGT 25000S1



35,5



Gas turbine engine UGT 25000 (DG80)



6490



Engine cover during assembling



UGT 25000C power unit during assembling at Beryozovskaya power station, Belarus.



UGT 25000C power unit at Beryozovskaya power station, Belarus.



UGT 25000 is the most powerful from the unified series of engines. It belongs to the forth generation of engines and is in serial production since 1995. It successfully combines the newest attainments of modern design ideas, advanced technologies and many years of experience in operation, which allows produce the high maneuverability and efficiency.



17



Power Plants With UGT 110000



Cycle



Power, MW



Installation



%



Electrical Simple cycle



Combined cycle



Fuel consumption



Efficiency



ВТU/kW.h



gas (m3 /h)



liquid (kg/h)



UGT 110000



110



35,5



9610



31100



26100



UGT 110000CC1 UGT 110000CC2



160 325



51,5 52,5



6758 6563



31810 63620



26700 53400



UGT 110000 at Ivanovskaya power station (Komsomolsk city, Ivanovskaya oblast, Rossia)



1 - Ga turbine engine UGT 110000 2 - Generator TVG-110-2 3 - Air inlet device 4 - Waste heat recovery boiler 5 - Steam turbine 6 - Transformers room



UGT 110000CC2 for Ivanovskaya power station (under construction, Komsomolsk city, Ivanovskaya oblast, Rossia)



UGT 11000CC1 (PGU-160) power units during construction in Kaborga village, Nikolaevskaya oblast, Ukraine



UGT 110000 is a new engine of the fourth generation designed according to single shaft configuration especially to drive the electric generator. The engine favorably differs from foreign analogues in weight which is only 50 tons and overall dimensions: 5.7x3.7x4.0 m. Engine #2 is under trial-commercial operation at Ivanovo power station in Russia. Engine #1 is being mounted now as a part of 160 MWcombined cycle power plant at the company's test plant in Kaborga for further commercial power generation.



UGT 110000 at “Zorya-Mashproekt” test bed



18



5



Power generation applications



TYPE



POWER MW



GTD-1



APPLICATION



LOCATION



NUMBER OF GAS TURBINES



BEGINNING OF OPERATION



REMARKS



YAKUTIYA



FLOATING POWER PLANT



RUSSIA



RAILROAD POWER TRAIN



RUSSIA



CHUKOTKA YAKUTIYA TUMEN REGION BURYATIYA



DO12



KOMI STATIONARY



RUSSIA



KHABAROVSKY KRAY AMUR REGION YAKUTIYA



FLOATING POWER PLANT



RUSSIA



RAILROAD POWER TRAIN



RUSSIA



KHABAROVSKY KRAY PRIMORSRY KRAY YAKUTIYA



2



1971-75



2 2 6 3



1970-74 1978-2000 1986 1976



TUMEN REGION KAZAKHSTAN TENGIZ RUSSIA TUMEN REGION



17 27 4



1980 1990 1998



AZERBAIJAN



13



CHUKOTKA DO14



TUMEN REGION YAKUTIYA KHABAROVSKY KRAY



KAZAKHSTAN STATIONARY



FLOATING POWER PLANT RAILROAD POWER TRAIN STATIONARY FLOATING POWER PLANT RAILROAD POWER TRAIN



DА14



DC59 STATIONARY



YUZHNAYA



RUSSIA



YAKUTIYA



RUSSIA



KHABAROVSKY KRAY YAKUTIYA



RUSSIA RUSSIA RUSSIA



RUSSIA



TURKMENIYA



TUMEN REGION YAKUTIYA SOVETSKAYA GAVAN



NEFTYANYE KAMNI TUMEN REGION



1986



YAKUTIYA



53



1982



NEBIT-DAG



21



1986



9



1980



KAZAKHSTAN JANAJOL



2



1998



TUMEN REGION



2



2002



RUSSIA



RYBINSK



10



1995-2003



Licence



UKRAINE



KHARKOV REGION



1



1997



manufacturing by



CZECH



BRNO, OLOMOUC



2



1994



RUSSIA



STATIONARY



UGT 2500



UGT 6000



CANADA



TORONTO



2



1995



RUSSIA



TUMEN REGION



4



2002-2003



UKRAINE



POLTAVA REGION



1



1999



STATIONARY



UKRAINE



NIKOLAEV REGION



STATIONARY



UKRAINE BELARUS



NIKOLAEV REGION



1 2



1996 2003-2005



STATIONARY



UKRAINE



STATIONARY



UGT 10000



UGT 15000



15



UGT 15000



FLOATING POWER PLANT RAILROAD POWER TRAIN STATIONARY STATIONARY



UGT 16000



UGT 25000 110



NIKOLAEV REGION CHUKOTKA



5



1992



YAKUTIYA



11



1993



RUSSIA



YAKUTIYA



4



1993



RUSSIA



KHABAROVSKY KRAY



2



1992



RUSSIA



BYELORUSSIA MOZYR TUMEN REGION RUSSIA



UKRAINE



UGT 110000



1990



12



2



1991



1



1995



ROSTOV REGION



3



1997



KRASNODARSKY KRAY



3



1992



SEVASTOPOL



3



1992



RUBEJNOYE



1



2003



STATIONARY



UKRAINE BELARUS



NIKOLAEV REGION BREST REGION



1 4



1996 2003-2005



STATIONARY



UKRAINE RUSSIA



NIKOLAEV REGION IVANOVO REGION



1 3



2004 2001-2005



19



“NPO SATURN” not completely included



Nikolaev at night



GTR&PC “Zorya”-“Mashproekt” Oktyabrsky prospekt 42a Nikolaev, 54018, Ukraine. Phone +38 0512 50-25-61, 55-69-92 Fax +38 0512 50-90-50, 55-68-68 E-mail: [email protected], [email protected] http:// www.zmturbines.com



2006