4 2009 Eng Full Web

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GAS TURBO
TECHNOLOGY
ISSUE,
2009
Specialised Information and Analytical Edition
CONTENTS
Publisher: Alexander Gorshkov
Editor-in-Chief: Jim Roberts
Editorial Board: Yuriy Anurov
(Energomash Corporation)
Meherwan P. Boyce
Operation Experience
GTU-50 MW gas turbine package experience
at Kazanskaya TETs-1 heat and power plant
(The Boyce Consultancy Group)
Oleg Bryndin
(Saturn Gas Turbines)
Viktor Chepkin
(Saturn)
Vladimir Lupandin
(Magellan Aerospace
Corporation)
Gurgen Olkhovskiy
(All Russian Thermal
Engineering Institute)
Alexander Shaykhutdinov
New Developments
New design of a multi-case turbine compressor
with a gas turbine drive
NK-20ST new engine development.

The prototype tests
12
The most stressed components

of GTE-65 gas turbine package:
the results of model tests
16
(Gazprom)
Senior Editor: Lyubov Rastorguyeva

Overseas
Manager: Kseniya Torochkova
Marina Stukota
News editor: Marina Malysheva
Designers: Olga Lebedeva
Natalya Repina
Federal Relation and Mass Communication

Supervision Agency.
Registration Certificate PI #FS77-34887
issued December 29, 2008.
Copyright 2007 Gas Turbo Technology JSC.
All rights reserved.
Reproduction without
a written permission prohibited.
Editorial office: P.O.Box 55, Rybinsk,
Yaroslavl region,
152900, Russia
Tel. +7 (4855) 295235,
295236
Fax +7 (4855) 295237
www.gtt.ru/en
info@gtt.ru
Discussion club
What mechanical drive gas turbine engines
are necessary for the Ukrainian pipeline network?
24
Analysis
The quality of gas treatment
at compressor stations
28
Economics and Finance

How to estimate efficiency
of energy supply systems
34
Operation Experience
Dry Gas Dynamic Seals And Buffer Gas Treatment:
The Commissioning Experience
At Ural Gas Compression Packages
40
The features of the air filtration systems

to the test results and operation experience
44
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 2
GAS TURBO TECHNOLOGY
OPERATION
EXPERIENCE
GTU-50 MW gas turbine package

experience at Kazanskaya TETs-1
heat and power plant
Renat Khaliullin
Power Generating Company, Kazanskaya TETs-1 heat and power plant
Viktor Borodin, Sergey Kulagin Motorostroitel
veraged electric power plants
necessiate modernisation,
reconstruction or construction
of new power generating facilities. The
application of several gas turbine packages
with heat recovery systems instead of
overaged gas boilers is efficient for small
electric power plants at the existing fuel
prices. The rest equipment comprising
of steam pipelines, a steam turbine, a
generator, water preparation units and
electric equipment can be used without
new capital costs.
The described variant was used by
Tatenergo. The tender was organised in
spring 2003 to select the gas turbine
package to modernise Kazanskaya TETs-1
heat and power plant. The tender winner
was Motorostroitel.
GTU-50 MW gas turbine package
(photo) consists of two packages each rated
at 25 MW. The arrangement scheme is
given in figure 1. The construction project
developer is BelNIPIEnergoprom (Minsk).
The powerplant is designed around NK-37
drive operated at Bezymyanskaya TETs
developed by Kuznetsov SNTK. The drive
Photo.
GTE-25/NK
external gas
turbine
package
at
Kazanskaya
TETs-1
heat and
power plant
Issue 4, 2009
features the three shaft scheme with

the free turbine designed to drive the
generator directly.
GTU-TETs gas turbine heat and power
plant includes two TAKAT 22/6-45UKhL1
booster gas compressors developed and
produced by Kazancompressormash
installed in the separate building. The gas
turbines with generators are packaged at
the site in front of the boiling plant of
Kazanskaya TETs-1 heat and power plant
first stage. The boiling plant consists
of two TKU-13 waste heat boilers (Krasny
kotelschik, Taganrog). T-25-25U3-GV
turbine generator was supplied by Privod
(Oil and Gas Systems); the automatic control
system was supplied by Sealtek (Moscow).
The steam with the pressure of 30 atm
and the hot water are connected to the
existing steam and hot water production
schemes.
The water preparation system of
Kazanskaya TETs-1 heat and power plant is
used at GTU-TETs gas turbine heat and
power plant. The power equipment
production required minimum charges.
Due to the calculations the new generators
rated at 25 MW maximum can be
connected to the existing 6 kV main
distribution device connected with 110 kV
closed distribution device. The generator
connection was performed by cable power
lines.
During commissioning and according
to the results of the acceptance tests
GTE-25/NK packages prototypes confirmed the announced parameters. The
engine efficiency under station conditions
is 36.4%, the efficiency at turbine generator
terminals is 33.5%; the total heat efficiency
considering the heat recovery is 80%.
HTTP://WWW.GTT.RU/EN
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 3
The gas turbine package startup and

connection to the electric main are
automated, they require 20 minutes
including the preparation and startup of
the booster compressor. The Federal
agency on ecological, technological and
nuclear supervision issued permission for
GTE-25/NK package operation.
The guarantee operation of
GTE-25/NK package at Kazanskaya TETs-1
heat and power plant started in July 1,
2006. The total operation time of the
packages by January 1, 2008 was over
18,000 hours. During the specified period
the packages produced about 370,000 kWh
of the electric power and 400,000 Gcal of
heat power. Due to the commissioning of
GTU-50 MW package the specific fuel flow
for the electric power production at
Kazanskaya TETs-1 heat and power plant
was reduced by 7.3%. The reference fuel
saving was about 21,000 t.
The presented data showed that the
one and a half year operation experience
of two GTE-25/NK packages confirmed
the advantages of gas turbine application
in the heat and power plants in general and
converted aircraft engines in particular. 27
unscheduled shutdowns with the total
downtime of 649 hours and 46 minutes
happened within the specified period of
time (figure 2, 3).
The analysis of the specified diagrams
showed that the main downtime reasons to
the frequency of demonstration and to the
time needed for the elimination are mainly
the production engine defects.
The most significant defects are:
n Damage of filter elements in air
filtration systems;
n Contamination of TVM 100-02 heat
exchanger internal water cavity in NK-37
engine oil supply system;
n Cracks in air duct cases, damper
damage of inlet and exhaust fans;
n Increased temperature of gas
duct external surface; leakage in the
compensators;
n Insufficient reliability of the
vibration stand seal assembly on NK-37
engine gas generator turbine frame;
n 56-2002834R2 roller bearing failure
on NK-37 engine gas generator middle
frame;
n Locking of 36.820.130 valve that
supplies compressed air to the starter.
1
2
3
4
5
6
7
8
9
10
11
12
13
The documentation and the supplied

equipment were modified according to the
determined design defects. The primary
filters of the air treatment system were
replaced by GFH-W (G2) metal filters,
the procedure of heat exchanger washing
was included into GTE-25/NK package
operation manual, the modified bearing
design and modernised bearing assembly
were introduced, the production defects
and the frequency of demonstration were
analysed. Thus the set of instruments
for equipment repair to reduce downtime
during further operation was formed.
air treatment unit

inlet noise silencer
suction chamber
turbine
turbine generator
automatic control
system
oil supply system
fire extinguishing
system
gas duct
exhaust silencer
ventilation system
site for engine
rolling out
waste heat boiler
Figure 1. Heat and power

plant arrangement based
on two GTE-25/NK packages
at Kazanskaya TETs
(the scheme represents one
package)
Figure 2. Diagram of downtime distribution:

a) to the frequency of happening in gas turbine package systems (in numbers);
b) to the time needed for the elimination (in hours, %);
engines
2 equipment
3 booster compressor
waste heat boiler
automatic control system
Figure 3.
Defects:
a) to the type
of defect;
b) to the type
of defect
(time for
elimination)
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 4
TURBOnews
The equipment assembly of the constructed package at Tumenskaya TETs-1 heat and power plant began
The investment project realised by Fortum (Fortum department in Russia) provides
for the installation of the new package with all necessary systems at the site of the
disassembled equipment in the existing main building.
Combined cycle package #2 rated at 190/220 MW is comprised of V64.3A gas turbine
produced by Ansaldo Energia with the electric power of 68.5 MW, E-500-13.8-560 GN
boiler (model TGE-435-A/PGU) produced by Krasny kotelschik, T-130/160-12.8 steam
turbine produced by Leningrad Metal Plant and TZFP-160-2MUZ turbine generator
produced by Elektrosila.
The site for the package was prepared, the frame of the waste heat boiler heating
surface was assembled, the gas turbine and the generator were produced, tested and
supplied, and the equipment for the steam turbine (electric generator and steam turbine
with the auxiliary equipment) was supplied. The package transformers produced by
ABB were manufactured and tested; the transformers will be supplied in August 2009.
The foundation for the steam turbine was prepared; the works on the construction of
the gas turbine foundation are finished. The project is agreed with the system operator
and network structures.
The turnkey construction of the combined cycle package is carried out by KvartsNew technologies. The general project of the construction was prepared by
VNIPIEnergoprom.
The operation experience of the first package built and commissioned in 2003 was
considered at the equipment manufacture for package #2.
Due to the project realisation the electric power will be increased by 190 MW
and the heat power by 225 Gcal; the economic and ecological characteristics of
the plant will be improved. The electric power production will be increased from
434 to 1715 million kWh annually; the economic efficiency due to the reduction of the
specific fuel flow will be over 150 million rubles annually.
The commissioning of the second package planned for April 2010 will provide the
balance of the electric power production and consumption in the south of Tumen
region, the necessary heat generating facilities for the new house construction.
The construction and assembly are carried

out at the site
The precommissioning began at the first package of Noyabrskaya PGE powerplant

The washing and hydraulic tests of the circulation system of
T-15.5/20.3-5.4/02 steam turbine produced by Kaluga Turbine
Works were carried out. The oil circulation through the
bearings is finished. The steam turbine is installed at the turbine
engine.
The washing and the circulation of the oil system and
the washing of the turbine generator closed cooling system were
performed at PG6581B gas turbine produced by GE. The
hydraulic tests of the fire extinguishing system were performed,
The main building of Noyabrskaya PGE powerplant

Issue 4, 2009
the ventilation system was checked. The gas turbines at

Noyabrskaya PGE powerplant are designed considering the
specific climatic conditions of Yamalo-Nenets autonomous
district. The equipment can withstand the temperature
difference from 60 C to +30 C.
The degreasing system of T-131 waste heat boiler produced
by ZIO-Podolsk was assembled; the preliminary hydraulic tests of
the boiler gas-air duct were performed. The feed electric pumps
with the automatic control system were tested.
The automatic control system based on PIK-Progress
equipment was assembled. The sensors to get information
for the automatic control system were installed at the main
and auxiliary equipment. All equipment data will be transferred
to the central control board to react rapidly on the changes of
the main and auxiliary equipment of Noyabrskaya PGE
powerplant.
TTK-25-2UKhL4-P turbine generator produced by
Elektrotyazhmash-Privod and the complex distribution device
produced by Siemens were assembled earlier. The application
of the complex distribution device instead of the open one
will increase the reliability, the service life and reduce
maintenance.
The specialists of New generation service were trained to GE
programme. According to the received certificates the specialists
can operate and service GE gas turbines installed at Noyabrskaya
combined cycle powerplant.
The construction of Noyabrskaya PGE powerplant is carried
out by Intertekhelektro-New generation. The installed electric
power is 124 MW; the heat power is 90 Gcal/h.
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 5
The construction of PGU-235 combined cycle package began at Syzranskaya TETs heat and power plant of Volzhskaya TGK
The initial construction works were completed on July 10.
The last pile was driven, then the manufacturing building will be
constructed and the fixed structures for the new turbines and
generators will be assembled.
The general contractor is Samara production and repair
company. 25% of the planned works have already been performed.
The new package of Syzranskaya TETs heat and power plant
will be equipped with the advanced equipment produced in
France, Czech Republic and Slovenia by General Electric, Siemens
and Istorenergo group. The reconstruction project named as
Volzhsky agat provides for the construction of the combined
cycle packages based on two PG6111 gas turbines produced by
GE Energy with the electric power of 80 MW each and SST-600
steam turbine rated at 65 MW produced by Siemens. The electric
generators are included in the supply of the main equipment.
The efficiency of the new package will be 52%. The combined
cycle package will include the waste heat boilers produced by
Istorenergo, booster compressors produced by Energaz, the
a u t o m a t i c c o n t ro l s y s t e m p ro d u c e d b y G E , t h re e
TDTs-125000/110-UKhL1 modular transformers.
Due to the realisation of the construction project the outdated
turbines will be removed from operation and the installed power
will be increased on over 52% from 255 to 392 MW considering
the removal of the old package. The power and economic
efficiency of Syzranskaya GRES powerplant will be considerably
increased: the specific flow of the reference fuel will be decreased
on over 22% for the electric power production, and on over 6%
for the heat power production.
The commissioning of the combined cycle package is
planned for the end of 2011. The cost of the project realisation
is about 9 billion rubles. The estimated payback period is about
13 years.
The name of the construction project at Syzranskaya GRES

powerplant is not accidental. All investment projects realised by
KES-Holding subsidiaries (11 mandatory investment projects and
5 large priority projects rated from 10 to 110 MW realised in 10
regions) are given the names of minerals or precious stones. The
investment programme of the holding is called Diadema.
Volzhsky agat was used for Syzranskaya GRES powerplant because
the mineral was found near Samara by the expedition of the
Saint-Petersburg Academy of Science in 1769 and can be found
only in Samara region.
Due to the crisis the power engineers doubted the necessity
of the new generating facilities construction. But the decision
taken before the crisis was efficient. According to the estimations
the electric power demand will be growing.
The construction site of the new package at Syzranskaya TETs

heat and power plant
The main equipment was delivered to Kirishskaya GRES powerplant

Two SGT5-4000G gas turbines with
the electric power of 286.6 MW produced
by Siemens were supplied to Kirishskaya
GRES powerplant on August 29 for
PGU-800 combined cycle package
construction.
The delivery of equipment with the

total weight of 2600 t took three weeks.
During the next construction stage the
generators and gas turbines will be
installed in the main building and the
assembly will begin.
The delivery of the gas turbine packages from the manufacturing plant was first made by
water and then using two heavy weight coupled carriers
The combined cycle package building

assembly is carried out by Stalkonstruktsiya.
SZEM is continuing the assembly of two
E-255/313/29-15.0/3.42/0.74540/540/265 (P-132) heat recovery
systems produced by ZIO-Podolsk and
supplied by EMAliance.
The general contractor of the
construction is VIS. The general project
was carried out by North-West power
engineering center.
Unit #6 (PGU-800 combined cycle
package) will help to increase the
economic characteristics of the powerplant due to the realisation of the
Modernisation of Kirishskaya GRES
powerplant condensing section based
on the combined cycle technology
investment project. As a result of the
combined cycle technology use the
specific flow of the reference fuel will
decrease from 353.1 g/kWh in 2008
down to 221.5 g/kWh, the efficiency will
increase from 34.8 to 55.5%.
The commissioning of the combined
cycle package is planned for 2010.
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 6
NEW DEVELOPMENTS
New design
of a multi-case turbine compressor
with a gas turbine drive
Vladimir Panenko, Vladimir Danileyko, Yury Zinchenko, Victor Timofeev,
Vasiliy Kholod Sumy Frunze NPO
In recent years Sumy Frunze NPO along with the traditionally supplied gas compression
packages performed several orders to develop the compressor equipment for oil and
petrochemical industry. The equipment featuring high pressure ratio and final pressure
of the compressed gas required the development of the multi-case compressors with a
step-up gear, the application of non-traditional approaches to the design and calculation
and also the development of the new compressor cases.
ccording to Surgutneftegaz
specifications Sumy Frunze NPO in
2007 designed TKA-Ts-16/037-14.2
package to compress the casing head gas.
The modular automatic packages were
designed around NK-16ST gas turbine
engines (figure 1) to use at Talakanskoye
field compressor station. The reference
data for the centrifugal compressor
designing is given in Table 1; the oil gas
composition is given in Table 2.
The method when a multicase
compressor is divided into sections was
used to define the design scheme of
the centrifugal compressor. The section
quantity and parameters were calculated at
the specified pressure distribution. The
centrifugal compressor includes 3 cases
(Table 3): 193GTs1-270/3.6-16M26 low
Compressed gas composition
The basic parameters

of the centrifugal compressor
Table 1
Issue 4, 2009
Initial pressure (abs.), MPa
0.36
Final pressure (abs.), MPa
14.40
Initial temperature, K
303
Capacity adjusted to the temperature

of 293 K and the pressure
of 0.101 MPa (million m3/day)
1.37
Gas temperature after

the intermediate cooler, K
313
pressure case; 173GTs1-67/15-50M26

medium pressure case; 184GTs2-19/48150M245 high pressure case.
To provide the specified compressor
parameters the development of a new
stepup gear was required in the existing
M40 case. After determination of the
basic case and stepup gear dimensions
the arrangement schemes of the package
and the turbine unit were developed
(figure 1, 2).
The development trends and the
experience of international companies
were considered for the arrangement
and determination of the centrifugal
compressor design. The technological
and manufacturing capabilities, the
repairability and convenience of operation
were considered, the standard parts and
Components
Methane, CH4
Ethane, C2H6
Propane, C3H8
i-butane, i-C4H10
n-butane, n-C4H10
n-pentane, n-C5H12
Nitrogen, N2
Carbon dioxide, CO2
Other gases
Table 2
Volume concentration
0.7558
0.1404
0.0609
0.0076
0.0027
0.0024
0.0122
0.0012
0.0168
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 7
Figure 1. TKA-Ts-16/0.37-14.2 gas compression package general view:

1 framing; 2 air intake duct; 3 exhaust duct; 4 package; 5 turbine unit; 6 oil system
components were used in the design of the

threecase centrifugal compressor.
Thus the diameter of the inlet and
exhaust nozzle in the low pressure case was
modernised; the medium pressure case
and high pressure case were designed
again. The threecasevcentrifugal
compressor (193GTs1 + 173GTs1 +
184GTs2) is comprised of the low pressure
case and the medium pressure case with
the horizontal split and the high pressure
case with the vertical split. The basic
diameters of the case internal boring
are 950, 850 and 900 mm. All three cases
feature standard rotor drive ends,
couplings; similar thrust and support
bearing assemblies. The number of stages
in the low pressure, medium pressure
and high pressure cases are 5, 6 and 7
correspondingly.
API 617, API 614 standard requirements
were considered during designing, material
selection, production and tests.
The longitudinal sections of the
centrifugal compressor cases are given in
Design parameters of the centrifugal compressor sections
Table 3
Low
Medium
High
pressure case pressure case pressure case
Capacity adjusted to the temperature
of 293 K (+20 C) and the pressure
of 0.101 MPa (1.033 atm), m3/sec
(million m3/day)
Capacity to the inlet conditions,
m3/sec (m3/min)
Initial pressure, design, MPa (kgf/cm2)
Final pressure, design, MPa (kgf/cm2)
Pressure ratio
Inlet gas temperature, K
Compressor rotor rotational speed,
design, 1/sec (rpm)
Section power, MW
15.85 (1.37)
4.60 (276.25) 1.15 (69.33) 0.32 (19.03)

0.36 (3.65) 1.43 (14.58) 4.72 (48.07)
1.58 (16.11) 4.86 (49.59) 14.40 (152.27)
4.41
3.40
3.05
303
313
313
191.7 (11,500)
4.01
Figures 3, 4, 5; the stepup gear during

assembly is presented in Photo 1.
M40-16-5.3/11.6 step-up gear (Table 4) is
single stage, horizontal, with cylindrical
double helical gear, designed for the
torque transfer from the gas turbine
engine to the centrifugal compressor
increasing the compressor rotational speed.
3.60
3.41
Figure 2. TKA-Ts-16/0.37-14.2
gas compression package
turbine unit: 1 power unit
based on NK-16ST gas turbine
engine; 2 step-up gear;
3 low pressure case;
4 medium pressure case;
5 high pressure case
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 8
Figure 3. 193GTs1-276/3.6-16M26 compressor:

1 case; 2 cover; 3 rotor; 4 compressor bundle stator; 5 thrust bearing;
6 support bearing; 7 sealing
Figure 4. 173GTs1-67/15-50M26 compressor
Figure 5. 184GTs1-19/48-150M25 compressor

Issue 4, 2009
The gear was designed and manufactured

to the license of Graffenstaden (France).
The main components of the gear are the
case, bearings and the gear pair comprised
of the driving and the driven wheel (tooth
gear). The gear profile is the involute curve
with the profile angle of 20 C. The gear
wheels are made of high alloy steel. To
provide the surface strength the wheel and
gear teeth are cemented, then hardened
and tempered. The hydrodynamic sliding
bearings are used in the gear.
During the threecase compressor
design the variant calculations were performed and the compressor bundles were
developed. The wheel diameters were 482,
381 and 298 mm correspondingly. After
specification of the compressor bundle
design parameters the check calculation of
the centrifugal compressor was performed
according to the check calculation
programme of the compressor bundle.
As specified above the nozzle diameters
of 193 case were modified during the
designing of the low pressure case. The
internal boring and other case components
remained unchanged. The medium
pressure case was designed again; the new
173 case with the horizontal split and the
internal diameter of 850 mm is the smallest
of all cases developed by Sumy Frunze
NPO. The difficulties of the development
concerned the final working pressure
(Pcomp. max > 5.0 MPa) that is high for
a horizontally split case with 6 stages. The
horizontal split of the medium pressure
case located between the other two cases
was necessary for the assembly works at the
operation site. The strengthened flanges
with the horizontal split, the optimised
contact surfaces of the joint plant and the
design of the pins and screws contributed
to the strength and leak resistance of the
medium pressure case.
The design feature of the high pressure
case (184 case with the vertical split) is the
small width of the working wheel channels
(84.6 mm) and the vaneless diffusers
(5.13.2 mm). The design required the
high accuracy during the manufacturing
of the internal case and the rotor (figure 6)
for the wheel and diffuser channels and
the adjustment of channels at the high
pressure case assembly. The increased
requirements are specified for the
compressor bundle working surface
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 9
Technical characteristics
of the step-up gear
Delivered power, design, kW
Drive shaft rotational speed, rpm
Driven shaft rotational speed, rpm
Speed increasing ratio
Table 4
16,000
5300
11,603
2.19 (81/37)
roughness. To provide the accuracy of the

geometry dimensions and the adjustment
of the compressor bundle channels the
method of rotor and internal case
manufacturing and assembly was changed;
the design scheme of the compressor
bundle (compared to the previously used
scheme) was modified. The new design
scheme features the thermal expansion of
rotor and stator in one direction.
The new designed external case
of the high pressure case designed for the
working pressure over 15 MPa was tested
under 1.5 maximum working pressure.
One more feature of the high pressure
case is the installation of the combined
compressor bundle internal sealings
the labyrinths combined with the dimples.
The design is related to the strength
of the sealing elements at high pressure
differences and also with the increased
damping characteristics of the sealings
required for the centrifugal compressor
with high gas pressure.
The development of the centrifugal
compressor, separate components and
parts was performed using Pro/Engineer
programme; the strength calculations
of the solid virtual model using ANSYS
programme. The general view of the
compressor with the step-up gear is given

in Photo 2.
During the manufacturing all rotors
of the centrifugal compressor were
balanced at the working rotational speed
at Schenck balancing test bench with
the vacuum chamber. Each case of the
centrifugal compressor was subjected to
the mechanical air test registering the gas
dynamic characteristics.
The gas dynamic characteristics of the
centrifugal compressor cases were defined
at the model rotational speeds of the
compressor conforming to the operation
mode at the compressor station (Figure 7).
Depending on the compressor inlet gas
temperature the rotational speed varied
from 10,300 to 10,700 rpm. During
tests the measurement of gas dynamic
parameters was performed at the steady
state mode of the compressor operation
after 30 minutes minimum after the
change of the operation mode. The
information measurement system was used
to register processing and calculation of
the gas dynamic characteristics. The
adjusted gas dynamic characteristics of
the centrifugal compressor cases confirm
the parameter conformance to the design
conditions. The content, the compressor
Photo 1. M40-16-5.3/11.6 step-up gear in the assembly shop

Figure 6. High pressure

compressor rotor
Photo 2. Turbine compressor with the step-up gear

9
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 10
Figure 7. Adjusted gas

dynamic characteristics
of the low pressure compressor
to the test results at the air test
bench
conformance to the drawings, the quality

of manufacturing and assembly, the value
of rotor vibration displacement and the
bearing temperature were checked during
the acceptance tests.
TURBOnews
Gosekspertiza approved
the feasibility study of PGU-410 combined cycle
package construction
at Srendeuralskaya GRES powerplant
The development of the feasibility
study of PGU-410 combined cycle
package construction was performed by
Ural power engineering center, a part
of Energostroyinvest-Holding. The
construction management of the
combined cycle package rated at 410 MW
at Sredneuralskaya powerplant to the
contract with OGK-5 is carried out by
Iberdrola. Ural power engineering
center is working on the adaptation of
the main drawings made by Iberdrola
engineers; the working documentation
for the booster compressor station and
coast pumping station.
The construction at the site is
carried out by EES Engineering center.
In accordance with the contractor
agreement made in January 2009 the
company shall provide the construction
of the foundations including the
foundations of the gas turbine, the steam
turbine, the waste heat boiler and the
Issue 4, 2009
T h e c o m p re s s o r d e ve l o p m e n t ,
production and tests were performed
according to the requirements of API
Standard 617 (Axial and Centrifugal
Compressors and Expander
compressors for Petroleum, Chemical and
Gas Industry Services), approved by
#ODC 0550-0010/1.2 Certificate issued by
S G S G ro u p ( S o c i e t e G e n e r a l e d e
Surveilance) on December 1, 2005. The
quality of development, production, repair,
installation and servicing is provided by the
Quality Management System Certificate
# 203218 to ISO 9001:2000 issued
by Bureau Veritas Quality International
on October 30, 2006. The centrifugal
compressor was manufactured, tested and
shipped in the first half of 2008.
The long experience on development,
m a n u f a c t u re a n d c o m m i s s i o n i n g ,
performing of complex compressor,
component and system tests at the test
benches of Sumy Frunze NPO provide
for the production of reliable, efficient
compressors convenient in operation.
exhaust stack, the coast pumping station,

the water treatment system, the sewage
pumping station of industrial and natural
flows, the booster compressor station, the
transformers with the moving lines.
The specifications for the builtin
parts of gas turbine and the waste heat
boiler foundation were modified by
the company specialists. At present time
the foundation frames are installed,
the foundations of the waste heat
boiler, the gas and steam turbines,
the main building, the transformers,
the gas treatment and control system,
the booster compressor station are
constructed.
The combined cycle package will

include MS9001FB General Electric gas
turbine, Nooter/Eriksen waste heat boiler
and Skoda steam turbine.
Due to the commissioning of
the new combined cycle package #12 at
Sredneuralskaya powerplant planned for
the fourth quarter of 2010 the technical
and ecological characteristics of the
powerplant will be improved, the efficiency
and competitiveness at the power market
will be increased, the necessary power
generating facilities margin for
modernisation of the existing equipment
at Sredneuralskaya powerplant will be
made.
The foundations
of the main
building
and the main
equipment
of the combined
cycle plant
are being built
at the construction
site
10
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 11
TURBOnews
KES and SOYUZ made the turnkey contract for the construction of a combined cycle package at
Permskaya TETs-6 heat and power plant of TGK-9
Gas turbine packages for combined cycle plant

at Igumnovskaya CHP were delivered to Dzerzhinsk
The contract for designing, supply and construction of the power generating
facilities at Permskaya TETs-6 heat and power plant with the total cost over 3 billion
rubles was awarded to SOYUZ to the results of negotiations carried out in
B2B-Center.
The reconstruction of Permskaya TETs-6 heat and power plant is one of the
priority investment projects of KES Holding (Ural generation division) and the basic
for the development of Perm region power system. A new building will be built on
the territory of the plant where the combined cycle plant with the electric power of
120 MW will be installed. The package will include two SGT-800 gas turbines and
SST-300 steam turbine produced by Siemens. The contract on the equipment supply
was made between TGK-9 and Siemens at the end of 2007.
The gas turbines were produced by Siemens Industrial Turbomachinery AB in
Finspong (Sweden). The equipment supply is planned for July.
Due to the commissioning of the combined cycle package planned for the end
of 2010 the electric power of Permskaya TETs-6 heat and power plant will be
increased up to 180 MW, the heat power up to 240 Gcal/h. The additional heat
power supply can provide heat to over 50 thousand of flats.
The new buildings and facilities of

PGU-125 combined cycle plant are
constructed at the site of the existing power
plant in the east industrial area of Dzerzhinsk
within Kvarts KES-Holding investment project
on the reconstruction of Igumnovskaya heat
and power plant. The combined cycle plant
will include two LM6000 PD Sprint gas
turbine packages produced by General
Electric.
The equipment supply contract was
signed in the beginning of 2008 between
TGK-6 (Generatsiya Tsentra, KES-Holding
division) and GE AERO ENERGY. Instar
Logistics was KES-Holding partner for
delivery of turbines to Igumnovskaya heat
and power plant. The equipment was
delivered to Dzerzhinsk by water from
Constanta (Rumania); after transfer in
Dzerzhinskkhimmash port the equipment
was delivered to the site.
The project of Igumnovskaya heat and
power plant reconstruction will contribute
to the development of power complex
in Nizhegorodskaya region, provide the
reliable electric power and steam supply
to the customers and considerably reduce
the specific fuel consumption. The obsolete
equipment of the powerplant will be
decommissioned after the introduction of
the combined cycle package planned for
2013.
The general project of the reconstruction
was performed by SOYUZ.
In September Igumnovskaya heat and
power plant (part of Generatsiya Tsentra)
was 70 years. The installed electric power is
75 MW, the heat power is 426 Gcal/h.
SGT-800 gas turbine produced by Siemens

The assembly of the gas turbine began at Pervomayskaya TETs heat and power plant of TGK-1
The project of Pervomayskaya TETs
heat and power plant reconstruction
provides for the construction of the new
package consisting of two combined cycle
packages with the total power of 360 MW
and 270 Gcal/h. Each combined cycle
package consists of V64.3A gas turbines
rated at 65 MW produced by Ansaldo,
T-50/64-7.4/0.12 steam turbine rated at
64 MW produced by Kaluga Turbine
Works and two Pr-E-99.5/13.5-7.61/0.59545/210 waste heat boilers produced by
Podolsk Machine Building Plant. The
gas turbines are equipped with the
automatic control system based on
Symphony Harmony automatic system
produced by ABB. They will be controlled

by the plant personnel via the heat and
power plant control system designed
around Kosmotronika-Venets software
and hardware produced by PIK
Progress.
The set of gas turbine equipment with
the total weight of 646 t and the volume
over 3000 m3 was delivered to SaintPetersburg by water in May. The main
components are the generator with the
weight of over 107 t, the gas turbine with
the weight of 57 t, and the generator rotor
with the weight about 25 t.
The general contractor of the turnkey
construction is EMK-Engineering, a part
11
of Energostroyinvest-Holding. The works

are carried according to the approved
schedules.
It is planned to commission the
combined cycle plant in December 2009.
The reconstruction of Pervomayskaya
TETs heat and powerplant is the priority
project of TGK-1 investment programme
aimed at the modernisation of the
outdated equipment of the heat and
power plant. The project is realised with
Gazprom support.
Pervomayskaya TETs heat and power
plant supplies heat power to the industrial
facilities, houses and public buildings of
Saint-Petersburg southwestern part.
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 12
NEW DEVELOPMENTS
NK-20ST new engine development.

The prototype tests
Rais Yusipov, Andrey Markushin KMPO
ue to the development of the

remote northern fields and the
growth of gas production Gazprom
needs to increase the power of the driving
engines. The application of the engines
rated at 2535 MW increases pressure in
the gas pipeline thus the number of the
compressor stations is reduced. Delivery
of powerful station engines to remote
stations is rather difficult thus light
and reliable aircraft drives will most likely
be preferable. New driving gas turbines
are designed around the 4th generation
aircraft engines (NK-36ST, NK-36ST-30),
the development itself takes time. Thus
one of the options is modernisation and
boosting of the existing engines. KMPO
together with Aviamotor used NK-16-18STD
engine, the modification of NK-16ST
the most reliable Gazprom drive.
To increase the power and efficiency
the following changes were introduced in
the design of NK-16-20ST engine relative
to NK-16-18STD engine:
1. The engine was cranked up to
nlp adj. = 5 430 rpm at the power of 20 MW,
NK-16-20ST
engine replaceable external oil
filter and the electric starter
Issue 4, 2009
12
the gain was due to the engine cycle

* = 0.66%).
improvement (ef.
2. The more efficient installed high
pressure compressor was installed along
with NK-86 engine with new blades of
* = 0.5%).
stages 49 (ef.
3. The new gas generator turbine rear
frame was installed with the modified
form of the transient channel between
the gas generator and the power turbine
to reduce hydraulic losses and form the
uniform gas speed field at the free turbine
* = 0.33).
inlet (ef.
4. The area of the turbine nozzle
guide vanes of stage 1 was reduced by
3.35% (the increase of the high pressure
compressor operating line to the high
* = 0.18%).
efficiency area) (ef.
5. The hard flange was used between
the gas generator and the power turbine
to reduce the working fluid leakage
from the flowpath to the cover and gas
* = 0.14%). Such
compressor section (ef.
design is successfully used at more
heat stressed NK-36ST and NK-38ST
engine thus the temperature in the gas
compressor section is reduced by 2030 C.
The introduction of the hard flange
required the modification of the engine
fixing on the frame.
6. The high pressure turbine single
crystal blades from NK-86A engine were
installed due to the gas temperature
* = 0.11%).
increase (ef.
7. The air bleeding to the engine
(charging of preoiling cavities and
labyrinth seals) was performed from stage
* = 0.13%).
3a (ef.
8. The radial clearances of the low
pressure compressor stage 3 and 3a were
decreased by 0.1 mm due to the special
* = 0.1%).
layer boring (ef.
9. The air flow supplied to the cooling
of the turbine nozzle guide vanes of stage 1
* = 0.08%).
is decreased (ef.
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 13
10. The radial clearances to the ends

of the low pressure compressor blades
of stage 1 and 2 are decreased by 0.2 mm
* = 0.06%).
(ef.
11. The air bleeding to the gas
compressor and the engine antiicing
system was transferred from stage 9 to
stage 7 of the high pressure compressor
* = 0.06%).
(ef.
12. The labyrinth clearances of the
high pressure compressor stages 7 and 8
were reduced from 1.1 mm to 0.7 mm
* = 0.06%).
(ef.
13. The radial clearances to the ends
of the high pressure compressor blades
of stage 4 are decreased by 1.1 mm due
to transfer of the air bleeding for the
engine to stage 3a and the special layer
* = 0.01%).
introduction (ef.
Thus the total efficiency increase
due to the introduced measures was
* = 2.28%.
ef.
To improve the operation characteristics
external filters with Regotmas replaceable
filter elements were installed at the engine.
The engine can be started using a standard
pneumatic or an electric starter consisting
of the high speed AC electric motor with
planetary reduction gear and the control
cabinet. The system is powered from the
standard threephase electric line with the
voltage of 380 V.
NK-16-20ST engine is interchangeable
with NK-16STD and NK-16-18STD engines
and designed to be used as a gas
compressor for GPA-Ts-16 gas compression
package with the increased power up
to 20 MW (with replaceable compressor
bundle and the pressure ratio increased
up to 1.7). All connection dimensions, oil
type, ecological and service characteristics
of NK-16-20ST engine do not differ from
TURBOnews
REP Holding will supply 19 Ladoga GPA-32
gas compression packages for Gazprom
The companies signed the contract
for 14 billion 970 million rubles
(341,277 million) without VAT on June
30, 2009.
Ladoga GPA-32 is a station gas
compression package rated at 32 MW
developed on the basis of MS5002F Italian
gas turbine designed for any operating
conditions, with high efficiency (36%)
NK-16-20ST engine
NK-16-18ST prototype engine. The low

emission combustor is developed; the
engine parameters are improved. Due to
use of the components and parts removed
from NK-8-2U and NK-86 aircraft engines
after the long-term operation the engine
price is not high compared to other
engines.
The demonstration engine was
assembled and tested at the independent
test bench. The following data were
received during tests (table):
nlp, rpm
nhp, rpm
npt, rpm
N, MW
Ggasgen.turb, kg/h
P2*
T 6*, K
T 7*, K
Efficiency, %
5428
7069.782
5465.917
20
4654
10.779
859.408
676.419
32.62
In 2008 KMPO plans to produce

and assemble two NK-16-20ST engines to
perform the pilot operation and to make
the decision on the serial production of the
engines.
and low emission (NOx =18 ppm), high

service life and good reparability. The gas
turbine production license was purchased
in 2008 from GE Oil & Gas (Nuovo
Pignone S.p.a).
According to the contract with
Gazprom three Ladoga gas compression
packages will be supplied in the fourth
quarter of 2009 for Vavozhskaya (Gazprom
transgaz Tchaikovsky) and Gryazovets
(Gazprom transgaz Ukhta) reconstructing
compressor stations. The next 16 packages
will be installed at the compressor stations
of the constructed Bovanenkovo-Ukhta
gas pipeline: Intinskaya KS-6 compressor
station, Syninskaya KS-7 compressor
13
station, Chikshinskaya KS-8 compressor

station and Maloperanskaya KS-9
compressor station. 12 packages will be
supplied in the third and fourth quarter
of 2010, the rest in the first quarter of
2011.
The project was realised by REP
Holding due to the carried out
reconstruction and modernisation of the
companies entering the holding. The
production of Ladoga GPA-32 gas
compression packages is carried out by
Nevsky Zavod, Zavod Elektropult,
K-Energo, Elektropult Sistema in
cooperation with Iskra and IskraEnergetika.
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 14
TURBOnews
The operating time of GTU-12PG gas turbine is 50,000 hours since the beginning
of operation at Fedorovskoye oil and gas condensate field
In July 2009 the operating time
of PS-90GP-1 leader engine included into
GTU-12PG gas turbine package
produced by Perm Engine Plant reached
50,000 hours since the operation
beginning at Fedorovskaya KS-42
compressor station of Surgutneftegaz
(Khanty-Mansijsk autonomous district).
After the first overhaul the operating
time of the engine is 26,500 hours at
the overhaul period of 25,000 hours
according to the specification.
P S - 9 0 G P - 1 l e a d e r e n g i n e wa s
supplied to Surgutneftegaz in June 2001,
it was overhauled in 2005. Now there
are 19 GTU-12PG gas turbine packages
operated at Surgutneftegaz; 6 packages
are used for the gas compression
package drive, 13 packages for gas
turbine powerplant drive. To provide
the uninterrupted operation of gas
compression packages and gas turbine
powerplants Surgutneftegaz purchased
four PS-90GP-1 backup engines.
GTU-12PG gas turbines

at Fedorovskaya KS-42
compressor station
The powerplant will operate in

cogeneration cycle providing the electric
and heat power for the customers. The
powerplant is designed around three
EGES-4-03 packages produced and
supplied by Iskra-Energetika. The general
contractor is Northern gas pipelines. The
general project was performed by
Giprospetsgaz.
EGES-4.0000-000-03 is developed by
Iskra based on GTU-4P gas turbine serially
produced by Perm Engine Plant. The
generators are produced and supplied by
Elektrotyazhmash-Privod.
As of 08.07.2009 Perm Engine Plant

produced 103 GTU-12P gas turbine
packages (including PS-90GP-1 backup
engines).
The total operating time of GTU-12P
packages since the operation beginning is
over 1700 million hours.
Saturn-Gas turbines completed the construction of the second stage

of the powerplant in Naryan-Mar
The ceremony on the commissioning of the second stage of
Naryan-Marskaya powerplant was held on September 11.
According to the contract made in September, 2007 between
Saturn-Gas turbines and the management of construction and
utilities infrastructure of Nenets autonomous district the company
developed the project of GTES-18 powerplant with the electric
power of 18 MW with the possibility of increasing up to 24 MW,
produced and supplied the main equipment consisting of three
GTA-6RM gas compression packages each rated at 6 MW,
performed construction and assembly, precommissioning, trained
the servicing personnel. The construction began in June 2008.
The modular GTA-6RM gas compression package consists
of GTD-6RM gas turbine produced by Saturn and TK-6-2RU3
turbine generator produced by Elektrotyazhmash-Privod.
GTD-6RM gas turbine is designed around D-30KU/KP serial
The second stage of Naryan-Marskaya powerplant

GTA-6RM package in GTES-18 powerplant
Issue 4, 2009
The auxiliary powerplant at Vuktylskaya

compressor station (Gazprom transgaz Ukhta)
was commissioned
14
aircraft engine. Each package is assembled with the special heat

and sound enclosure. The electric efficiency is 23.6%, the specific
fuel flow is 305 g/kWh, the oil flow is 0.4 kg/h, the noise at the
site is 80 dB maximum, NOx is 60 mg/m3 maximum, the
assigned service life is 120,000 hours.
The package control board is located on the second floor of
the building. The automatic control system of the upper level
controls the powerplant operation in automatic mode. The data
on the package operation is displayed; the package operation can
be controlled on the real time basis.
To increase the fuel gas pressure DKKS-19-3 booster
compressor station is installed. It consists of three RT-R14T-28
compressors produced by NOEMI (2 compressors are operated,
1 is backup).
The second stage of the powerplant is constructed using
advanced technologies and materials specially tested for operation
in severe climate and stable to humidity, temperature changes
and wind. Two engines of the three can operate on two types of
fuel gas and liquid fuel. The space is backed up for the fourth
engine. The project was financed from the budget of Nenets
autonomous district (totally over 450 million rubles).
The first stage of Naryan-Marskaya powerplant consists of
GTES-12 package rated at 12 MW based on two GTA-6RM
packages. The first stage was assembled in one station building
and commissioned in May 2003. It was the first turnkey Saturn
project after GTES-12 successfully operated in Rybinsk since
September 2002 at the territory of the company.
The powerplant is the only electric power supply in NaryanMar. As Naryan-Mar is being built, the power demand is growing.
The second stage will cover the existing electric power demand.
As a rule such powerplants operate in more efficient
cogeneration mode. For example the total efficiency of GTES-12
powerplant with heat recovery increases up to 81.5%. Due to
absence of the centralised heat supply in Naryan-Mar it was
decided not to install waste heat boilers. However, in case of heat
power demand the gas turbine powerplants can be reequipped.
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 15
OGK-1 got the permission to construct the new power package

at Urengoyskaya GRES powerplant
The administration of New Urengoy gave the permission to
Urengoyskaya GRES powerplant for the construction of the
new power package based on the combined cycle package rated
at 450 MW.
11% of works to the project were already performed. In
particular, the feasibility study was developed, examined and
approved by Glavgosekspertiza, the detailed design is carried out.
OGK-1 organises the open single stage tenders for the supply of
steam turbine and electric generator for PGU-450 MW package,
two waste heat boilers, and travel cranes for the turbine section.
The main equipment was produced: two GTE-160 gas turbines
produced by Power Machines and two SGen5-100A turbine
generators produced by Siemens (the supplier is Power
Machines). The design organisation is E4-SibCOTES with the
participation of Tepengineering for subcontracting. It is planned
to define the general contractor to the project till the end of the
year.
The preliminary stage of the project was finished; the preparation for the main construction is performed. The works in the
turbine section of the main building to arrange PGU-450 package
are carried out. The wall and roof panels are assembled; the heating
supply system is laid. Thus the construction and assembly can be
performed in winter.
The main stage of the project realisation will start after determination of the sources and the finance schemes. The total volume of investment is about 25 billion rubles.
The frame of the turbine section in the main building

of the powerplant was assembled
It is planned to commission the package rated at 450 MW as
the total package is performed in two stages (the commissioning
of the gas turbine rated at 320 MW with the following
modernisation using the combined cycle package rated at
450 MW). Thus the construction cost will be reduced; the
parameters of the equipment operation in combined cycle will be
improved. The powerplant capacity will be increased 18 times;
the power reserve will be formed. It is planned to complete the
project at the end of 2012.
Power Machines will supply equipment for the combined

cycle package at Adlerskaya TES powerplant
The feasibility study on Krasnodarskaya TES powerplant made by E4 Group

was approved by Gosekspertiza
The contract on the equipment supply for the

combined cycle package with the electric power of
360 MW (the heat power is 227 Gcal/h) at Adlerskaya
TES powerplant was signed between Power Machines
and TEK Mosenergo, the general contractor of the
construction. The construction of the powerplant
will start in March 2010. The companies were the
winners of the tender held by MezhregionEnergostroy, the customer of Adlerskaya TES powerplant construction. The investor is Gas Energy
Company, the subsidiary of Gazprom.
Power Machines will supply two T-48/62-7.4/0.12
steam turbines rated at 60 MW (the turbines
will be produced by Kaluga Turbine Works) and two
TZFP-63-2-MU3 turbine generators produced by
Elektrosila, Power Machines department. Besides,
Power Machines will supply the equipment
produced by Ansaldo Energia, that is four
V64.3A gas turbines with generators rated at 65 MW
each.
According to the contract the specialists of
Power Machines will supervise the installation of all
the equipment. It is planned to finish the equipment
supply in the first quarter of 2011.
Adlerskaya TES powerplant will be one of the
main facilities for winter Olympic Games in Sochi in
2014. It will supply the electric and heat power to the
sport objects, the Olympic village houses, and the
houses of the neighboring districts.
The powerplant construction will be finished in
2012.
The decision of Gosekspertiza on the design documentation on the

Modernisation of Krasnodarskaya TETs heat and power plant using PGU-410
combined cycle plant was issued by the Federal Agency on the construction
and utilities infrastructure on August 26, 2009. The general designer is
E4-SibCOTES.
The project of Krasnodarskaya TETs heat and power plant modernisation
is unique concerning the equipment arrangement (the customer is
YuGK-TGK8, a part of LUKOIL, the general contractor is E4 Group). The
combined cycle package will include M701F4 gas turbine with the nominal
power of 303.4 MW produced by Mitsubishi Electric, the steam exhaust
turbine with the nominal power of 140 MW produced by Ural Turbine Works
and the steam turbine generator with air cooling produced by ELSIB.
During the project development the demand in the electric power
increase (after carrying out all works it will increase from 648 MW to 1058 MW)
and heat power increase by 220 Gcal/h was considered. Thus the heat will be
additionally supplied to 200 thousand m2 of housing. In summer when the
electric power demand in the
region is higher the package will
produce the electric power of
450 MW.
The project is realised
according to the approved
schedule. The site for the construction needs was prepared,
the engineering networks and
utility lines were transferred
from PGU-410 combined cycle
package site. The construction
works began. The commissioning
The scheme of the future combined cycle
of the package is planned for the
package
first quarter of 2011.
15
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 16
NEW DEVELOPMENTS
The most stressed components

of GTE-65 gas turbine package:
the results of model tests
Alexander Lebedev, Nikolay Simin Power Machines
Vladimir Mikhailov TsKTI
Vladimir Gusev Ivchenko-Progress
Power Machines realises the project of GTE-65 gas turbine package of the average
capacity class. One of the important stages in the development of the package prototype
is the performing of the model tests of the most critical components at the special test
benches.
Introduction
ccording to the world classification
the prototype of GTE-65 gas turbine
package of the average capacity
class (photo 1, table 1) corresponds to F
technology [1].
GTE-65 package is designed for
the electric generator drive and can
carry the base, semipeak and peak load
independently and within the combined
cycle package.
The package was designed to the simple
thermal scheme representing the single
stage double support turbine compressor
with the rotor rotation speed of 5440 rpm
and the electric generator gear drive.
The turbine section consists of the inlet
confuser, 16 stage axial compressor with
three inlet guide vanes, low emission
combustor, 4 stage cooled turbine with the
initial gas temperature of 1270 C and the
Photo 1. GTE-65 packages

at the assembly stand:
1 compressor;
2 turbine;
3 combustor (together with
Ivchenko-Progress)
Issue 4, 2009
16
turbine outlet gas temperature of 555 C,

and the outlet diffuser.
The turbine compressor rotor is
made of separate disks with the installed
compressor and turbine blades. The disks
are centered in between and at the end
parts using the Hirth coupling. The rotor
stiffness is provided by the central
tightening part.
The main components of GTE-65
package including the compressor,
combustor and the turbine cooled blades
were tested at the test bench before the
prototype production.
Tests of the model

compressor
The 16 stage compressor was designed
around the working part developed
by CIAM together with TsKTI; the model
tests were performed. Two outlet blade
stages were added; the first three
stages were modernised at Kuznetsov
SNTK [2].
The experience of development
and 40 year operation of power generating
and gas compression packages produced
by Leningrad Metal Plant and other
Russian and foreign companies was
considered during the compressor
designing. However, due to the introduced
changes additional research was needed.
The 6 stage model compressor (figure 1)
with the first three modified stages was
examined. The model coefficient of the
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 17
Figure 1. GTE-65 package model compressor. Measurement of the channel pressure and temperature at the inlet and outlet.
The strain measurement of the blades of 1-4 stages
standard compressor according to the used

drive is 1:2.23.
The experimental test bench of TsKTI
with reconstructed and modernised
measuring systems was used for the model
compressor examination [5].
The main gas dynamic characteristics
of the compressor were defined during
the tests: the flow, efficiency, pressure
ratio within rotor rotational speed of
adj = 0.71.05. The operation compliance
of the first three modernised stages with
the other stages was assessed.
The compressor was tested at the full
open inlet guide vanes (inlet guide
vanes, figure 2) and at semiclosed inlet
guide vanes to determine the optimal
installation angle for partial load and
startup modes of the gas turbine package.
The received results were compared with
the preliminary design of the gas dynamic
parameters of the model compressor
including the application of 3D CDF flow
analysis.
The comparison results confirm the
correspondence of the research data to
the design data on the scale.
The vibration stress measurements in
the blades were performed together with
the gas dynamic tests of the model: the
strain gauges are installed on 5 blades of
stage 1 and 2, on 8 blades of stage 3, on 9
blades of stage 4 with the determination of
the resonance and transient oscillations
within the rotational speed from 5000 to
Figure 2. Design and experimental characteristics of the first three stages at the full
open inlet guide vanes
GTE-65 package in base mode adjusted

to the nominal conditions to GOST 20440
Shaft rotational speed, rpm
Gas flow at the outlet, kg/s
Mass average physical temperature in the throat of the nozzle guide vanes
of the first stage, C
Turbine outlet gas temperature, C
Compressor pressure ratio
Power at the electric generator terminals, base/peak, MW
Electric efficiency, %
Combined cycle package power (single/two boiler turbine)
Combined cycle package efficiency, %
NOx emission, ppm
17
Table 1
5440
184.4
1280
555
15.6
61.5/65.0
35.2
90/180
52
<25
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 18
Figure 3.
Results of the vibration stress
tests of the model compressor
blades of 1 and 2 stage
Photo 2.
Test model of the combustor
at the test bench of Leningrad
Metal Plant
Issue 4, 2009
12,500 rpm. The comparison of design and

experimental blade resonance frequency
and the vibration stress levels for the blades
of stage 1 and 2 are given in Figure 3.
The strain measurement results of the
model compressor confirm the vibration
adjustment of the blades. The difference
of design and experimental data is
insignificant and can be explained by the
scale factor at the manufacture of the
model compressor blade roots. The level
of maximum vibrations in the blades at
transient resonance speed and at operation
modes is not dangerous.
18
Tests of the combustor model section

GTE-65 package combustor is annular
with the horizontal split for easy disassembly without rotor removal. The lean
homogeneous airgas mixture with low
NOx and CO is burned [3].
120 burners of the combustor are
arranged in two rows. The burners of
each row are divided in four groups with
separate fuel supply with the shutoff valve.
Each burner has two fuel circuits. The fuel
homogenously mixed with the air before
the supply to the combustion area is
supplied to the first circuit; the so called
diffusion fuel is supplied to the second
circuit. The fuel is distributed to the
circuits using two metering units, one for
each row of burners. Two pilot burners are
available.
The combustor model 1/12 of natural
size was developed to confirm the
correctness of the engineering solutions
(photo 2). The watercooled walls are
installed at the model sides. 100
thermocouples were installed in the most
high heat areas. The temperature field
outside the model external section was
measured using thevwatercooled
measuring turret with eight open
thermocouples arranged in radial
direction.
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 19
The tests of the combustor model

section were performed in two stages.
The first stage is performed at the
combustor test bench of IvchenkoProgress. The preliminary tests at the
pressure of 0.7 MPa were performed at full
load mode. The flame tube temperature,
nonuniformity of temperatures after the
combustor, NOx emission were measured;
the fuel supply algorithm was adjusted.
At the second stage the fullsized test
bench specially developed at Leningrad
Metal Plant, Power Machines department,
in 20032005 was used for the flame tests
[6]. The combustor was operated on gas
fuel.
The operation algorithms including
the determination of the stable firing
range, the operation in diffusion mode,
and the preliminary mixing mode at
various loads were developed during the
tests. The temperature fields of the flame
tube walls, the temperature nonuniformity
at the outlet, the pressure pulsations and
emission were checked.
The results of the performed tests
confirmed the compliance to ecological
requirements concerning NOx emission
under the test bench conditions.
The design (CFD analysis) and
experimental temperature field
distribution at the combustor outlet
and the comparison with the standard
requirements to the limits of temperature
nonuniformity specified to the fullscale
combustor are given in figure 4. The
comparison of the design and experimental
data confirm the compliance of radial
temperature nonuniformity to the
experimental data mainly within the
tolerance limit. The quantity difference
of design and experimental temperature
distribution can be explained by the
influence of the combustor model
watercooled side walls on the temperature
field.
solution the cooling schemes were checked

at the test benches.
The thermal hydraulic tests of guide
vanes and turbine blades of stage 1 and 2
were performed at TsKTI package test
bench [5]. The blade packages with
instrumentation prepared for tests are
shown in photo 3.
The comparison of theoretical and
experimental dependence data of blade
cooling depth from the relative flow
received during the package tests
under the heating of the cooling air
and hot gas flow (up to 1000 C) is given in
figure 5.
The cooling depth is evaluated
traditionally
Tgas Tblade,
1
=
Tgas Tair
where
Figure 4.
Radial temperature
distribution at the combustor
model outlet at full load:
calculation
experiment
maximum admissible
temperature
minimal admissible
temperature
Photo 3.
GTE-65 package blades with
instrumentation for tests
Tests of cooled turbine blades

Seven of eight turbine tips in GTE-65
package are cooled. The most stressed are
the blades of stage 1 and 2. To provide the
acceptable thermal state the convective
film cooling is used for vanes and blades of
stage 1, the convective cooling is used for
blades of stage 2 [4]. To assess the design
19
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 20
confirm that the received fatigue strength

data meet the material specification data.
The results of compressor and turbine
blade fatigue tests after strain measurement
of GTE-65 package tests can prove the
blading vibration strength.
Examination of turbine
blade characteristics
Figure 5.
Design and experimental
efficiency of blade cooling:
leading edge;
center part of the profile;
trailing edge
Tgas is the gas temperature to all

parameters;
Tblade is the blade wall temperature;
Tair is the cooling air temperature at the
blade inlet.
There was no thermal barrier coating
of the examined blades available on the
vanes and blades with the convective film
cooling.
The experimental data to the flow
characteristics of the cooling systems and
blade thermal state were used to verify the
blade design models, assess the blade service
life and develop the recommendations on
the service life increase.
Fatigue tests of the compressor

and turbine blades
Figure 6.
Fatigue test results
of compressor and turbine
blades
To provide the vibration strength of

compressor and turbine blades the fatigue
tests (figure 6) of compressor blades of
stages 1, 3, 8 and 16 and of turbine blades
of stages 14 were performed. 16 blades of
each stage were tested. The received results
compressor blade of stage 1
turbine blade of stage 4
Several blades of the standard lot were

cut to examine the quality metal of GTE-65
package cast turbine blades. The following
characteristics were examined:
n Chemical composition;
n Mechanical properties at 20 and
800 C;
n Phase composition, porosity, macro
and microstructure;
n Creeping and lowcycle fatigue.
The results of mechanical property
examination and the comparison with
ChS-70 specification data and the similar
data of IN 738 are given in table 2.
The specimens of turbine blade of
stage 4 cutting and some results of the
microstructure, creeping and lowcycle
fatigue examination are given in figure 7.
The results of mechanical property
examination showed that the mechanical
properties are higher than the specified
required data. The microporosity of the
examined blades is less than 0.5%
meeting the specification requirements.
The microporosity was provided by gas
isostatic strengthening. All blades have
the similar microstructure typical for
ChS70U-VI alloy after the standard heat
treatment contributing to the receiving of
necessary material characteristics.
The results of creeping and lowcycle
fatigue examination confirm that the levels
of the creep strength and lowcycle fatigue
curves are higher than the level of the
similar IN 738 LC material.
Conclusion
crack
after fatigue tests
design stress distribution

in the blade
1 on the blade = 0.88 1 on the specimen
Issue 4, 2009
1 on the blade = 10.22 1 on the specimen

20
The set of the performed tests of

GTE-65 package components: compressor,
combustor, turbine cooled blades,
compressor and turbine blade fatigue
strength and the characteristics of material
and coatings allowed carrying out the
fullscale tests of gas turbine package at
Mosenergo TETs-9 heat and power plant.
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 21
References
1. Lebedev A.S., Varlamov I.S., Roslyakov
M.V. GTE-65 gas turbine package of the average
capacity class: design and production. Electric
power plants, #1, 2007, pp. 1922.
2. Lebedev A.S., Latypov G.G.,
Solomatnikov A.A., Nechkin B.V, Naryshkin
V.F. Selection of parameters, development and
model tests of compressor of GTE-65 package of
the average capacity class. Heavy engineering,
#1, 2007, pp. 26.
3. Lebedev A.S., Lesnyak O.B., Kravchenko
I.F., Gusev V.N. Development of low emission
combustor of GTE-65 package of the average
capacity class. Heavy engineering, #11, 2007,
pp. 1216.
4. Lebedev A.S., Sundukov Yu.M.,
Krivonosova V.V. High temperature turbine
cooled blades of GTE-65 package of the average
capacity class. Heat power engineering, #4,
2008.
5. Lebedev A.S., Simin N.O., Petrenya
Yu.K., Mikhailov V.E. GTE-65 package: tests
of the main components, application and
further development. Heat power engineering, #4,
2008.
6. Lebedev A.S., Ponomarev N.N. Test
benches for low emission combustor examination.
Gas Turbo Technology, #5 (40), 2005, p. 44.
TURBOnews
KS-7/2 compressor station will be reconstructed
at Fedorovskoye field of Surgutneftegaz
Sumy Frunze NPO will produce
three TKA-Ts-16/76-4.0 gas compression
packages each rated at 16 MW and the
equipment for the reconstruction of
KS-7/2 compressor station at Fedorovskoye
oil field (Tumen region). The capacity
of TKA-Ts-16/76-4.0 gas compression
packages is 360 m3/min. The drive is
NK-16ST converted aircraft gas turbine
engine produced by KMPO. The nominal
power is 16 MW, the pressure ratio is 10,
and the efficiency is 29%. The centrifugal
compressor produced by Sumy Frunze
NPO provides for the gas compression
from the nominal value of 0.39 MPa to the
outlet pressure of 7.5 MPa.
It is planned to finish the equipment
supply till August 31, 2009. Sumy NPO
specialists will perform the installation
supervision and the commissioning,
the training course in the equipment
operation. The contract cost is
18.9 million euros.
Minimal values of mechanical properties
Table 2
Specimens
T, C
20
800
Specification
20
800
Yield strength, MPa
767
757
735
680
Tensile strength, MPa
833
803
830
735
Relative elongation, %
3.6
18.3
>3
>3
Relative contraction, %
7.9
23.1
Figure 7. Examination of turbine blade of stage 4 material
The similar order was carried out for

Surgutneftegas in 2005. KS-7/1 compressor
station was reconstructed at Fedorovskoye
f i e l d . Two T K A - Ts - 1 6 / 7 6 - 4 . 0 g a s
compression packages were commissioned.
ORGRES developed the standard startup time
for the combined cycle and gas turbine
packages for the first time in Russia
The standard startup time for the
combined cycle package with the electric
power of 39-450 MW and the gas
turbine package rated at 100-150 MW is
the period from receiving the operators
command for a start till switching on and
achieving the nominal power. It is the first
specification in Russia for the equipment
of this type.
The customer is System operator EES.
The works were performed by ORGRES
(department of Engineering center EES)
since July 2008.
The reference data received from
PGU-450 combined cycle package of
Severo-Zapadnaya TETs, Kalinigradskaya
TETs-2 and Mosenergo TETs-27 heat and
power plants, PGU-325 combined cycle
package of Ivanovskaya GRES powerplant,
Tumenskaya TETs-1 heat and power plant,
21

Mezhdunarodnaya TES powerplant,
GTU-100 and GTU-150 gas turbine
packages at Mosenergo GRES-3 powerplant
were used for the development.
The project included the selection of
operating and design materials (schemes,
startup diagrams, instructions, etc.), the
preparation of report forms sent to the
powerplant personnel, the analysis of the
received data, the examination of the
startup technologies and determination
of the startup time for the combined
cycle and gas turbine packages, the
development of the standard time of
startup and loading till achieving the
nominal power.
The specification was considered,
discussed and approved at the meeting of
Engineering center EES scientific and
technical council, sent to the customer
and shall be introduced as the managing
document.
The operating capability of the combined cycle and gas turbine packages is
defined in the developed specification
determining the period of startup and
loading of the packages from various
initial thermal state. Due to the developed
specification the reasonable power system
loading diagrams can be made.
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 22
TURBOnews
Two powerplants based on Capstone C65 small turbines were
commissioned in Kobyaisky district of the Republic of Sakha (Yakutia)
In the beginning of July 2009 the specialists of BPC Power
Systems performed precommissioning of two small powerplants
each rated at 195 kW in Tyaya and Chagda settlements of
Kobyaisky district, on July 22 the powerplants were commissioned.
The customer is Sakhaenergo, the subsidiary of Yakutskenergo.
The production of six Capstone C65 turbines each rated at
65 kW for two powerplants started last summer. At the end of
2008 the powerplants were transported to Yakutsk and then to
Kobyaisky district to the ice road where the packages were
assembled on the foundations and the external gas supply
systems were installed.
Capstone C65 engine consists of the generator with
the permanent magnet in the rotor and the electric inverter
instead of synchronous generator with the reduction gear typical
for the turbines, the small turbine rotor rotational speed increases from 45,000 to 96,000 rpm and has no connection with
the output voltage. Thus the turbine can operate in the range
from 0 to 100% of nominal power; the fuel flow is proportional
to the load.
Due to high automation level of the powerplant the remote
monitoring, inspection and control from the main center in
Yakutsk is possible. The pressure, temperature, load and other
parameters at the site are controlled by the operator.
The power supply project of Tyaya and Chagda settlements of
Kobyaisky district provides not only the electric power supply but
Small turbine powerplant in Chagda settlement

also the heat power supply. From the beginning of the next
year the small powerplant in Tyaya settlement will operate in
cogeneration mode.
The small turbines can produce 2 kW of the heat power per
1 kW of the electric power. To provide the heat power supply BPC
Power Systems will supply and supervise the installation of the
equipment for small turbine emission heat recovery used for heat
and hot water supply. The planned efficiency of the cogeneration
system based on the small turbines is up to 92%.
Sakhaenergo plans to build the powerplants based on
Capstone small turbines in other settlements of Kobyaisky
district.
EMAliance and E4 Group, the general contractor of Nyaganskaya GRES powerplant construction, signed the contract on the supply of waste heat boilers
EMAliance will perform the
designing, production and supply of
t h re e wa s t e h e a t b o i l e r s f o r t h e
constructing Nyaganskaya GRES
powerplant (Fortum), inspect the assembly
and precommissioning, perform tests and
commission the equipment.
The contract cost is over 3 billion
rubles (68, 392 million).
The powerplant will consist of

three combined cycle packages
with the electric power of 420 MW
each.
Each combined cycle package will
include SGT5-4000F gas turbine with
the nominal electric power of 286.6 MW
with the efficiency of 39.5%, the steam
turbine and generator produced by
The model of Nyaganskaya GRES powerplant
Issue 4, 2009
22
Siemens and the waste heat boiler produced by EMAliance.

According to the contract the waste
heat boilers with the steam capacity
over 600 t/h will be specially designed
and produced for Nyaganskaya GRES
powerplant. Due to use of the advanced
technologies the metal consumption will
be decreased and the operation reliability
of the equipment will be increased.
The designing will be carried out
by the specialists of EMAliance-BSKBU
KU Engineering center; the main
equipment will be produced by Krasny
kotelschik.
All works to the project will be carried
out together with the American specialists
under the license agreement between
EMAliance and NOOTER/ERIKSEN,
INC (USA).
It is planned that the first waste heat
boiler will be supplied in stages from
January 2010 till January 2011.
The project documentation of
Nyaganskaya GRES powerplant was
approved by Gosekspertiza on September
7, 2009.
It is planned to commission the first
package till the end of 2011.
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 23
Mobile GTES commissioned three more mobile

powerplants in Moscow region
Three FT8 mobile powerplants
produced by Pratt & Whitney Power
Systems with the total power of 67.5 MW
were commissioned in Dmitrovsky district
of Moscow region near Ignatovo #555
substation on July 30, 2009. The general
project was carried out by Tepengineering,
the general contractor is Energoproekt.
MOBILEPAC powerplant consists of
FT8-3 package produced by Pratt &
Whitney Power Systems (based on GG8-3
two shaft gas generator and PT8 power
turbine),
BDAX62-170ER
electric
generator produced Brush, transformer,
NOx emission control system and the gas
turbine package control system. GG8 gas
generator is designed around JT8D-219,
the last version of JT8D turbofan engines.
The gas turbine package operates in
simple cycle.
The gas turbine powerplants are the
additional electricity source increasing
the reliability of the electric power supply
during the reconstruction of Tempy
220 kV substation in Dmitrovsky district.
The equipment can be operated in peak
hours in the morning and in the evening.
The decision on the arrangement of
the mobile powerplants was made after
carrying out the analysis of the power
system operation modes, construction
plans and power facilities repair.
Ignatovo 110 kV substation was
included in the list of districts where
the operation of mobile powerplants
will allow to eliminate the emergency
situations in peak hours.
The installation of mobile powerplants
in Dmitrovsky district will cover the
electric power demand in Dmitrov and
the power cutoffs in the dwelling areas
including Podcherkovo-2 in case of
emergency situations can be eliminated.
After commissioning the powerplants
near Ignatovo substation the number of
the electric powerplants operated by
Mobile GRES is 15; the total installed
power is 337.5 MW.
FT8 MOBILEPAC powerplants

The precommissioning started at two

GPA-16DKS-09 gas compression packages
at Yuzhno-Russkaya compressor station
of Severneftegazprom
Five Ural-2500 gas turbine packages were

commissioned at Bovanenkovskoye field
Four Ural GPA-16-DKS-09 gas

compression packages produced by
Iskra-Turbogaz were supplied. Each gas
compression package consists of GTU-16P
gas turbine engine (PMZ), Ural
NTs-16DKS-02 compressor (Iskra) and
MSKU-5000 automatic control system
(Sistema-Servis). Ural NTs-16DKS-02
compressors with John Crane dry gas seals
and S2M Magnetic Bearings magnetic
suspension are the first Ural compressors
to equip the gas compression packages
rated at 16 MW at booster compressor
stations with the working pressure from
3.0 to 8.5 MPa and the pressure ratio from
1.44 to 3.0.
The gas produced at YuzhnoRusskoye field (Krasnoselkupsky district
of Yamalo-Nenets autonomous district) is
used for the first line of North-European
gas pipeline, the new route of Russian gas
to Europe. It is planned to achieve
the rated power of the field 25 billion
m3 of gas annually in the current year.
The equipment is the part of the

auxiliary powerplant at Bovanenkovskoye
oil and gas condensate field of Gazprom
dobycha Nadym. The main supplier of
the packages is Iskra-Aviagaz.
GTU-2.5P/1000 gas turbine engine
with the peak power of 2.75 MW
p ro d u c e d b y P M Z i s u s e d . T h e
a djustment of the output shaft rotational
speed with the generator is provided
by R-25MKU reduction gear developed by
Aviadvigatel.
The powerplant features
SGSB-14-100-6U2 synchronous electric
generators supplied by Rosenergomash
and SSNK.421457.03-03 advanced
automatic control system supplied by
Sistema-Servis.
The general project of the powerplant
c o n s t r u c t i o n wa s c a r r i e d o u t b y
VNIPIgazdobycha.
The commissioned Ural-2500 gas
compression packages will supply the
electric power for the field support
facilities, production and transport
infrastructure.
Gas compression packages

of the booster compressor station
at Yuzhno-Russkoye field
It is planned to construct the second

stage of the powerplant comprising
of 5 Ural-2500 gas turbine packages
Three GPA-16M-04 gas compression packages were commissioned at Purtazovskaya compressor station
T h re e m o re G PA - 1 6 M - 0 4 g a s
compression packages supplied by
Iskra-Turbogaz were commissioned at
Purtazovskaya-4 compressor station of
Gazprom transgaz Surgut. Each package is
equipped with GTU-16P gas turbine
drive (PMZ), 398-26-1LSM centrifugal
compressor (Compressor Complex) and
MSKU-5000 automatic control system
supplied by Sistema-Servis.
The general designer of the
construction is VNIPIgazdobycha, the
general contractor is Yamalgazinvest.
The first two startup complexes

(4 gas compression packages) were
commissioned in 2008.
The compressor station pumps
300 million m3 of gas daily.
Gas compression packages

at Purtazovskaya-4
compressor station
23
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 24
DISCUSSION CLUB
What mechanical drive gas

turbine engines are necessary
for the Ukrainian pipeline network?
Artem Khalatov Institute of Engineering Thermophysics,
National Academy of Sciences of Ukraine (Kiev)
Dmitry Kostenko VNIPITransGaz (Kiev)
The International Power Summit and Power Forum concluded on May 23, 2008 in Kiev.
It was declared the Ukraine requested the help of the European Union in the
development of the joint energy policy including the reconstruction of the Ukrainian
pipeline network. As supposed, the volume of natural gas transit to Europe will remain
the same. The European commission will allocate 2.5 billion dollars in the autumn
of 2009.
he Ukrainian pipeline network is
the second one in Europe and one
of the largest in the world. Its total
length is 37.6 thousand km including 22.2
thousand km of the large diameter (up to
1420mm) main pipelines. The annual inlet
natural gas capacity is 290 billion m3; while
the outlet gas capacity is 175 billion m3.
The gas transportation network provides
the natural gas supply to the industrial
facilities and utilities of Ukraine, as well as
transit of the natural gas from Russian and
Central Asia to the Western and Eastern
Europe, the Balkans and Turkey. The
infrastructure of the Ukrainian gas
transportation network consists of 81
compressor stations equipped with 765 gas
compression packages with the total
operating power of 5.6 million kW. The gas
transportation network includes also
1600 gas distribution stations and 13
underground natural gas storages, 6 border
gas measuring stations and 89 gas filling
stations.
The stationary gas turbines, converted
aircraft and marine gas turbine engines,
electric drive units and internal combustion
engines are used to drive gas compression
packages. The mechanical drive gas
turbines prevail in the Ukrainian
network, they include 455 units with the
total power of 4.6 million kW that is over
Issue 4, 2009
24
82% of the total power of packages

installed in the gas transportation network
of Ukraine (in Russia it is 86.9%). The
mechanical drive gas turbines installed
in the Ukraine include the industrial gas
turbines (267 units), converted aircraft
(98 units) and marine gas turbine engines
(90 units).
The first stationary industrial gas
turbine engines installed in the Ukrainian
gas transportation network had the high
specific metal quantity and low efficiency.
A bit later the converted aircraft and
marine gas turbine engines designed on the
base of military engines were introduced
into practice. Many years of operational
experience of gas compression packages
equipped with the converted gas turbine
engines in the gas transportation network
of Ukraine showed that their application
was a temporary measure. The military
engines have a short nonfailure operation
time, the short service and overhaul life,
high repair cost and low efficiency. It is
associated with the design features of
military gas turbine engines, where the
power and maneuvering characteristics are
preferential, while the reliability, service
life and the efficiency which are important
characteristics of the gas transportation
network are secondary factors at some
degree.
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 25
In recent years the serious problems

aroused in the operation of the gas
transportation network of the Ukraine as
the service life (100 thousand hours) of
over 70% of the gas compression packages
equipped with the mechanical drive gas
turbines is actually over. Thus, 204 gas
turbine engines should be decommissioned
in 2008-2015 years (figure). The further
operation of the worn and obsolete
equipment will lead to the degradation of
the Ukrainian gas transportation network
and failure to provide the reliable supply
of natural gas to the country and gas transit
to Europe. The main reason for operation
of obsolete gas turbine engines is
insufficient financing of the compressor
station reconstruction programmes, only
1015% of them (35 gas turbine engines
annually) are financed since 1992 year.
Another disadvantage of the gas
turbine engines operated in the gas
transportation network of Ukraine is their
low efficiency that is only 1825%. The
basic characteristics are lower than those
for similar foreign engines (1025 MW)
with service life up to 150 thousand hours
and the efficiency of 34-38%. Under these
conditions the annual natural gas over
consumption for auxiliary needs is very
high in the gas transportation network of
Ukraine. For example, in 2006 this over
consumption was about 2 billion m3 that is
equivalent to 400 million US dollars.
The development of a new generation
of gas turbine engines is required to meet
the primary operation requirements of
the gas transportation network of Ukraine.
To solve these specified problems the gas
turbine engines should be designed using
the advanced gas turbine technologies
widely applied in the aircraft and marine
military applications. The specific operation
characteristics of the Ukrainian pipeline
should also be considered. The most
important criteria of these are the safety
and reliability during the longterm
operation, as well as high efficiency,
relative design simplicity and low life cycle
cost.
The gas turbine engineering is one of
the most high-tech industries. The Ukraine
has saved its engineering and scientific
potential being included into the top ten
world countries providing the complete
cycle of design, development and
production of industrial gas turbines,

aircraft and marine gas turbine engines.
Therefore, the Ukraine is able to develop
independently the gas turbine engines for
The infrastructure of the gas turbine
engineering in Ukraine includes the
following companies Ivchenko
Progress and Motor Sich (Zaporozhye),
Zorya-Mashproekt (Nikolaev) and Sumy
Frunze NPO (Sumy). The last one is the
leading enterprise in the production of gas
compression packages.
The achievement of high efficiency,
which defines the fuel consumption for
auxiliary needs and the level of CO2
emission is directly associated with the
level of gas turbine inlet temperature.
Both the modern level of gas turbine
technologies and high-resistant materials
are unable to increase the efficiency of
simple gas turbine cycle over 3435% at
the power of 10 MW and 3738% at the
power of 25 MW. That is why, much
attention in recent years is given to develop
industrial gas turbines based on the
complex thermodynamic cycle.
The application of compound cycle
allows increasing the efficiency and
the specific power of gas turbine engine
without significant increases in the
combustor outlet gas temperature. At the
same time it enables using the advanced
materials and sustainable gas turbine
technologies. One of compound
thermodynamic cycles is the regenerative
cycle. In this case the heat recovery unit
(regenerator) is installed at the gas turbine
engine outlet, where the flow outlet
temperature is from 450 to 550 C. The
heat recovery unit is used to heat the
25
The decommissioning
schedule of gas compression
packages equipped
with gas turbine drives
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 26
compressed air supplied into combustor

from the compressor.
The analysis given above was used to
develop the basic requirements to the
industrial mechanical drive gas turbines
for the Ukrainian gas transportation
network. These requirements were
presented in the special document
named as Development of Industrial Gas
Turbines for Gas Transportation Network
of Ukraine, developed in 20072008
years by the National Academy of Science
of Ukraine and the National Commission
of Ukraine on the industrial gas turbines.
This Commission consists of the leading
Ukrainian experts in the design,
development and operation of gas turbine
engines at the compressor stations of
Ukraine.
The gas turbine engines rated from 6
to 25 MW are mostly required for
According to the specified concept the
best method to increase the efficiency of
gas turbine engines in the given power
range is the application of regenerative
cycle. The analysis showed that the
advanced gas turbine technologies applied
in the aircraft and marine engineering
and the last achievements in the material
science, metal welding and brazing,
thermal physics, combustion theory,
strength of materials enable development
of the high technology gas turbine engine
of the regenerative cycle with the efficiency
of 3841% in the specified power range.
The main problem in this case is the
development of the heat exchanger
(regenerator) resistible to the thermal
cycle loading and having the efficiency of
0.85-0.88 at the minimal compressed air
leakages (0.1-0.2%) during the longterm
operation. If these parameters are
achieved then the CO2 emission would
be reduced by 3.5 million tons providing
the additional potential for the country
economy due to CO2 quota sales for
100 million dollars annually. The cost
of a heat exchanger should be within
4060 US dollars for 1 kW of the installed
heat power.
The other requirements for the gas
turbine engine are the following: the
engine design is two-shaft on the single
frame and of the modular configuration
(gas generator and power turbine), the
Issue 4, 2009
26
service life is 150 thousand hours as

a minimum, the non-failure operation
time is 5 thousand hours as a minimum,
the average overhaul life is 30 thousand
hours, design and operation safety and
simplicity, high reliability, the modern
diagnostics and automatic control systems.
The level of NOx emission should be not
more than 80 mg/nm3; while the CO
emissions should not exceed 100 mg/nm3.
According to the developed concept
the development and testing of two basic
engines rated at 12 (GT-12) and 16 MW
(GT-16) should precede the serial
production of the mechanical drive gas
turbines for the gas transportation network
of Ukraine. In the future these engines
will be used as the basis for development
of industrial gas turbines for various
applications. The development of GT-12
and GT-16 gas turbine engines will require
36 million US dollars and 48 million US
dollars, correspondingly. The development
program will take 3 years corresponding
to the outdated gas turbine engine
decommissioning schedule. The associated
research program estimates as being
about 20% of the total cost of the engine
development that is 17 million US
dollars.
Thus the total cost of the development
of two basic gas turbine engines for the
gas transportation network of Ukraine
rated at 12 and 16 MW will be 101 million
U.S. dollars or 34 million US dollars
annually. The analysis made indicates that
total saving figure due to increase in the
gas turbine engine efficiency, reduction in
the natural gas consumption for auxiliary
needs and sales of CO2 emission quota
will give around 500 million US dollars
annually. Considering constant growth
in the world natural gas price, the total
economic efficiency will increase. As
expected, in 2009 year this figure is around
700 million U.S. dollars.
The development of high-tech gas
turbine engines is a rather serious
scientific problem which requires
government support and large finance
investments. It also requires the
development of National program
involving the scientific, engineering and
production potential of the Ukrainian
companies with sufficient qualification
and longterm experience.
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 27
TURBOnews
The first in Russia TTK-110 turbine generator
with tubular case was delivered to the customer
Fortum defined the contractor

for the construction works
at Nyaganskaya GRES powerplant
The prototype model of TTK-110 turbine

generator with tubular case rated at 110 MW
produced by Elektrotyazhmash-Privod was
delivered to the customer, NPO Saturn.
TTK-110 turbine generator will be a part of
the gas turbine designed for the operating
package rated at 310 MW at Ryazansaya GRES
powerplant.
The generator of such power was produced
by Lysva plant for the first time. The factory
tests of TTK-110 turbine generator were
successfully finished in April 2009. The tests
confirmed that the generator meets all stated
characteristics; several characteristics are
higher than the specified ones. For instance
the heating level of the core and the rotor
winding has the margin of 16 C, the stator TTK-110 generator shipment
40 C. The tests performed in various modes
confirmed that the vibration level of the turbine generator is lower than specified in GOST.
The turbine generator features two air coolers in the form of semicylinder located at
the sides of the case. Due to TTK-110 generator arrangement with minimal number of parts
and components the weight and the overall dimensions of the generator are by 15% lower
than of similar generators.
The supply and assembly of GTD-110 gas turbine produced by Saturn is planned for the
end of 2009. It is planned to complete works at unit #7 (PGU-420 combined cycle plant) in
the first quarter of 2010. As a result of the modernisation project realisation the powerplant
capacity will be 420 MW.
NPO Saturn will continue the development of gas turbines and packages to equip the sea platforms,
gas turbine locomotives and high speed ferryboats
To the results of the tender held by the
Ministry of industry and trade of the
Russian Federation NPO Saturn received
the right to make the state contracts under
the federal special programme of the civil
marine engineering development till 2016.
The tender concerned the Development of
the marine gas turbine engine with the
service life up to 100 thousand hours rated
at 8 MW (based on the gas turbine engine
M75RU, the first Russian

marine gas turbine engine
of fourth generation developed for the

military customer) and the gas turbine
package designed around marine gas
turbine rated at 8 MW. The period of
development is 2 years.
The company will also participate in the
development of the gas turbine engine rated
at 16 MW that will start till the end of 2009.
NPO Saturn is the only manufacturer
of gas turbine engines for the navy in
Russia. It is planned that the development
of the new gas turbine packages will be
based on M70FRU and M75RU marine gas
turbines of the automatic marine gas turbine
engines family of the fourth generation
designed around the standard gas generator.
It is planned to finish the construction
of the test bench for marine gas turbine
packages till 2013 under the special
programme of the import substitution.
The state tests of M75RU, the first
Russian marine gas turbine engine with the
maximum power of 7000 h.p., were carried
out at the end of 2006. The tests of M70FRU
gas turbine engines were finished two years
later.
To the results of tender held by

Fortum (before April 2009 the company
name was TGK-10) E4 Group was
defined as the contractor for the
construction of Nyaganskaya GRES
powerplant in West Siberia to the
Greenfield project. E4 Group offered
the best conditions of the project
implementation. Stroytransgaz,
Technopromeksport and Engineering
center EES also participated in the
tender. The winner was defined to
the following criteria: the price and
technical offer, the system of technical
and finance guarantees, the realisation
periods, the high level of technologies,
competence, own means, contract
implementation guarantees.
The contract involves the
construction including the auxiliary
systems and lines and also the
construction of the external
nfrastructure. The cost of the contract
works is about 13 billion rubles or
about 300 million euros. The total
project cost is about 1.4 billion euros.
In August 2008 E4 Group was
the tender winner for the supply,
assembly, commissioning of the main
equipment and management of the
construction project of Nyaganskaya
GRES powerplant (EPC contract).
In March 2009 E4 Group and the
government of Khanty-Mansijsk
autonomous district Ugra signed
the cooperation agreement for the
close cooperation with the district
management during the powerplant
construction.
The new powerplant will cover the
growing electric power demand of oil
and gas companies in the region. The
powerplant will consist of 3 combined
cycle packages with the electric power
of 420 MW each. According to the
contract signed in August 2008
Siemens will supply three single shaft
SCC5-4000F-SS packages including
SGT5-4000F gas turbine with the
nominal electric power of 286.6 MW
and the efficiency of 39.5%, the steam
turbine, SGen5-2000H generator and
the auxiliary equipment.
The site is prepared for the
construction that will start this year.
About 3000 workers will take part in
the construction. It is planned to
commission the first package by the
end of 2011.
27
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 28
ANALYSIS
The quality of gas treatment

at compressor stations
Vladimir Pchelkin, Stepan Podlegaev, Dmitry Sivkov, Olga Lisitsyna VNIIGAZ
or economic, efficient and reliable
operation of gas transportation system
it is necessary to remove solid and
liquid impurities from the transported
gas. If the content of impurities in the
transported gas is high the gas flow in the
gas pipeline is reduced due to the increase
of pressure losses at transportation, the
reduction of efficiency and reliability of gas
compression equipment at the compressor
stations. Impurity removal provides the
increase of efficiency and the reduction of
power consumption by gas compression
equipment. Thus providing the economic,
efficient and reliable operation of gas
treatment equipment and facilities at
gas pipeline compressor stations is an
important and topical problem.
The content of impurities in the
transported gas is defined by the quality of
Figure. The schematic

diagram of gas treatment
facility for compressor shop
Issue 4, 2009
28
gas treatment at gas production and

transportation companies, by the condition
of gas pipeline and gas treatment equipment
of the compressor station (OST 51.40-93
Combustible natural gas delivered and
transported to gas pipelines).
Over 5500 units for preparation of
process gas, that is fuel, start and impulse
gas for gas compression package are used
at pipeline stations of Gazprom.
The scheme of gas treatment facility in
a compressor room is given in the figure.
The scheme is applied in the most severe
conditions of gas treatment facility
operation at the compressor station. The
conditions depend on the quality of gas
treatment at the fields, the conditions of
linear pipeline sections, etc.
It is necessary to mention that due to
the increase of gas compression package
power (the compressed gas flow) the gas
treatment facility (besides the room) can
be modular. The composition of the gas
compression facility should be the same.
The liquid collector is installed at the
gas treatment facilities of main and part of
linear compressor stations where liquid
(condensate) discharge is possible. It is
located at the supply pipeline of gas
treatment facility at dust collector inlet
manifold.
The liquid collector is the container or
system of pipelines where gas flow (slug)
speed is reduced due to the increase of the
flow section along with the change of
movement direction (flow change, vortex,
baffles, etc.).
At linear compressor stations solid and
liquid impurities are removed from gas
with the dust collector. The filter separators
(the second stage of cleaning) can be
provided at main and separate linear
compressor stations.
The dust collectors and filter separators
shall be of the same capacity to provide
the possibility of consecutive connection
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 29
Technical characteristics of dust collectors and filter separators operated more than 25 years
Unit
GP-199,
TsKBN
GP-144,
TsKBN
Type
Multicyclone
5-cyclone
1972
1975
1976
1976
1979
Efficiency, million ncm/day
8.0
20
17.6
13.3 (one unit);

40 (three units)
15
30
20
Working pressure, kgf/cm2
3075
Up to 75
4560
3045
Up to 75
80 120
80120
Year of manufacture
Peerless,
USA
CMP,
France
Table 1
Multicyclone Filter separator
GPR-138,
TsKBN
GP-584,
TsKBN
GP-585,
TsKBN
Filter separator
5-cyclone
Filter separator
1981
1981
pilot specimen pilot specimen
Weight, ton
13
22
20.4
28.7
30
54.5
60
Admissible pressure losses, kgf/cm2
0.5
0.5
0.3
0.7
0.7
0.8
1.0
without intermediate collectors and fixtures.

The packaged arrangement of dust
collectors and filter separators is optimal.
The dust collectors and filter separators
are cylindrical units arranged vertically or
horizontally. The inertial cleaning is used
in the dust collectors, coalescent filters are
used in the filter separators.
The installation of intermediate drain
collectors should be provided for the units
arranged horizontally. The drain is collected
by natural flow. The collectors shall be
provided within the configuration for the
units arranged vertically.
After the treatment provided by
the dust collectors and filter separators
the gas conforms to the commercial gas
requirements (GOST 5542-87 Natural
gases for commercial and domestic use).
The fuel, start and impulse gas
treatment facilities are designed for
preparation and supply of gas with the
required characteristics and quality. They
are located in the compressor room
(compressor station).
The fuel, start and impulse gas treatment facilities provide the preparation of:
n Fuel gas for gas compression package
powerplant;
n Start gas for gas compression package
turbine expander;
n Impulse gas to use as working fluid
in the drives to control the valves of
compressor shop and connection point.
The gas treatment facility provides the
gas conformance to the requirements of
the commercial gas.
For gas cleaning minimum two units
shall be installed. In case of one unit
deactivating the capacity should be 100%.
The gas drying unit provides the
impulse gas adsorption.
Gas must be additionally cleaned from

solid and liquid impurities prior to supply
to gas drying units. The level of solid and
liquid impurities at the absorber inlet is
0.05 mg/ncm maximum.
The draining shall be removed to E1
and E2 (figure).
The list of dust collectors and filter
s e p a r a t o r s o p e r a t e d a t G a z p ro m
compressor stations over 25 years is given
in Table 1. Part of the equipment is
outdated and does not provide design
parameters. Thus the quality of gas
treatment is decreased. The efficiency of
the outdated compressor stations is lower;
the hydraulic resistance is higher than at
modern compressor stations. The power
consumption for gas transportation can be
Condition and composition of dust collector fleet
at the compressor station
The total number of dust collectors, pcs.
of Russian production
of foreign production
Table 2
Installed, pcs.
~ 4000
~ 3500 (87.5%)
~ 500 (12.5%)
Defective, %
1,7
2
0
Composition of filter separator fleet at the compressor station

Number of filter separators, pcs.
of Russian production
of foreign production
Table 3
1030
722 (70.1%)
308 (29.9%)
Gas heater fleet
Table 4
Number of gas heaters, pcs.

(% of the total number)
Number of defective gas heaters, pcs.
(% of the total number of defective)
Number of manufacturers
Types of gas heaters (total)
29
Russian
companies
CIS countries
companies
Foreign
companies
197 (23.1)
456 (53.5)
200 (23.4)
18 (24.7)
43 (58.9)
12 (16.4)
9
20
3
8
10
11
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 30
New gas treatment facilities of Russian production
Table 5
TsPU-7.5 (ZIOMAR)
Dust collector with multitube collector produced by Pekoe
TsPU-8.3 A (ZIOMAR)
Dust collector with multicyclones produced by Prosernat
GP 2101, GPR 2129 R (TsKBN) Dust collector with counterflow cyclones produced by TsKBN
Gas treatment units (TsKBN):
GP 1891.27
GP 1891.24
GP 1891.23
GP 1891.28
GP 1891.25
GP 1891.05
Cleaning unit
Pressure reduction unit
Measuring unit
Drying unit
Auxiliary unit
Capacity unit
Gas treatment units (Uromgaz):

BPTPG
UPIG-600
Fuel and start gas treatment unit

Impulse gas treatment facility
PTG-15M (Gazstroydetal)
Fuel gas heater
GPM-PTPG-30 (Gazprommash) Fuel and start gas heater

BPTPG (Kompressor)
UPIG (Kompressor)
Fuel, start and impulse gas treatment unit (is developed)

Impulse gas treatment facility
decreased due to the improvement of the

specified parameters.
The condition and composition of
the dust collectors, filter separators and
gas heaters at the operated compressor
stations is given in Tables 2, 3 and 4.
As can be seen from Tables 2 and 3 the
rate of defective dust collectors and filter
separators is not high. The efficiency
increase and reduction of pressure losses
is possible due to the equipment
modernisation and replacement. The
offers of developers and suppliers of
dust collectors and filter separators are
limited.
The data on the operated gas heaters
conforms low reliability of gas heater
operation. Due to the variety of types and
suppliers the maintenance and repair is

complicated.
New Russian dust collectors and gas
treatment facilities are presented in Table 5.
The data on modern dust collectors, filter
separators and impulse gas treatment
facilities is given in Table 6.
The parameters of modern dust
collectors, filter separators and impulse gas
treatment facilities are given in Tables 7, 8.
The basic reliability data of the gas
treatment facilities are:
n Time between failures is 15,000 hours
minimum;
n The overhaul life is 50,000 hours
minimum;
n The operating life is 33 years
minimum.
The recommended range of gas
treatment facility design pressure is 5.50,
7.36, 8.34, 9.81, 11.78 MPa.
The standard sizes to the capacity:
50010,000 ncm/hour;
50020,000 ncm/hour;
50030,000 ncm/hour.
The standard sizes to the design pressure
are 75, 100 and 120 kgf/cm2.
Conclusions:
1. The considerable part of gas
treatment facilities is outdated requiring
re c o n s t r u c t i o n , m o d e r n i s a t i o n o r
replacement;
2. The assessment of condition and
operating terms of gas treatment facilities
can be useful to prepare recommendations
for technical requirements, selection
of units for compressor stations and
Technical characteristics of modern dust collectors (design pressure is 7.35 MPa (75 kgf/cm2))
Table 6
TsPU-7.5 dust
Dust collector
GP 628 cyclone Dust collector for main gas Dust collector
collector (ZiO Podolsk) (OMNI Technologies)* dust collector pipeline compressor stations
(Ruspolmet)
Nominal capacity, million ncm/day
21
25
25
25
24.7
Liquid weight concentration
5000/80
5000/15
5000/750
5000/50
in gas at inlet/outlet, mg/m3:
Degree of gas cleaning
> 40 m 100%
> 40 m 100%
> 40 m 100%;
> 1 m 98.9%
from solid particles
2040 m
2040 m
> 40 m 100%
2040 m
> 3 m 99%
with the dimensions
98%
99%
0.15 mg/m3 maximum > 5 m 99.99%
Hydraulic resistance, MPa
0.033
0.05
0.045
0.035
0.03
(at nominal capacity)
Specific metal content,
881
1436
1152
1016
1660
kg/million ncm3/day
Erosion hazard 20
* 12 MPa project
Issue 4, 2009
30
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 31
application of the new types of gas

treatment facilities at the compressor
stations. The development of quality
requirements for gas treatment is
important;
3. The requirements for gas
treatment facilities parameters for effective
operation of compressor stations and gas
transportation systems were developed
together with gas transportation companies.
The requirements were included into the
Standard technical requirements to gas
stations developed by Gazprom;
4. The parameters of modern gas
stations are better than the characteristics
of the operated equipment at gas
treatment facilities. The modernisation
(reconstruction) or replacement of gas
treatment facilities can reduce the power
consumption for gas transportation;
5. For assessment of the gas treatment
facilities at the gas pipeline compressor
stations it is necessary to take into account
the fact that the operation requires
financial and power costs. The main task
of gas treatment facility development is
cost reduction. The various schemes of
arrangement and composition depending
on the gas pipeline length and the
TURBOnews
Parameters of modern gas cleaning facilities
Table 7
Dust separators
Filter separators
For particles
with the dimension
over 20 m 100%
For particles
with the dimension
over 10 m 100%
Outlet concentration
of mechanical impurities, mg/ncm
Up to 1 (for a short
period of time, 100 h/year
maximum, up to 3)
1 maximum
Outlet liquid
concentration, mg/ncm
Up to 100 (for a short

period of time, 100 h/year
maximum, up to 4000)
1 maximum
0.03
0.03
Efficiency of gas cleaning

from solid impurities
Design hydraulic
pressure, MPa, maximum
Parameters of impulse gas facilities

Impurities at the facility inlet, mg/ncm maximum
solid
including with the dimension over 10 m
liquid
Capacity, ncm/hour
Size of the mechanical particles at the facility outlet, m
Water dew point at gas working pressure, C
Content of liquid in gas (drops, aerosol)
Table 8
0.5
0.2
1.0
300-500
5 maximum
55
Not admitted
parameters of the units used in the gas

treatment facilities shall be considered and
validated. The protection and increase of
reliability of compressor station equipment
shall be considered as well as reduction of
costs for gas transportation.
The installation
of the gas turbine
on the foundation
The equipment assembly began

at the constructed powerplant of Tedinskoye field
Energotech completed the equipment supply for the
construction site of Tedinskoye field (Nenets autonomous
district) developed by LUKOIL-Severneftegaz of LUKOIL-KOMI
in February 2009. Three Solar Centaur GS40 gas turbines each
rated at 3.5 MW (the efficiency is 27.9%) with KATO generators,
the fuel gas treatment station based on Grasso screw compressors
produced by Technofrigo, KU 6.8 waste heat boilers produced
by ORMA, the automatic control system produced by Ritemp,
0.4 kV low voltage module and 6.3/0.4 kV step down transformer
were delivered to the facility.
The casing head gas with the hydrogen sulfide content about
1.22 g/m3 (0.08 %) will be used as the fuel. The heat recovery
system for the oil dehydration technological process is included
in the powerplant project. 18 MW of the heat power are used for
heating and water separation from the fuel.
The general project of the construction was carried out by
NIPIKBS SOM (Tumen).
Before the beginning of equipment supply the customer
performed the initial construction works. The works included
the filling and the construction of the piled foundation of the
powerplant and the fuel gas treatment station building; reinforced

concrete foundations were prepared for the gas turbines.
The assembly is carried out at the facility now, the gas
turbines, the booster compressor station with the coalescing
filter were installed at the foundations, the greater part of the
powerplant building was assembled.
Energotekh is the assembly and commission supervision contractor.
It is planned to commission the powerplant at Tedinskoye
field at the end of 2009.
31
Issue 4, 2009
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TURBOnews
ORMA-Gazprom meeting
The meeting of Gazprom, the
Department on gas transportation,
underground storage and use and ORMA
specialists was held at ORMA on
September 3. The meeting was devoted
to vane repair problems of GTK-10I,
GTK-25I, and PGT-10 industrial gas
turbines. The presentation of ORMALiburdi Turbine Service Limited joint
company was made during the first
meeting in July 2006. The present
meeting concerned the work results of
the company the development concept of
which is closely connected with the gas
transportation and repair facilities of
Gazprom.
The meeting was opened by Igor
Pustygin (Gazprom) presenting the
damage statistics of gas compression
package mechanical components. The
absence of the standard documentation,
failure of design specification preparation
and delivery terms, the absence of general
repairability criteria to assess the initial
condition and the allowed repair, the
absence of repair efficiency criteria were
specified among the problems of the
repair companies. It was noted that the
gas compression package repairability
is a priority for the gas transportation
companies, and Uralaviaspetstekhnologia
and Tribonika repair companies do not
always manage with the vane repair.
The meeting was continued by Alexey
Orberg, ORMA general director, reporting
about the technologies used for vane and
impeller repair using the powder
a)
metallurgical technique. Due to use of the
specified technologies the service life of
vanes can be increased up to 100,000 h;
the technique was demonstrated on GE
Frame 7EA package vanes. The repair
technologies were developed in the USA
and Canada by Liburdi Turbine Service
Limited thus GTK-10I, GTK-25I and
PGT-10 gas turbines of foreign production
were repaired first. The technology is
based on the powder metallurgical
technique. The intellectual property is
strictly limited: Liburdi supplies the
prepared powder and the heat treatment
technology for the specific order, ORMA
performs the specified process. Due to use
of the powder metallurgical technique the
material properties of the repaired part
can be kept. If necessary the repair
composition with the specified
c h a r a c t e r i s t i c s c a n b e p re p a re d
beforehand. The technology provides
the recovery of the mechanical properties
of vanes, the stability to the thermal
influence and the increase of the
overhaul period up to the service life of
the new parts (24,000 hours). It is possible
to perform over 3 repair cycles.
132 guide vanes of the first stage of
Frame 3 and Frame 5 turbines were
repaired using the powder metallurgical
technique in 2008-2009 for Gazprom and
Naftogaz of Ukraine gas transportation
companies. The longest operation period
of the repaired guide vanes over 8300
hours was in Gazprom transgaz Yyugorsk.
The fault detection after 8000 operation
b)
Example of GE Frame 7EA guide vanes

components repair:
a) prepared for the repair
b) after repair to LPMTM technology
hours confirmed the absence of defects at
the repaired sections.
After the discussion the meeting was
continued at ORMA production plant.
The facilities of ORMA-Liburdi joint
company, GTK-10 gas turbine repair
shop, as well as production of heat
exchangers for gas turbines and piston
engines with the heat power of 0.2-32 MW,
combustors of GT750-6 and GTK-10 gas
turbines, the components of gas turbine
high temperature and exhaust ducts were
demonstrated.
Gas turbine equipment of PGU-450 combined cycle package at Yuzhnaya TETs-22 heat and power plant was installed at the foundation
Under the turnkey construction contract of power package
#4 at Yuzhnaya TETs-22 heat and power plant of TGK-1 in SaintPetersburg the specialists of Technopromeksport assembled
GTE-160 gas turbines and TZFG(P)-160-2MU3 turbine generators
without a crane. The generators with air cooling were produced
by Power Machines.
The new technology developed by Russian designers allowed
the assembly without a heavy-duty travel crane installed inside
the main building. The reduction of construction material and
the volumes of construction works resulted in the cost saving.
The combined cycle package with the electric power
of 450 MW and the heat power of 350 Gcal/h includes two
PR-228/47-7.86/0.62-515/230 waste heat recovery boilers
(Podolsk Machine-Building Plant) and T-125/150-7.4
cogeneration steam turbine (Power Machines). The general
project was performed by Zarubezhenergoproekt.
The package is designed for the centralised heat and electric
power supply in Saint-Petersburg. Due to commissioning of the
combined cycle package the installed electric power of the heat
and power plant will increase up to 1250 MW; the heat power
up to 2600 Gcal/h.
GTE-160 gas turbine unloading

Issue 4, 2009
32
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The first unit of PIKV air starter was tested

The assembly of two PIKV air starting
units to the design documentation of
Turbopnevmatik was finished in the
beginning of September 2009 at
Proton-PM.
PIKV is the dry air oil-free compressor
with the outlet air pressure of 5 kgf/cm2
and the air supply of 5000 m3/h designed
to Gazprom specifications for NK-4, NK16, NK-36, NK-38, AL-31ST, GTU-10P,
GTU-12P, GTU-16P, GTU-25P. The unit
includes the high-speed electric motor
equipped with magnetic bearings produced by S2M.
The declared characteristics of the air
starting unit #1 were confirmed during
the tests carried out on September 16:
c=4.81; Gair=1.42 kg/s; the efficiency is

0.81; N=270 kW ( at the compressor shaft).
Such equipment is not produced in
the CIS countries. The similar foreign
model is the air centrifugal compressor
produced by Atlas Copco. The compressor development was initiated by
Gazprom department on gas transportation, underground storage and use.
The development of an advanced
compressor for a gas turbine start is
realised as a joint project of Proton-PM,
PNPPK and Turbostone. Proton-PM will
be the main manufacturer performing the
production of separate parts, assembly,
and installation of electric equipment,
tests and shipment. The powerplants can
be used in oil and gas, chemical, paper
industry; and also for the sewage treat-
ment and water supply systems in large

cities and production facilities in Russia.
The first customers will be Proton-PM and
Gazprom.
Air starting unit at the test bench
The assembly of PGU-210 combined cycle plant is continued

at Novgorodskaya TETs heat and power plant
The equipment supply

for the gas turbine powerplant at Severo-Labatyuganskoye field began
TGK-2 continues the investment project on the expansion

of Novgorodskaya TETs heat and power plant. The gas turbine
package with the electric power of 210 MW has been installed.
The assembly of the new power unit and the basic equipment
started at the plant. GTE-160 gas turbine produced by Power
Machines was installed on the foundation. The complex air filtration system produced by G+H Schallschutz GmbH is
assembled. The high and low pressure cylinders are installed on
the foundation of P-137 waste heat recovery boiler produced and
supplied by ZioMAR ZiO-Podolsk.
TZFG-160 generator produced by Power Machines with the
weight of 171 tons was delivered to the construction site.
Sevzapenergomontazh specialists have installed the turbine with
the weight about 200 tons and the generator on the foundation.
Mosenergomontazh specialists have assembled the complex air
filtration system, the waste heat recovery boiler and the piping.
The project of Novgorodskaya TETs heat and power plant
expansion developed by E4-SibCOTES started in June 2008. The
project provides for the installation of GTE-160 gas turbine with
the waste heat recovery boiler operating for PT-60-130/13
turbine. The project is realised under the agreement between
Business Alliance and TGK-2. The total cost is over 4.5 billion
rubles. Due to the commissioning of the new equipment planned
for 2010 the reliability of the electric power supply in Veliky
Novgorod will be increased.
Kazan Engine Building Production Association (KMPO)

delivered the first of three NK-16ST gas turbine engines
with the nominal power of 16 MW and the efficiency of 29%
designed for the operation within GTES-36 gas turbine
powerplant.
The tender for the engine supply was held by
Surgutneftegaz. The tender winners were KMPO and Sumy
Frunze NPO. The packages shall be delivered till 31.03.2010.
Three TS-12-2R generators rated at 12 MW produced by
Elektrotyazhmash-Privod will be supplied by Neftegazovye
Sistemy. RENK AG (Germany) bearings will be installed at the
generators instead of Russian bearings. The bearings feature
high service life and reduce the total level of vibration.
The general designer of the construction is SurgutNIPIneft
with the participation of UralVNIPIenergoprom. The general
contractor is Sumy
Frunze NPO. In
2007 Sumy Frunze
NPO built GTES-24
gas turbine
powerplant based
on the similar
equipment on this
field.
NK-16ST gas turbine engine
GTNR-16 package modernisation
GTE-160 gas turbine installed on the foundation

The modernised electric starter for GTNR-16 turbines will

be tested in December 2009 at the test bench of Nevsky Zavod
(part of REPKh).
The tests and commissioning of GTNR-16 turbines
equipped with the electric drive modernised by Elektroprivod
(Kirov) designers will be performed at the plant.
It is planned the modernised GTNR-16 packages will be
supplied to Kazym, Sindor and Mokrous compressor stations in
the first half of 2010.
33
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 34
ECONOMICS
AND FINANCE
How to estimate efficiency

of energy supply systems
Sergey Zharkov Energy Systems Institute of the SB RAS
ow measures of environmental
pollution reduction, economy of
fuel, development of CHP and
largescale use of renewable energy
sources and, accordingly, estimation of
their efficiency are very important,
therefore this paper is urgent.
I. Cogeneration (combined heat and power,

CHP)
W CHP
se
OA
x=
=
;
sq
OA+OB W CHPse + Q CHP
Q CHP
sq
OB
.
y=
=
sq
OA+OB W CHPse + Q CHP
Hence:
The electricity cost price is
S CHP
=
e
xS CHP
W CHP
S CHP
se
se + Q CHP
sq
W CHP
The heat cost price is

S qCHP =
yS CHP
Q CHP
S CHP
sq
se + Q CHP
sq
W CHP
II. Polygeneration (P)

In general case the problem of cost
sharing in the combined production by the
equireprofitability (equal profitmaking)
criterion is solved by:
n
W CHP
se
OA=
CHP electricity total
cost
CHP electricity delivered to

W CHP
consumers in a reporting period
se electricity market cost
O= Q CHP
sq CHP heat cost
Q CHP CHP heat delivered to

consumers
sq heat market cost
If there are no markets of heat and
electricity, one should calculate several
options of heat and electricity separate
production and determine the se and sq.
S CHP
CHP total expenses,
OE= x electricity portion in S CHP
OF= y heat portion in S CHP, i.e.

x+y=1
(1)
As the rectangles are similar, then
x
y
OA = OB
(2)
By solving the system of (1) and (2)
equations, we find:
Issue 4, 2009
34
xi = 1;
x1
x2
xi
xn ,
P A= P A = P A= P A
A1 s1 A2 s 2 A i s i A n s n
i=1
where A Pi is the amount of the i energy

product delivered, sAi is the i product
alternative (market) cost, n is the number
of the products delivered.
Then
S P s Ai
s Pi = n P A = s Ai k FP,
[A j s j ]
j=1
kPF =
S P ,
[A Pj s Aj ]
j=1
(3)
k PF is the factor of financial (economic,

commercial) effect of the combined
production/supply, S P is the total expenses
of the combined production/supply, s Pi
is the i energy product cost price. If kPF >1,
the system is inefficient.
The formulas are true for
producers/suppliers of electricity, heat,
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 35
industrial steam, conditioning cold,

gasoline, diesel fuel, coke, hydrogen, etc.
from petroleum, natural gas, coal, etc.
By optional calculations one may
determine the optimal structure of
products from the viewpoint of maximal
profitmaking: k PF min.
III. Energy supply systems (ESS) of a region
(province, territory (T), or city)
Here s Ai = fAi is a specific heat
equivalent consumption of fuel to supply
an i consumer alternatively, S P = F T is the
total fuel consumption for energy supply of
a territory.
When importing energy (for example,
electricity), the ESS contains a virtual
power plant (VPP), which parameters are
determined by consumption of fuel to
produce and deliver energy up to
the VPP. When exporting energy, the fuel
consumption for its production is excluded
from the territory energy supply balance,
but it is taken into account as a virtual
consumer.
f Ti = f Ai k TFl,
(4)
F
k TFl = n T T A ,
[A i f i ]
i=1
k TFl is the effect of the combined supply
fuel economy factor, A Ti is i energy product
delivered to consumers, f Ai is a specific
heat-equivalent consumption of fuel to
supply an i consumer.
Example for CHP:
F CHP is the CHP fuel total heat
equivalent input.
h
e
f HB
, f PP
are specific fuel consumption
of a separate heat and electricity
production: for a heatonly boiler (HB)
and a poweronly plant (PP).
F CHP
,
k Fl
=
CHP
fPP + QCHP
fHB
W CHP
The CHP specific fuel consumption:
e
e
f CHP
= f PP
k Fl
CHP for electricity,
h
e
f HB = f PP k Fl
CHP for heat
(1 k Fl
)100%
CHP percentage fuel
CHP
saving
Or:
e
CHP
= W CHP
/F CHP
the CHP thermal
efficiency for electricity
h
CHP
= Q CHP
/F CHP
the CHP thermal
efficiency for heat
e
PP
the PP thermal efficiency,
e
e
f PP = 1/PP
h
f HB
h
HB
the HB thermal efficiency,
e
= 1/HB
The fuel use efficiency is
e
h
CHP
CHP
1
Ef
Fl
.
k CHP = e + =
h
PP HB kCHP
Then
ext e
e
CHP = PP
k Ef
CHP,
ext h
h
CHP = HB k Ef
CHP
are external (apparently outside compared

with other energy sources or suppliers)
fuel use efficiencies for heat and electricity
production/supply.
Ef
(kCHP
1)100% percentage additional
fuel over CHP.
e
e
h
f CHP
= 1/extCHP
, f hCHP = 1/extCHP
:
the results are in relative units, for
example, kJ/kJ, BTU/ BTU, MW/MW or
kWh/kWh, etc.
e
e
Here, not absolute values of PP
(f PP
)
h
h
and HB(f HB) are important, but rather
their ratio which determines the fuel
consumption distribution. Therefore, one
may fix it on the basis of the most
advanced technologies (combined cycle
power plant and condensing boiler),
standard, or average for the country
(region). For example,
e
PP
/hHB = 0,6(LHV)/1,08 (LHV) = k =
= 0,556 = 0,5/0,9 = 0,4/0,72
etc.
Within reasonable limits of variation
this parameter does not essentially change
the order of ranking the technologies,
stations and ESSs by fuel efficiency.
Thus, one may determine the optimal
structure of the station or ESS equipment,
its capacity and operating conditions:
Fl
k Fl
HP min, k T min
Ff
Ff
or k ESS max , k ESS is ESS fuel use efficiency.
These parameters characterize ESS
efficiency and are integrated taking into
account losses by energy manufacture, and
transfer, penetration level of renewable
(secondary) energy sources and energy
stations modes.
When calculating the CHP (territory)
parameters based on (4) and (3) formulas
each consumer can be presented by its i
and f Ai (s Ai); by several, if it consumes
different energy products (electric
power, heat, hot water, cooking energy,
conditioning cold, etc.) or one, but at
different levels of the load curve. For
example,
35
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 36
Q CHP
=
mh
Q kCHP, W CHP
=
me
W CHP
l ,
k=1
l=1
mh is the number of heat consumers, me is
the number of power consumers.
IV. Use of resources (R)
R
s R
k i = n Si i , s r ij = s k Ri r ij ,
[A j r j ]
j=1
R i is
the i resource consumption in the

system (S), n is the number of products
obtained, s r ij is the i resource specific
consumption to manufacture the j
product.
r ij is the i resource standard (target)
specific consumption to manufacture the j
product. As r ij one may use the parameters
of best companies, worldwide average,
country average, normative, theoretically
achievable or the parameters of separate
manufacture (if any exists). The probable
r ij: electricity, heat, labor resources, raw
materials, equipment, water, air, fuel, etc.
The resources use total effectiveness
factor is
m
s R
k = i=1
[s k Ri
i],
m is the number of the resources used, i is

the relevance (weight) of the i resource in
the enterprise's total consumption. For
example, i is the share of the i resource in
the total cost of the resources consumed,
i.e.
m
= 1.
i=1 i
V. CO2 emissions
C S
, c S = cN k CO2,
2 = n
k CO
i S
S
i
S N
[A
c
]
i i
i=1
where c Si is the CO2 specific emissions
when manufacturing (delivering) the i
energy product; C S is the CO2 total
emissions by a station or system (S); A iS
is the amount of the i energy product
delivered, n is the number of i products
manufactured or delivered to consumers;
2
cNi is the normative specific emissions, k CO
S
is the effectiveness factor of energy
manufacture/supply from the viewpoint
of emission minimization.
VI. Environmental pollution
s V
ki
Issue 4, 2009
V i
= n V i , s ij = s k Vi ij ,
[A j N j ]
j=1
36
V i is the i kind of pollution, n

is the number of products manufactured,
s i
j is the i specific pollution when
manufacturing the j product, ij is the
normative specific i pollution when
manufacturing the j product.
The total pollution factor is
m
s V
k = [s k Vi
i=1
i],
m is the number of pollution kinds, i

is the danger of the i pollution; it is expert
fixed.
VII. In total
k S = k Fs F + s k R R + s k V V
is the system's total effectiveness factor,
F, R, V is the relative importance of
the activity aspect.
VIII. Efficiency of investment
1) by reduction of the current costs
E FI = kF/K,
F
F
k = (k CHP, kFP, kFT, kFESS,kFS)
2) by fuel saving
Fl
E Fl
I = k /K
3) by resource saving
E RI = kR/K
4) by CO2 emission reduction
E CIO2 = kCO2/K
5) by environmental pollution reduction
E VI = kV/K
6) in total
E I = k/K or
E I = (kFF + SkR R + SkV V)/K
kF, kFl, kR, kCO2, kV, k are
the expected change of factors as a result
of implementing the update arrangements,
K is the investment required, EI is the
relative efficiency of investment. To obtain
absolute values one should multiply E FI,
CO2
by S , F and C of the considered
E Fl
I , EI
systems, respectively. For example,
(kFl/k 0Fl)100% update arrangement
percentage fuel saving, k Fl
0 initial meaning
of the parameter.
e
The fixed parameters s Ai , f Ai (PP
, hHB),
i N
i
r j, c i , j determine a level (a benchmark)
relative to which one estimates (compares)
the efficiency of energy supply systems,
energy technologies and manufactures,
update arrangements.
The above mentioned is true also
for nonenergy manufactures. Probable
directions of update are: reducing losses
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 37
and cost, optimizing the structure of

products manufactured, outputting new
products from wastes, etc, for example,
cultivating fish and vegetables by using
waste heat.
Thus, one may rank the planned
measures by efficiency and implement
priority. The tables, ranked by reducing E I,
may be a basis for a company's investment
plans. In essence, the offered method
enables to determine a vector for the
most effective energy development, as well
as economy in whole, of the territory
(company) at a certain instant of time.
The probable arrangements in energy
are: effectiveness increase of fuel use
(including steam turbine CHP with
condensing boiler), reduction of energy
losses, and replacement of fuel by
renewable energy sources or atomic
energy. For example, introducing large
wind farms (WFs) in the power system is
followed by increase in operational
nonuniformity of the existing thermal
power plants (TPPs) with the respective
decrease in their efficiency, especially at
CHPs. I.e. the total efficiency of the
investment for fuel saving (emission
reduction) is low. The use of WFs combined
with TPPs [1, 2] is more effective [3].
The use of TPP+WF coastal stations
in combination with heatconsuming
industries (for example, manufacturing
liquid fuel from natural gas, desalination,
extraction of gold, uranium etc. from sea
water) is especially effective. Such a station
is capable of smoothing the nonuniformity
of WF power producing and imported
natural gas consumption, it is able to
produce hydrogen and oxygen from water,
as well as liquid fuel from hydrogen and
carbon dioxide.
Also, transmission lines connecting
WFs and the power system are used more
TURBOnews
Iskra-Turbogaz supplied three
Ural GPA-10DKS-07 gas compression packages
The packages were supplied to the
booster compressor station of UKPG-5V
gas treatment plant at Urengoyskoye oil
and gas condensate field. The customer is
Gazprom dobycha Urengoy.
effectively. Here, the experience of

developing a solar power station [4] can
be used. Solar and wind energy is effective
to use jointly with a TPP+WF station, as
their intensity variations usually occur in
antiphase. Such a technology eliminates
the wind and solar energy technological
limits in energy supply systems of regions
and countries. Accordingly, there is an
opportunity to widely use renewable
energy sources without applying expensive
accumulators of the electric power and,
hence, reductions of CO2 emissions
without applying expensive CCS(Carbon
Capture and Storage)-technologies.
For example, there is a project of power
supply of Europe using a solar energy of
the African deserts. Also it is possible to use
a wind power of the Siberian tundra with
accumulation of hydrogen in the exhausted
gas deposits [5].
References
1. Zharkov S. Wind use at thermal power
plants//RE-GEN. Wind. Modern Power Systems
Publication, Wilmington Media Ltd. 2004.
March. P. 13-15.
2. Zharkov S.V. Wind energy use at
gasturbine and steam-turbine plants//EW.
VWEW Energieverlag GmbH, Verlagsleiter
Corporate Publishing. 2004. 11. P. 58-61.
3. YuanZhao, Li-ShaHao,Yu-PingWang.
Development strategies for wind power industry
in Jiangsu Province, China: Based on the
evaluation of resource capacity//Energy Policy
37 (2009). P. 1736-1744.
4. Dr. Reiner Buck, Peter Schwarzbzl.
Solarized gas turbine power systems//
Gas Turbo Technology. 2009. 2.
http://www.gtt.ru/en/content/view/291/36/
5. .. (With hydrogen power on a way)//
: , , .
2006. 3. . 35-38.
Ural GPA-10DKS-7 gas compression

package (developed by Iskra) with the
nominal power of 10 MW is equipped
with Ural NTs-10DKS-01 compressor
(the final pressure is 7.45 MPa maximum,
pressure ratio is 1.7, nominal polytropic
efficiency is 82%, the capacity is
9.4 million m3/day) with John Crane dry
gas seals and oil bearings.
Ural NTs-10DKS-01 compressor is
designed to replace compressor bundles
with the pressure ratio up to 4.5.
37
The gas compression package is

equipped with the power unit based on
GTU-10P gas turbine with PS-90GP-3
engine (the power is 12 MW maximum,
the efficiency is 31.4%) developed by
Aviadvigatel; UTO-5 heat exchangers are
installed for exhaust gas heat recovery via
heating of water used in the heat supply
system.
MSKU 5000-01 automatic control
s y s t e m wa s s u p p l i e d b y S i s t e m a Servis.
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 38
TURBOnews
The tests of GTK-10 package startup system
were performed
The second stage of a small heat

and power plant at Vologda optical and
mechanical plant was commissioned
The commissioning ceremony
took place on September 24, 2009.
The small heat and power plant
is designed around OPRA DGT1.8/2G gas turbine package.
The turbine generator is based on
OP-16 engine. The package
operates on natural gas in
cogeneration mode; the electric
power is 1.8 MW, the heat power is
3.6 MW. The fuel efficiency is 90%.
The construction began in
July 2008. BPC Power Systems
supplied the equipment,
supervised the installation and
performed the commissioning.
The project was financed by the
optical plant. To the assessment Small heat and power plant designed
of the company management around OPRA gas turbine package at
the payback period will be about Vologda optical and mechanical plant
3.5 years.
OPRA turbine features a single shaft engine with bearings in the cold area,
engine air cooling, Allen Bradley control system, load flexibility, quick startup,
long overhaul period (60,000 hours), low noise level (85 dB at 1 m distance)
and low emission level (20 ppm NOx maximum).
The first stage of the heat and power plant based on the steam turbine rated
at 3.5 MW was built in 2003 providing 40% of the electric power for the
company. The complete electric power demand of the company is covered due
to commissioning of the second stage. Besides, the released facilities can be
used to cover the power demand in the regional center or at large construction
facilities. The new heat and power plant will increase the power of the boiling
plant that provides heat for the company and the central part of the city.
The project of the new small heat and power plant includes the installation
of the second OPRA gas turbine package in the future. It will increase power
demand of the company and supply the electric power for other enterprises.

based on the electric starter were successfully
finished on August 25, 2009 on the test bench of
Nevsky Zavod, a part of REP-Holding. The electric
engine produced in Russia with the adjustable
rotational speed was used.
The gas turbine packages produced by Nevsky
Zavod are started using the turbine expanders
operating on natural gas then it is released into the
atmosphere.
The electric starter is designed for installation
instead of turbine expanders at GTK-10 and
GT-750-6 packages operated at Gazprom. The
introduction of the new startup system was initiated by the designers of Nevsky Zavod. Due to use of
the electric starter the gas losses at the startup
can be eliminated, the ecological situation at the
compressor stations can be improved, the turbine
service life can be increased.
To the result of tests the specialists of
REP-Holding defined the programme of the electric starter modernisation and the availability of
application at GTNR-16 packages.
Kardam-2 compressor station (Bulgaria) was reconstructed

Sumy Frunze NPO produced and supplied five GPA-Ts-8S
gas compression packages rated at 8 MW (the efficiency is 33.2%)
to replace the obsolete equipment at the station. Each gas
compression package is equipped with DT70P gas turbine
produced by Zorya-Mashproekt and GTs2-6.3 compressor
produced by Sumy Frunze NPO.
The engines were replaced during the station continuous
operation without failures in the transient pipeline network
operation.
Sumy Frunze NPO developed the engineering solution of
the compressor station reconstruction acting as the general
supplier of equipment, performing the commissioning and
startup, supervising the installation, carrying out the training of
Bulgartransgaz specialists and guaranteeing maintenance and
aftersale servicing. Beside gas compression packages the station
was equipped with the automatic control and antisurge systems.
Kardam-2 compressor station modernisation was performed
to increase the reliability, safety and improve the equipment
operation characteristics to meet the European Union standards
and requirements.
Kardam-2 compressor station was built on the base of Sumy
Frunze NPO packages and commissioned in 1989. The station is
Issue 4, 2009
38
the start point for Bulgartransgaz gas pipelines, it is designed for

natural gas transportation along the transit pipeline from Russia
to Turkey, Greece and Macedonia.
Kardam-2 compressor station after reconstruction

#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 39
Siemens will supply the equipment

for the powerplant construction
at Tuapse oil processing plant
Tuapse oil processing plant (100% subsidiary of Rosneft)
made the supply contract with Siemens AG for six SGT-800
gas turbine packages and six generators totally for about
90 million euros.
The efficiency of SGT-800 package with the electric power
of 47 MW is 37.5%. The most important requirement to the
gas turbines supplied to Tuapse oil processing plant is low NOx
emission level at operation on various fuels.
The construction of an auxiliary cogeneration powerplant at
Tuapse oil processing plant is necessary to modernise the plant
increasing the production capacity from 5 to 12 million tons
annually. The depth of oil processing will simultaneously be
increased from 56 to 95%.
SGT-800 gas turbine package

Including the abovementioned order the number of
SGT-800 packages purchased by Russian companies or supplied
to Russia is 29.
LUKOIL-West Siberia commissioned the power complex at Pyakyakhinskoye field

The auxiliary powerplant with the electric power of 24 MW
consists of 4 Ural-6000 packages produced by Aviadvigatel. The
packages were designed around GTU-6P gas turbines (Perm
Engine Plant). The upper level automatic control system based
on Siemens controllers was installed.
The agreement on the production and supply of the basic
and station equipment was made between Iskra-Energetika
and Yamalneftegaz (subsidiary of LUKOIL-West Siberia) in 2008.
In April 2009 all power packages were delivered to the customers;
within the shortest period of time Aviadvigatel specialists
performed the assembly, commissioning and put the equipment
into commercial operation.
To the customer request each Ural-6000 package is equipped
with an independent fire extinguishing system. All four powerplants are synchronised and can operate independently and in
parallel. The equipment will operate on casing head gas. The fuel
gas treatment system was supplied by Uraltekhnostroy.
The powerplant will provide the electric power for the
processes of well boring, field development, production and
social infrastructure development. Due to the commissioning of
the power complex the large scale development of gas condensate
and oil fields can be started. It is planned to bore 55 gas condensate
and 186 oil wells. Two boring plants operate at the field now. The
powerplant can provide the electric power for 7 similar plants
minimum.
By 2010 the power plant will produce 150 million kWh of the
electric power annually using 34 million m3 of gas.
The power complex commissioning at Pyakyakhinskkoye

field LUKOIL-West Siberia finished the first preliminary stage of
the field development. The proved reserves are 70 million barrels
of oil, 1.9 billion cubic feet of gas, 216 million tons of reference
fuel as of the end of 2008.
14 gas turbine packages produced by Aviadvigatel with the
total power of 138 MW operate at LUKOIL-West Siberia facilities
beside Pyakyakhinskaya powerplant. These are three GTU-4P
packages with the total power of 12 MW and Ural-600 gas turbine
package rated at 6 MW at Severo-Gubkinskoye oil and gas field,
GTES-72 powerplant consisting of 6 EGES-12S packages operating at Vat-Eganskoye oil and gas field and GTES-48 powerplant
consisting of 4 EGES-112S packages operating at TevlinskoRusskinskoye oil and gas field. Four more EGES-12S packages
with the total power of 48 MW have been delivered.
The powerplant at Tevlinsko-Russkinskoye field developed by
Kogalymneftegaz was commissioned in June 2009. GTES-48
powerplant is comprised of four EGES-12S packages designed
around GTU-12PG-2 gas turbines. The packages are located in
the easyassembled building (two packages in each building). The
casing head gas produced at the field is used as the fuel.
The powerplant construction began in May 2008 as part of
the Programme on increasing the electric power reliability of oil
and gas production and gas compression LUKOIL companies in
20082010. Due to the object commissioning the existing power
demand will be covered; the field production capacity can be
increased.
Power complex at Pyakyakhinskoye field
GTES-48 powerplant at Tevlinsko-Russkinskoye department
39
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 40
OPERATION
EXPERIENCE
Dry Gas Dynamic Seals

And Buffer Gas Treatment:
The Commissioning Experience
At Ural Gas Compression Packages
Mikhail Yunitskiy Iskra-Turbogaz, Ltd
Sergey Fedoseev Iskra RPA JSC
Since 2003 Iskra-Turbogaz has collected the significant experience on the production,
assembly, commissioning and start-up of Ural gas compression packages with compressors
equipped with dry gas seals.
he application of dry gas seals is
the advanced and hightechnology
solution for compressor rotors seals.
Gradually the dry gas seals replace the
traditional oil seals. Due to the application
of dry gas seals the operation costs are
reduced, the reliability is increased, the oil
penetration to the compressor internals is
eliminated thus the service life of the
compressor equipment is increased and
the ecological parameters are improved.
Besides, the use of dry gas seals allows
installing the compressor internals with
various pressure ratio without updating
the sealing systems, thus simplifying the
modernisation.
At the same time the advanced and
complicated equipment as the dry gas seals
has some features to be considered during
the operation.
The operation principle of dry gas
seal is the provision of minimal sealant
flow through the clearance in the endseat
contact pair. Considering the absence
of friction in the given contact pair
and the related damage of surfaces and
heat production the regular servicing
as lubrication or coolant supply is not
required for the dry gas seals. At the
same time the sensitivity of the working
clearance with the value of 35 m to
the influence of liquid and abrasive
particles requires the special treatment
of buffer gas and dividing air. Thus
the operation reliability and service life of
Issue 4, 2009
40
the seal are determined by the quality of

the supplied gases.
The introduction of dry gas seals at
Gazprom compressor stations began
from the modernisation of the existing
compressors with oil seals. Due to the
received experience the main problems of
the dry gas seals application and package
and station equipment designing providing
the reliable operation of the dry gas seals
were determined. The development of
designing solutions during the serial
application of dry gas seals within the
packages supplied for the constructed
facilities was the responsibility of Iskra, the
designer of gas compression packages
and the designer and manufacturer of
Ural compressors, and Iskra-Turbogaz, the
manufacturer and supplier of gas
compression packages.
The most frequent problem is
the absence of buffer gas of the required
treatment, in particular, for the period of
the first package start at the shutdown
shop equipment.
The basic document for designing
and application of dry gas seals in the gas
compression packages is the Standard
requirements for the dry gas seals of
natural gas centrifugal compressors and
the systems providing their operation
capability, issued by Gazprom in 2006.
According to the Requirements it is
preferable to use the unit supply system of
buffer gas bleeding it from the exhaust
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 41
nozzle and further filtration to the control

boards. The experience of Ural gas
compression packages operation showed
that the application of such scheme is not
always optimal due to two reasons.
First, if the buffer gas is bled from
the discharge the filling of the package
circuit with the technological gas and
the initial cranking of the compressor
rotor is performed without the required
overpressure of buffer gas over the
compressor pressure (without gasgas
difference). Thus at each gas compression
package start the contamination can

penetrate on the seal contact pair reducing
the service life of the dry gas seal.
Besides, the gas bled for the seals often
contains (especially at new constructed
facilities) mechanical impurities and liquid
hydrocarbons, the oil from the packages
located higher to the gas pipeline. The
parameters of the pumping gas specified in
the section named the Requirements for
the customer practically are not provided
by any compressor station. Thus the service
life of the fine filters within the control
Ural gas compression packages supplied by Iskra-Turbogaz

Type of gas
compression package
Ural GPA-16-03
Ural GPA-10DKS-04
Compressor station, operating company
Number
Vuktyl compressor station, Gazprom transgaz Ukhta
DKS-3 booster compressor station, UKPG-14, 15 gas treatment plants,

Gazprom dobycha Orenburg
With dry With magnetic

gas seal suspension system
Ural GPA-16-04
Purtazovskaya compressor station, 3 stage, Gazprom transgaz Surgut
Ural GPA-10PKhG-01
Sovkhoznoye underground gas storage, Gazprom dobycha Orenburg
Ural GPA-10PKhG-01
Kanchurinskoye underground gas storage, Gazprom transgaz Ufa
Shatrovskaya compressor station, Gazprom transgaz Ekaterinburg
Ural GPA-16-05
Gornozavodskaya compressor station, Gazprom transgaz Tchaikovsky
Ural GPA-16DKS-04
Yamsoveiskaya booster compressor station, Gazprom dobycha Nadym
Ural GPA-10PKhG-01
Elshanskoye underground gas storage, Gazprom transgaz Saratov
Volokolamskaya compressor station, Gazprom transgaz Moscow
Volokolamskaya compressor station, Gazprom transgaz Moscow
Kamensk-Shakhtinskaya compressor station, Gazprom transgaz Moscow
Ural GPA-16-01
Ural GPA-16NK
Ural GPA-12-05
Ural GPA-16-03
Ural GPA-12-06
Ural GPA-16-02
Ural GPA-16DKS-07
Ural GPA-25DN
Ural GPA-16-04
Mikun compressor station, Gazprom transgaz Ukhta
Sokovka compressor station, Gazprom transgaz Samara
Yubileynaya booster compressor station, 2 stage, Gazprom dobycha Nadym
Tayozhnaya compressor station, Gazprom transgaz Yugorsk
Purtazovskaya compressor station, 4 stage, Gazprom transgaz Surgut
Ural GPA-12-07
Voskresenskaya compressor station, Gazprom transgaz Moscow
Ural GPA-12-07
Tuma compressor station, Gazprom transgaz Moscow
Ural GPA-12-01
Myshkino compressor station, Gazprom transgaz Ukhta
Gryazovets compressor station, Gazprom transgaz Ukhta
Ural GPA-16DKS-07
Yamsoveiskaya booster compressor station, 2 stage, Gazprom dobycha Nadym
Ural GPA-16DKS-08
Zapando-Tarkosalinskaya booster compressor station, Gazprom dobycha Noyabrsk
Zapolyarnaya compressor station, Gazprom transgaz Surgut
Ural GPA-12-06
Ural GPA-25
Ural GPA-16DKS-09
Booster compressor station of Yuzhno-Russkoye oil and gas field, Severneftegazprom
Ural GPA-10DKS-08
Priobskaya compressor station, Rosneft
Ural GPA-10DKS-07
Booster compressor station, UKPG-5V gas treatment plant of Urengoyskoye oil

and gas condensate field, Gazprom dobycha Urengoy
Ural GPA-16-07
Baidaratskaya compressor station, Gazprom dobycha Nadym
6*
Ural GPA-16-06
Elizavetinskaya compressor station, Gazprom transgaz Ukhta
4*
Babaevskaya compressor station, Gazprom transgaz Ukhta
5*
109
96
Ural GPA-25
Total 2003-2009:
28
* these gas compression packages will be supplied till the end of 2009
41
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 42
board can be reduced to 50100 operation

hours without the preliminary treatment
of the buffer gas. Such frequency of
regeneration or replacement of filter
elements is not efficient.
In practice it results in contamination
and damage of the contact pair working
surfaces and further seal failure. Besides,
the undesired physical mechanical
processes take place during the cooling of
compressor operated on nontreated gas.
The oil and heavy hydrocarbon vapors
during the cooling are condensed in
the dry gas seal grooves, channels and
clearances between the parts. If the period
between the starts is long the hydrocarbons
can polymerise on the metal surface. All
the factors can result in the sticking of
endseat contact pair, the break of geometry
and reduction of groove lift, the formation
and development of small dimples on the
working surfaces.
The specified problems were
determined by the specialists of IskraTurbogaz commissioning GPA-12-05,
GPA-16NK gas compression packages
(Volokolamskaya compressor station of
Gazprom transgaz Moscow), GPA-12-07
gas compression package (Voskresenskaya
compressor station of Gazprom transgaz
Moscow), GPA-10PKhG-01 gas compression
package (Kanchurinskoye underground
g a s s t o r a g e o f G a z p ro m t r a n s g a z
Ufa, Elshanskoye underground gas
storage of Gazprom transgaz Saratov),
GPA-10DKS-04K gas compression package
(DKS-3 booster compressor station
UKPG-14, 15 gas treatment plants of
Gazprom transgaz Orenburg). To the
results of the problem study together with
Iskra specialists the designers of dry gas
seals and the design institutes decided to
equip Ural gas compression packages
with the additional buffer gas treatment
system to improve the buffer gas quality
and increase the service life of seals and
fine filters. The system includes:
n Backup primary filters with high
capacity, for example, FS-12-80 or FS-50-80.
The filtration degree is 10 m; the
condensed moisture cleaning is provided
by the design;
n Heating unit and heat tracers
required for maintaining of the buffer gas
temperature at the control board inlet on
20 C higher than the dew point (API614
Issue 4, 2009
42
standard recommendations aimed at

the elimination of the liquid phase falling
possibility in the course of gas throttling in
the system);
n Required piping and valves.
The decision was evaluated at GPA-12-05
gas compression package (Volokolamskaya
compressor station). The efficiency of the
taken decision was confirmed.
Now it is planned to install the similar
filtration system at other packages supplied
earlier; at the designing packages the system
represents a separate buffer gas treatment
unit.
In Ural gas compression package the
buffer gas supply system recommended by
the Requirements is modernised providing
two bleeding sources: from the package
exhaust nozzle and the station discharge
collectors (behind valve #2). The bleeding
behind valve #2 is the main bleeding supposing the presence of gas of required
excessive pressure in all modes including
the start. The bleeding from the exhaust
nozzle is backup and used only for the start
of the first package of the shutdown shop.
The period of no gasgas pressure
difference in the dry gas seals corresponds
to the time since the filling of package with
the technological gas till gas turbine drive
reaches the idling. The bleeding from the
discharge is stopped after change from the
Ring mode to the Pipeline mode. The
operation of valve to control the bleeding
is automated and carried out by the gas
compression package control system.
Currently Iskra-Turbogaz produced
and supplied 96 gas compression packages
to Gazprom compressor stations; 28 gas
compression packages are also equipped
with the magnetic suspension system
(Table). Practically all packages rated at
16 MW produced now to the order of
G a z p ro m a re e q u i p p e d w i t h t h e
compressors with dry gas seals, the first two
packages rated at 25 MW with dry gas seals
were supplied in 2009 to Zapolyarnaya
compressor station.
The participation of Iskra-Turbogaz
specialists in the commissioning and
first startups helped to find the problem
solution. Due to that the reliable
information was received, the offered
solutions were optimised, the expensive
equipment malfunction and forced
downtime were eliminated.
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 43
TURBOnews
Luzhskaya gas turbine heat and power plant was commissioned
The gas turbine heat and power plant
with the electric power of 36 MW was
commissioned on September 10 at
Luzhskoye highroad in Veliky Novgorod.
The gas turbine heat and power plant
was put into the electric network, the
current frequency was synchronised. The
powerplant consists of 4 GTE-009 packages
each rated at 9 MW. The pilot startup was
made in August 2009. After comprehensive
tests had been performed; the ecological
and sanitary examinations were carried out.
The project was developed and
realised by GT TETs Energo, a part of
Energomash. The project cost was about
Engine room of the powerplant
900 million rubles. The project was

financed by the company itself and bank
credits. The planned payback period is 57
years. The basic equipment was produced
by Energomash in Russia. The powerplant
personnel training was performed by GT
TETs Energo at own facilities.
The powerplant construction began in
2002; initially the commissioning was
planned for 2005. The problems with the
gas emission resulted in the commissioning
delay.
Luzhskaya heat and power plant is
located on the area of 2.7 ha. The land
lease agreement is made for 49 years. The
basic and auxiliary equipment and the
automatic control system are located in
the main building. The engineering lines
are under ground. The works on the heat
pipeline arrangement with the length of
4.7 km are to be finished in 2010.
Due to the commissioning of the new
heat and power plant the production of
the electric power in the region will
increase by 25%. The powerplant will
substitute 7 boiling plants providing heat
to 40 nine-floor apartment houses. The
produced electric power (36 MW) will be
The acceptance tests of Ural NTs-25DKS-01 compressor were completed

The acceptance tests of Ural compressor rated at 25 MW with John Crane
dry gas seals and the magnetic suspension produced by VNIIEM were
completed in April.
Ural NTs-25DKS-01 compressor was designed and produced at Iskra
for the constructed gas compressor station of Zapolyarnoye oil and gas
condensate field (Gazprom transgaz Surgut). The compressor is the basic
Ural compressor rated at 25 MW for booster compressor stations with the
working pressure up to 12 MPa and pressure ratio in the flowpath up to 2. The
maximum polytropic efficiency is 0.867.
The general contractor of the gas compressor station construction is
Stroygazconsulting. Iskra-Turbogaz supplied two GPA-25M gas compression
packages designed around GTU-25P gas turbine engine produced by Perm
Engine Plant. The assembly is planned for the third quarter of 2009. The
tender on the equipment and automatic systems was won by Siemens.
The station is located 100 km to the north of Purtazovskaya compressor
station and is constructed in two stages. It is planned to commission the
first stage in the
fourth quarter of
2009. The first stage
will include two gas
compression shops.
A year later another
shop will be
commissioned.
Gas compression
package rated
at 25 MW
43
Main building at heat and power plant

supplied to the wholesale market of the
electric power industry; the heat power
(about 80 Gcal/h) will be supplied to
Teploenergo facilities and to separate
objects. It is planned the prices will be
lower by 17% during the payback period
and by 42% in the future.
The similar powerplants operate
in Velsk, Belgorod, Rezh, Vsevolozhsk,
B a r n a u l , K r y m s k , O re l , S a r a n s k ,
E k a t e r i n b u r g a n d Ta m b o v. T h e
construction of gas turbine heat and
power plants is continued in Aleksandrov,
B o r i s o g l e b s k , Vo l o g d a , K a s i m o v,
Magnitogorsk, Novocherkassk, Saratov,
Sasovo, Schelkovo and Elista.
Iskra-Turbogaz will supply five Ural GPA-2 gas compression

packages for Babaevskaya compressor station (Gazprom
transgaz Ukhta, North Stream gas pipeline)
Each package includes GTU-25P gas turbine
drive produced by Perm Engine Plant (the nominal
power is 25.6 MW, the efficiency is 40% in station
conditions), NTs-25M/MKhI-01 compressor
produced by Iskra/Mitsubishi Heavy Industries.
MSKU 5000 automatic control system will be
supplied by Sistema-Servis.
The general designer is Giprospetsgaz. The
general contractor is Gazprom invest Zapad. It is
planned to commission the new packages in the
second quarter of 2010.
BPC Power Systems supplied Capstone C30 small turbine
for Energotekhmontazh
The package consisting of Capstone C30 gas
turbine generator produced by Capstone Turbine
Corporation (USA), GFL-200 Vacotin Heater boiler
produced by Takuma Boiler Company (Japan) and
NPR-500 boiler produced by Garioni Naval (Italy)
was commissioned at Energotekhmontazh power
center. The total electric power is 30 kW; the heat
power is 0.75 Gcal/h.
The power center supplies the electric and
heat power for Energotekhmontazh facilities
(Schelkovo).
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 44
OPERATION
EXPERIENCE
The features of the air filtration

systems to the test results
and operation experience
Roman Konovalov, Alexander Agafonov Karat RSK
The results of gas turbine package air filtration system operation research are given
in the article. The gas turbine packages installed at the enterprises of the Moscow
integrated power company were used for the research. The following points were covered:
the comparative characteristics of the air filtration quality using various filter elements,
the relation of the ambient conditions with the initial dust content and the air filtration
system efficiency, the main reasons of the compressor flowpath contamination. The
necessity of the gas turbine package operation based on the actual state of the flowpath
contamination is noted.
he right choice, operation and
diagnostics of the complex air
filtration system provide for the
proper cleaning of the atmospheric air
supplied to the gas turbine package
flowpath. Therefore the cyclic air
preparation system can provide the high
reliability and efficiency of the package
operation or cause the unscheduled stops
and emergency situations.
The operation results and tests of
the complex air filtration systems at three
small heat and power plants of the Moscow
integrated power company are given in the
article:
n Lyublino-Mariyno plant #6 of YugoVostochny department #5 (Lyublino district
heat and power plant);
n Mariyno-Pechatniki plant #7 of YugoVostochny department #5 (Kurianovo
GTES-12 gas turbine powerplant);
n Plant #9 of Zapadny department #8
(Peredelkino GTES-12 gas turbine
powerplant).
The comparison of the filter element
efficiency is given. The disadvantages of
the complex air filtration systems and the
auxiliary equipment location detected at
various operation conditions are specified.
The tests of the filtration system
elements to define the functional
characteristics were performed by
Issue 4, 2009
44
Karat RSK specialists within the adjustment

and development operations since May
2006 and till August 2007.
The interest for the present research
is determined by the fact that as specified
in [1], due to the fine sticking dust in
the industrial areas with lots of organic
substances and oils the deposits are
accumulated faster that at dry mineral
dust. It is also noted that the salt used on
the roads in winter can penetrate in the
compressor flowpath. The lead can get in
the compressor flowpath from the car
exhaust.
The official foundation for the research
was Rostekhnadzor instruction concerning
the necessity of carrying out functional
complex air filtration system tests to provide
the realisation of the electric plants and
Russian networks operation rules to 4.6.6
and 4.6.7.
To define the quantity and fraction
composition of particles in the air samples
GHF 0014 membrane filtration and optical
microscopy laboratory produced by
PALL additionally equipped with the gas
sampling component, special optical
microscope with the electronic device and
the air flow indicator was used.
The air flow indicator was calibrated to
define the vacuum pump capacity for air
sampling. The calibration was performed
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 45
using the water drainage method. The

water was drained into the graduated
glass within the definite period of time.
The calibration results showed that the
vacuum pump capacity is constant and is
0.72 m3/h. The position of the air flow
indicator upper ball (at the point of 5.5
along the lower limit) corresponds to the
specified capacity.
The preliminary tests determined the
necessity of grounding the test component
for the air filtration. The grounding is
necessary to eliminate the influence of
the electrostatic charge on the uniformity
of hard particles distribution on the
analytical membrane: without grounding
the particles were concentrated along the
membrane edge.
The method of particlesize
composition definition using the optical
microscopy is based on ISO 4407 standard
and GHF 0014 laboratory operation
instruction [2]. The mass fraction of hard
particles on the membrane was defined to
the difference of membrane weight before
and after filtration of the air samples on
AVD-200M analytical balance of the second
accuracy class (the low limit is 0.1 mg).
The air sampling at the filter element
outlet was carried out from one section
point of the air duct. Thus to verify the
results and eliminate the influence of the
filtration system elements on the uniformity
of the air composition the preliminary
threads along the section of test fields were
carried out. The received data confirmed
the uniformity of the suction air; the air
sampling from one point is admissible for
further tests.
The influence of the external factors
on the operation of the complex air
filtration system elements was determined
at different day time and various weather
conditions. The electric load at the
generator terminals and the cleanness of
the gas turbine flowpath were considered

as the internal factors. To determine the
influence of the compressor contamination
on the characteristics and operation
parameters the thermal express tests were
performed. Besides, the compressed air
sampling to the compressor was performed
through the hole in the combustor (with
the cooling of the taken air before
b)
Photo 1. Air sampling cooler

at the compressor outlet of
GTE-6 package at Lyublino
district heat and power plant
Photo 2. Side area

of the slot filter
Photo 3. FV1000000G
fine filter view from
the air supply side
45
Photo 4. Results
of air sampling at the tests
of gas turbine package complex
air filtration system, unit 1,
at Lyublino district heat and
power plant on 26.05.06:
a) sample 1 the air before
the complex air filtration
system;
b) sample 2 the air after filtration by the complex air filtration system
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 46
b)
Photo 5. Results
of air sampling at the tests of
gas turbine package complex
at Kurianovo GTES-12
powerplant on 23.06.06:
the complex air filtration system;
b) sample 2 the air after
filtration at the first stage
(slot filter) of the complex air
filtration system;
c) sample 3 the air after
filtration at the second stage
(fine filter) of the complex air
filtration system
Photo 6. Results of air

sampling at the tests
of gas turbine package complex
at Peredelkino GTES-12
powerplant on 15.06.07:
the complex air filtration system;
b) sample 2 the air after
filtration at the first stage
(slot filter) of the complex air
filtration system;
c) sample 3 the air after
filtration at the second stage
(fine filter) of the complex air
filtration system
the supply to the filter Photo 1). It was

supposed that the air analysis can help to
get information on the intensity and
degree of particle sedimentation on the
compressor flowpath elements.
The inertia filter elements of the first
stage are used within the air filtering units;
the cyclone filters are used at GTE-6 plants.
The inertia slot elements are used as
the first stage filter elements at the
equipment produced and supplied by
Saturn for GTES-12 powerplant. The
elements are the cases tapering from the
sides with the pocket cuttingout (Photo 2).
The case is ended by the separate vertical
channel. The channels of five air filter
elements are put into the container by
the low ends. The container is tapering
ended by the cylindrical air duct with
the flange to connect the air duct
of VR 90-66-4.2-00 dust suction fan.
It is necessary to note that inertia
filter elements have some advantages
compared to the filters of other types: the
operation under the continuous high
impurity concentration in the filtering
air (up to 200 mg/m3 and higher) and
the absence of replaceable components
with less operation life than the life of the
complex air filtration system.
The second stage filter elements at
GTES-12 powerplant are FV1000000G
storage fine filters (Photo 3). Each fine filter
is a synthetic bag with 8 pockets attached to
Issue 4, 2009
the square metal frame. Each section of the

engine air intake duct includes 20 filters.
At GPA-16.0300-000 package complex
air filtration system at Lyublino district heat
and power plant the pocket fine filters (the
second filtration stage in the complex air
filtration system) were disassembled during
commissioning due to some reasons and to
the recommendations of GTE-6 package
manufacturing plant specialists. Due to
that fact the research of the air filtration
system operation was very interesting.
The view of the membrane areas used
for air sampling before and after the complex air filtration system elements is given
in Photos 4, 5, 6. At the given photos the
picture is magnified 40 times, the scale
value is 24 m.
The parameters of the complex air
filtration system operation meet the
requirements of the manufacturing plants
specified in the supply technical
documentation, the requirements of
GOST 29328, item 2.4.1 providing the
required level of the atmospheric air
filtration at all modes and operation
parameters.
References
1. Olkhovsky G.G. Gas turbine powerplants//1985.
2. Instruction on GHF 0014 membrane filtration and optical microscopy laboratory operation. Pall Industrie-Hydraulik GmbH.
b)
)
46
c)
c)
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 47
TURBOnews
Two GE 6FA gas turbines for the constructed Kurganskaya TETs-2 heat
and power plant were tested
The tests carried out at GE Energy in Belfort (France)
included the examination of the mechanical condition,
aerodynamic and thermodynamic characteristics and
vibrations at the turbine bearings. The turbines were
operated at full power without load for several hours, and
then the temperature between the turbine stages, the
compressor, bearings and oil temperature was measured.
The bearing and turbine shaft vibration was measured at
various operating stages.
The test results confirmed the conformance of the
turbine operating characteristics to the specified
parameters and the readiness of equipment for delivery
and operation.
Kurganskaya TETs-2 heat and power plant will consist
of two packages each rated at 111 MW. Each package will
include PG 6111A gas turbine with the electric power of 76
MW, SST-400 steam turbine rated at 35 MW produced by
Siemens and the waste heat boiler. The gas turbine
efficiency is 35% in simple cycle and over 54% in combined
cycle. The installed electric power of the heat and power
plant is 222 MW; the heat power is 250 Gcal/h.
GE 6FA gas turbine is designed around F class
technology. The operating time of such packages is over
2 million hours in 30 countries of the world. The 100th GE
6FA gas turbine will be installed at Kurganskaya TETs-2
heat and power plant; it will be the first package of this
type in Russia. It is planned to finish the turbine supply
to the construction site and start the assembly in
September-October 2009.
CTF 180/V mechanical cooling tower was produced
and tested at FANS in Glinsko (Czech Republic). The
tower is designed for the cooling of water used for the
plant equipment operation. The tower will be soon
delivered to the construction site.
Intertekhelektro-New generation, the owner of
Kurganskaya TETs-2 heat and power plant, will operate the
powerplant; the project is realised by PSG-International,
the EPC contractor, in cooperation with Intertekhelektro.
The commissioning of the combined cycle package
planned for 2010 will cover 40% of the power shortage
in Kurgan region, thus city and region social and economic
development will be encouraged.
GE 6FA gas turbine at the company plant

GTES-30 powerplant will be built in Kharyaga settlement

To the order of Total, the operator of Kharyaginskoye filed
development (Nenets autonomous district), Solar Turbines will supply
two Titan 130 packages with the nominal power of 15 MW each; the
efficiency is 35.2%, the voltage at generator terminals is 6.6/13.8 kV.
The powerplant will be equipped with the generators produced by
ABB; the automatic system will be supplied by Solar Turbines.
The powerplant will operate on casing head gas. The commissioning
is planned for the first quarter of 2010.
According to the estimation the reserves of Kharyaginskoye filed
in the specified area are 97 million tons. It is planned to produce
45 million tons of oil till 2032.
Kolomenskoye GTES powerplant was commissioned
Kolomenskoye GTES powerplant was commissioned in Moscow
after the adjustment. The construction investor was NaftaSibEnergia
(the subsidiary of NaftaSib). The acceptance act was signed on June 16.
All packages were tested during 72 hours.
The cogeneration gas turbine powerplant (the electric power is
136 MW, the heat power is 171 Gcal/h) is comprised of three SGT-800
gas turbines produced by Siemens, three KUV-60/150 waste heat
boilers produced by Podolsk Machine Building Plant, AMS generators
produced by ABB (Sweden), SPPA-T3000 automatic control system
produced by Siemens.
The general project was performed by Tepengineering. The assembly
of the main equipment was carried out by Karat RSK specialists. The
feature of Kolomenskoye GTES powerplant is the construction in the
dwelling area with more strict requirements to the ecological and noise
characteristics of the equipment.
It is planned that the annual heat power production will be over
1 million Gcal and the electric power production will be about 77 million
kWh. Thus the power demand under the growing power consumption
in Moscow will be decreased; the reliability of the electric and heat
power supply of the customers in Moscow region will be increased. The
construction project was performed under the Moscow power strategy
till 2025. Totally the government of Moscow plans to construct 8 gas
turbine powerplants based on district heat power plants.
The construction of Kolomenskoye GTES powerplant is the first
power engineering project in Russia realised on the project financing
principles. The powerplant was constructed using the investors funds
and Vneshekonombank credits with the application of the equipment
supply leasing scheme of VEB-Leasing. The financing volume is about
262 million dollars.
The new gas turbine powerplant is located close to the district heat
power plant and will substitute the heat production at the district heat
power plant and also at Nagatino and Lenino-Dachnoye powerplants
47
Issue 4, 2009
#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 48
TURBOnews
The equipment was supplied to the construction site of combined cycle package at Permskaya TETs-6 heat and power plant
KES-Holding constructs the building at the existing powerplant site to
install the new PGU-124 combined cycle package as part of Malakhit investment
project. The equipment produced by Siemens was supplied. The combined
cycle package will include two SGT-800 gas turbines with the electric power of
47 MW and the efficiency of 37.5% and SST-600 steam turbine. The equipment
was selected by Siemens considering the international standards (ISO, EN,
and IEC) and modernised in accordance with the Russian requirements.
The general designer is Institute Teploelektroproekt, Engineering Center EES
department. The specialists of Siemens and the Engineering center of Ural
power engineering participated in the design documentation development.
The project was approved by the State examination.
The main components of the combined cycle package turbines, generators and other equipment were supplied to Perm by water under the contract
of KES-Holding and Siemens held at the end of 2007. Siemens specialists will
carry out the tests and equipment startup, check the quality of the construction
works, and perform the training of TETs-6 heat and power plant specialists.
The general contractor of the construction is SOYUZ.
After the project realisation the powerplant electric power will increase
3 times, the heat power will be increased by 240 Gcal/h. The annual output of
the electric power will be about 1 billion kWh; the heat power output will be
about 2200 thousand Gcal a year. Due to the high efficiency of the new package
the annual emission of greenhouse gas will be decreased by 600 thousand tons.
Permskaya TETs-6 heat and power plant commissioned in 1942 is one of
the main power supplies in Perm providing the heat power to Sverdlovsky,
Leninsky and Motovilikhinsky districts and large industrial facilities.
Beside Malakhit KES-Holding is finishing Granat project in Perm region
(reconstruction of Permskaya TETs-13 heat and power plant) and carries out
the preliminary works on Ametist project (increasing Permskaya TETs-9 heat
and power plant capacity).
The first gas turbine package was supplied to Syzranskaya TETs heat and power plant
The first Frame 6FA (PG6111) gas turbine package produced by General
Electric with the electric power of 80 MW was supplied to Syzranskaya heat and
power plant construction site on October 11 (Volzhskaya TGK) to realise
Volzhsky agat investment project performed by KES-Holding.
PGU-325 combined cycle plant will include SST-600 steam turbine rated
at 65 MW produced by Siemens, waste heat recovery boilers produced by
Istorenergo, booster compressors produced by Energaz and the automatic
control system produced by GE.
The prime contractor is Samara Repair Company. The commissioning
of the combined cycle plant is planned for the end of 2011.
Under Diadema investment project KES-Holding ordered 9 turbines
produced by GE rated at 630 MW for the construction projects of new power
generating facilities at Syzranskaya heat and power plant, Novokuybyshevskaya
TETs-1 heat and power plant (3 Frame 6FA turbines), Igumnovskaya heat and
power plant (2 LM 6000 PD turbines) and Kirovskaya TETs-3 heat and power
plant (2 Frame 6FA turbines).
.
The
construction
site at
Syzranskaya
TETs heat
and power
plant
Issue 4, 2009
48
Unloading of equipment at the construction site

The combined cycle plant will be constructed
at Ufimskaya TETs-2 heat and power plant
of Bashkirenergo
The decommissioning of medium pressure
packages at Ufimskaya TETs-2 heat and power
plant began in January 1, 2009. The corresponding
permission was issued at the end of the last year.
The equipment to decommission includes the
steam turbines #1 and 2, and waste heat recovery
boilers #1 and 2. The packages had not been used
for over 4 years. The heat and power plant capacity
is reduced by 14 MW.
At present the disassembly works are practically
finished.
The medium pressure package will be the base
for the combined cycle package. The delivery
of SGT-800 gas turbines with the electric power of
45 MW produced by Siemens and the waste heat
recovery boiler produced by EMAliance are planned
for May 2010.
Now the construction project is developed.
The general designer is the Engineering center of
Bashkortostan power engineering, part of
BashUralEnergoStroy. The project development is
to be finished till the end of 2009 and the working
documentation is to be issued in 2010.
The decommissioning of the obsolete packages
at Ufimskaya TETs-2 heat and power plant is one
of the stages of Bashkirskaya power generating
company facilities modernisation.
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#4_eng_2009_obl:Goloshanjv_Orenburg098.qxd 08.12.

2009 10:05 Page 2

#4_eng_2009_obl:Goloshanjv_Orenburg098.qxd 08.12.2009 10:06 Page 3

#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 1

Specialised Information and Analytical Edition

(The Boyce Consultancy Group)

NK-20ST new engine development.

The most stressed components

Senior Editor: Lyubov Rastorguyeva

Federal Relation and Mass Communication

Economics and Finance

The features of the air filtration systems

#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 2

GAS TURBO TECHNOLOGY

GTU-50 MW gas turbine package

features the three shaft scheme with

#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 3

GAS TURBO TECHNOLOGY

The gas turbine package startup and

The documentation and the supplied

air treatment unit

Figure 1. Heat and power

Figure 2. Diagram of downtime distribution:

#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 4

The construction and assembly are carried

The precommissioning began at the first package of Noyabrskaya PGE powerplant

The main building of Noyabrskaya PGE powerplant

the ventilation system was checked. The gas turbines at

#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 5

The name of the construction project at Syzranskaya GRES

The construction site of the new package at Syzranskaya TETs

The main equipment was delivered to Kirishskaya GRES powerplant

The delivery of equipment with the

The combined cycle package building

#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 6

GAS TURBO TECHNOLOGY

Compressed gas composition

The basic parameters

Initial pressure (abs.), MPa

Final pressure (abs.), MPa

Capacity adjusted to the temperature

Gas temperature after

pressure case; 173GTs1-67/15-50M26

#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 7

GAS TURBO TECHNOLOGY

Figure 1. TKA-Ts-16/0.37-14.2 gas compression package general view:

components were used in the design of the

Design parameters of the centrifugal compressor sections

4.60 (276.25) 1.15 (69.33) 0.32 (19.03)

Figures 3, 4, 5; the stepup gear during

#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 8

GAS TURBO TECHNOLOGY

Figure 3. 193GTs1-276/3.6-16M26 compressor:

Figure 4. 173GTs1-67/15-50M26 compressor

Figure 5. 184GTs1-19/48-150M25 compressor

The gear was designed and manufactured

#4_eng_2009:#3_eng_2008 04.12.2009 13:58 Page 9

GAS TURBO TECHNOLOGY

roughness. To provide the accuracy of the

compressor with the step-up gear is given

Photo 1. M40-16-5.3/11.6 step-up gear in the assembly shop

Figure 6. High pressure

Photo 2. Turbine compressor with the step-up gear