GAS TURBINES FOR POWER GENERATIONS AND GAS TURBINE POWER PLANTS

50 years for marine gas turbine manufacturing

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

35 years - industrial gas turbines manufacturing

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

Gas Turbines For Power Generations

(D049)

Power, MW

Ambiet air temperature,

Efficiency, %

Ambiet air temperature,

Rated power, kW Efficiency, % Fuel gas consumption, nm /kW .h Exhaust gas mass flow, kg/sec
3

2850 28,5 0,353 16,5

Exhaust gas temperature, C Dimensions (L x W x H), m Weight, t

460 3,512,521,93 4,25

Features
1 2 3 4 5 6 7 - ower flange - Gearbox - Electric starter - Compressor - Combustion chamber (CC) - Turbine - Frame

7
Gas turbine generating set UGT 2500

Gas Turbines For Power Generations

UGT 6000, UGT 10000, UGT 15000, UGT 25000 Gas Turbine Design Features

56 1 2 3 4

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

10

(DV71)

Power, MW

Ambiet air temperature,

Efficiency, %

Ambiet air temperature,

Rated power, kW Efficiency, % Fuel gas consumption, nm /kW .h Exhaust gas mass flow, kg/sec
3

6360 31,5 0,319 30,5

Exhaust gas temperature, C Dimensions (L x W x H), m Weight, t

428 4,61,81,8 4,5

Gas Turbines For Power Generations

(DN70)

Power, MW

Ambiet air temperature,

Efficiency, %

Ambiet air temperature,

Rated power, kW Efficiency, % Fuel gas consumption, nm /kW .h Exhaust gas mass flow, kg/sec
3

10500 36,0 0,279 36,0

Exhaust gas temperature, C Dimensions (L x W x H), m Weight, t

490 4,01,81,7 5

UGT 15000
(DB90)

Power, MW

18

Ambiet air temperature,

Efficiency, %

Ambiet air temperature,

Rated power, kW Efficiency, % Fuel gas consumption, nm /kW .h Exhaust gas mass flow, kg/sec
3

17500 35 0,287 72,2

Exhaust gas temperature, C Dimensions (L x W x H), m Weight, t

414 4,7x2,1x2,2 9

 Gas Turbines For Power Generations UGT 16000

(DJ59)

Power, MW

Ambiet air temperature,

Efficiency, %

Ambiet air temperature,

Rated power, kW Efficiency, % Fuel gas consumption, nm /kW .h Exhaust gas mass flow, kg/sec
3

15900 31,4 0,324 96,0

Exhaust gas temperature, C Dimensions (L x W x H), m Weight, t

UGT 25000
(DG80)

Power, MW

Ambiet air temperature,

Efficiency, %

Ambiet air temperature,

Rated power, kW Efficiency, % Fuel gas consumption, nm /kW .h Exhaust gas mass flow, kg/sec
3

26200 36,3 0,277 87,5

Exhaust gas temperature, C Dimensions (L x W x H), m Weight, t

485 6,42,52,7 16

Gas Turbines For Power Generations

UGT 110000
(GTD110)

Power, MW

Ambiet air temperature,

Efficiency, %

Ambiet air temperature,

Rated power, kW Efficiency, % Fuel gas consumption, nm /kW .h Exhaust gas mass flow, kg/sec
3

114500 36,0 0,279 365

Exhaust gas temperature, C Dimensions (L x W x H), m Weight, t

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

1
Waste heat recovery boiler and contact condenser Starting frequency converter Generator Control system

Air inlet device

Gas turbine exhaust

2
3
7

6 4

5
9
11 10

14 13

Zorya-Mashproekt Complete Power Plants

9
12

Lub oil tank

15

Gas turbine

Gas Turbine Power Plants

Zorya-Mashproekt offers a wide choice of gas turbine based combined heat and power plants: -simple cycle plants; -cogeneration plants; -steam injection plants including Aquarius type units; -combined cycle plants; -cogeneration plants with distilling desalting units (DDU). Every type of plants has its own advantages for operation under certain conditions. What the Customer has to know for optimal selection of the plant type? All the plants can operate using liquid or gaseous fuel; they also have dual-fuel capability or can use alternative types of fuel (biofuel, gas oil etc.) Simple cycle installations feature small dimensions, low weight, high maneuverability and fast start up; they can be used at mobile platforms. Such units have an advantage of being used as an emergency or peak power plants as well as stationary power plants in areas where cheep fuel is available and when a consumer needs only electric power. Cogeneration plants are designed for simultaneous production of electric and heat power as steam or hot water. Electric power is directly related to the mechanical power of the gas turbine. As for heat it significantly varies in a wide range depending on the selected waste heat recovery configuration (steam or water type, or combined steam and water type, or use of supplemental firing). Such plants are most effective for manufacturing enterprises and public utilities with stable demand for electric power and heat as steam or hot water. Steam injection plants (STIG) utilizing steam injection into the gas turbine hot gas path are also designed for power generation. Steam produced in a waste heat recovery boiler is supplied to a gas turbine as additional working media. STIG type plants feature: -the most increase of electric power up to 90%; -cost effective low NOx, CO emission levels; -cost effective level of capitals $/kW installed electric power. Steam injection plants can be produced as gas turbine based of non-covered (S1) and converted (S2) gas path versions. Such plants have advantages when used as power plants for industrial enterprises and as small regional power plants where maximum electric power is required and a source of fresh water is available. Aquarius type units also operate according to STIG cycle. They have a contact water condenser installed over the waste heat recovery boiler to return water condensed into the cycle. Their main application is implementation in regions suffering from fresh water shortage or in areas where are difficulties in treatment of boiler water large amounts. This type of units also has the ability to generate surplus of distilled water. At ambient air temperature the unit can increase the power of the electric power plant due to water injection at the engine inlet. Combined cycle power plants are designed for the highest possible effectiveness of power generation. Steam generated in waste heat recovery boiler is supplied to separate gas turbine. Electric power is the total power of gas turbine engine and a steam turbine. The plants are offered with two basic configurations: CC1 - one gas turbine with waste heat recovery boiler plus one steam turbine; CC2 - two gas turbines with two waste heat recovery boilers and one steam turbine operating for its own generator. The power plants have advantages when used as regional power stations and also as power stations for big industrial enterprises in areas with the high prices power resources. Cogeneration with distillationdesalinating plants are introduced for the countries with the fresh water shortage. Certain quantity of distillate when used for water injection to gas turbine inlet, allows providing nominal power output at high ambient temperatures.

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Gas Turbine Power Plants Thermal Diagrams

Steam-in-gas (stig)
Exhaust gas Exhaust gas

Simple cycle
Fuel

Feed water

Air Fuel

1 - Gas turbine. 2 - Generator.

Air

Co-generation

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

Aquarius
Exhaust gas

Exhaust gas

Condensate Steam

Feed water
Steam

Feed water

Fuel Fuel
Steam-gas mix

Air

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

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

Co-generation with sea water distillation

5
Exhaust gas

Combined cycle CC1

6
Feed water

Exhaust gas

Distilled water

Steam
Sea water

Steam

Feed water

Fuel

Fuel

Air

Air

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

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

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Power Plants With UGT 2500

Power, MW Electr. Therm. Simple Co-generation Steam-in-gas STIG Aquarius UGT 2500 UGT 2500C UGT 2500S1 UGT 2500S1A 2,5 2,5 4,15 4,0 4,7 Efficiency Fuel consumption

Cycle

Installation

% 26,0 26,0 33,1 33,1

U/kW.h 11975 12411 9614 9922

gas (m3 /h) 1010 1010 1225 1225

liquid (kg/h) 840 840 1020 1020

All data according to the ISO 3410

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

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

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

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

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Power Plants With UGT 6000

Cycle
Simple Co-generation Steam-in-gas STIG

Installation

Power, MW E lectr. Therm. .

Efficiency

Fuel consumption

% % 31.5

U/kW.h 10835 11339

gas (m3 /h) (3/) 2130 1990

liquid (kg/h) 1790 1680

UGT 6000 UGT 6000C

6 6 11.1

73,2

UGT 6000S1

36.3

9402

2210

1860

UGT 6000 generating set

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

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

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

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Power Plants With UGT 10000

Power, MW Electr. Therm. Simple Co-generation Steam-in-gas STIG Aquarius Combined UGT 10000 UGT 10000C UGT 10000S2 UGT 10000S2A UGT 10000CC1 UGT 10000CC2 10,5 10,0 16,0 15,7 13,5 27,5 15,04 Efficiency Fuel consumption

Cycle

Installation

% 36 85,6 43 42,2 45,8 46,3

U/kW.h 9481 9980 7937 8146 7452 7371

gas (m3 /h) 2950 2960 3760 3760 2980 5960

liquid (kg/h) 2460 2470 3140 3140 2500 4940

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

Exhaust Waste heat recovery boiler Contact condenser Condensate return Steam pipe Separator Air inlet device

Generator Gas turbine Thermal and sound insulating container

Aquarius installation layout

Aquarius-16K installation at Stavishchy compressor station

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Power Plants With UGT 16000

Power, MW Electr. Therm. Simple
UGT 16000

Efficiency

Fuel consumption

Cycle

Installation

U/kW.h

gas (m3 /h)

liquid (kg/h)

16 300 14 500 18 400

27, 04

31,0 79,9 36,2

11010 4270 9430

5320 5260 5260

4430 4380 4280

Co-generation Combined

UGT 16000C UGT16000CC1

Three UGT 16000C units at Kzyll-Orda, Kazakhstan

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

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

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

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

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Power Plants With UGT 15000

Power, , MW E lectr. T . . herm. Simple Co-generation Steam-in-gas STIG Aquarius Combined UGT 15000 UGT 15000C 16.0 16.0 23,9 Efficiency Fuel consumption
3 3 gas (m /h) ( /)

Cycle

Installation

% % 33.5 32.5

.h .h U/kW U/kW 9740 10490

liquid (kg/h) (/) 4215 4150

5020 4940

UGT 15000S2 UGT 15000S2 UGT 15000CC1 UGT 15000CC2

25.0 25.0 22.7 45.8

42.0 42.0 45.3 45.9

8120 8120 7530 7430

5960 5960 4940 9880

5020 5020 4150 8300

Assembling of UGT 15000 gas turbine engine

UGT 15000C power unit at Kostyukovichy cement works, Belarus

UGT 15000 in the container

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

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

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Power Plants With UGT 25000

Power, MW Electr. Therm. Simple Co-generation Steam-in-gas STIG Aquarius Combined UGT 25000 UGT 25000C UGT 25000S1 UGT 25000S2 UGT 25000S1 UGT 25000S2 UGT 25000CC1 UGT 25000CC2 25 25 30.8 40.7 30.8 40.7 34.7 70.6 35,5 Efficiency Fuel consumption

Cycle

Installation

% 35,0 34.8 40 42.8 40 42.8 47.5 48.5

U/kW.h 9402 9807 8533 7974 8533 7974 7185 7037

gas (m3 /h) 7330 7220 7720 9570 7720 9570 7220 14440

liquid (kg/h) 6170 6060 6490 8020 6490 8020 6060 12120

Gas turbine engine UGT 25000 (DG80)

Engine cover during assembling

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

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

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

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Power Plants With UGT 110000

Power, MW Electrical Simple cycle UGT 110000 UGT 110000CC1 UGT 110000CC2 110 160 325 Efficiency Fuel consumption

Cycle

Installation

% 35,5 51,5 52,5

U/kW.h 9610 6758 6563

gas (m3 /h) 31100 31810 63620

liquid (kg/h) 26100 26700 53400

Combined cycle

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

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

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

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

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

UGT 110000 at Zorya-Mashproekt test bed

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Power generation applications

TYPE
GTD-1

POWER MW

APPLICATION
FLOATING POWER PLANT RAILROAD POWER TRAIN RUSSIA RUSSIA

LOCATION
YAKUTIYA CHUKOTKA YAKUTIYA TUMEN REGION BURYATIYA KOMI

NUMBER OF GAS TURBINES

BEGINNING OF OPERATION

REMARKS

DO12 STATIONARY RUSSIA

KHABAROVSKY KRAY AMUR REGION YAKUTIYA KHABAROVSKY KRAY PRIMORSRY KRAY YAKUTIYA CHUKOTKA TUMEN REGION YAKUTIYA KHABAROVSKY KRAY

FLOATING POWER PLANT

RUSSIA

1971-75

DO14

RAILROAD POWER TRAIN

RUSSIA

KAZAKHSTAN STATIONARY RUSSIA

YUZHNAYA YAKUTIYA KHABAROVSKY KRAY YAKUTIYA TUMEN REGION YAKUTIYA SOVETSKAYA GAVAN 2 2 6 3 17 27 4 13 12 53 21 9 2 2 10 1 2 2 4 1 1970-74 1978-2000 1986 1976 1980 1990 1998 1990 1986 1982 1986 1980 1998 2002 1995-2003 1997 1994 1995 2002-2003 1999
Licence manufacturing by NPO SATURN not completely included

D14

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

RUSSIA RUSSIA RUSSIA RUSSIA

TUMEN REGION KAZAKHSTAN TENGIZ RUSSIA TUMEN REGION AZERBAIJAN RUSSIA NEFTYANYE KAMNI TUMEN REGION YAKUTIYA NEBIT-DAG

DC59

TURKMENIYA

KAZAKHSTAN JANAJOL RUSSIA RUSSIA UGT 2500 STATIONARY UKRAINE CZECH CANADA RUSSIA UGT 6000 STATIONARY UKRAINE UGT 10000 STATIONARY UKRAINE POLTAVA REGION NIKOLAEV REGION TUMEN REGION RYBINSK KHARKOV REGION BRNO, OLOMOUC TORONTO TUMEN REGION

UGT 15000

15

STATIONARY

UKRAINE BELARUS UKRAINE RUSSIA RUSSIA RUSSIA

NIKOLAEV REGION

1 2

1996 2003-2005

UGT 15000

STATIONARY FLOATING POWER PLANT RAILROAD POWER TRAIN STATIONARY STATIONARY

NIKOLAEV REGION CHUKOTKA YAKUTIYA YAKUTIYA KHABAROVSKY KRAY 5 11 4 2 2 1 3 3 3 1 1 4 1 3 1992 1993 1993 1992 1991 1995 1997 1992 1992 2003 1996 2003-2005 2004 2001-2005

UGT 16000

BYELORUSSIA MOZYR TUMEN REGION RUSSIA ROSTOV REGION KRASNODARSKY KRAY UKRAINE SEVASTOPOL RUBEJNOYE

UGT 25000 UGT 110000 110

STATIONARY STATIONARY

UKRAINE BELARUS UKRAINE RUSSIA

NIKOLAEV REGION BREST REGION NIKOLAEV REGION IVANOVO REGION

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Nikolaev at night

GTR&PC Zorya-Mashproekt Oktyabrsky prospekt 42a Nikolaev, 54018, Ukraine. Phone +38 0512 50-25-61, 55-69-92 Fax +38 0512 50-90-50, 55-68-68
E-mail: spe@mashpoekt.nikolaev.ua, omito1@zorya.com.ua http:// www.zmturbines.com

2006