PERM GIGAWATT OF SMALL-SCALE POWER GENERATION
On the eve of the 70 anniversary of Aviadvigatel OJSC, total capacity of power equipment developed and put into service by its specialists exceeded 1 gigawatt. Nowadays perm engineers work in designing, manufacturing and maintenance of gas turbines and gensets is an important and promising line of business.
How did Perm power gas turbine design school organize its work? What is its range of customers today?
To answer these questions we asked Daniil Sulimov, Deputy General Designer, Chief Designer of gas turbine generator drives for gensets and facilities of their application.
BEGINNING
This line of activity started in 1992, when Gazprom units power engineers on their Moscow conference discussed emergency state of drilling rigs, compressor stations and gas storages power supply.
PAES-2500M genset was a good start of Aviadvigatel OJSC in power gas turbine design
They focused on insufficient for gas workers performance efficiency of mobile PAES-2500 GT gensets with AI-20DKE drive. They were designed in the 60-s of the past for power supply of oil and gas minings.
As these gensets were manufactured in Ukraine that became independent by the moment, it caused many problems in custom procedures, accessory supplies and after-sale service conditions in Tyumentransgaz OJSC (now Gazprom transgaz Yugorsk). During the conference Aviadvigatel OJSC offered the largest Russian Gas Concern management to design a new home made drive in Perm, based on converted aircraft engine D-30, to redesign PAES-2500 and EG-2500.
In 1993 Aviadvigatel OJSC, Tyumentransgaz OJSC and Gazprom OJSC entered into a contract (base for the «Ural-Gazprom» program) on designing and delivery of module gensets rated up to 4.5 MW. Since then Aviadvigatel has been actively developing its power generating line of products.
The first modernized PAES-2500M was put in operation in 1994. Nowadays 102 GTU-2.5P with mounting kits for modernized PAES-2500M and EG-2500M gensets have been delivered to Gazprom and Jug company in partnership with Iskra-Aviagaz CJSC.
GAS WORKERS
The received experience of reconstruction PAES-2500 and EG-2500 allowed Aviadvigatel OJSC to move further and continue to expand the line of power-applied products. The question of working out its own package for GT gensets became actual. Specialists of the Aviadvigatel's leading unit of power drives for gensets designed Ural-2500, a package-type GT genset for autonomous electricity supply of trunk pipelines line production management departments. The first deliveries of the Urals were performed for Jubilee BCS of Gazprom dobycha Nadym Ltd, and Sos'va, Ural and Peregrebnenskoye LPM of Gazprom transgaz Yugorsk.
Ural gensets work properly in all climatic conditions.
Ural-2500 genset,
Gazprom dobycha Nadym Ltd
Ural-6000 GT genset. LUKOIL-Zapadnaya Sibir Ltd
With the increase in the number of orders customers required to shorten the duration of gensets input in operation. The task was to expand test facilities. Together, Aviadvigatel OJSC, Proton-PM OJSC and Iskra-Avigaz CJSC in late 2005 built a test bench for testing full-size Ural genset series. This bench allowed to shorten assembly and commissioning periods sufficiently and increase the genset ready-to-operate condition because actually all the genset systems (engine, gearbox, generator, automatic control system) were commissioned at the Manufacturer's bench. The equipment stated performance was validated by the genset tests performed just here at the bench in the presence of the Customer representatives.
Ural-2500 genset on Kharasavey GCS, located on the bank of the Kara Sea
New orders were not long to wait. Gazprom dobycha Nadym Ltd needed reliable modular gensets able to operate in harsh climatic conditions of the Yamal Peninsula - on Kharasavey gas compressor station, located on the coastline of the Kara Sea. Besides that, the company was interested in genset choice to provide the work of drilling rigs on the largest Russian Bovanenkovskoye gas condensate field.
Experts of the Gazprom Office of Energy together with VNIPIgazdobycha OJSC, and Gazprom dobycha Nadym Ltd, along with equipment produced by Aviadvigatel OJSC, reviewed the proposals of well-known foreign companies. The selection criteria were as follows: high reliability, high operational availability and the possibility of early entry of equipment into operation, modular construction and transportability, operating temperatures from -60 to +40 °C, and the shortest terms of manufacturing. Preference was given to Perm, able to provide all the requirements of the customer.
During the years of Aviadvigatel and the country's leading gas producer fruitful cooperation 148 gas turbines for PAES-2500M, EG-2500M, GTES-4, EGES Ural-2500, GTES Ural-6000 gensets were manufactured, including 46 gas turbines for Ural series. Total operation time of power gas turbines fleet at Gazprom sites exceeded 2.6 million hours, installed capacity is 401.5 MW.
OILERS
The longstanding experience of work with Gazprom allowed our design office to open a new market sector for gas turbine product sales. Cooperation with the oil and oil and gas companies has begun in 2001 from Surgutneftegaz OJSC (Konitlorskoye oil and gas field) and JUNG-Energoneft (Prirazlomnoye oil and gas field).
By request of Iskra-Energetika carrying out complex delivery of power equipment to these objects, Aviadvigatel OJSC worked out a GTU-4P gas turbine assigned to use with GTES-4 genset designed by Iskra scientific-production association OJSC.
The governmental order of the Russian Federation «About measures on reduction of atmospheric air pollution by products of associated oil gas torch burning» has pushed oil industry workers to solve the problem of associated passing oil gas utilization at 95%.
For the rational decision of the problem Perm designers have offered oil industry a wide choice of gas turbine equipment from 2.5 to 22.5 MW for producing power and heat using natural gas or associated oil gas as a fuel.
Assembling of gas turbines based on PS-90GP-2 engine. Perm Engine Company OJSC
Surgutneftegas OJSC has become a pioneer among the oil companies to develop and implement a technology for utilization of associated gas using Perm gas turbines. Aviadvigatel OJSC with Iskra-Energetika CJSC determined the unit capacity of a gas turbine generator set necessary for oil and gas fields. GTU-12PG-2, a promising 12 MW GT genset, was found suitable to use with gas transfer units and as a basis for EGES-12S power generating module.
Since 2004 13 EGES-12S power generating modules with total capacity of 156 MW were put into operation at Bittemskoye, Lyantorskoye, Luk'yavinskoye and Russkinskoye oil and gas fields.
Since 2006, the problem of associated gas utilization is dealt seriously by LUKOIL-Zapadnaya Sibir Ltd. Our Perm Design Bureau took part in the tender for gas turbine power equipment supply for Vat'-Yoganskoye oil and gas field and won it. The Company offered to the Customer the 12 MW gas turbine wich had already showed excellent operational results as strategic facilities of Gazprom and Surgutneftegaz.
Bittemskaya GTES-36 genset of Surgutneftegaz OJSC based on three EGES-12S power modules
A minimum time of equipment delivery, as well as the willingness to cooperate in design and new solutions introduction, paying attention to the customer's wishes, played an important role in the choice of Aviadvigatel products. As a result a new-generation GT genset appeared to be operated in Far North regions.
The first contract between Aviadvigatel OJSC and LUKOIL-Zapadnaya Sibir Ltd for the supply of six EGES-12S generating modules for Vat'-Yoganskoye oil and gas field was signed in February 2007. In early 2008 the GTES-72 GT genset was put in commercial operation.
The ability of Aviadvigatel OJSC to fulfill the obligations properly was highly appreciated by LUKOIL-Zapadnaya Sibir Ltd. In 2008 two more contracts were signed: one of them - for the delivery of eight EGES-12S sets based on GTU-12PG-2 gas turbines for the Tevlinsko-Russkinskoye and Pokachevskoye gas fields, and another one - for the delivery of four modular gas turbine genset Ural-6000s on the GTU-6P basis for the Pyakyakhinskoye gas and oil field. All in all gas and oil fields of LUKOIL-Zapadnaya Sibir Ltd have received 22 gas turbine power stations in total.
This 2008 year, jointly with Iskra-Energetika CJSC, Aviadvigatel OJSC started a new GTES-48 project based on four GTU-12PG-2 gas turbines included into the construction of EGES-12S with a single unit capacity of 12 MW for the Yuzhno-Priobskoye gas field of Gaspromneft-Khantos LLC.
Besides capturing the Russian gas turbine equipment market, Aviadvigatel OJSC never gave up its attempts to enter the world arena. That is why the experience of work with Sakhalin Energy Investment Company Ltd as part of the oil-and-gas companies cooperation was so important within the framework of project Sakhalin-2. At present three gas turbine gensets Ural-4000 with the total capacity of 12 MW are on the way to putting into operation at the customer's site.
Assembly of Ural-4000 gas turbine generating set Gastello settlement, Sakhalin Island
The equipment developed for the Sakhalin-2 project has unique advantages. First of all it fully complies with the foreign standards; secondly it meets the complicated climatic conditions of operation, i.e. specific ambient air temperatures, wind rushes, increased seismic activity.
The participation in the Sakhalin-2 project was the acknowledgement of Aviadvigatel's competitive ability not only in the domestic power and oil equipment market but in the world's market as well. It is a significant fact that Perm Ural units will be running together with the Rolls Royce equipment, and the world's oil and gas market consumers will see the true value of the equipment manufactured in Russia.
There are 60 gas turbines and power stations manufactured for oil producing companies. They are GTES-4, GTES Ural-4000, EGES-12S with the total capacity of 522 MW; their running time being 1.5 mln hour.
POWER ENGINEERS
The business contacts with power generating companies were gradually added to the cooperation with the oil producing companies aimed at their power demand satisfaction. This sphere of Aviadvigatel's activities is not only up-to-date but has good developmental opportunities. At present about 18 000 boilers are being used in Russia. Due to their high wear rate and inefficient natural gas use for the heat generation without cogeneration, 49% of the boilers need to be replaced or reconstructed. Besides, the heat generating and hydraulic power stations need to be also replaced because of the equipment excessive wear and inefficient natural gas use in the steam power cycle: a quarter of them should be replaced even today, 37% - by the year of 2012.
The current situation with the lack of energy could be largely solved by using the combined cycle of the power generation aimed at the power efficiency increase and resources saving.
Advanced energy generating companies have long ago recognized the importance of the minor power development and the possibilities of the old generating equipment reconstruction via the new gas turbine equipment introduction. Bashkirenergo OJSC is among such far-seeing companies. It is a long time since the Bashkiria power generating companies started to purposefully implement the minor power projects.
The first joint project of Bashkirenergo OJSC and Aviadvigatel OJSC started almost 10 years ago. In the year of 2000, power and heat generation plant GTU-TEC Shigili based on generating modules GTES Ural-4000 started its operation. The electrical capacity of the first in Russia municipal gas turbine power and heat generation plant was 4 MW, with the heating capacity being 8.3 Gcal.
Ural-6000 gas turbine generating set TEC-1, Ivanovo
Ural-4000 gas turbine generating set Bashkirenergo OJSC
The power and heat generating plant is located in the Bolsheust'ikinskoye district center and it reliably provides the settlement people with the heat and electricity during the whole heating season. High operational parameters of the GTU-TEC Shigili caused a new heat generation plant bringing into life in 2002. It was the GTU-TEC Agidel of 8 MW total capacity and 16.6 Gcal heat capacity. The Bashkirenergo OJSC managers say that the principal economic parameter characterizing the efficiency of the Perm power equipment is the low heat and electrical energy generation cost which is much lower at Shigili and Agidel than the current official tariffs.
The experience obtained by Bashkiria and Perm engine builders allowed for the continuation of the cooperation in the sphere of the republic minor power development on the basis of Aviadvagatel's gas turbines. The first in Russia modular GT genset GTES-25P was put into operation at Ufa's oldest heat generation plant TEC-1 in 2009. In 2010 the 16 MW GTES-16PA gas turbine genset will start its operation in the city of Sibay.
One more old and important partner of Perm engine builders is Ivanovskaya Generating company. Five years ago here, in the very center of Russia, the first in Russia power and heat generating plant reconstruction project was carried out. Gas turbine power and heat generation plant GTU-TEC was built on the basis of GT genset GTES Ural-6000 having the total capacity of 12 MW and heat capacity of 52 Gcal/hour and equipped with three-mode steam boilers E-50.
The specialness of the Ivanovo project is in the placement of the complicated technological equipment in the old boiler premises and their turning into a modern gas turbine power and heat generation plant. As a result, the successfully implemented project provided for a reliable heat delivery to the districts located in the central and northern parts of the city. Besides, the famous Ivanovo's textile factories got a new improved steam source.
GTES-16PA genset. TEC-13, Perm. KES-Holding Generatsiya Urala
GTES-25P genset Bashkirenergo OJSC
The construction of gas turbine power and heat generating plants is being carried out in the Perm region on the basis of Aviadvigatel's gas turbines. In quarter 4 of 2009 the first modular power GT genset GTES-16PA developed by our Design Bureau started its operation included into the structure of gas turbine power plant GTU-TEC of Perm TEC-13 (the division of the KES-Holding Generatsiya Urala). The power station is equipped with modern gas turbine with 35.5% efficiency in simple cycle and 86% in cogeneration cycle. The start-
up of the TEC-13 station will allow to provide the biggest Russian cable manufacturer Kamkabel OJSC and the Gaiva district citizens with electricity and heat.
Currently the power producing companies' plants are equipped with 10 gas turbine gensets GTES Ural-4000, GTES Ural-6000, GTES-16PA and GTES-25, the total capacity of them being 62.5 MW. Their total running time exceeds 80 500 of hours.
INDUSTRIAL COMPANIES
Industrial companies do not dominate so far in Agiadvigatel's gas turbine equipment consumers. There are many objective reasons for that. The approval of the necessary gas volume and technical specifications of the connection to the power generators' lines, finding the project financing source are among the problems to be solved by the industrial companies when creating their own energy generation system.
In 1999 Aviadvigatel OJSC and Perm Engine Company OJSC erected a cogeneration gas turbine power station in their own premises, turning a test stand for turbojet aircraft engines into the Yanus gas turbine power and heat plant. The original electrical capacity of the plant was 4 MW with the heat capacity being 8.3 Gcal. Putting this plant into operation in the premises of the Perm Engine Company OJSC allowed for the solution of two principal tasks:
- increasing the power efficiency of the Perm engine building companies;
- creating a test stand for testing serial gas turbines.
The genset GTES-4 with the electrical capacity of 4 MW was put into operation at the Perm Gas Processing Plant in parallel with GTU-TEC Yanus construction.
The private independent energy generation of Perm engine builders became a meaningful example for the others. So in 2005 the cooperation started with Italian industrial company Electronic Solar S.R.L. Aviadvigatel OJSC worked out and shipped two GTES Ural-4000 to the city of Adria against the contract with the company.
The First in the Perm region GTU-TEC based on two gensetsUral-6000 developed turnkey by Aviadvigatel OJSC
for the Silvinit OJSC
The regional manufacturers were also involved. In 2007 the first in the Perm region gas turbine power station was put into operation. The GTU-TEC of Silvinit OJSC based on two GTES Ural-6000 satisfies 60% of the electricity power demand and 100% of the heat demand of the First Mining Department and the halurgic factory of the company. Within this contract it was the first time that Aviadvigatel OJSC acted as the main contractor and performed all the types of works beginning with the equipment delivery and finishing with the turnkey object acceptance.
So far there are 6 gas turbine Ural units supplied for the needs of the industrial companies, the total capacity of them being 30 MW. Their total running hours exceeded 100 thousand.
RESULTS
Starting with 1993 Aviadvigatel's specialists have developed and created a full range of the power gas turbines and power gensets with a single unit capacity range from 2.5 to 22.5 MW. The total number of the gas turbines and GT gensets supplied to the customer's premises is 225. By the beginning of November their total running time exceeded 4.35 mln hours, and total capacity exceeded 1 gigawatt.
