PERM URAL-SERIES ARE AT PYAKYAKHINSKOYE OIL AND GAS FIELD
TAKHIR KHAIRULIN
Deputy General Designer of gas turbine drives for power generating sets and facilities of their application,
Aviadvigatel OJSC
In September 2009 gas turbine generating set rated at 24 MW was put into industrial operation at Pyakyakhinskoye oil and gas field of Yamalneftegas territorial production plant of LUKOIL-Zapadnaya Sibir Ltd.
The new power generating set consists of four Ural-6000 power generating modules rated at 6 MW each. This is the fifth small-scale power generating facility developed and produced by Perm engine builders at the fields of LUKOIL-Zapadnaya Sibir Ltd.
Installation of Pyakyakhinskaya GTES-24 power generatin gmodules on pile foundation.
The photo is from the editorial archive
The agreement concerning the production of Ural-6000 gas turbine generating set for LUKOIL-Zapadnaya Sibir Ltd was achieved in August 2008. In April 2009 all power generating modules were delivered to the customer and within the shortest possible period of time (from July to September) Aviadvigatel specialists installed, commissioned and put the equipment into operation.
Perm GT gensets run on associated oil gas, supporting the needs of drill rigs and field men settlements. Today two drill rigs are installed at Pyakyakhinskoye field. A power generating package based on four Ural-6000 gas turbine generating sets can supply power to at least 7 similar rigs. By 2010 the package will generate 150 million kW/hours of electric power per year using only 34 mln. m3 of gas.
PROJECT DESIGN FEATURES
Pyakyakhinskaya GTES-24 power generating modules of block container configuration are practically completely factory assembled. This design ensures easy transportation and the earliest possible date of putting the equipment into operation.
The use of the pile foundation for the GT genset can be considered as the unique design solution. Four power generating modules with independent fire-extinguishing modules are installed on the platform, which is located at the pile field 3 meters high from the ground with the required structural stiffness.
To ensure industrial safety Ural-6000 genset container is divided into 3 compartments: engine compartment, reducing gear compartment and automatic control system compartment.
The power generating set is based on the GTU-6P gas turbine with D-30EU-6 gas turbine engine developed in Perm on the basis of D-30 engine which is one of the most reliable aviation engines in Russia. Today its «ground» modification is successfully operating at Severo-Gubkinskoye oil and gas field, in Ivanovo and Solikamsk. In the nearest future six similar engines will be put into operation as part of Ural-6000 power generating sets at Bovanenkovskoye oil and gas field as well as in gas turbine-driven cogeneration heat and power plant in the suburb of Moscow - Zvenigorod.
| URAL-6000 GAS TURBINE GENERATING SET MAIN SPECIFICATIONS | |
| Rated electric power, kW | 6 000 |
| Voltage, kV | 6.3 |
| Current frequency, Hertz | 50 |
| Fuel flow at nominal conditions, kg/h | 1 715 |
| Exhaust gas flow at power turbine outlet, kg/sec | 32.5 |
| Gas temperature at power turbine outlet, oC, maximum | 543 |
| NOx/CO Emission (at 15% O2) mg/mn3, maximum | 50/50 |
| Life - between overhauls, hour - assigned life, no more hour | 25 000 100 000 |
R-60 reducing gear and GTG-6-2RUHLZ synchronous bipolar turbo-generator are placed in generator compartment. The turbo-generator is designed to generate alternate three-phase current with frequency of 50 Hertz, power of 6000 kW and voltage of 6.3 kV.
Automatic control system compartment incorporates MSKU-5000 device which is a microprocessor monitoring and control system of the GT genset completed on element base and designed to collect and process data from sensors and alarm devices of the genset, control commands of the control panel and then to generate control signals for the genset actuators.
Additional to MSKU-5000 the automatic control system compartment incorporates other systems equipment: generator excitation control cabinet, electric starter control module, control cabinet of the generator emergency oil pump, main distribution cabinet, uninterrupted power supply cabinet, power cabinet, air-conditioner, etc.
Taking into consideration the complexity of the facility such as its remoteness from well-developed infrastructure and severe climate conditions Aviadvigatel specialists improved several components of Ural-6000 generating set including ignition device, fuel system production units, gas generator and free turbine rotation velocity sensor, etc.
Instead of one ventilation fan used earlier for engine case cooling and engine-generator compartment ventilation, two separate systems are installed - the system of engine case cooling and engine compartment ventilation equipped with two ventilation fans and generators ventilation system with two blower fans.
Air starting system was replaced by electric starting system equipped with STVD-25-9000 electric starter. It is necessary to point out that according to customer wish all equipment is explosion-proof. It means high operational reliability and uninterruptable power supply to the consumer.
Another design solution of this project was block-modular fire-fighting system. The block-module consists of the container placed separately from the power generating set. Fire-fighting system controller, CO2 cylinder and utilities are placed in the container.
CONFIGURATION
Globalstroy-Engineering OJSC became a general contractor of Pyakyakhinskoye oil and gas condensate field construction. TUMENNIIGIPROGAS company was the designer of Pyakyakhinskoye GTES-24.
Aviadvigatel OJSC developed, produced and delivered the gas turbine generating sets, carried out installation supervision and commissioning.
Assemble units are produced in cooperation with Perm industrial enterprises - Perm Engine Company, Reductor-PM OJSC, Perm Plant Mashinostroitel OJSC, Proton-PM OJSC.
Iskra-Energetika CJSC being an old partner of the Perm Design Bureau was the power equipment package supplier.
Specialists of construction and erection company Volgoneftekhimmontazh Ltd, engineers of I. Rumyantsev Production Enterprise OJSC, Elektrotyazhmash-Privod Ltd, Sputnik-Energetika Ltd and Systema-Service CJSC Research and Production Company took part in the GTES-24 commissioning and handing over to the customer.
Putting into operation the next power generating set based on Ural series Perm gensets, LUKOIL-Zapadnaya Sibir continued to implement its program of associated oil gas recovery and so decreased significantly the production price and provided Pyakyakhinskoye oil and gas field with electric power taking into consideration the increase volume of oil and gas production.
