Two months ahead of time, the third power unit of the Pregolskaya TPP was commissioned

6 December 2018

In Kaliningrad, the construction of the third combined cycle gas turbine unit (CCGT) of the Pregolskaya TPP has been completed. Commissioning was carried out two months ahead of schedule.

Power unit No.3 was successfully tested for certification. For 72 hours of testing, the CCGT operated at maximum and minimum load, unloaded to the lower limit of power, passed testing of load increase and load rejection. In addition, the stable operation of the equipment for 8 hours at the load of the process minimum, as well as during tests on a dedicated area, was confirmed.

Currently, experts are performing start-up and adjustment works at CCGT-4. The planned completion date for the construction of the entire power plant is the first quarter of 2019.

The creation of the Pregolskaya TPP with a capacity of 454 MW composing of four CCGTs is being carried out upon the request of Kaliningrad Generation LLC. The project is managed by Inter RAO-Electricity Generation Management. General contractor is Inter RAO-Engineering.

The main equipment of the plant is produced by domestic enterprises. Each power generating unit includes gas turbine of type 6F.03 (produced by the Russian Gas Turbines LLC), generator (SPA Elsib), steam turbine (Power Machines PJSC), waste-heat boiler (Machine-Building Factory of Podolsk JSC). Dry fan cooling towers are applied at the facility.

Fuel supply for turbines 6F.03 is provided by gas treatment unit (GTU), manufactured by ENERGAS Company. GTU is installed at the territory of the Kaliningrad CHPP-2, which is adjacent to the TPP under construction. Gas treatment unit is a process unit, including several block-boxes with equipment for various purposes, which, when assembled, are docked together in a single building with a common roof. An exception is the inlet filtration module, which has an outdoor design on open frame.

In addition to the inlet filtration module, the unit is equipped with a fine gas purification system, a condensate drainage unit (with a 10 m3 drainage tank), a gas metering station with ultrasonic flow meters, a gas heating unit, and a reduction system. To determine the component composition and calorific value of fuel, the GTU is also equipped with a continuous on-stream gas chromatograph (calorimeter) with a sampling device.

Gas pressure at the GTU inlet is 1.2 ... 4.14 MPa. The rated capacity of the unit is 106,000 Nm3 / h.

ENERGAS also supplied for the Pregolskaya TPP a booster compressor station consisting of four units. BCS will provide gas supply to the power units if the pressure of the fuel gas entering the power plant is below the design parameters set by the manufacturer of gas turbine equipment.

Block-modular compressor units (CU) are made on the basis of screw oil-filled compressors. The pressure on the discharge line varies in the range 2.6 ... 3.45 MPa. The unit capacity (gas flow rate) of CU is 35,500 Nm3 / h and is controlled by a two-tier regulation system.

The gas filtration system in the CU is reinforced – an additional (insurance) gas fine filter is built into each block-module. The oil vapor analyzer in gas is installed on the common BCS outlet manifold (permissible level – no more than 0.5 ppm). The process scheme of the BCS also provides for a stable maintenance of the design gas feeding temperature to CCGT turbines.

Gas treatment unit and booster compressor units are fully automated. Their automated control systems implement launch (and preparation for start), shutdown, and maintaining the optimal operation mode; they control the process parameters; they provide automatic protection and alarm system; they handle the parameters of the workflow and emergency events with the issuance of information via a standard exchange protocol.

The local ACSs of the GTU and CU have been output into a common control module placed in a separate enclosure and mounted at the site of gas facilities of the power plant. There are connected uninterruptible power supplies; software is installed and configured. The complex is integrated with the upper level of APCS and provides remote equipment control, indoor gas hazard monitoring, output of status information for all elements and systems to the operator panel.

GTU, BCS and control module constitute a single gas treatment and gas supply system of the Pregolskaya TPP.

REFERENCE. After the Blackout of 2013, it was decided to secure the power grid of the Kaliningrad region. This task is assigned to four new power plants – in Gusev (Mayakovskaya TPP), Sovetsk (Talakhovskaya TPP), Kaliningrad (Pregolskaya TPP) and Svetlovskiy urban district (Primorskaya TPP). To implement these projects, Kaliningrad Generation LLC was established. The first two facilities were launched in March 2018 with the participation of Russian President Vladimir Putin.

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