16 May 2021

ENERGAS compressor unit (CU) was commissioned on May 16, 2011 during the trial launch of the GTU-30 gas-turbine power unit at the Kaluga CHPP of Quadra PJSC. The modular CU, made based on screw oil-filled compressors, serves to compress and feed fuel gas to the turbine.



In two-stage CU there is applied technology of gas compression in two steps, without intermediate cooling. This allows the compressor unit to operate stably throughout the entire range of pressure changes at the suction, regardless of the supply line. Two-stage compressing also provides a high compression ratio: the minimum gas inlet pressure is 0.3 MPa, the maximum delivery pressure is 3.7 MPa (limited by the GTU settings).

The volume capacity of CU is 11,600 m3 / h. Gas flow rate depends on the dynamics of changes in the load of the GTU, and is controlled in the range from 0 to 100% of nominal. For this purpose, a special two-circuit regulation system is used.

The first circuit (control by the compressor spool valve) provides smooth, stepless gas flow regulation in the range of 15 ... 100%. To control the capacity in the lower range 0 … 15%, the first circuit is combined with a gas recirculation system (second circuit), that allows the unit to respond quickly and correctly on a sharp change in load during transient operating modes of conjugated turbine.

The process flow scheme provides for the stable maintenance of the calculated fuel temperature. The delivery line of the compressor unit is equipped with a shell-and-tube heat exchanger that cools the working medium and ensures the optimum gas supply temperature (+60°C) set by the turbine manufacturer and design requirements.

The required parameters of the fuel gas in terms of purity are guaranteed by the filtration system of CU: inlet strainer, gas-oil separator of the 1st stage of purification and coalescing (safety) filter of the 2nd stage. The content of oil aerosols in gas at the outlet is not more than 1 ppmw (mg / kg), liquid impurities are absent.



Gas booster unit is housed in its own shelter of container type, equipped with life support systems. According to safety requirements, CU is equipped with fire detection, gas detection, alarm systems, fire-extinguishing systems.

Compressor unit is fully automated. Its control system (ACS), made based on microprocessor technology, is placed inside the block-module of CU – in the special compartment separated from the process part by gas-tight fire-resistant partition.

The local ACS is integrated into facility's APCS. It provides remote control of unit, automatic protections and alarm; monitors the process parameters of the CU and the gas contamination in the machine room; handles the parameters of the workflows and emergency events; issues information to the operator panel. Control from the upper level is carried out in full, similar to the control "in site".

The ENERGAS compressor unit began its work two months before the official launch of the gas-turbine power unit. This allowed Quadra's power engineers to conduct a full range of tests of the generating equipment and put the GTU-30 into operation in a timely manner.



The construction of GTU-30 was carried out under the investment program of Quadra PJSC, according to which a number of new facilities with a total installed capacity of 1,092 MW were built until 2015. Power unit, created as part of the reconstruction of the Kaluga CHPP, consists of a LM2500+G4 DLE gas turbine unit produced by GE Energy and a steam waste-heat boiler manufactured by NPO Barnaul boiler equipment plant.

After the upgrade, the electric capacity of the CHPP increased by 30 MW and amounted to 41.8 MW. The use of modern technology has significantly reduced here the specific fuel consumption and decreased the prime cost of produced energy.

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