Gas compressor station for the factory power supply complex of the new HAYAT enterprise has been tested
9 December 2022
This process equipment is part of the ENERGAS comprehensive gas treatment system which will provide the SOLAR Mars 100 turbines with fuel with specified design parameters in terms of purity, temperature, pressure and flow rate.
HAYAT Russia is increasing its production capacities – a large plant for the production of sanitary and hygienic paper products was built at the Borovsk site of the Kaluga special economic zone.
An autonomous (decentralized) power supply complex is also being prepared for launch here to supply production with its own energy resources. Electricity will be generated by the two SOLAR Mars 100 gas turbine units (GTU) with an installed capacity of 10 MW each. The production of high-potential process steam will be provided by the two waste heat boilers with a productivity of 15 t / h each. In addition to the cogeneration power unit, the structure of the power supply complex includes an auxiliary gas boiler house.
The supply of the GTU and boiler house with fuel with the specified design parameters in terms of purity, temperature, pressure and flow rate will be guaranteed by the ENERGAS multifunctional system – a block-type gas treatment station (BGTS) and a booster compressor station (BCS).
At present, the specialists of the ServicENERGAS company (ENERGAS Group) have carried out adjustment works at the BCS. Pre-start activities were completed with own (individual) testing. There has been checked the functioning of process, compressor, measuring and analytical, electrical equipment and automated control system. Integrated tests of the station as part of the power supply complex are planned, which will take place under load – in conjunction with the Mars 100 turbines.
The screw-type booster compressor station is intended to compress the fuel treated in the BGTS and feed it to the turbines at a pressure of 2.6 MPa. The maximum volume capacity of BCS is 6,336 Nm3 / h, gas flow rate depends on the load of the GTU and is controlled in the range from 0 to 100% by a special two-circuit regulation system.
The process flow scheme of the BCS provides for stable maintenance of the design fuel temperature necessary for the normal operation of turbines. The delivery line of the station is equipped with a heat exchanger which cools the working medium to the level of the optimum gas supply temperature (+70°C) set by the GTU manufacturer and terms of the project.
Taking into account the stringent requirements for the purity of fuel gas, the basic filtration system of the BCS, consisting of a gas-oil separator of the 1st stage of purification and a coalescing filter of the 2nd stage, is enhanced due additional elements: 1) a protective strainer is installed on the suction line of the compressor station; 2) a safety filter for fine purification of gas is built into BCS module. Eventually, the content of impurities in the fuel at the inlet to the GTU shut-off valve block does not exceed 0.1 ppmw (mg / kg).
Gas booster unit is fully automated and housed in individual all-weather shelter of container type equipped with life support systems (heating, ventilation, and lighting). According to safety requirements, BCS is equipped with fire detection, gas detection, alarm, and fire extinguishing systems.
Block-type gas treatment station, which is part of the ENERGAS system, is used to measure the volume, filter, reduce and stabilize the pressure of gas. BGTS was put into operation in February this year and at this stage (before the GTU launch) provides fuel to the boiler house of power supply complex.
This unit with a throughput of 9,317 m3 / h is equipped with highly efficient coalescing filters, reduction module, units for process and commercial metering of gas, and bilinear subassembly for fuel quality control.
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Among the priorities of the ENERGAS Group are production, comprehensive commissioning and maintenance of gas treatment and compression units for generating facilities in the electric power industry, oil and gas complex and industrial enterprises. The ENERGAS process equipment today provides high-quality fuel for 230 gas turbines and gas-reciprocating units with a total capacity of over 6.7 GW.
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