27 May 2022

The experts of the ServicENERGAS (part of ENERGAS Group) performed the maintenance of the booster compressor station operating as part of the complex for testing gas turbine units (GTU) of JSC Nevsky Zavod. This BCS feeds the testable turbines with gas with specified parameters in terms of purity, temperature, pressure and flow rate.

The frequency of BCS maintenance depends here on the number of starts. Comprehensive maintenance (according to Regulations-8000) was carried out after reaching 200 starts performed as part of GTU tests.

In the course of service and technical measures, the station was upgraded. The oil system of BCS now uses ester synthetic oil of the new generation ESTSYN, which is specially created for units made based on screw compressors. The oil of ESTSYN CE100 brand ensures efficient operation of such units, increases their reliability and service life.



At Nevsky Plant (REP Holding, St. Petersburg), this BCS for fuel gas was commissioned by ENERGAS in February 2016. Equipment was devised to operate in conditions of various tests duration and high intensity of starts.

The project requirements for the gas purity are ensured by the multistage filtration system of BCS: inlet protective strainer, gas-oil separator of the 1st stage of purification and coalescing (safety) filter of the 2nd stage. Thus, compliance of the fuel with the set parameters is guaranteed: the content of impurities in gas at the outlet is no more than 2 ppmw (mg / kg), the degree of purification from solid particles larger than 10 microns and liquid fraction is 100%.

Highly efficient compressor module gives a high gas compression ratio:
- Minimum pressure at the suction is 0.55 MPa,
- Pressure at the delivery line is provided in the range of 1.5 ... 4.3 MPa – depending on the type and settings of conjugated GTU and the testing algorithm.

The process flow scheme provides for the stable maintenance of the calculated fuel temperature. The delivery line of the BCS is equipped with a heat exchanger that cools the working medium and guarantees the optimum gas supply temperature (not higher than +50°C).

The maximum volume productivity of compressor station is 11,000 m3 / h. The actual gas flow rate depends on the capacity and dynamics of the load of associated turbine, and is controlled in the range from 0 to 100% of nominal. For this purpose, a special two-tier productivity regulation system is used, which allows the BCS to respond as quickly and correctly as possible to changes in the operating mode of the testable GTU and fluctuations in the parameters of the inlet pipeline, as well as, if necessary, to operate the station in the gas recirculation mode.

Packaged BCS is fully automated and is housed in its own all-weather shelter, equipped with life support systems (heating, ventilation, and lighting). According to safety requirements, process unit is equipped with fire detection, gas detection, alarm and fire fighting systems.



REFERENCE:

Among the priority areas of activity 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.

Today, the ENERGAS process equipment provides high-quality fuel for 220 gas turbines and gas-reciprocating units with a total capacity of over 6.7 GW.

The launch of the BCS at the Nevsky Plant is the one of four projects completed for power engineering enterprises. By specially devised compressor stations there are also equipped gas turbines test benches of PJSC Proton - Perm Motors, PJSC UEC - Ufa Motor-Building Production Association and JSC UEC - Gas Turbines.

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