A new gas compressor station has been prepared for commissioning at Minsk CHPP-3
22 March 2021A new booster compressor station (BCS-2) has been prepared for commissioning at the site of the combined cycle gas turbine unit of Minsk CHPP-3 (a branch of RUE Minskenergo), designed to supply the CCGT with fuel gas with pre-set parameters for purity, pressure, temperature and flow rate.
The equipment underwent comprehensive testing under load – in conjunction with an Alstom GT13E2 gas turbine unit. 72-hour tryout was carried out stepwise under various turbine capacity modes; during testing, BCS-2 has operated normally, without any complaints. The station confirmed the main design characteristics and achieved guaranteed functional indicators:
- Capacity is 38,160 kg / h;
- Rated delivery pressure is 2.75 MPa;
- Gas fuel temperature at the BCS outlet is +50°C;
- Range of volume capacity control is 0...100%;
- Vibration state of the gas compressor – in accordance with the manufacturer's technical documentation;
- Sound pressure level at a distance of 1 m from the BCS-2 is no more than 80 dBA.
The project is being carried out as part of the upgrade (enlargement) of CCGT gas treatment system, which was originally based on BCS-1 manufactured by VPT Kompressoren GmbH.
BCS-2, supplied by ENERGAS, is made on the basis of a screw oil-filled compressor and is a block-modular process unit with a maximum integration of the components on a single frame. The station is placed in its own sound-absorbing shelter which equipped with the necessary engineering systems, including life support and safety systems.
This BCS is the second most powerful among all 234 gas compressor stations of screw type, put into operation by ENERGAS. Unit will compress fuel to the required designed values and feed it to the gas turbine of CCGT. Gas flow rate depends on the dynamics of changes in the turbine load; to control the capacity, a special two-circuit regulation system is applied.
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, the first circuit is combined with a gas recirculation system (second circuit), that allows you to respond quickly and correctly on a sharp change in load during transient operating modes of conjugated turbine.
Fuel gas filtration system is composed of gas-oil separator of the 1st stage of purification and the coalescing (safety) filter of the 2nd stage. Residual content of impurities in gas at the outlet of the BCS is not more than 1 ppmw (mg / kg). The process flow scheme and configuration of elements of the compressor station provide for stable maintenance of the project temperature of fuel.
The oil system of BCS-2 uses ester synthetic oil of the new generation ESTSYN, which is specially created for screw gas booster units. The oil of ESTSYN CE100 brand ensures efficient operation of such units, increases their reliability and service life.
The new equipment also includes an air compressor station. The modular auxiliary air CS, housed in a separate block-box, provides compressed, dry and pure air for the pneumatic components of the BCS-2.
In addition to the fuel gas treatment system, the gas supply scheme for the CCGT is being upgraded. BCS-1 and BCS-2 will function alternately, evenly distributing the operational load. When one unit is turned on, the second one switches to the hot-standby mode. Their own ACSs implement launch (and preparation for start), shutdown, and maintaining the optimal operating mode; they control the working characteristics and gas pollution in the process compartments of BCSs; they provide automatic protections and alarm; they handle the parameters of the main processes and emergency events with the issuance of information to the operator panel via a standard exchange protocol.
ENERGAS has equipped the compressor equipment with a two-tier automated control and regulation system (ACRS), which combined local ACS of both BCS and integrated them into the automated processes control system of a facility. Remote control (operator workstation - WKS) is placed in the control room of the CCGT.
The ACRS made based on microprocessor technology, using modern software, switching equipment and communication channels and protocols. Control from the upper level is carried out in full, similar to the control "in site".
The comprehensive commissioning of the BCS-2, air CS and ACRS (erection supervision, start-up and adjustment works, individual and integrated tests), as well as training of the operating personnel were fulfilled by the specialists of the ServicENERGAS (ENERGAS Group). The implementation of the project increases the reliability of fuel supply to the combined-cycle power unit and ensures its uninterrupted operation in all modes and under any climatic conditions.
In the power grid of the Republic of Belarus, Minsk CHPP-3 has been operating since 1951, its installed capacity today is 542 MW. MCHPP-3 is part of a single production and process complex for the generation, transmission and distribution of thermal and electric energy.
Highly efficient CCGT-230 with an electric capacity of 222 MW and a thermal capacity of 136 Gcal/h was created on the basis of the GT13E2 gas turbine (Alstom), the HRSG/DP01.1 waste heat boiler (SES ENERGY) and the T-53/67-8.0 (UTW) steam turbine. The power generating unit efficiency is 52.5%. The main and reserve fuel is natural gas.
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