26 April 2011

A combined cycle gas turbine unit has been commissioned at the Astrakhan SDPP site (LUKOIL-Astrakhanenergo), which became the first new-generation facility built by OJSC LUKOIL in the South of Russia. CCGT-110 will replace the power plant that had worked out its resource, and the obsolete equipment will be dismantled.

Investments in the reconstruction of AstraSDPP came to 4.6 billion rubles. The implementation of the project not only increased the electrical capacity – also, the technical, economic and environmental characteristics of the facility have been significantly improved.

- Efficiency factor increased from 29% to 51%;
- Annual electricity generation will be doubled;
- Specific reference fuel consumption will be decreased almost by 2 times;
- Emissions of nitrogen oxides and carbon monoxide into the atmosphere will be decreased by 2-3 times.

Overall, the commissioning of CCGT-110 will minimizes the negative impact on the environment, increases the generation of electricity in the power grid of the Astrakhan Region, optimizes the city heating system, increases the reliability of energy supply to the housing complex and industrial enterprises, which will create conditions for the development of infrastructure in Astrakhan.

Combined-cycle plant is equipped with efficient equipment with high technical indicators. There are two air-craft derivative GE gas turbine units – GTUs of the type LM6000 PF DLE with a power boost system SPRINT. This technology helps to reduce the temperature in the combustion chamber of the turbine due to the spraying of fine-dispersed water dust. In this case, the compressor compresses and supplies more air, that increases the output capacity of the turbine.

Each GTU is equipped with a combustion chamber type DLE with a system for dry suppression of nitrogen oxide emissions in the entire power range. This allows maintaining a low level of emissions even with incomplete loading of the turbine. The unit electric capacity of gas turbine units at CCGT-110 is 46.64 MW.

From turbines, exhausted hot gases (fuel combustion products) with a temperature of about 450°C enter waste-heat boilers of two pressures KGT-44/4.6-435-13/0.5-210 (Belenergomash). Two WHBs with a capacity of 58 t / h generate steam for secondary power generation.

The steam produced in the WHBs is sent to a steam turbine unit (STU) based on a stationary cogeneration turbine T-14/23-4.5/0.18 manufactured by the Kaluga Turbine Plant. The maximum electric capacity of the STU is 23.8 MW. Part of the steam in a controlled mode is taken from the STU (heating offtake) to heat the network water, which then supplied to the city network for heating and hot water supply.

Therefore, the technologies used in the combined-cycle plant provide combined energy generation, high fuel efficiency and overall facility efficiency. The designed electric capacity of the CCGT is 110 MW (actual - 121 MW), thermal capacity – 66 Gcal / h. Local natural gas is used as the main and reserve fuel.

The CCGT-110 also includes a booster compressor station. BCS from ENERGAS consists of two modular compressor units (CUs) and serves to compress and feed fuel gas to the turbines of combined-cycle plant. CUs were made based on screw oil-filled compressors, operation mode as a part of the CCGT is uninterrupted with scheduled shutdowns for maintenance.

High-tech equipment provides a high compression ratio: the gas inlet pressure is 1 MPa, the delivery pressure is 4.8 MPa (limited by the settings of gas turbine units).



The rated capacity of each CU is 13,000 m3 / h. Gas flow rate depends on the dynamics of changes in the load of the associated GTU, and is controlled in the range from 0 to 100%. For this purpose, a special two-circuit regulation system is applied.

The first circuit (control by the compressor slide 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 turbines.

The process flow scheme of the BCS provides for stable maintenance of the designed gas temperature necessary for the normal operation of turbines. The optimal fuel supply temperature was set by the manufacturer of GTU (GE) and is +60°C.

Project requirements for the purity of fuel gas are ensured 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.

Compressor units are located in their own shelters of container type, equipped with life support systems. According to safety requirements, each CU is equipped with fire detection, gas detection, alarm systems, fire-extinguishing systems. BCS is fully automated, local ACSs of units are integrated with the upper level of the automated process control system of facility.

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