Thermal tests of the 9FB gas turbine unit produced by general electric

In July 2011, a PGU-410 combined-cycle power plant was commissioned at the Srendeuralsk district power station owned by Enel OGK-5. The main equipment of this power plant includes an MS9001FB gas turbine unit (produced by GE Energy Power Plant Systems, the United States), a heat recovery boiler (produced by Nooter/Ericsen, the United States), and a >Skoda KT-140-13.3 two-cylinder condensing and cogeneration turbine with steam reheating. In 2011–2012, specialists of the All-Russia Thermal Engineering Institute carried out thermal tests of this power plant in a wide range of loads and under different external conditions. The results from thermal tests of the MS9001FB gas turbine unit are presented and analyzed. The actual indicators of the gas turbine unit and its elements are determined and their characteristics are constructed.     

Substantiation of the cogeneration turbine unit selection for reconstruction of power units with a T-250/300-23.5 turbine

The selection of a cogeneration steam turbine unit (STU) for the reconstruction of power units with a T-250/300-23.5 turbine is substantiated by the example of power unit no. 9 at the cogeneration power station no. 22 (TETs-22) of Mosenergo Company. Series T-250 steam turbines have been developed for combined heat and power generation. A total of 31 turbines were manufactured. By the end of 2015, the total operation time of prototype power units with the T-250/300-23.5 turbine exceeded 290000 hours. Considering the expiry of the service life, the decision was made that the reconstruction of the power unit at st. no. 9 of TETs-22 should be the first priority. The main issues that arose in developing this project—the customer’s requirements and the request for the reconstruction, the view on certain problems of Ural Turbine Works (UTZ) as the manufacturer of the main power unit equipment, and the opinions of other project parties—are examined. The decisions were made with account taken of the experience in operation of all Series T-250 turbines and the results of long-term discussions of pressing problems at scientific and technical councils, meetings, and negotiations. For the new power unit, the following parameters have been set: a live steam pressure of 23.5 MPa and live steam/reheat temperature of 565/565°C. Considering that the boiler equipment will be upgraded, the live steam flow is increased up to 1030 t/h. The reconstruction activities involving the replacement of the existing turbine with a new one will yield a service life of 250000 hours for turbine parts exposed to a temperature of 450°C or higher and 200000 hours for pipeline components. Hence, the decision has been made to reuse the arrangement of the existing turbine: a four-cylinder turbine unit comprising a high-pressure cylinder (HPC), two intermediate pressure cylinders (IPC-1 & 2), and a low-pressure cylinder (LPC). The flow path in the new turbine will have active blading in LPC and IPC-1. The information is also presented on the use of the existing foundations, the fact that the overall dimensions of the turbine unit compartment are not changed, the selection of the new turbine type, and the solutions adopted on the basis of this information as to LPC blading, steam admission type, issues associated with thermal displacements, etc.     

Development of a thermal scheme for a cogeneration combined-cycle unit with an SVBR-100 reactor

At present, the prospects for development of district heating that can increase the effectiveness of nuclear power stations (NPS), cut down their payback period, and improve protection of the environment against harmful emissions are being examined in the nuclear power industry of Russia. It is noted that the efficiency of nuclear cogeneration power stations (NCPS) is drastically affected by the expenses for heat networks and heat losses during transportation of a heat carrier through them, since NPSs are usually located far away from urban area boundaries as required for radiation safety of the population. The prospects for using cogeneration power units with small or medium power reactors at NPSs, including combined-cycle units and their performance indices, are described. The developed thermal scheme of a cogeneration combined-cycle unit (CCU) with an SBVR-100 nuclear reactor (NCCU) is presented. This NCCU should use a GE 6FA gasturbine unit (GTU) and a steam-turbine unit (STU) with a two-stage district heating plant. Saturated steam from the nuclear reactor is superheated in a heat-recovery steam generator (HRSG) to 560–580°C so that a separator–superheater can be excluded from the thermal cycle of the turbine unit. In addition, supplemental fuel firing in HRSG is examined. NCCU effectiveness indices are given as a function of the ambient air temperature. Results of calculations of the thermal cycle performance under condensing operating conditions indicate that the gross electric efficiency η _{el NCCU} ^gr of = 48% and N _{el NCCU} ^gr = 345 MW can be achieved. This efficiency is at maximum for NCCU with an SVBR-100 reactor. The conclusion is made that the cost of NCCU installed kW should be estimated, and the issue associated with NCCUs siting with reference to urban area boundaries must be solved.     

Economic effectiveness of using super-high values of initial steam parameters in cogeneration power units

The present paper reports the results of numerical investigations into both thermodynamic and economic components of the effect of an increase in the initial steam parameters to super-high values for cogeneration power units. As an initial variant, the heat flow diagram of the turbine plant equipped with the T-250/300-23.5 TMZ steam turbine was adopted. In the course of investigations, the ranges of initial steam pressure p ₀ = 23.5–30.0 MPa, steam temperature t ₀ = 540–600°C, and steam pressure after single reheat p _rh = 3.6–4.5 MPa were considered. In the calculations of the thermodynamic efficiency, the extent of the effect of an increase in steam parameters on the out and the electric efficiency of a power unit when a cogeneration steam turbine operates in condensing and heat-extraction modes were estimated. In the economic part of the calculations, indicators of the commercial efficiency of investments into appropriate projects and the levels of total investment and production costs were determined. The results of the calculations made it possible to estimate the optimum level of super-high values of the initial steam parameters for a cogeneration power unit equipped with the T-280/335-26.1 steam turbine. The best indicators of the commercial efficiency were achieved for the variant with the following parameters of live steam and steam in the reheater: p ₀ = 26.1 MPa, p _rh = 4.035 MPa, t ₀/t _rh = 575/575°C. In this case, the following values were obtained: 42.56% gross efficiency, 40.94% net efficiency, 334 MW rated capacity in the condensing operation mode, and 279.1 MW in the heat-extraction mode at Q _T = 1381.6 GJ/h (330 Gcal/h). The use of higher steam parameters would result in a significant increase in the cost of projects. It has been shown that the restoration of initial design values of both live steam temperature and its temperature after reheat t ₀/t _rh = 565/560°C may be advisable at the upgrading of power units equipped with T-250/300-23.4 steam turbines.     

基于能耗特性分析的双抽燃煤机组供汽优化

以优化运行、降低能耗为研究目标,考虑到大型燃煤机组热电联产变工况供汽运行模式的复杂性,建立了供热机组能耗分析模型.以某1 GW双抽机组为例,对9种供汽方案进行了能耗特性分析.结果表明,电负荷较低时,最优的供汽方式为冷再供中压、冷再供低压运行方式;电负荷较高时,最优的供汽方式为冷再供中压、中排供低压运行方式.在典型工况(...     

Studying the advisability of using gas-turbine unit waste gases for heating feed water in a steam turbine installation with a type T-110/120-12.8 turbine

Results of calculation studying of a possibility of topping of a steam-turbine unit (STU) with a type T-110/120-12.8 turbine of the Urals Turbine Works (UTZ) by a gas-turbine unit (GTU) of 25-MW capacity the waste-gases heat of which is used to substitute for high-pressure bleedoffs of STU is considered. It is shown that this makes it possible to increase electric power up to 130 MW and reduce fuel consumption by 2.5–4.0% while operating in the condensing mode and by 1.5–2.0% in the cogenerating mode.     

Ways for Improving Efficiency and Reliability of Steam Turbines at Nuclear Power Stations

The current state and ways for improving the effectiveness of steam turbine units at nuclear power stations (NPS) are examined. The specifics of NPS turbines is described. The comparison of NPS steam turbine performance with the performance of steam turbines at thermal power stations (TPS) demonstrates that power units of NPSs are much poorer in effectiveness due to relatively low steam conditions at the inlet and the presence of wet steam already in the first stages of turbines. A decrease in the relative internal efficiency of NPS turbines results from the enhanced negative effect of wetness in the expansion process: in modern NPS turbines, more than two-thirds of the heat drop is spent in the two-phase region, while less than one fourth in TPS turbines. It is demonstrated that the effectiveness of NPS steam turbine units can be increased drastically in the future only through a considerable rise in the turbine inlet steam conditions. This can be achieved by using a heat carrier at supercritical conditions in the NPS reactor. The dependence of the effectiveness of NPS modern turbines on the turbine inlet steam conditions in the applicable pressure ranges of the saturated steam and vacuum in the condenser, as well as on the turbine exhaust area, is examined. For a 1000 MW turbine, increasing the inlet pressure from 6.0 to 8.0 MPa raises the turbine power and efficiency by 3.5%. At a condensing turbine outlet pressure ranging from 2.5 to 7.5 kPa and a constant velocity downstream of the last stage, the turbine power and efficiency can be increased by 7%. The importance of the exhaust area for the turbine effectiveness is revealed. Alternative designs of the flowpath in a low-pressure cylinder are analyzed. A unique configuration of a steam turbine unit with two-stage moisture separation is proposed. The comparison of high-speed turbines with low-speed ones was performed. It is demonstrated that the efficiency of the examined turbines is nearly the same within the accuracy of design calculations and the test results, and it is slightly higher for low-speed turbines due to lower losses with outlet velocity.     

All-regime combined-cycle plant: Engineering solutions

The development of distributed power generation systems as a supplement to the centralized unified power grid increases the operational stability and efficiency of the entire power generation industry and improves the power supply to consumers. An all-regime cogeneration combined-cycle plant with a power of 20–25 mW (PGU-20/25T) and an electrical efficiency above 50% has been developed at the All-Russia Thermal Engineering Institute (ATEI) as a distributed power generation object. The PGU-20/25T two-circuit cogeneration plant provides a wide electrical and thermal power adjustment range and the absence of the mutual effect of electrical and thermal power output regimes at controlled frequency and power in a unified or isolated grid. The PGU-20/25T combined-cycle plant incorporates a gas-turbine unit (GTU) with a power of 16 MW, a heat recovery boiler (HRB) with two burners (before the boiler and the last heating stage), and a cogeneration steam turbine with a power of 6/9 MW. The PGU-20/25T plant has a maximum electrical power of 22 MW and an efficiency of 50.8% in the heat recovery regime and a maximum thermal power output of 16.3 MW (14 Gcal/h) in the cogeneration regime. The use of burners can increase the electrical power to 25 MW in the steam condensation regime at an efficiency of 49% and the maximum thermal power output to 29.5 MW (25.4 Gcal/h). When the steam turbine is shut down, the thermal power output can grow to 32.6 MW (28 Gcal/h). The innovative equipment, which was specially developed for PGU-20/25T, improves the reliability of this plant and simplifies its operation. Among this equipment are microflame burners in the heat recovery boiler, a vacuum system based on liquid-ring pumps, and a vacuum deaerator. To enable the application of PGU-20/25T in water-stressed regions, an air condenser preventing the heat-transfer tubes from the risk of covering with ice during operation in frost air has been developed. The vacuum system eliminates the need for an extraneous source of steam for the startup of the PGU-20/25T plant. The vacuum deaerator provides prestartup deaeration and the filling of the entire condensate feed pipeline with deaerated water and also enables the maintenance of the water temperature before the boiler at a level of no lower than 60°C and the oxygen content at a level of no higher than 10 μg/L during operation under load. The microflame burners in the heat recovery boiler enable the independent adjustment of the electrical power and the thermal power output from the PGU-20/25T plant. All the innovative equipment has been tested on experimental prototypes.     

Starting the water treatment system of the 410-MW combined-cycle plant at the Krasnodar cogeneration station

The process diagram of a water treatment plant constructed on the basis of integrated membrane technologies with the use of two-stage reverse osmosis for the PGU-410 power unit at the Krasnodar cogeneration station is presented.     

Diagrams of regimes of cogeneration steam turbines for combined-cycle power plants

General considerations regarding the form of the steam-consumption diagram for a three-loop cogeneration-type combined-cycle plant are formulated on the basis of well-known approaches. According to these considerations the diagram should consist of the main chart and numerous corrections that must be taken into account in using the diagram. The steam-consumption diagram of the T-113/145-12.4 steam turbine for the PGU-410 combined-cycle plant at the Krasnodar cogeneration station is presented.     

汽轮机中间分隔轴封漏汽对热耗率影响的分析与计算

利用小偏差理论,分析了汽轮机定主蒸汽流量时,中间分隔轴封漏汽量变化对汽轮机各缸做功量、过再热吸热量以及热耗率的影响。结果表明,当中间分隔轴封漏汽量变化时,汽轮机高压缸做功量与再热吸热量变化较大,中低压缸做功量变化较小。同时,对某台超临界660 MW机组进行了变工况计算。结果显示,当中间分隔轴封漏汽量增加时,汽轮机各段做功量、再热吸热量及热耗率近似线性变化,各部分的变化情况与理论分析结果一致,漏汽主要是通过影响高压缸做功和再热吸热量来改变热耗率,但由于低压缸做功量占汽轮机总功量的比例较大,其变化对热耗率的影响也不可忽视。     

大型天然气联合循环电厂对汽轮机的选择

为适应联合循环蒸汽系统优化的需要和机组快速启动的要求，选择合适结构形式的汽轮机至关重要。文章阐述联合循环汽轮机的特点，对联合循环汽轮机的汽缸和排汽形式进行分析比较，推荐适合于三压再热蒸汽系统最合理的汽轮机。     

汽轮机状态估计建模与数据校验

提出了在汽轮机状态估计检测中应用结合Givens正交变换的Levenberg-Marquardt(LM)算法的思想.将LM算法应用于300 MW再热凝汽式汽轮机,应用结果表明,在大范围的测量误差和测量冗余比率下,结合Givens正交变换的LM算法进行汽轮机状态估计检测具有良好的稳定性.     

Some matters concerned with selecting steam parameters and process-circuit solutions to optimize the parameters of steam turbine equipment and engineering design developments

The possibility and advantages of increasing steam pressure in the steam-turbine low-pressure loop for combined-cycle power plants are considered. The question about the advisability of developing and manufacturing steam turbines for being used in combined-cycle power units equipped with modern class F gas turbines for supercritical and ultrasupercritical steam parameters is raised.     

100MW机组连通管打孔抽汽供热改造方案与实施

介绍了北京高井热电厂100MW纯凝汽式汽轮机的供热改造方案，在保证汽轮机的安全性，并兼顾机组以后进行通流改造时与现有供热系统和设备相匹配的前提下，实施了连通管打孔抽汽供热改造。分析了供热改造对机组高低压缸的影响，进行了机组安全校核计算，并设置了相应保护，如低压缸最小流量控制、DN1000快关调节蝶阀控制等。改造后电厂的热经济性大大提高，1台机组一年可节省约1178．4万元。     

Delivery-water heaters used in cogeneration steam turbine units produced by Ural Turbine Works

The designs of horizontal delivery-water heaters used as part of steam-turbine units equipped with the cogeneration turbines developed at Ural Turbine Works are described. The design features of the apparatuses relating to the specific nature of their operation as part of combined-cycle plants equipped with cogeneration turbines are pointed out.     

Concept of turbines for ultrasupercritical,supercritical, and subcritical steam conditions

The article describes the design features of condensing turbines for ultrasupercritical initial steam conditions (USSC) and large-capacity cogeneration turbines for super- and subcritical steam conditions having increased steam extractions for district heating purposes. For improving the efficiency and reliability indicators of USSC turbines, it is proposed to use forced cooling of the head high-temperature thermally stressed parts of the high- and intermediate-pressure rotors, reaction-type blades of the high-pressure cylinder (HPC) and at least the first stages of the intermediate-pressure cylinder (IPC), the double-wall HPC casing with narrow flanges of its horizontal joints, a rigid HPC rotor, an extended system of regenerative steam extractions without using extractions from the HPC flow path, and the low-pressure cylinder’s inner casing moving in accordance with the IPC thermal expansions. For cogeneration turbines, it is proposed to shift the upper district heating extraction (or its significant part) to the feedwater pump turbine, which will make it possible to improve the turbine plant efficiency and arrange both district heating extractions in the IPC. In addition, in the case of using a disengaging coupling or precision conical bolts in the coupling, this solution will make it possible to disconnect the LPC in shifting the turbine to operate in the cogeneration mode. The article points out the need to intensify turbine development efforts with the use of modern methods for improving their efficiency and reliability involving, in particular, the use of relatively short 3D blades, last stages fitted with longer rotor blades, evaporation techniques for removing moisture in the last-stage diaphragm, and LPC rotor blades with radial grooves on their leading edges.     

Using computer-aided design systems for developing layouts of steam-turbine units

Results of work on developing a system of computer-aided tools for designing the layouts of steamturbine units are described. An example illustrating how this technology is implemented for a steam-turbine unit equipped with a T-50/60-8.8 cogeneration turbine is given.     

Process-circuit and layout solutions for steam-turbine units and performance efficiency of thermal power plants

Criteria for evaluating process-circuit and layout solutions adopted in designing steam-turbine units are presented together with their values for a number of steam-turbine units produced by the Ural Turbine Works. The presented values of the criteria are recommended for being used as tentative ones in designing new thermal power plants or in upgrading them with the use of steam turbine units operating both as basic power installations and as part of combined-cycle power plants. The influence of process-circuit and layout solutions adopted for steam-turbine units on the effectiveness of thermal power plant construction and plant performance efficiency is shown.