Comparison of thermal testing of MS9001FA type GTPs at shatura and nizhnevartovsk GRES

Domestic power plants use combined-cycle plants in which a gas-turbine plant (GTP) and a steam turbine rotate a common electric generator. In this instance, it is impossible to measure the power of each of them, so we have to resort to some assumptions. We have succeeded to check the validity of these assumptions and possible errors of their application testing combined-cycle plants (CCP) with the same GTP and a steam turbine but operating each on its own electrical generator. Comparative tests of a MS901FA GTP of the PGU-400 power-generating unit commissioned at Shatura GRES (a thermal power station) and a GTP of the same type installed at Nizhnevartovsk GRES were performed. As a result of these tests, dependences of the electric power of both gas-turbine plants and a turbine outlet temperature on the inlet temperature were obtained. A relation of the GTP efficiency, heat and air rate on the load are determined, and characteristics of compressors and turbines of both GTPs are defined. The performed tests have confirmed the accuracy of the determined characteristics of the two GTPs using both a direct measurement of net power (Nizhnevartovsk GRES) and an indirect measurement (Shatura GRES).     

Combined cycle plants: Yesterday,today, and tomorrow (review)

Gas turbine plants (GTP) for a long time have been developed by means of increasing the initial gas temperature and improvement of the turbo-machines aerodynamics and the efficiency of the critical components air cooling within the framework of a simple thermodynamic cycle. The application of watercooling systems that were used in experimental turbines and studied approximately 50 years ago revealed the fundamental difficulties that prevented the practical implementation of such systems in the industrial GTPs. The steam cooling researches have developed more substantially. The 300 MW power GTPs with a closedloop steam cooling, connected in parallel with the intermediate steam heating line in the steam cycle of the combined cycle plant (CCP) have been built, tested, and put into operation. The designs and cycle arrangements of such GTPs and entire combined cycle steam plants have become substantially more complicated without significant economic benefits. As a result, the steam cooling of gas turbines has not become widespread. The cycles—complicated by the intermediate air cooling under compression and reheat of the combustion products under expansion and their heat recovery to raise the combustion chamber entry temperature of the air—were used, in particular, in the domestic power GTPs with a moderate (700–800°C) initial gas turbine entry temperature. At the temperatures being reached to date (1300–1450°C), only one company, Alstom, applies in their 240–300 MW GTPs the recycled fuel cycle under expansion of gases in the turbine. Although these GTPs are reliable, there are no significant advantages in terms of their economy. To make a forecast of the further improvement of power GTPs, a brief review and assessment of the water cooling and steam cooling of hot components and complication of the GTP cycle by the recycling of fuel under expansion of gases in the turbine has been made. It is quite likely in the long term to reach the efficiency for the traditional GTPs of approximately 43% and 63% for PGUs at the initial gas temperature of 1600°C and less likely to increase the efficiency of these plants up to 45% and 65% by increasing the gas temperature up to 1700°C or by application of the steam cooling in the recycled fuel cycle.     

燃气-蒸汽联合循环进气冷却系统对机组性能影响研究

以PG9171E型燃气-蒸汽联合循环电厂为研究对象,对联合循环及进气冷却系统进行建模。分析了该机组加装进气冷却系统后燃机侧、余热锅炉侧和蒸汽轮机侧系统性能的变化情况。结果表明该E型联合循环机组加装进气冷却系统后,进气温度每降低10 ℃,燃机侧出力上升约9%,余热锅炉效率下降约3%。通过蒸汽参数的调整充分利用余热资源能使汽轮机多出力2.1 MW,联合循环效率上升约0.3%。     

PG9171E型燃气轮机温度控制分析

燃气轮机进气温度影响燃机的输出功率和热效率,温度控制最终在于控制燃气轮机进气温度。利用燃气轮机进气温度和燃气轮机排气温度的关系,测量燃气轮机排气温度,间接求得燃气轮机进气温度,引入控制逻辑对燃气轮机排气温度的各项保护和控制曲线作了分析。并且研究了外部环境条件对温度控制的影响,基于实际工作数据,对温度控制参数的调整给出说明。分析表明：PG9171E型燃气轮机主要参数测点的准确性和工作环境的变化对其温度控制有着重要影响。     

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.     

Combustion of bark and wood waste in the fluidized bed boiler

In the Energy Development Strategy of Russia for the Period until 2035, special attention is paid to increased use of local fuel kinds—one of which is biofuel, in particular, bark and wood waste (BWW)— whose application at thermal power plants in Russia has been not developed due to the lack of appropriate technologies mastered by domestic energy mechanical engineering. The article describes the experience of BWW combustion in fluidized bed boilers installed on the energy objects of northern European countries. Based on this, reference points were defined (it is the section of boiler air-gas path where initially the approximate temperatures are set), making it possible to carry out a thermal design of a boiler and ensure its operation reliability. Permissible gas temperature at the furnace outlet at BWW combustion amounted to 950–1000°C. Exit gas temperature, depending on the implementation of special measures on protection of air heater from corrosion, amounted to 140–190°C. Recommended hot air temperature is within the range of 200–250°C. Recommendations for determining the boiler furnace dimensions are presented. Based on the presented reference temperatures in the main reference points, the thermal design of hot water boiler of KV-F-116-150 type with 116 MW capacity was carried out. The analysis of the results and comparison of designed boiler characteristics with operating energy boilers, in which a fuel is burned in a fluidized bed, were carried out. It is shown that, with increasing the boiler capacity, the ratio of its heating power Q to the crosssectional area of furnace chamber F rises. For power-generating boiler of thermal capacity of 100 MW, the ratio is within 1.8–2.2MW/m². The boiler efficiency exceeds 90% in the range of changes of exit gas temperature typical for such equipment.     

燃气-蒸汽联合循环进气冷却系统技术经济分析

燃气-蒸汽联合循环机组燃气轮机输出功率受环境气温影响明显,对进口空气(进气)进行冷却,可提高输出功率。介绍了一种两种工况交替运行的燃气轮机进气冷却系统:在进气温度高、投用进气冷却工况时,能有效增加燃气轮机输出功率;在进气温度低、投用低压加热器工况时,通过回收烟气余热,增加余热锅炉蒸汽蒸发量,提高汽轮机功率,实现烟气余热的全年回收利用。技术经济分析和初步运行结果表明,该进气冷却系统具有显著的经济效益。     

Prospects for the development of coal-steam plants in Russia

Evaluation of the technical state of the modern coal-fired power plants and quality of coal consumed by Russian thermal power plants (TPP) is provided. Measures aimed at improving the economic and environmental performance of operating 150–800 MW coal power units are considered. Ways of efficient use of technical methods of NO _x control and electrostatic precipitators’ upgrade for improving the efficiency of ash trapping are summarized. Examples of turbine and boiler equipment efficiency upgrading through its deep modernization are presented. The necessity of the development and introduction of new technologies in the coal-fired power industry is shown. Basic technical requirements for a 660–800 MW power unit with the steam conditions of 28 MPa, 600/600°C are listed. Design solutions taking into account features of Russian coal combustion are considered. A field of application of circulating fluidized bed (CFB) boilers and their effectiveness are indicated. The results of development of a new generation coal-fired TPP, including a steam turbine with an increased efficiency of the compartments and disengaging clutch, an elevated steam conditions boiler, and a highly efficient NO _x /SO₂ and ash particles emission control system are provided. In this case, the resulting ash and slag are not to be sent to the ash dumps and are to be used to a maximum advantage. Technical solutions to improve the efficiency of coal gasification combined cycle plants (CCP) are considered. A trial plant based on a 16 MW gas turbine plant (GTP) and an air-blown gasifier is designed as a prototype of a high-power CCP. The necessity of a state-supported technical reequipment and development program of operating coal-fired power units, as well as putting into production of new generation coal-fired power plants, is noted.     

整体煤气化联合循环系统变工况特性研究

采用ThermoFlex软件建立了200 MW级整体煤气化联合循环(integrated gasification combined cycle,IGCC)系统模型,从系统的角度出发计算研究了200 MW级IGCC系统的变工况特性。详细讨论了燃气轮机负荷、大气环境条件和整体空分系数对系统性能的影响。结果表明,燃气轮机采用压气机进口可转导叶角度调节–等燃气透平初温的调节方式降负荷时,燃气透平排气温度先增加后降低,而系统效率先缓慢降低后快速降低。随大气温度增加,燃气轮机功率、汽轮机功率和系统净功率均下降。在大气温度不变的条件下,大气压力对燃气轮机效率和系统净效率基本没有影响。增加整体空分系数可提高系统净效率,却使系统净功率降低。     

300MW汽轮发电机组增容改造后的验收试验探讨

针对某300 MW汽轮发电机组有关单位提供的增容改造验收试验中的数据及结论,在分析现行各种标准及规范中对发电机组各主机的容量匹配要求的基础上,提出了机组增容改造后验收试验中对发电机组各个主机试验应达到的具体要求。分析结果表明,机组在TRL工况下的出力试验及VWO/BMCR工况下的进汽量/蒸发量裕度验证试验是验收试验中必须达到的要求,而采用VWO工况下比铭牌出力留有5%裕量的标准需要重新考虑。     

Evaluating the Effect from Constructing Binary Geothermal Power Units Based on Spent Petroleum and Gas Boreholes in the South Regions of Russia

The article substantiates the possibility of efficiently harnessing the geothermal resources available in the North Caucasian region through constructing binary geothermal power plants (GeoTPPs) using idle petroleum and gas wells. The power capacities of GeoTPPs are evaluated, and the basic characteristics of these power plants in case of constructing them in the promising areas are determined. The overall useful GeoTPP capacity equal to approximately 330 MW can be obtained from using the entire fleet of idle wells available in these areas. Diagrams confirming the possibility of reaching the optimal flowrate of geothermal heat carrier circulating in the geothermal circulation system loop are presented. This flowrate corresponds to a binary GeoTPP’s maximal useful power output. The article shows, taking the Ternair geothermal field as an example, that it is inefficient to use medium-enthalpy thermal waters for generating energy at a binary GeoTPP involving reinjection of a spent heat carrier. It is shown that good prospects can be expected from applying a hybrid geothermal and combined-cycle technology, by means of which it is possible to use lowenthalpy (80–100°С) thermal waters for generating electricity in a highly efficient manner. In accordance with such technology, geothermal heat is used in the binary GeoTPP cycle for heating low-boiling working fluid to its evaporation temperature. The working fluid is evaporated and superheated by using the heat of exhaust gases from a gas turbine power unit. Owing to combined use of the thermal water heat potential and the heat of exhaust gases from a gas turbine power plant in a hybrid process system, it becomes possible to obtain high power performance indicators of hybrid geothermal and combined-cycle power plants. This conclusion is confirmed by the results from numerical evaluations carried out as applied to the Ternair geothermal field. With the fully harnessed resource potential of the Ternair field, the total capacity of hybrid geothermal and combined-cycle power plants may reach 60 MW, a level that would make it possible to relieve a significant part of energy, environmental, economic, and social problems faced by the city of Makhachkala.     

International Experience in Developing Low-Emission Combustors for Land-Based,Large Gas-Turbine Units: Mitsubishi Heavy Industries’ Equipment

This is the second paper in a series of publications summarizing the international experience in the development of low-emission combustors (LEC) for land-based, large (above 250 MW) gas-turbine units (GTU). The purpose of this series is to generalize and analyze the approaches used by various manufacturers in designing flowpaths for fuel and air in LECs, managing fuel combustion, and controlling the fuel flow. The efficiency of advanced GTUs can be as high as 43% (with an output of 350–500 MW) while the efficiency of 600–800 MW combined-cycle units with these GTUs can attain 63.5%. These high efficiencies require a compression ratio of 20–24 and a temperature as high as 1600°С at the combustor outlet. Accordingly, the temperature in the combustion zone also rises. All the requirements for the control of harmful emissions from these GTUs are met. All the manufacturers and designers of LECs for modern GTUs encounter similar problems, such as emissions control, combustion instability, and reliable cooling of hot path parts. Methods of their elimination are different and interesting from the standpoint of science and practice. One more essential requirement is that the efficiency and environmental performance indices must be maintained irrespective of the fuel composition or heating value and also in operation at part loads below 40% of rated. This paper deals with Mitsubishi Series M701 GTUs, F, G, or J class, which have gained a good reputation in the power equipment market. A design of a burner for LECs and a control method providing stable low-emission fuel combustion are presented. The advantages and disadvantages of the use of air bypass valves installed in each liner to maintain a nearly constant air to fuel ratio within a wide range of GTU loads are described. Methods for controlling low- and high-frequency combustion instabilities are outlined. Upgrading of the cooling system for the wall of a liner and a transition piece is of great interest. Change over from effusion (or film) cooling to convective steam cooling and convective air cooling has considerably increased the GTU efficiency.     

Estimation of Efficiency of the Cooling Channel of the Nozzle Blade of Gas-Turbine Engines

The main direction of improvement of gas-turbine plants (GTP) and gas-turbine engines (GTE) is increasing the gas temperature at the turbine inlet. For the solution of this problem, promising systems of intensification of heat exchange in cooled turbine blades are developed. With this purpose, studies of the efficiency of the cooling channel of the nozzle blade in the basic modification and of the channel after constructive measures for improvement of the cooling system by the method of calorimetry in a liquid-metal thermostat were conducted. The combined system of heat-exchange intensification with the complicated scheme of branched channels is developed; it consists of a vortex matrix and three rows of inclined intermittent trip strips. The maximum value of hydraulic resistance ξ is observed at the first row of the trip strips, which is connected with the effect of dynamic impact of airflow on the channel walls, its turbulence, and rotation by 117° at the inlet to the channels formed by the trip strips. These factors explain the high value of hydraulic resistance equal to 3.7–3.4 for the first row of the trip strips. The obtained effect was also confirmed by the results of thermal tests, i.e., the unevenness of heat transfer on the back and on the trough of the blade is observed at the first row of the trip strips, which amounts 8–12%. This unevenness has a fading character; at the second row of the trip strips, it amounts to 3–7%, and it is almost absent at the third row. At the area of vortex matrix, the intensity of heat exchange on the blade back is higher as compared to the trough, which is explained by the different height of the matrix ribs on its opposite sides. The design changes in the nozzle blade of basic modification made it possible to increase the intensity of heat exchange by 20–50% in the area of the vortex matrix and by 15–30% on the section of inclined intermittent trip strips. As a result of research, new criteria dependences for the complicated systems of heat exchange intensification were obtained. The design of nozzle blades can be used when developing the promising high-temperature gas turbines.     

基于冷却幅高的间接空冷塔冷却特性分析与评价

自然通风间接空冷塔的冷却性能直接关系到机组运行的经济性和安全性,为了更加直观、全面地描述空冷塔运行状态和冷却性能,针对某1 000 MW机组间接空冷系统,提出空冷塔冷却幅高的概念,建立理论计算模型,结合现场实测和机组运行数据,研究了环境条件及机组运行参数对冷却幅高的影响规律,通过对比实测冷却幅高与实测工况参数无风条件下冷却幅高计算值,分析了环境风对间接空冷塔冷却性能的影响。结果表明:冷却幅高随环境温度的升高而减小,随进水温度的升高而增大;环境风条件下,主导风向迎风面扇区的冷却幅高低于侧风面扇区。研究结果可为间接空冷系统防冻运行调控、空冷散热器管束清洗和间接空冷塔冷却性能的评价和改善提供依据。     

超临界600MW汽轮机组能耗分析

针对某电厂超临界600MW机组存在汽轮机本体通流效率偏低、再热减温水用量偏大、低负荷凝汽器端差偏大等情况,致使汽轮机能耗偏高,采用机组大修前热力性能考核试验,分析了汽轮机本体通流和辅机存在的问题以及对汽轮机组能耗的影响,可为电厂节能工作提供参考。     

葛洲坝3号机相对效率试验结果分析

相对效率试验是评价水轮机效率特性的重要手段。葛洲坝3F机为轴流转浆式机组,本文介绍了葛洲坝3号机125-150MW改造增容后相对效率试验的情况。对全水头协联试验时相对效率曲线与及中低水头时的出力余量进行了分析,比较了最优协联效率曲线与现有协联效率曲线,使用插值法比较了水轮机改造前后机组的效率,并对试验过程中发现的异常噪声进行了分析。结果表明:3号机高效区较宽,中低水头时出力余量较大,能达到保证出力;通过提高协联控制水头的精度与及改善协联关系能够提高机组效率;水轮机改造后机组的效率在高水头时得到了提高;试验中发现的异常噪声由卡门涡与叶片共振引起,叶片出水边修型后,异常噪声消失。     

进气加热对燃气-蒸汽联合循环性能影响

以某200 MW级燃气-蒸汽联合循环机组为研究对象,利用余热锅炉尾部烟道废热加热给水并通过气-水换热器提高压气机进口空气温度,采用Aspen Plus模拟计算进气加热系统投运前后联合循环参数变化,分析空气进气加热对机组性能影响.研究结果表明,压气机进口空气温度由12.5℃提高至35℃时,50％、75％、87％负荷下燃机...     

Characteristics evaluation of a CO2‐capturing power generation system with reheat cycle utilizing regenerative oxygen‐combustion steam‐superheater

A new CO₂‐capturing power generation system is proposed that can be easily realized by applying conventional technologies. In the proposed system, the temperature of medium‐pressure steam in a thermal power plant is raised by utilizing an oxygen‐combusting regenerative steam‐superheater. The CO₂ generated by combusting the fuel in the superheater can be easily separated and captured from the exhaust gas at the condenser outlet, and is liquefied. The superheated steam is used to drive a steam turbine power generation system. Using a high‐efficiency combined cycle power generation system as an example, it is shown that the proposed system can increase the power output by 10.8%, and decrease the CO₂ emissions of the entire integrated system by 18.6% with a power generation efficiency drop of 2.36% compared with the original power plant without CO₂ capture, when the superheated steam temperature is 750 ^°C. © 2008 Wiley Periodicals, Inc. Electr Eng Jpn, 165(1): 35–41, 2008; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/eej.20575     

微燃机冷热电三联供系统建模及热力学分析

某200 k W微燃机冷热电三联供系统按季节负荷特点分为热电联供和冷电联供2种模式,基于Ebsilon软件对该系统构建模型并进行仿真模拟及性能分析,分别计算出不同工况下冷热电三联供系统的一次能源利用率和效率。结果表明:冷电联供时,环境温度从24℃变化到38℃,系统一次能源利用率为65.2%~68%;热电联供时,环境温度从-10℃变化到24℃,系统一次能源利用率为66.4%~74.2%。系统冷电联供(取环境温度为32℃)运行时,效率为31.1%,损失之和为451.92 kW,当微燃机负荷率在30%~100%变化,系统一次能源利用率为60.3%~66.9%;系统热电联供(取环境温度为0℃)运行时,效率为38.5%,损失之和为408.4 kW,当微燃机负荷率在30%~100%变化,系统一次能源利用率为54.4%~68.5%。通过搭建的微燃机三联供系统模型对实际运行数据进行分析,结果认为:实际运行工况主要存在冷负荷较小的问题,通过蓄冷罐蓄存多余冷量,系统的一次能源利用率可提高13.8%。