Turbine Catalog

GAS TURBINES FOR POWER GENERATIONSAND

GAS TURBINE POWER PLANTS

GAS TURBINES FOR POWER GENERATIONSAND

GAS TURBINE POWER PLANTS

The State Gas Turbine Research & Production Complex “Zorya-Mashproekt” since 2001 has combined with R&D production enterprise “Mashproekt” and mass production line “Zorya” one of the world leading manufacturer of gas turbine engines and gearboxes. Since 1954 more than 30 types of marine propulsion units have been delivered and proven on successful operation.

The ships powered by propulsion units operate Navies of Ukraine, Russia, Bulgaria, Romania, Poland, Germany, India, Vietnam, China, USA, and other countries.

In the middle of 60th “Zorya-Mashproekt” began conversion of naval production for civil application. Gas turbines designed for severe marine conditions possess high reliability, durability and compact design; they are economically attractive in comparison with industrial gas turbine engines.

Application of “Zorya-Mashproekt” engines was performed parallel in two parallel directions for power generation and the gas pipeline industry.

Spurt construction of transcontinental gas pipelines from European part of the former Soviet Union to Western Europe required a large number of gas pumping units fueled by natural gas. The first gas pumping unit of “Zorya-Mashproekt” GPA-10 of rated 10MW power was derived from marine gas turbine engine of M8 type.

Near 500 of such gas pumping units have been delivered to gas pipelines.

The leading engines have accumulated more than 100,000 firing hours with no overhaul and are still under operation. Later on other marine gas turbines were also powered gas pipeline industry. Nowadays gas turbine movers rated at 3, 6, 10, 15, 16 and 25MW are offered for application in gas pipeline industry. At present gas turbines manufactured by “Zorya-Mashproekt” are widely used to drive gas superchargers on gas pipelines of Russia, Ukraine, Kazakhstan and Belarus, at compressor stations in Iran, underground gas storage in Czech Republic.

To meet customer's specific requirements concerning rotational speed “Zorya-Mashproekt” has its own gearbox manufacturing facility and got wide experience in the development variety of reduction gears.

50 years for marine gas turbine manufacturing50 years for marine gas turbine manufacturing

22

In 1969 the first floating co-generating power plant “Severnoie Siyanie” ( “Northern Lights”) rated 24MW was equpped by “Zorya-Mashproekt” gas turbines. Since then for more than 30 years several such power plants have provided heat and power in distant regions of Siberia and the Far East.

In 70th mobile power trains were developed for power supply to constructed “Baikal-Amur” rail road, operating until now.

In 90th third and the fourth generation gas turbines were introduced to the power market of CIS countries and abroad.

At the beginning of 21 century, gas turbine engines energize more than 50 power plants from Turkmenistan in the East to Canada in the West. “Zorya Mashproekt” turbines operate in various climatic conditions from cold upper Arctic zones down to hot central Asian deserts.

Present time “Zorya-Mashproekt” offers a wide choice of turbo generating sets and gas turbine plants ranged from 2.5 to 325MW of:

-simple cycle plants;-cogeneration plants;-steam injection plants including “Aquarius”

type units;-combined cycle plants;-cogeneration plants with distilling desalting

units (DDU).

33

35 years - industrial gas turbines manufacturing35 years - industrial gas turbines manufacturing

44

Gas Turbines For Power GenerationsGas Turbines For Power Generations

Gas turbine generating set UGT 2500

1 2 3 4 5 6 7

(D049)

Features

Rated power, kW

Efficiency, %3 .Fuel gas consumption, nm /kW h

Exhaust gas mass flow, kg/sec

Exhaust gas temperature, C

Dimensions (L x W x H), m

Weight, t

о2850

28,5

0,353

16,5

460

3,51х2,52х1,93

4,25

оAmbiet air temperature, С о

Ambiet air temperature, С

Po

we

r, M

W

Effic

ienc

y, %

1 - Рower flange2 - Gearbox3 - Electric starter4 - Compressor5 - Combustion chamber (CC)6 - Turbine 7 - Frame

55

UGT 6000, UGT 10000, UGT 15000, UGT 25000Gas Turbine Design Features

5 7

1 2 3 4

6

8 9 10


6360

31,5

0,319

30,5

428

4,6х1,8х1,8

4,5

(DV71)

Rated power, kW





Weight, t

о



Po

we

r, M

W

Effic

ienc

y, %

Features

1 - Variable geometry inlet guide vane2 - Low pressure compressor3 - High pressure compressor4 - Combustion chamber5 - High pressure turbine6 - Low pressure turbine7 - Power turbine 8 - Auxiliary drive gearbox9 - Electric starter10 - Frame

2

17500

35

0,287

72,2

414

4,7x2,1x2,2

9

UGT 15000(DB90)

66

10500

36,0

0,279

36,0

490

4,0х1,8х1,7

5

(DN70)


Rated power, kW





Weight, t

о



Po

we

r, M

W

Effic

ienc

y, %

Rated power, kW





Weight, t

о



Po

we

r, M

W

Effic

ienc

y, %

18

Газотурбинные двигатели для привода генераторовГазотурбинные двигатели для привода генераторовГазотурбинные двигатели для привода генераторовГазотурбинные двигатели для привода генераторов

UGT 25000(DG80)

26200

36,3

0,277

87,5

485

6,4х2,5х2,7

16

77

15900

31,4

0,324

96,0

UGT 16000(DJ59)


Rated power, kW





Weight, t

о



Po

we

r, M

W

Effic

ienc

y, %

Rated power, kW





Weight, t

о



Po

we

r, M

W

Effic

ienc

y, %

88

UGT 110000(GTD110)

114500

36,0

0,279

365

2 3 41 5


Rated power, kW





Weight, t

о



Po

we

r, M

W

Effic

ienc

y, %

Features

1 - Variable geometry inlet guide vane2 - Compressor 3 - Combustion chamber 4 - Turbine5 - Frame

“Zorya-Mashproekt” Complete Power Plants“Zorya-Mashproekt” Complete Power Plants

99

11

2244

55

66

12

12

15

15

10

10

13

13

14

14

88

Ga

s tu

rbin

e

exh

au

st

Wa

ste

he

at re

co

very

bo

iler

an

d c

on

tact

co

nd

en

se

r A

ir in

let

de

vice

Ge

ne

rato

r

Lu

b o

il ta

nk

Ga

s tu

rbin

e

Co

ntr

ol s

yst

em

33

99

77

1111

Sta

rtin

g

fre

qu

en

cy c

on

ve

rte

r

“Zorya-Mashproekt” offers a wide choice of gas turbine based combined heat and power plants:

-simple cycle plants;-cogeneration plants;-steam inject ion plants including

“Aquarius” type units;-combined cycle plants;-cogeneration plants with distilling

desalting units (DDU).Every type of plants has its own

advantages for operation under certain conditions. What the Customer has to know for optimal selection of the plant type?

All the plants can operate using liquid or gaseous fuel; they also have dual-fuel capability or can use alternative types of fuel (biofuel, gas oil etc.)

feature small dimensions, low weight, high maneuverability and fast start up; they can be used at mobile platforms. Such units have an advantage of being used as an emergency or peak power plants as well as stationary power plants in areas where cheep fuel is available and when a consumer needs only electric power.

are designed for simultaneous production of electric and heat power as steam or hot water. Electric power is directly related to the mechanical power of the gas turbine. As for heat it significantly varies in a wide range depending on the selected waste heat recovery configuration (steam or water type, or combined steam and water type, or use of supplemental firing). Such plants are most effective for manufacturing enterprises and public utilities with stable demand for electric power and heat as steam or hot water.

utilizing steam injection into the gas turbine hot gas path are also designed for power generation. Steam produced in a waste heat recovery boiler is supplied to a gas turbine as additional working media. STIG type plants feature:

-the most increase of electric power up to 90%;

-cost effective low NOx, CO emission levels;

-cost effective level of capitals $/kW

Simple cycle installations

Cogeneration plants

Steam injection plants (STIG)

installed electric power.Steam injection plants can be produced as

gas turbine based of non-covered (S1) and converted (S2) gas path versions. Such plants have advantages when used as power plants for industrial enterprises and as small regional power plants where maximum electric power is required and a source of fresh water is available.

also operate according to STIG cycle. They have a contact water condenser installed over the waste heat recovery boiler to return water condensed into the cycle. Their main application is implementation in regions suffering from fresh water shortage or in areas where are difficulties in treatment of boiler water large amounts. This type of units also has the ability to generate surplus of distilled water. At ambient air temperature the unit can increase the power of the electric power plant due to water injection at the engine inlet.

are designed for the highest possible effectiveness of power generation. Steam generated in waste heat recovery boiler is supplied to separate gas turbine. Electric power is the total power of gas turbine engine and a steam turbine. The plants are offered with two basic configurations: CC1 - one gas turbine with waste heat recovery boiler plus one steam turbine; CC2 - two gas turbines with two waste heat recovery boilers and one steam turbine operating for its own generator. The power plants have advantages when used as regional power stations and also as power stations for big industrial enterprises in areas with the high prices power resources.

plants are introduced for the countries with the fresh water shortage. Certain quantity of distillate when used for water injection to gas turbine inlet, allows providing nominal power output at high ambient temperatures.

“Aquarius” type units

Combined cycle power plants

Cogeneration with dist i l lat ion-desalinating

1010

Gas Turbine Power PlantsGas Turbine Power Plants

1111

Simple cycle

1 - Gas turbine.2 - Generator.

“Aquarius”

1 - Gas turbine. 2 - Generator 3 - Steam contact condenser.4 - Steam condensate collector. 5 - Steam condensate cleaning unit.6 - Feed water tank. 7 - Water cooler. 8 - Pump. 9 - Waste heat recovery boiler.

.

SteamSteam

Steam-gasmix

Feed water

Feed water

Condensate

Combined cycle CC1

1 - Gas turbine. 2 - Generator. 3 - Steam turbine.4 - Waste heat recovery boiler. 5 - Condenser. 6 - Feed water pump. 7 - Pump.

Air

AirAir

Air

Air

Air

SteamSteam

Fuel

FuelFuel

Fuel

Fuel

Fuel

Feedwater

Feedwater

Exhaustgas

Exhaustgas

Exhaustgas

Exhaustgas

Exhaustgas

Feed water

Exhaustgas

1 - Gas turbine. 2 - Generator. Waste heat recovery boiler.

4 - Feed water tank. 5 - Pump.3 -

1 - Gas turbine. 2 - Generator. Waste heat recovery boiler.

4 - Feed water tank. 5 - Pump.6 - Heat energy consumer.

3 -

Steam-in-gas (stig)

1 - Gas turbine. 2 - Generator.3 - Distillation unit. 4 - Waste heat recovery boiler.5 - Feed water tank. 6 - Pump.

Sea water

Distilled water

5

6

Co-generation with sea water distillation

Co-generation

Gas Turbine Power Plants Thermal Diagrams Gas Turbine Power Plants Thermal Diagrams

Gas turbine power plant UGT 2500C in Toronto, Canada.

Gas turbine power plant UGT 2500C in Rybinsk, Russia.

Gas turbine power plant UGT 2500C in Brno, Czechia.

All data according to the ISO 3410

Power Plants With UGT 2500Power Plants With UGT 2500

Gas turbine engine UGT 2500 is specially designed to drive the electric generators. The engine has an integrated gearbox and can be applied to generators with 50 and 60 Hz frequencies.According to the order from Canadian company “ORENDA Aerospace Corporation” such engine is adapted to work on biofuel (liquid wood) operates since 1995.

1212

UGT 2500

UGT 2500C

UGT 2500S1

UGT 2500S1A

2,5

2,5

4,15

4,0

11975

12411

9614

9922

1010

1010

1225

1225

840

840

1020

1020

4,7

26,0

26,0

33,1

33,1

Power,MW

Power,MW

.ВТU/kW h

.ВТU/kW hElectr.Electr.

Therm. T erm.h

3gas (m /h)3gas (m /h)

Efficiency Efficiency Fuel consumptionFuel consumption

% %

Cycle Installation

“Aquarius”

Simple

Co-generation

Steam-in-gasSTIG

liquid (kg/h) liquid (kg/h)

551313

Co-generating power plant in Zapolyarie (Nother Russia) with 4 UGT 6000 gas turbines

Co-genereting power plant UGT 6000C at Yablunevka refinery, Poltavskaya oblast, Ukraine

UGT 6000 generating set

Gas turbine engines of UGT 6000 type are in serial production since 1978 and have 6 modifications with different rotational speed and power take-off (from compressor side, from power turbine side and simultaneously from both sides).This class engines combine considerable specific power and high efficiency with reliable operation and simplicity in maintenance. More than 300 engines of UGT 6000 type are in operation all over the world. They are used at Naval ships of different classes and also as supercharges and electric generator drives of power stations.


UGT 6000

UGT 6000C

газ6

6

31.5

73,2

10835

11339

UGT 6000S1 8 36.3 9402 1860

2130

1990

2210

1790

168011.1

Эл.Эл. 3газ (м /ч)3газ (м /ч) % %

Power,MW

Power,MW

.ВТU/kW h




% %

Cycle Installationliquid (kg/h) liquid (kg/h)

Simple

Co-generation

Steam-in-gasSTIG

Therm. T erm.h

1414

“Aquarius-16K” installation at Stavishchy compressor station

UGT 10000S2A (DU70) Gas turbine engine

UGT 10000 engine has several modifications including flow path modification for STIG cycle which increases the engine power and reduces NOx emissions level to 25 ppm.UGT 10000S2A engine of “Aquarius” power plant was tested as electric generator drive at “Zorya”-“Mashproekt” test facilities.The power plant “Aquarius-16K” with UGT 10000S2A engine was set into experimental and commercial operation in 2003 at Stavishchenskaya compressor station (Kiev region, Ukraine).


UGT 10000

UGT 10000C

UGT 10000S2

UGT 10000S2A

10,5

10,0

16,0

15,7

9481

9980

7937

8146

2950

2960

3760

3760

2460

2470

3140

3140

15,04

36

43

42,2

UGT 10000CC1UGT 10000CC2

13,527,5

45,846,3

74527371

29805960

25004940

85,6

Power,MW

Power,MW

.ВТU/kW h




% %


“Aquarius”

Simple

Co-generation

Steam-in-gasSTIG

Combined

Therm. T erm.h

“Aquarius” installation layout

Thermal and sound insulating container

Gas turbine

Air inlet device

Steam pipe

Separator

Condensate return

Contactcondenser

Exhaust

Waste heat recovery boiler

Generator

Power station at Salekhard, Russia with one DC59 and two UGT 16000 gas turbines

Two UGT 16000C power units at Mozyr petroleum refinery, Belarus

Three UGT 16000C units at Kzyll-Orda, Kazakhstan

Floating power station “Aurora borealis” with two UGT 16000C power units

UGT 16000 is the modernized engine of the 2nd generation. Still it remains popular among the Customers due to its high reliability, easy maintenance and optimal relation between price and quality. Some of the engines have accumulated 80-100 thousand hours without overhaul. Dual fuel version engine is able to switch over from gas to diesel fuel was implemented at Salekhard power station.

1515


16 300

14 500

18 400

UGT 16000

UGT 16000C

UGT16000CC1

31,0

79,927, 04

5320

5260

5260

4430

4380

4280

4270

11010

943036,2

Power,MW

Power,MW

.ВТU/kW h




% %


Simple

Co-generation

Combined

Therm. T erm.h

1616

Assembling of UGT 15000 gas turbine engine UGT 15000C power unit at Kostyukovichy cement works, Belarus

“Aquarius” power station with UGT 15000S2 gas turbine at “Zorya-Mashproekt” testbed

55

Gas turbine engines of UGT 15000 type are in serial production since 1991. They are used at Navy ships, as gas supercharges drives and electric generators drives for power stations. The serial engine of DG90 modification with operation on natural gas reached NOx emissions level of 37.5 ppm and CO emissions level of 26 ppm. While operating on diesel fuel the decrease of NOx and CO emissions to 25 ppm is achieved by means of steam injection into combustion zone.GTRPC “Zorya-Mashproekt” manufactures and supplies container power stations with UGT 15000 engine.

UGT 15000 in the container


Мощность,МВт

Мощность,МВт

.ВТU/kW h

.ВТU/kW hЭл.Эл.

тепл. тепл.

3газ (м /ч)3газ (м /ч) жидкое (кг/ч)жидкое (кг/ч)

Эффективность Эффективность Расход топливаРасход топлива

% %

Цикл Установка

16.0

16.0

22.7

45.8

UGT 15000

UGT 15000C

UGT 15000CC1

UGT 15000CC2

33.5

32.5

45.3

45.9

9740

10490

7530

7430

5020

4940

4940

9880

4215

4150

4150

8300

UGT 15000S2

UGT 15000S2

25.0

23,9

25.0

42.0 8120 5960 5020

42.0 8120 5960 5020

Power,MW

Power,MW

.ВТU/kW h




% %


“Aquarius”

Simple

Co-generation

Steam-in-gasSTIG

Combined

Therm. T erm.h

UGT 25000C power unit during assembling at Beryozovskaya power station, Belarus.

Gas turbine engine UGT 25000 (DG80) Engine cover during assembling

UGT 25000C power unit at Beryozovskaya power station, Belarus.

UGT 25000 is the most powerful from the unified series of engines. It belongs to the forth generation of engines and is in serial production since 1995. It successfully combines the newest attainments of modern design ideas, advanced technologies and many years of experience in operation, which allows produce the high maneuverability and efficiency.

1717


UGT 25000

UGT 25000C

UGT 25000CC1

UGT 25000CC2

UGT 25000S1

UGT 25000S2

UGT 25000S1

UGT 25000S2

30.8

40.7

30.8

40.7

40

42.8

40

42.8

8533

7974

8533

7974

25 35,5

34.7

70.6

25

34.8

47.5

48.5

35,0

9807

7185

7037

9402 7330

7220

7220

14440

6060

6060

12120

6170

7720

9570

7720

9570

6490

8020

6490

8020

Power,MW

Power,MW

.ВТU/kW h




% %


“Aquarius”

Simple

Co-generation

Steam-in-gasSTIG

Combined

Therm. T erm.h

1 - Ga turbine engine UGT 1100002 - Generator TVG-110-23 - Air inlet device4 - Waste heat recovery boiler5 - Steam turbine6 - Transformers room

UGT 110000 at Ivanovskaya power station (Komsomolsk city, Ivanovskaya oblast, Rossia)

UGT 110000CC2 for Ivanovskaya power station (under construction, Komsomolsk city,

Ivanovskaya oblast, Rossia)

551818

UGT 110000 is a new engine of the fourth generation designed according to single shaft configuration especially to drive the electric generator. The engine favorably differs from foreign analogues in weight - which is only 50 tons and overall dimensions: 5.7x3.7x4.0 m. Engine #2 is under trial-commercial operation at Ivanovo power station in Russia. Engine #1 is being mounted now as a part of 160 MW-combined cycle power plant at the company's test plant in Kaborga for further commercial power generation.

UGT 110000 at “Zorya-Mashproekt” test bed

UGT 11000CC1 (PGU-160) power units during construction in Kaborga village, Nikolaevskaya

oblast, Ukraine

110

160325

35,5

51,552,5

9610

67586563

31100

3181063620

26100

2670053400

UGT 110000

UGT 110000CC1UGT 110000CC2

Simple cycle

Combined cycle

Power,MW

Power,MW

.ВТU/kW h

.ВТU/kW hElectricalElectrical

3gas (m /h)3gas (m /h) liquid (kg/h) liquid (kg/h)


% %

Cycle Installation


1919

DO14

REMARKS

2 1971-75

DА14 1970-7422 1978-20006 1986

SOVETSKAYA GAVAN 3 1976

1727

4

13

12

53

21

9

19801990

1998

1990

1986

1982

1986

1980

2 1998

2 2002

JANAJOL

Power generation applications

GTD-1

DO12

DC59

LOCATION NUMBER OFGAS TURBINES

BEGINNING OFOPERATION

POWERMW

APPLICATIONTYPE

FLOATING POWER PLANT



RAILROAD POWER TRAIN



STATIONARY

STATIONARY

STATIONARY

RUSSIA

RUSSIA

RUSSIA

RUSSIA

RUSSIA

RUSSIA

KAZAKHSTAN

TURKMENIYA

YAKUTIYA

CHUKOTKA

YAKUTIYA

TUMEN REGION

BURYATIYA

KOMI

KHABAROVSKY KRAY

AMUR REGION

YAKUTIYA

KHABAROVSKY KRAY

YAKUTIYA

CHUKOTKA

TUMEN REGION

YAKUTIYA

KHABAROVSKY KRAY

YUZHNAYA

YAKUTIYA

KHABAROVSKY KRAY

TUMEN REGION

TENGIZ

TUMEN REGION

NEFTYANYE KAMNI

TUMEN REGION

YAKUTIYA

NEBIT-DAG

RUSSIA

KAZAKHSTAN

RUSSIA

AZERBAIJAN

RUSSIA

PRIMORSRY KRAY

RUSSIA

KAZAKHSTAN

RUSSIA

RUSSIA

RUSSIA

4

1

2002-2003

1999



STATIONARY

STATIONARY

STATIONARY

STATIONARY

STATIONARY

STATIONARY

RUSSIA

UKRAINE

UKRAINE

UKRAINE

UKRAINE

UKRAINE BELARUS

RYBINSK

KHARKOV REGION

BRNO, OLOMOUC

TORONTO

Licence

manufacturing by

“NPO SATURN” not

completely included

RUSSIA

UKRAINE

CZECH

CANADA

1995-2003

1997

1994

1995

10

1

2

2

POLTAVA REGION

NIKOLAEV REGION

STATIONARY UKRAINE BELARUS

UGT 15000UGT 15000

UGT 10000UGT 10000

UGT 6000UGT 6000

UGT 2500UGT 2500

UGT 15000UGT 15000

UGT 16000UGT 16000

UGT 25000UGT 25000

15 NIKOLAEV REGION

STATIONARY UKRAINE RUSSIA

UGT 110000UGT 110000 110 NIKOLAEV REGIONIVANOVO REGION

NIKOLAEV REGION

NIKOLAEV REGIONBREST REGION

14

13

12

20042001-2005

19962003-2005

19962003-2005

CHUKOTKA

YAKUTIYA

YAKUTIYA

KHABAROVSKY KRAY

MOZYR

TUMEN REGION

ROSTOV REGION

KRASNODARSKY KRAY

SEVASTOPOL

RUBEJNOYE

5

11

4

2

2

1

3

3

3

1

1992

1993

1993

1992

1991

1995

1997

1992

1992

2003

RUSSIA

RUSSIA

BYELORUSSIA

RUSSIA

RUSSIA

STATIONARY

TUMEN REGION

TUMEN REGION

YAKUTIYA

YAKUTIYA

TUMEN REGION

FLOATING POWER PLANTRAILROAD POWER TRAINSTATIONARY

20062006

Nikolaev at night Nikolaev at night

GTR&PC “Zorya”-“Mashproekt”Oktyabrsky prospekt 42a

Nikolaev, 54018, Ukraine.Phone +38 0512 50-25-61, 55-69-92

Fax +38 0512 50-90-50, 55-68-68

E-mail: [email protected], [email protected]:// www.zmturbines.com

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