IN BRIEF #5-2016

•    Zapadnaya thermal power station in Kurgan – power station for industrial park and residential districts.
Thermal power station with electric output of 25 MW and thermal output of 46 Gcal/hour was commissioned in Kurgan. All generated electric and thermal power will be used for the needs of industrial enterprises situated on the territory of industrial park. The customer of the project is Kurganskaya generating company. General contractor for the project is Intertehelectro Group of companies. Investments of the project was realized in cooperation with Vnesheconombank. The station was developed on the base of three Wartsila 16V34SG gas engine power plants each rated at 7.76 MW.
•    T16 advanced gas turbine is REP Holding and GE Oil & Gas novel solution.
The heavy-duty gas turbine rated at 16 MW was designed by REP Holding engineers in cooperation with GE Oil & Gas to perfectly match Russian market requirements. It is the first heavy-duty Russian-manufactured GTU within such power range. The machine's cost effectiveness, performance efficiency and emission characteristics knows no equals in Russia. TI6 has a high efficiency and low level of polluting emissions. It is highly flexible for on-site service maintenance due to the modular service concept. Advanced GTU system design allows easy access to GTU assemblies in order to enable proper on-site maintenance.
•    Siemens and Power Machines JSC: 25 years of successful development.
The cooperation of Siemens AG and Leningradsky Metallicheskiy Zavod started in 1991. That time the companies created Interturbo Ltd. joint venture (Leningradsky Metallicheskiy Zavod –55 %, Siemens AG – 45%). The main task of the new company was assembling of V94.2 gas turbine plants from the parts and components supplied from Siemens factory in Germany and produced by LMZ. V94.2 gas turbine plants were used for the construction of combined cycle power plants in Russia. The second stage of Siemens and Power Machines cooperation was creating of new joint venture, Siemens Gas Turbine Technologies, in 2011 (Siemens – 65% of shares. Power Machines, РАО – 35%).
•    GE’s Waukesha VHP engines: guaranteed reducing of operating costs.
GE's Waukesha VHP generator sets are built for efficiency, durability and longevity, and provide reliable power for continuous and intermittent power applications. The versatile, gaseous-fueled VHP series is available in 6-, 12-, and 16-cylinder configurations with rich-burn and lean-combustion systems. The VHP series produces more power on the hottest field gases, at higher altitudes in remote locations, all while delivering lower emissions.
GE's ESM engine system manager provides comprehensive control capability to help enhance uptime and boost performance for a variety of Waukesha VHP and VGF engines. Designed for ease of use and enhanced serviceability, the ESM integrates spark timing control, speed governing, knock detection, start-stop control, diagnostic tools, fault logging, engine safeties, and air / fuel ratio control. GE's Distributed Power business signed an agreement with Hoerbiger to be an authorized distributor for GE's Waukesha gas engine products in Russia.
•    Shell Mysella S5 N 40 lubricating oil: application in Perkins 4012 gas engines.
The article presents performance features of and Shell Mysella S5 N 40 lubricating oil and benefits of its application in Perkins 4012 gas engines. Shell Mysella S5 N 40 is a premium gas-engine oil formulated for use in the latest generation of highly rated gas or dual-fuel engines that require a low-ash oil. The product has been specially developed to provide extended oil-drain intervals in those natural gas engines where oil life is a limiting operational factor. It offers excellent engine protection and extended overhaul intervals for critical components such as valves, seats, pistons and liners. In addition, Shell Mysella S5 N 40 is designed to reduce heat-exchanger fouling to enhance plant efficiency. Shell Mysetla S5 N 40 is suitable for all types of four-stroke gas engine that burn natural gas, bio-gas or landfill gas, including those with spark or pilot ignition, and lean or rich burn. It is also suitable for four-stroke dual-fuel engines that use gas as their main fuel, and two-stroke gas engines where a low-ash oil can be used.
•    Steam & power ORC system – a new cogeneration alternative for manufacturing processes.
CHP systems are universally acknowledged as an efficient, sustainable and profitable way of generating energy for manufacturing industries and they have been widely applied by production facilities with significant energy costs for their processes. One of the key driver for a CHP system integration in a manufacturing facility is the flexibility to satisfy directly internal process heat demands, which often could be at relatively high temperature. Actually many manufacturing plants require large amount of electricity and saturated steam, for internal processes.
•    SDMO project – generating set on heavy fuel oil for Russian producer of aluminum in Guiana.
One of the high-priority areas of activity of SDMO (Kohler Power Group) not only in Russia but also in other countries is the realization of specialized projects. Engineering department of the company consisted of skilled professionals develops under turn-key basis power generation projects for various spheres of application. Engineers of the company support customers on each stage of projects realization. They provide the development of projects, manufacturing of generating sets, their commissioning and maintenance. Each project is considered with the customer. One of the last realized projects for Russian customer is the development of generating set operating on heavy fuel oil. The output of the plant is 2240 kW at a temperature of 40 °C. The term of equipment manufacture is eight months. The power plant was installed on the site of new Kurubuka mine in Guiana. A2800U generating set was developed on the base of ABC 12DZC engine and LS54VLI00 electric generator.
•    Siemens Ltd. in Kazakhstan – advanced equipment for oil & gas industry and power engineering.
Siemens operates in Kazakhstan in all its traditional business segments. The company is one of the leading suppliers of equipment, services and comprehensive solutions for the development of key branches of economy and infrastructure. Energy is one of the main business segments of the concern. In Kazakhstan it is presented by «Power and gas» department. It offers up-to-date technologies for power generation, oil and gas sphere and industrial sector. They cover whole range of energy solutions from the production of thermal and electric power up to its transportation and distribution. All proposed solutions are reliable, highly effective, environmentally friendly and safe.
•    Energas Company: 9 years of dynamic development.
After 9 years of effective work were created business structure of the company. At present it consists of Energas professional engineering corporation, Belgorod Energas engineering-production company, ServiceEnergas maintenance technical department. Each company has well-defined functions, competence and areas of responsibility. Energas Ltd., Belgorod Energas, ServiceEnergas are united by not only common brand. These companies have agreed goals and tasks, which are achieved by means of professional specialization and mutual responsibility for high quality of technological equipment for fuel gas treatment on various sites of power engineering, oil and gas and petrochemical branches of industry. Energas Ltd. operates in the energy sector and the oil and gas industry. At present the company has implemented more than 120 projects in 40 regions of Russia and CIS countries.
•    Evaluation of gas compressor station operation.
The number of gas compressors being installed on each compressor station of cross-country pipeline and their arrangement effect significantly to the availability, fuel consumption and effectiveness of the whole system. The article presents the degree of impact evaluation of such factors as gas turbine type and arrangement of compressors at the site of compressor station. Economic benefit of gas compressor station operation significantly depends on the type of compressors. Important factors at that are also operation costs (fuel cost especially) and the price of the equipment taking into account service life of the equipment. The number and arrangement of the compressors at the site, driver type and presence of stand-by power plants, driver and compressors types effect to the costs, fuel consumption, operational flexibility. Capital costs for the project consist of the equipment price and costs for its installation. The price of the equipment includes the price of driving engine, compressor and baseplate, but also the price of auxiliary systems.
•    Kawasaki gas turbines: advanced technologies, high quality and reliability.
Kawasaki gas turbine generator sets are created first and foremost with performance in mind. Each set is specifically designed to minimize maintenance and avoid costly downtime. Special inspection ports allow internal components to be checked without tedious disassembly or long waits. Gas turbine split case design allows for tolerance adjustments during hot section inspections for higher overall efficiency between overhauls. And all rotating parts are precisely balanced to reduce vibration and minimize failures of key electronic components. Finally, high performance ignition system ensures high starting reliability, even in cold weather conditions. Kawasaki GPB Series is designed for base toad applications, for both parallel operation with the grid and island mode operation. GPB Series gas turbines are able to operate in cogeneration cycle.
•    Laser thermal quenching for the extension of machine components lifetime.
The basis for stable development of Russian economy in present situation is forehanded retrofitting and upgrading of all branches of industry. Taking into account the current condition of Russian industry many-fold development of labour productivity is necessary to meet the world's requirements. Such development will be possible only by applying of advanced technologies. According to the evaluation of foreign experts more than a half of all metal working (thermal machining, cutting, welding, overlaying, metal refining and coating) in the world will be produced by means of laser technologies especially on the base of CO2 lasers and fiber-optics lasers. It is the priority guideline for processing technologies development not only metals but also other materials. Laser thermal quenching technology has noticeable advantages in comparison with traditional technologies of metal processing.
•    Scientific and technical session of Russian Academy of Sciences devoted to gas turbines issues.
This year the session devoted to gas turbine and combined cycle power plants issues was held on the site of NPO Saturn JSC in Rybinsk. Traditionally in Russia gas turbine plants are applied for gas transportation and for power generation on power stations of various cycles. Now this sector develops very rapidly. Most of the reports presented during the event were devoted to fundamental challenges of the localization of hot gas path components production in Russia. More than 100 specialists from Russia and Ukraine took part in the session. Mr. Olkhovsky mentioned that the main problem now is the restitution of skills set necessary for localization in Russia the production of gas turbine components.