Beruflich Dokumente
Kultur Dokumente
The State Enterprise Zorya-Mashproekt Gas Turbine Reasearch & Production Complex has a 50-years experience in designing & production gas turbines for Navies, commercial and passenger vessels, power plants and gas piping units and drivers for production equipments. The turbines developed for marine application have been excellently proven on land. Since 1953 over 3000 marine & industrial gas turbines have been produced and supplied. Thousands of varies reduction gears for different class displacement ships, hovercrafts & hydrofoils also for industrial application have been produced. Ships of 20 countries worldwide, over 60 power stations, more than 100 gas pipelines compressor stations in Russia, Ukraine, Kazakhstan, Belarus, Czechia, Canada, Azerbaijan, Iran and other countries are equipped with Zorya-Mashproekt gas turbines. The total power of the turbines exceeds 24 million kW and total firing time over 26 million hours. According to GAZPROM statistics, the gas pumping units (GPU) driven by our gas turbines have been acknowledged most reliable comparing to driven by another companies. They have highest mean value of technical utilization coefficient, maximum time between failure and the highest availability factor. Owing to the constant work on support and upgrade of the technical level, the of-time of many turbines exceeded 80000 firing hours without factory repair. UGT16000 (DR59) second generation leading turbine have accumulated over 35000 hours, UGT25000 fourth generation turbine over 28000 hours, UGT10000 fourth generation turbine has been put in to trialcommercial operation at Kirovogradskaya compressor station (Ukraine) in 2002. Zorya-Mashproekt gas turbines were created for naval applications; they are also adjusted for working off-shore, on floating & stationary oil & gas platforms.
The specialist of Mashproekt (Scientific Research & Experimental-Design Works Center) is constantly working at creating new & upgrading early-developed gas turbines widely using modern sophisticated CAD\CAM systems. Zorya-Mashproekt facilities & laboratories have been equipped with up-to-date tools, equipment & technologies, the personnel there is well trained. High-temperature steel & alloy precision casting, precise isothermal & impulse extrusion, electro-beam welding, electro-beam & plasma coatings, laser cutting, electric methods of metal treatment-these make an incomplete list of advanced technologies applied at the enterprise. Possessing tooling allows realizing on time & qualitative production preparation. Gas turbines parts & assembling operational development & testing are held on the test-beds of the Scientific Research Department. 11 test-beds for full-scaled turbines & units testing are situated on the main territory, & 5 test-beds are in Kaborga village where is a marine test station, & a special loading gas ring for testing GPU is built. The specialist of the complex perform contract supervision, adjustment & alignment, guaranteed maintenance of prototype & stock-produced items on-site of the customer, and also after-sale maintenance through the whole service life.
Features
1 - Variable geometry inlet guide vane 2 - Low pressure compressor (LPC) 3 - High pressure compressor (HPC) 4 - Combustion chamber (CC) 5 - High pressure turbine (HPT) 6 - Low pressure turbine (LPT) 7 - Power turbine (PT) 8 - Auxiliary drive gearbox 9 - Electric starter 10 - Frame
Efficiency, %
Power, kW Efficiency, % Heat rate, nm3/kW-hr Exhaust gas mass flow, kg/sec
Engine Power, kW Efficiency, % Heat rate, nm /kW-hr Exhaust gas mass flow, kg/sec
Note: ISO condition
3
Efficiency, %
Power, MW
Compressor - axial, 9 stages LPC, 9 stages HPC. Pressure ratio - 19,5. Combustion chamber - can-annular reverse flow with 10 combustion liners, TIT - 1200 0C. Gas generator turbines - axial, single stage LPT and HPT. Power turbine speed - 3600, 4800, 6500 rpm. Start - electric motors AC U=380 V, N= 70 kW.
Power, kW Efficiency, % Heat rate, nm3/kW-hr Exhaust gas mass flow, kg/sec
Power, MW
Engine
Power, kW Efficiency, % Heat rate, nm /kW-hr Exhaust gas mass flow, kg/sec
3
Engine
Exhaust gas temperature, 0C Dimensions (LxWxH), m Weight, ton
24
34
Efficiency, %
35 45
Power, MW
20
Power, kW Efficiency, % Heat rate, nm /kW-hr Exhaust gas mass flow, kg/sec
3
25 20 15 10 -35
Efficiency, %
-25 -15 -5 5 15 25 35 45
Power, MW
30
38 34 30 26 22
-35 -25
-15
-5
15
25
35
45
Power, kW Efficiency, % Heat rate, nm /kW-hr Exhaust gas mass flow, kg/sec
3
ZORYA-MASHPROEKT Gas Turbines For New & Modernized Gas Pumping Units
Experience of using Zorya-Mashproekt gas turbines as integrated parts of gas pumping units achieves over 25 years. To date most of the gas pumping units based on the DR59 gas turbine has exhausted their service life. The specialists of the company have developed the concept of using the third & fourth generation gas turbines in gas pumping units of compressor stations under construction & modernization for drive replacement, both domestic & foreign ones. 34 modernization projects have been developed for gas pumping units in operation. They include replacement of out-of-date drives with exhausted life by modern, more economical Zorya-Mashproekt gas turbines. As a result of such reconstruction, at the working compressor station the modern technical level is being provided something nonstop. The greatest economical effect attributes to the upgrading of the working compressor shops in the conditions, when the new shop construction is either impossible or extremely difficult (in the mountainous pipeline sections, frozen grounds of the Extreme North, in the swamped territories when there are problems with land a purchasing). Zorya-Mashproekt performs projects of on-site drive adjustment in the units under upgrading. It also prepares equipment sets document necessary for gas pumping units upgrading. They include field changing of the equipment available on site (blowers, supports, air intake devises, exhausters, serving the auxiliary equipment). By the customer's desire, the experts of the company can perform automatic control system engineer's project of the units under upgrading. To increase independence of the compressor stations work when the outer power source is off & with the purpose to decrease cost on buying electric power, Zorya-Mashproekt suggests using free space after outof-date engines removed for construction own power station for providing compressor station uninterruptible power supply. Zorya-Mashproekt offers power stations with rated power 2.5, 6, 16 MW as well as turboexpander generating sets.
DE76 gas turbine modification with speed 9700 rpm was developed for the direct drive Prague Energo 3RSC56/3RSD56 centrifugal compressor without gearbox. This unit is used for gas pumping in and out at underground gas storage in Czech. The turbine has absolutely new two channel burners for NOx reduction and a special cage design with many layer sound isolation. The DE76E gas turbine can be used also in URAL GPU-3C compressor set developed by ISKRA SPE, Perm, Russia.
Gas pumping unit driven by DE76E at Stramberk underground gas storage engine room
The UGT6000 (DT71) gas turbine engine is used in GPU-C-6,3C unit produced by the FRUNZE company as serial production. It is also used to replace NK-12ST aeroderivated engine while upgrading GT-750-6 gas pumping units. This gas turbine is possible to be used for upgrading GTN-6 and GT-6-750 units produced by Russian company Turbomotorworks. There is UGT6000+ boosted version with rated power up to 8MW.
The UGT10000 fourth generation gas turbine has been developed with several modifications: DN70L with 4-stage left-rotated power turbine and rated speed 4800 rpm for GTC-10-2, GTC-104 and GTU-10 gas pumping units upgrading; DI70P with 3-stage right-rotated power turbine and rated speed 6500 rpm for GTC-10I gas pumping units upgrading; DI70L with 3-stage left-rotated power turbine and rated speed 6500 rpm for GT-750-6 gas pumping units upgrading; DU70L gas turbine with modernized flowing part to the power of 16MW by means of steam injection with 4-stage left-rotated power turbine and rated speed 4800 rpm is used in Aquarius GPU-16K unit.
GTK-10-I gas pumping unit modernization via replacing old MS3002 by new one DI70P gas turbine
Air inlet modernization Exhaust gas vent DI70P Auxiliary mechanism gearbox
Auxiliary alternator
Air inlet
Gas compressor
One of the features of this upgrading is the new gas turbine building in the acting design scheme of the original unit maintaining all of its functions including house generating drive & united lubricating oil system. Frequency converter provides constancy of the frequency of the electrical energy produced by the house generator. This converter is used also for gas turbine starter control and provides smooth gas pumping unit starting.
Modernized GTK-10-4 gas pumping unit with air inlet chamber and lubricating oil unit in the assembling workshop
Container with gas turbine is manufactured with highest noise insulation degree. Turboblock and air inlet unit integral design gives opportunity to reduce building and assembly jobs period. Gas compressor lubricating is integrated with gas turbine lubricating oil system, this design gives opportunity to exclude electrically driven pump.
Modernized gas pumping unit GTK-10-4 with DN70L gas turbine at CS Kirovogradskaya, Ukraine
The UGT 15000 gas turbine engine has the following modifications: DG90L, DG90L2 with power turbine frequency 5300 rpm of left rotation to be used in new GPUs of compressor shops: GPA-C-16S - developed by "Frunze" company (Sumy, Ukraine); GPA-16 "Ural" - developed by "Iskra" company ((Perm, Russia); GPA-16 "Volga" (Kazan, Russia); GPA-16 "Neva" (St. Peterburg, Russia); while upgrading GPUs increasing the drive power: GTK-10-4 (GTK-10-2) developed by NZL (St. Peterburg, Russia) GPU-10 developed bu "Zorya"-"Mashproekt" (Nikolayev, Ukraine), GPU-16 developed by "Frunze" company (Sumy, Ukraine). - DG90P with power turbine speed of 5300 rpm of right rotation for upgrading Coberra-183 imported units by Cooper -Rolls company. The main pattern of DG90P engine was installed in 1994 at Bogandinskaya compressor station (Surgutgasprom) as a part of Coberra-182 upgraded unit. Two compressor shops were upgraded with DG90P engines at Bogandinskaya and Turtasskaya compressor stations. Some compressor stations with actual efficiency of no more then 20% were upgraded with DG90L2 engine (Surgutgasprom & Volgotransgas companies). GPU-10 (GPU10-01) upgrading is held by means replacing DR59L second generation engine rating at 10 MW & efficiency of 27% with DG90L rating at 16 MW. While upgrading new DG90L installation provided housed in the finished serial block from the reserve recourse stock. They perform upgrading or replacement of the blower supercharger, complex air cleaner, gas exhaust path, automatic control system, as well as ventilation, fuel & lubrication systems changes. At Vyngapurovskaya compressor station there's also a shop equipped with upgraded GPU16-16S units powered by DG90L2. DG90L2 engnes as part of new gas pumping units are used by gas transportation & production companies of Ukraine, Russia, Belarus, Turkistan (over 50 engines? As well as to power ammonia compressors at Odessa Port Plant (two engines). "Zorya"-"Mashproekt" has totally produced over 140 UGT15000 engines in different modifications. The leading engines at Surgutgasprom compressor station have accumulated over 37.00 fire hours.
GTE cooler
Luboil unit
Container with ammonia compressor driven by UGT15000 gas turbine at Odessa Port Plant
Bt their design & parameters turbines of UGT16000 family (DR59, DJ59) are of the second generation, but they have proved themselves as the most reliable at the gas pumping stations. 10MW DR59 with efficiency of 28% is used in GPU-10 & GPU-10-01. Zorya-Mashproekt and KRTZ VOSKHOD have produced 536 turbines totally. The leading DR59 turbines have accumulated over 100000 firing hours. DJ59 with efficiency 30% and rated power 16MW is used in GPU-16 developed by Ukrainian company FRUNZE. Totally over 120 units like this have been manufactured. Beginning in 1992, DH59L2 have been widely used for replacing out-of-date drives while upgrading GTC-10-4 & GPU-25/76 units developed by Nevskiy Zavod from St. Petersburg, Russia, and replacing COBERRA-182 gas generator from Cooper-Rolls company. 33 DJ59L2 turbines are working in the upgraded units at 9 compressor stations of Permtransgas ltd and Vologotransgas ltd companies.
UGT25000 fourth generation gas turbine also has several versions of power turbines in speed & rotation direction: DN80L with speed of 3300 rpm is used for upgrading GPU-25/76 at Ukrainian & Russian gas pipelines as well as at underground gas storages in Gasli (Uzbekistan). DI80P with speed of 4850 rpm & right rotation is intended to replace MS5003 engines (manufactured by General Electric) in GTC-25I units produced Nuovo Pignone. DU80L with speed 4850-5000 rpm and left rotation is intended for URAL GPU-C-25 and GPU-25C gas pumping units manufactured by Russian company ISKRA and Ukrainian company FRUNZE. Over 40 DN80L gas turbines have been produced and leading turbine has been accumulated over 28000 firing hours. Gas pumping unit GPA-26/76 modernization project with using of DN80L gas turbine
Modernized GPA-25/76 gas pumping in the Sofievskaya compressor station engine room
Energetical STIG
Steam-Gas Mix
1 - gas turbine 2 - waste heat recovery boiler 3 - contact condenser 4 - condensate collector 5 - condensate cleaning unit 6 - feed water tank 7 - water cooler 8 - pump 9 - gas compressor
Ecological STIG
Energetical STIG
Center address: 1, Khutoryanskiy Square, Tyumen-625014, Russia Tel/Fax: (3452) 21-34-74, 21-60-46, 21-09-37 (095) 719-60-99, e-mail: gazts@tyumen.ru
New and up-dating gas pumping units with "Zorya-Mashproekt" gas turbines
Efficiency, % (at station) Initial DE76 GPA-3S "Ural' DT71 GPA-C-6,3 GT-6-750-6 GT-6-750 GTN-6 GTK-10-2 GTK-10-4 GPU-10 GPU-10-1 DI70P DI70L DU70L GTK-10I GT-750-6 GPU-16K"Vodoley" New
Engine Type
Model
Power, MW
Speed, rpm
Units Type
DN70L
DG90L2
DG90P1 DG90P1
GTK-10-2 GTK-10-4 GPA-C-16S GPU-16S GPA-C-16S "Ural" GPA-16 "Volga" GPA-16 "Neva" GPU-16A Coberra-182 GPA STD 12,5
DJ59L2
15
7 7 7
3 3 3
8 8 8 8 4
1981
1990
7 7 7
DR59 (prolongation)
Beginning of operation
1991 1996
Location
Prikarpattransgas. Total number 8 GPU, total power 80 MW CS Golyatinskaya, Zakarpatie region Cherkassytransgas. Total number 7 GPU, total power 70 MW CS Gusyatinskaya, Ternopol region
7 7 8 7
UGT16000 (DJ59)
Beginning of operation Location
RUSSIA. Total number 133 GPU, total power 2128 MW
1995 1995 1998 Volgotransgas, 22 GPU, total power 352 MW CS Vyatskaya, Kirov region CS Morkinskaya, Maryi El Republic CS Pilnenskaya, Gorky region Permtransgas, 48 GPU, total power 768 MW CS Dobryanskaya, Perm region CS Ocherskaya, Perm region CS N. Kungurskaya, Perm region CS Almaznaya, Perm region CS Agryzskaya, Perm region CS Vavolzhskaya, Perm region CS Igrinskaya, Perm region CS Ordinskaya, Perm region 8 (3 modernization GPA-25/76) 8 (3 modernization GPA-25/76) 6 (GPU-16)
7 (3 modernization GPA-25/76) 5 (GPU-16) 8 (GPU-16) 10 (GPU-16) 5 (modernization GTK-10-4) 5 (GPU-16) 5 (GPU-16) 3 (modernization GTK-10-4)
1995-1997
1990-2002
10 (GPU-16)
Yamburggasdobycha, 30 GPU, total power 480 MW DCS-1, Yamburg DCS-6, Yamburg DCS-2, Yamburg DCS-5, Yamburg DCS-3, Yamburg DCS-7, Yamburg
1997
4 (GPU-16)
UGT3000 (D76)
Beginning of operation Location
CZECH, 1 GPU, power 3 MW 1995 CS Shtremberg 1 (3RS56/3RD56)
UGT6000 (DT71)
Beginning of operation Location
RUSSIA. Total number 3 GPU, total power 18,9 MW 1995 1995 1996 Mostransgas, Total number 3 GPU, total power 18,9 MW CS Gavrilov Yam, Yaroslavl region CS Oktyabrskaya, Stavropol territory CS Tchaplyginskaya, Lipetsk region UKRAINE. Total namber 16 GPU, total power 100,8 MW 1995 2001 1993 Kievtransgas, 7GPU, total power 44,1 MW CS Diranka, Poltava region Prikarpattransgas 7 GPU, total power 18,9 MW , CS Yzhgorodskaya, Zakarpatie region Kharkovtransgas, 2 GPU, total power 12,6 MW CS Kupyanskaya, Khharkov region 7 (GPA-C-6,3S) 7 (GPA-C-6,3S) 2 (modernization GPA-C-6,3S) 1 (modernisation GPA-C-6,3S) 1 (modernisation GPA-C-6,3S) 1 (modernisation GPA-C-6,3S)
1998 2002
6 4
5 (modernization GTK Coberra-182) 5 (modernization GTK-10-4) 5 (modernization GTK Coberra-182) 6 6 (modernization GTK-10-4) 6 (modernization GTK-10-4)
6 6 6
3 1 2 "Coberra"
1999
UGT25000 (DN80)
Beginning of operation Location Russia. Total number 15 GPU, total power 375 MW Permtransgas, 6 GPU, total power 150 MW CS Agryzskaya, Perm region CS Ordinskaya, Perm region Tyumentransgas, 9 GPU, total power 225 MW 2002 2002 2002 CS Tayozhnaya-4, Tyumen region CS Tayozhnaya-5, Tyumen region CS N.Komsomolskaya,Tyumen region UKRAINE. Total number 8 GPU, total power 200 MW Kievtransgas, 4 GPU, total power 100 MW CS Romnenskaya, Sumy region CS Grebenkovskaya, Poltava region Cherkassytransgas, 4 GPU, total power 100 MW CS Sofievskaya, Cherkassy region CS Barskaya, Vinnitsa region 3 (modernization GTK-25/76) 3 (modernization GTK-25/76) 3 (modernization GTK-25/76) Number of gas turbines
2002 2002
1998 1998
1995 1998
19
SRDP GC Zorya-Mashproekt also offers:
Industrial and marine gas turbine engines Gas turbine propulsion plants Gas turbine power plants Gas pumping units Fuel and pneumatic equipment for gas turbine engines Waste heat recovery boilers Another tailor-made industrial equipment
Everybody need reliable machines and reliable partners. We make reliable machines.
GTR&PC Zorya-Mashproekt 42a Oktyabrsky prospekt Nikolaev, 54018, Ukraine. Tel. +38 0512 50-90-40, 50-25-61, 55-69-92, Fax +38 0512 50-90-50, 55-68-68