MOTOR SICH EG-6000 AND EG-8000 GAS-TURBINE POWER GENERATING SETS 1
MOTOR SICH JSC: GENERAL INFORMATION Zaporozhye Motor Sich Public Joint Stock Company, with its headquarters plant established in 1916, since then has gained a firm and worthy status among the world s leading aircraft engine manufacturers. Long way has been passed from creating and putting into production aircraft piston water-cooled engines to production of up-to-date, competitive on the world market, turbojets, turbofans, turbopropfans as well as gas-turbine drives (GTD) and power generating units. Several tens of thousands of engines manufactured by the Company are operated in 61 models of airplanes and helicopters in 114 countries of the world. Vyacheslav A. Boguslayev, Chairman of Board Motor Sich JSC quality system is certified by Bureau Veritas Quality International (BVQI) for conformity to International Standard ISO-9001 (also accredited in the USA) as regards production, overhaul and maintenance of aeroengines, GTD of the D-336 family and designing the gas turbine power generating units. Production of aeroengines is certified by the Aviation Register of Interstate Aviation Committee (IAC) and the State Aviation Administration of Ukraine. Motor Sich JSC is sertified by the Aviation Register of IAC as the Designer and the overhauling agency of aeroengines. Motor Sich JSC has certified production of GTD and quality system relating to production, overhaul and maintenance of GTD in accordance with certification system GOST R (Russia). High quality and reliability of manufactured articles are ensured by the use of advanced technologies, modern equi pment and high level of production engineering. Services provided: marketing, export and import, warranty and post-warranty servicing, overhaul and running repairs, training of technical personnel, establishing overhaul facilities, selling licences, patents and know-how. You may find Motor Sich not only as a highly potential and efficient Company but as a reliable partner as well, ready to satisfy customer s demands. 2
PART I FAMILY OF POWER GENERATING SETS EG-6000 AND EG-8000 3
FAMILY OF POWER GENERATING SETS EG-6000 AND EG-8000 EG-8000 EG-6000 2003 start of production 2001 start of production 4
PURPOSE AND FIELD OF APPLICATION Modular-transportable gas-turbine power generating sets EG-6000T-Ò10500-3VNMIUKHL1 (EG-6000) and EG-8000T-T10500-3VNM1TS1 (EG-8000) are designed to supply electric power to industrial and residential consumers at base load and semi-peak load. The sets can supply power to individual consumer and operate in parallel with electric power system of any power, for which purpose they are furnished with all necessary equipment. The power generating sets operate within the temperature range of 60 Ñ to + 60 Ñ at relative humidity up to 90% at altitude up to 1000 m depending on version. 5
BASIC SPECIFICATIONS EG - 6 000 EG - 8 000 Power, kw: rated 6 000 7 830 maximum 7 200 7 830 Three-phase alternating current voltage, V 10 500 10 500(11 000) Current frequency, Hz 50 50 Fuel natural or casing-head gas Gas cosumption at rated power, kg/h 1 510 1 875 Drive effective efficiency at rated power, % 32 32.5 Overall dimensions, m: (when assembled) length 13.70 15 width 9.50 9.50 height 11.77 11.77 Mass, t 75 80 6
ELECTRIC POWER QUALITY In steady state thermal condition at unchangeable balanced load: steady state voltage deviation, % ±1 steady state frequency deviation, % ±0.5 At 50% shedding/surging of the load: transient voltage deviation, % ±20 transient frequency deviation, % ±10 Duration of transient process of voltage and frequency recovery (within specified limits) at 50% shedding/surging of the loads, s, not more than ±5 7
ECOLOGICAL INDICES EG - 6 000 EG - 8 000 The equivalent noise level measured at a distance of 1 m from external contour of power generating unit, db(a) 80 80 The content of harmful emissions in exhaust gases when operating at rated load, mg/nm 3 NO x 150 150 ÑÎ 300 300 8
RELIABILITY INDICES EG - 6 000 EG - 8 000 First overhaul life and T.B.O., h 25 000 25 000 Total service life, h 100 000 100 000 Service life, years 12 12 Reliability is ensured by: high level of design development; up-to-date engineering basis; high culture of production. 9
POWER GENERATING SET DESIGN Power generating set features modular design which helps to provide for prompt transportation and installation at the place of operation and minimum time to be started. All supplied modules are subjected to full-load test at the manufacturing plant in order to avoid any unexpected malfunctions. Basic modules of power generating set are as follows: power generating set container; inlet section noise suppressor; exhaust unit noise suppressor; control unit. 10
Power generating sets are furnished with the following systems, which provide for self-contained operation of the units, independently from external power sources: lubrication system fuel supply system cooling and ventilation system automatic control and monitoring system starting system high voltage equipment system low voltage equi pment system heating system noise suppressing system fire extinguishing system gas alarm system vibration survey system POWER GENERATING SET SERVICEABILITY SYSTEMS 11
MODULES AND UNITS OF POWER GENERATING SET 12
POWER GENERATING UNIT CONTAINER 1 Container 5 Reduction Gear 2 Inlet Section 6 Friction Clutch 3 Gas-Turbine Drive 7 Synchronous Generator 4 Exhaust Unit 13
SYNCHRONOUS GENERATOR EG-6000 EG-8000 Type ÒÊ-6-2-RU3 GTG-8-2RT3(U3) Current three-phase, alternating Power: active, kw 6 000 8 000 full, kv À 7 500 10 000 Voltage, V 10 500 10 500(11 000) Current frequency, Hz 50 50 Rotor speed, rpm 3 000 3 000 Efficiency, % 97.4 97.5 Mass, t 20.2 28.0 14
SYNCHRONOUS GENERATOR The enclosed-type turbogenerator of reduced weight and overall dimensions is furnished with ventilation and air-cleaning system. The excitation is effected by means of brushless system. 15
REDUCTION GEAR OF HIGH EFFICIENCY AND RELIABILITY FEATURING REDUCED OVERALL DIMENSIONS AND LOW MASS Type two-stage Rotational speed, rpm: of driven shaft 8560 of driving shaft 3000 Efficiency, % 99.5 Mass, kg (lb) 650 (1433) 16
INLET SECTION NOISE SUPPRESSOR Featuring: high efficiency relatively small overall dimensions high standard of protection against ingress of foreign objects and precipitations into air-gas flow duct 17
EXHAUST UNIT NOISE SUPPRESSOR Featuring: plate-type, two-stage design; ensures reduction of noise level down to sanitary norms. 18
OPERATOR'S ROOM Operator's room is the working station of the power generating unit operator and accommodates the following: Switch gear cabinets KRUPE-10-20 for EG-6000: ShTI1-N, ShTI2-N cabinets with current and voltage measuring transformers; ShVV1-N cabinet with HV circuit breaker; ShTS cabinet with auxiliary transformer; ShKA cabinet with overvoltage limiter; Operator working station with control automatic equipment; Auxiliary equipment. Switch gear cabinets KRUPE-10-20 for EG-8000: PU-G generator control panel; ShVV1 cabinet; ShT1 cabinet; ShR cabinet. 19
DELIVERY SET The power generating unit delivery set includes the following: construction modules and systems ensuring self-contained operation of the unit; kit of tools and mounting appliances operation and maintenance documentation set of spare parts for the whole maintenance warranty period. 20
IN-SERVICE MAINTENANCE LOW OPERATION COSTS: minimum capital expenditure for preparing the operating site, fuel supply, reception of generated electric power low maintenance costs self-supply with power long service life high operational stability low fuel consumption insignificant irretrievable oil losses 21
IN-SERVICE MAINTENANCE EASE OF MAINTENANCE: easy access to specific zones for inspections and adjustments remote monitoring and assessment of power generating set equipment condition set of spare parts and all necessary tools give possibility to correct any malfunction SERVICING: timely delivery of modules and accessories to replace those with expired service life 'on-condition' maintenance theoretical and practical training of Customer's specialists at the manufacturing plant or in the place of unit operation anywhere in the world supply in case of necessity of a reserve gas-turbine drive to ensure uninterrupted functioning of the power generating set for the whole period of overhaul deputing of experts for the time of power generating set starting and operation are provided and supervised by the Manufacturer delivery of units and modules required for running repair is ensured 22
REPAIR SERVICES Gas-turbine drive and reduction gear are overhauled at the manufacturing plant manufacturer is ready to cooperate with companies which intend to establish the overhauling facilities of their own. 23
PART II FAMILY OF GAS-TURBINE DRIVES GTE-6.3/MS AND GTE-8/MS 24
FAMILY OF GAS-TURBINE DRIVES GTE-6.3/MS AND GTE-8/MS GTE-6.3/MS GTE-8/MS 25
PURPOSE AND FIELD OF APPLICATION OF GTE-6.3/MS AND GTE-8/MS GTE-6.3/MS and GTE-8/MS gas-turbine drives are designed to drive the synchronous 3-phase AC generator through reduction gear. The drives are incorporated into modular-transportable power generating sets EG-6000, EG- 8000, and operate within range of temperatures from 213 to 323 Ê (-60 C to +60 Ñ) at elevation up to 1000 m above sea level. The drives can be operated on natural gas or liquid fuel (achieved by replacement of fuel equi pment and combustion chamber). 26
SPECIFICATIONS GTE-6.3/MS GTE-8/MS Rated power conditions (sea level, ISA): Power, kw (hp) 6300 (8442) 8000 (10720) Net efficiency, % 32.0 32.5 Minimum power conditions (sea level, ISA): Power, kw (hp) 2000 (2682) 2000 (2682) EGT, K ( C) 704 (431) 725 (452) Rated power turbine rotor rotational speed, rpm (c -1 ) 8560 (146.67) 8560 (146.67) Mass, kg (lb) 1470 +30 (3240 +65 ) 1470 +30 (3240 +65 ) 27
CHARACTERISTICS OF GTD Characteristic of GTD power GTE-6.3/MS (with no losses at reduction gear, generator and power generating set auxiliaries taken into account) Characteristic of GTD power GTE-8/MS (with no losses at reduction gear, generator and power generating set auxiliaries taken into account) Ne 8000 7560 7000 kw hð 10130 10000 Max power Ne=7560kW=10130hð Ne kw hð 9000 12000 11000 10720 8000 Ìàõ power (Rated power)ne=8000kw=10720hð 6300 6000 9000 8442 8000 Rated power Ne=6300kW=8442hð 7000 10000 9000 5000 7000 6000 8000 6000 5000 7000 4000 5000 4000 6000 5000 3000 4000 3000 4000 2000 3000 2682 Ìin power Ne=2000kW=2682hð 272 2000 213 223 233 243 253 263 273 283 288 293 303 313 323 333 Ê 1000-60 -50-40 -30-20 -10-1 0 10 15 20 30 40 50 60 Ñ 2000 t 1000 amb 3000 2682 Ìin power Ne=2000kW=2682hð 213 2000 223 233 243 253 263 273 283 288 293 303 313 323 333-60 -50-40 -30-20 -10 0 10 15 20 30 40 50 60 Ê Ñ t amb 1hð=0.7457 kw 1hð=0.7457 kw 28
CHARACTERISTICS OF GTD GTD GTE-6.3/MS net efficiency versus power at P amb ISA, t amb =15 0 Ñ (288Ê) and n PT =8560 rpm (146.67ñ -1 ) GTD GTE-8/MS net efficiency versus power at P amb ISA, t amb =15 0 Ñ (288Ê) and n PT =8560 rpm (146.67ñ -1 ) η e % η e % 33 34 32 33 32,5 31 32 30 31 29 30 28 27 26 25 29 28 27 26 25 24 24 23 23 22 22 21 2682 8442 10130 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 hð 20 Ne 1000 2000 3000 4000 5000 6000 6300 7000 7560 8000 kw 21 2682 10720 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 20 1000 2000 3000 4000 5000 6000 7000 8000 9000 hð kw Ne 1hð=0.7457 kw 1hð=0.7457 kw 29
CHARACTERISTICS OF GTD Altitude correction factor to determine available power P amb δ =, where δ correction factor; P amb ISA P amb ambient pressure at a spesific altitude, mm Hg (kpà, in Hg, psia); P amb ISA 760 mm Hg (101kPà; 29.83 in Hg; 14.7psia) Ð amb ISA Ð amb, mm Hg Ð amb, kpà Ð amb, in Hg Ð amb, psia 30
DESIGN OF GTE-6.3/MS AND GTE-8/MS DRIVES The GTE-6.3/MS and GTE-8/MS feature a three-shaft design with the axial two-rotor thirteenstage compressor (LPC and HPC), intermediate casing, annular combustion chamber, two stages of compressors turbines (HPT and LPT), two-stage power turbine and exhaust unit. The compressor incorporates two independent rotors, each driven by its own turbine, thus forming a low pressure and high pressure spools. The rotors rotate at different rotational speeds, optimum for each rotor, and are linked to each other and to power turbine rotor only by the gas-dynamic link. The rotors supporting system employs six bearings, i.e. each of the three rotors runs in two bearings. The start-up is performed from electric starter by transmitting torgue to high pressure rotor via upper uccessory drive gearbox. The drive operates as follows: air entering the engine inlet is compressed in the LP and HP compressors and delivered into the combustion chamber, wherein it gets mixed with natural gas or liquid fuel supplied through the fuel burners to produce fuel-air mixture. The temperature of gas flow rises due to combustion of this mixture. Gas comes to the turbine, where the gas flow energy is converted into mechanical work used for driving the LP and HP compressors and the generator which is driven through reduction gear. 31
LONGITUDINAL SECTION OF GTE-6.3/MS LPC Intermediate casing HPT LPT Power turbine HPC Combustion chamber Tapered boom Power shafting 32
LONGITUDINAL SECTION OF GTE-8/MS LPC Intermediate casing HPT LPT Power turbine HPC Combustion chamber Tapered boom Power shaft-drive 33
MODULES OF GTE-6.3/MS AND GTE-8/MS The engine design is based on the modular principle. The drive is broken down into nine basic modules, and each of them is a complete design and production assembly and can be (except for the main, the second, module) dismantled and replaced without removal of the engine from power generating unit. The drive modular design provides for possibility of restoring its operational serviceability by replacing parts and assemblies in service. 34
MODULES OF GTE-6.3/MS 1 Low-pressure compressor; 5 High-pressure and low-pressure turbines 2 Intermediate casing and high-pressure support case; compressor assembly (Main module); 6 Low-pressure turbine rotor; 3 Combustion chamber; 7 Power turbine; 4 High-pressure turbine rotor; 8 Tapered boom; 9 Power shaft-drive. 35
MODULES OF GTE-8/MS 1 Low-pressure compressor ; 5 High-pressure and low-pressure turbines 2 Intermediate casing and high-pressure support case; compressor assembly (Main module); 6 Low-pressure turbine rotor; 3 Combustion chamber; 7 Power turbine; 4 High-pressure turbine rotor; 8 Tapered boom; 9 Power shaft-drive. 36
ECOLOGICAL CHARACTERISTICS GTE-6.3/MS The level of harmful matters mg/nm 3 (ppm) contained in exhaust gas at nominal power condition. 300 (240) 45 (21.9) GTE-6.3/MS 150 (73) Level to State Standard (GOST) 28775-90 80 (64) GTE-6.3/MS Level to State Standard (GOST) 28775-90 NO x CO 37
ECOLOGICAL CHARACTERISTICS GTE-8/MS The level of harmful matters mg/nm 3 (ppm) contained in exhaust gas at nominal power condition. 300(240) 50 (24.3) GTE-8/MS 150 (73) Level to State Standard (GOST) 28775-90 80 (64) GTE-8/MS Level to State Standard (GOST) 28775-90 NO x CO 38
CONTROLLABILITY The efficient and safe operation of the GTE-6.3/MS and the GTE-8/MS on on condition basis is ensured by the high level of their controllability. The running monitoring of the GTE-6.3/MS and the GTE-8/MS is effected utilizing 15 condition monitoring parameters and 50 messages about GTD condition monitoring. The automatic control system (ACS) of the GTE-6.3/MC and the GTE-8/MC permits to timely receive information about the state and trend of the GTD and its systems principal parameters changing and to predict the GTD and its systems technical condition on the basis of collected information. The GTD design provides for periodical inspection of the air-gas flow duct parts and assembly units (compressors and turbines rotor blades of all stages, outer surface of the combustion chamber flame tube) through special observation ports with the use of optical instrument to assess the technical condition of the parts. Special places are provided on the GTD for taking samples of oil to be periodically checked for presence of wear products. The GTD is also furnished with a required quantity of chi p detectors and three overheat/chi p detectors. 39
TECHNICAL SUPPORT OF GTE-6.3/MS AND GTE-8/MS OPERATION Technical support of engines and GTD operation is effected by the wide network of Product Support Department (PSD) experts. PSD is a basic link between the Company and operators: It has its representatives at more than 100 sites worldwide; It sends its representatives to Operator when sending to operation engines, incorporated by airplane/helicopter or GTD, incorporated by the units of industrial application; It maintains full cooperation with the representatives at the sites 24 hours a day. PSD provides for: warranty and post-warranty servicing of the engines/gtd in any region of the world; efficiency and timeliness in correction of faults; timely and efficient response to satisfy requests of the Operators; accumulation and processing of data related to engines /GTD operation for their further improvement; performing works at Operators facilities aimed at further increase of reliability of the engines/gtd and improvement of their technical characteristics; restoration of engines/gtd in service by replacing engine units and modules; preparation and rendering the «engineering-type» services; operation of engines/gtd on «on condition» basis; proficient consultations for all the matters concerning operation of engines/gtd; theoretical and practical training of the Operators specialists anywhere in the world. 40
DESIGNER AND MANUFACTURER: MOTOR SICH JSC Zaporozhye 69068, Ukraine Phone: (380612) 61-49-53, 65-69-65 Fax: (380612) 61-45-52, 65-01-60 E-mail: untv.vtf@motorsich.com www.motorsich.com 10.2003 ÎÀÎ «Ìîòîð Ñè» çàê. 3831 òèð. 15