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Главная Expander-generator 5000 kW

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Expander-generator set with a rating of 5000 kW PDF Печать

PURPOSE AND FIELD OF APPLICATION

Turbo-expander sets TDA are designed to convert gas flow pressure differential into mechanical work and in order to reduce gas pressure.

Combined with a gas-reducing point at a heating and power plant , they are used to drive the turbo-generator at an energy utilization complex


PROCESS FLOW DIAGRAM

The process flow diagram of the turbo-expander set together with a gas-distributing station of a heating and power plant is shown in Figure 1.

The TDA is connected parallel to the gas-reducing point and does not affect its operation.

Natural gas from the gas main is transmitted through gate valve 9, heat exchanger 4 and metering unit 5 to turbo-expander 1, where it expands and, with reduced pressure, goes through gate valve 12 to the user's gas pipeline . As the gas flow to the TDA increases, the gas flow through the gas-reducing point decreases right up to its possible complete closing.

Hot water and steam are used as a heat-transfer medium for gas heating in the heat exchanger 4.

Process Flow Diagram of TDA for Gas-Reducing Point

Fig.1.

1- turbo-expander, 2- turbo-generator, 3- oil cooler, 4-- heat exchanger, 5- metering unit, 6- by-pass unit, 7- turbo-generator air cooler, 8…13 – gate valves

By the flow at the inlet of the turbo-expander 1, the metering unit 5 maintains a constant TDA outlet gas pressure, which lies within the adjustment tolerances. At a normal shutdown or in an emergency, the emergency stop valve of the metering unit 5 will instantly cut off the gas supply to the TDA (operating time 0.2 second).

In an emergency, when the stop valve of the metering unit is closed and there is no gas passage through the turbo-expander 1 but the gas-reducing point has not yet become operational, the designed pressure in the user's gas pipeline is provided by the gas pressure regulator in the by-pass unit 6, which is parallel to the turbo-expander 1, until the gas-reducing point begins to operate.

Gas potential energy is converted into mechanical work of turbo-expander rotor rotation, the latter being connected with the turbo-generator 2 through the reduction gearbox (not reflected on the diagram), thus matching rotational speeds.

Cooling of the oil, applied for the TDA and turbo-generator 2, occurs in the oil cooler at the expense of water. Turbo-generator windings are cooled down in the air cooler 7, according to the closed cycle. Water, which is used for the process, comes from the water supply, shared with the oil cooler 3.


Technical Data on Turbo-Expander Sets

Parameter

 ТDА-2500

ТDА-4000

ТDА-6000

1.Gas flow, ths m3/h 40...85 80...130 130...170
2.Inlet gas pressure, MPa  0,6...1,2 0,6...1,2 0,6...1,2
3.Outlet gas pressure, MPa  0,1...0,2 0,1...0,2 0,1...0,2
4.Inlet gas pressure, ?С  60...100  60...100  60...100
5.Exhaust temperature, ?С minus 15  minus 15  minus 15
6.Power at turbo-generator terminals, kW  see Fig. 2  see Fig. 3  see Fig. 4
7.Turbo-generator speed, rpm 3000 3000 3000
8.Insensitivity level of the gas pressure regulating system, %  0,2 0,2 0,2
9.Overhaul period, h  24000 24000 24000
10.Service life, yr  15 15 15

Fig.3. TDA-4000 output vs gas flow at various inlet gas temperatures


Fig.4. TDA-6000 output vs gas flow at various inlet gas temperatures


TDA DESIGN FEATURES

TDA has a unit-type design: a turbo-expander unit and metering and bypass units in the regulating system. Each unit has a separate frame on which the interacting assemblies and mechanisms are mounted. The turbo-expander unit incorporates a turbo-expander, a reduction gearbox, a shaft line and supporting systems. The metering unit has a metering valve and an emergency stop valve. The bypass unit comprises a gas pressure regulator and a safety valve.

The turbo-expander is a two-stage axial-flow turbine with a compression ratio of 4.8. The nozzle sets have variable blades with a change-over mechanism to provide a wider operational range. Gas-tightening seals are of a hydraulic groove type.

Single-stage helical reduction gearbox, 3.2 gear ratio, plain bearings, circulating force-feed lubrication.

The regulating system includes two units: a metering unit for gas supply and its prompt cut-off , and a bypass unit to compensate a lag in the gas-reducing point operation in case of a TDA sudden shutdown. The units are hydraulically discharged, their valves have puppet shut-off elements.

The turbo-generator is connected with the TDA by means of the shaft line and a coupling with destructible elements.

Lubrication system is a circulating system, force-fed from a separate electric pump unit.

Transducers on the TDA generate signals as regards condition and operational modes of assemblies and systems and provide their transmission to the automatic control system.


PERFORMANCE

  • Automatic or remote startup and load pickup
  • Automatic maintenance and remote regulation of the designed pressure in the pipeline at the turbine outlet
  • Maximum output at various gas parameters
  • Automatic control system
  • Possibility of remote control from the control desk
  • Automatic unattended operation option with the automatic control system available
  • Technical condition control
  • Capability of units' control from a local control desk in the process of maintenance

Protection of friction units during run-outs


UNIT-TYPE DESIGN

  • Replacement of units without complete disassembly
  • Separate location of the automatic control system

PERFORMANCE RELIABILITY

  • Pre-service no-failure round-the-clock performance owing to its operational reliability
  • Capability of maintenance scheduling in accordance with the requirements of an operational mode, due to operational reliability
  • Reliability provided by production quality control

SERVICE

  • Installation under Manufacturer's supervision
  • Adjustment and start-up operations, commissionin
  • Training of the Customer's technical personnel
  • Guarantee and post-guarantee maintenance, repair
  • Manufacturer's supervision
  • Consulting

EQUIPMENT DELIVERY OPTIONS

  • Turbo-expander unit, including:
    - turbo-expander
    - reduction gearbox
    - shaft line
    - supporting system
  • Dosing unit, including:
    - metering valve
    - emergency stop valve
  • Bypass unit, including:
    - gas pressure regulator
    - safety valve
  • Packages for all units
  • SPTA set
  • Set of special tools and devices
  • Set of assembly parts
  • Set of operational documents
  • Possibility of custom-made packaged electric power plant supply, including:
    - turbo-generator unit
    - electrical equipment unit

For the maximum benefit and flexibility, a Customer may order a range of equipment at his choice


DEVELOPMENT POTENTIAL

Custom-made turbo-expander sets can be delivered to a Client, with various economically expedient gas rates, outputs of 100 to 2500 kW and inlet pressure of 0.3 to 1.2 MPa.


Application

Number

Russia
DGА-5000

ТEZ-21

ОАО Mosenergo,

Moskow

2

Belarus
DGА-5000

Nowolukoml GRES-1

ОАО Gomelenergo

   
 
 
 
   
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