Главная Expander-generator set with a rating of 6000 kW

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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-distributing station on a gas main, they are used to drive the turbo-generator at an energy utilization complex.


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

The TDA is connected parallel to a gas-distributing station 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 the 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-distributing station decreases right up to a possible complete closing of the latter.

Natural gas combustion products, extracted from the gas main, are used as a heat-transfer medium for gas heating in the heat exchanger 4.

Process Flow Diagram of TDA for Gas-Distributing Station


1- turbo-expander, 2- turbo-generator, 3- oil cooler, 4- gas heater, 5- metering unit, 6- bypass unit, 7- turbo-generator air cooler, 8…13 – gate valves

By throttling gas 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 standard shutdown or in an emergency, the emergency stop valve of the metering unit 5 will instantly cut off 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-distributing station 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-distributing station 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 by means of 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





1.Gas flow, ths m3/h 40...80 120...160 130...170
2.Inlet gas pressure, MPa  6...4 6...4 6...4
3.Outlet gas pressure, MPa  0,6...1,2 0,6...1,2 0,6...1,2
4.Inlet gas temperature, ?С  60...100  60...100  60...100
5.Exhaust temperature, ?С  15...0  15...0  15...0
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.2 TDA-2500VD output vs. gas flow at various angles of blades in the nozzle set

Fig.3. TDA-4000VD output vs. gas flow at various outlet pressures and inlet gas temperatures


The 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 three-stage axial-flow turbine with a compression ratio of 3.77. The first two stages of the nozzle set 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-distributing station 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.

The 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.


  • Automatic or remote startup and load pickup
  • Automatic maintenance and remote regulation of the designed pressure in the pipeline at the turbine outlet
  • Maximum power 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


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


  • 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 is provided by production quality control.


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


  • 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 documentation
  • 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


Custom-made turbo-expander sets can be delivered to a Customer, with various economically expedient gas rates, with outputs of 1000 to 2500 kW and an inlet pressure range of 3 to 6 MPa.