Open Access Open Access  Restricted Access Access granted  Restricted Access Subscription Access

Vol 63, No 8 (2016)

Steam-Turbines, Gas-Turbines, Combined-Cycle Power Plants, and Their Auxiliaries

Problems in creation of modern air inlet filters of power gas turbine plants in Russia and methods of their solving

Mikhaylov V.E., Khomenok L.A., Sherapov V.V.

Abstract

The main problems in creation and operation of modern air inlet paths of gas turbine plants installed as part of combined-cycle plants in Russia are presented. It is noted that design features of air inlet filters shall be formed at the stage of the technical assignment not only considering the requirements of gas turbine plant manufacturer but also climatic conditions, local atmospheric air dustiness, and a number of other factors. The recommendations on completing of filtration system for air inlet filter of power gas turbine plants depending on the facility location are given, specific defects in design and experience in operation of imported air inlet paths are analyzed, and influence of cycle air preparation quality for gas turbine plant on value of operating expenses and cost of repair works is noted. Air treatment equipment of various manufacturers, influence of aerodynamic characteristics on operation of air inlet filters, features of filtration system operation, anti-icing system, weather canopies, and other elements of air inlet paths are considered. It is shown that nonuniformity of air flow velocity fields in clean air chamber has a negative effect on capacity and aerodynamic resistance of air inlet filter. Besides, the necessity in installation of a sufficient number of differential pressure transmitters allowing controlling state of each treatment stage not being limited to one measurement of total differential pressure in the filtration system is noted in the article. According to the results of the analysis trends and methods for modernization of available equipment for air inlet path, the importance of creation and implementation of new technologies for manufacturing of filtering elements on sites of Russia within the limits of import substitution are given, and measures on reliability improvement and energy efficiency for air inlet filter are considered.

Thermal Engineering. 2016;63(8):529-535
pages 529-535 views

Thermal tests of the SGT5-4000F gas-turbine plant of the PGU-420T power-generating unit at Combined Heat And Power Plant 16 of Mosenergo

Teplov B.D., Radin Y.A., Filin A.A., Rudenko D.V.

Abstract

In December 2014, the PGU-420T power-generating unit was put into operation at the Combined Heat and Power Plant 16, an affiliated company of PAO Mosenergo. In 2014–2015, thermal tests of the SGT5- 4000F gas-turbine plant (GTP) integrated into the power-generating unit were carried out. In the article, the test conditions are described and the test results are presented and analyzed. During the tests, 92 operating modes within a wide range of electrical loads and ambient air temperatures and operating conditions of the GTP when fired with fuel oil were investigated. In the tests, an authorized automated measuring system was applied. The experimental data were processed according to ISO 2314:2009 “Gas turbines—Acceptance tests” standard. The available capacity and the GTP efficiency vary from 266 MW and 38.8% to 302 MW and 39.8%, respectively, within the ambient air temperature range from +24 to–12°С, while the turbine inlet temperature decreases from 1200 to 1250°С. The switch to firing fuel oil results in a reduction in the turbine inlet temperature and the capacity of the GTP. With the full load and a reduction in the ambient temperature from +24 to–12°C, the compressor efficiency decreases from 89.6 to 86.4%. The turbine efficiency is approximately 89–91%. Within the investigated range of power output, the emissions of nitrogen oxides do not exceed 35 ppm for the gas-fired plant and 65 ppm for the fuel-oil-fired plant. Within the range of the GTP power output from 50 to 100% of the rated output, the combustion chamber operates without underburning and with hardly any CO being formed. At low loads close to the no-load operation mode, the CO emissions drastically increase.

Thermal Engineering. 2016;63(8):536-543
pages 536-543 views

Development of a self-contained device for rapid detection of volatile impurities in the oil system of a turbine

Starostin A.A., Shangin V.V., Bukhman V.G., Volosnikov D.V., Skripov P.V.

Abstract

The research is devoted to development of a self-contained device for rapid detection of volatile impurities in the oil system of a turbine and testing it using the operating equipment. The device consists of a remote sensor, whose sensitive element is a 3–5-mm long wire probe 20 microns in diameter, and a measurement unit that comprises a microcontroller with a set of peripherals. The design of the device enables automation of the measurement procedure with a minimum number of preset settings and real-time output of information to the operator console. The software of the device provides two-stage pulse heating of the wire probe and a resistance temperature detector. The two-stage mode proves to be the most sensitive to appearance in the system of moisture, including its trace amounts. The characteristic time of the heating is of the order of 10 ms. The measurement procedure is based on a method that consists in automatic search for spontaneous boiling-up temperature of the oil accompanied by a characteristic response signal. The results were interpreted by formal correlation of the measured values with an array of calibration data obtained in similar experiments with well-defined oil samples. An experimental method for application of the device has been developed that takes into account technological factors, such as comparatively high values of the flow rate and the temperature of the oil in locations of the oil drain from bearings, the variability of these values, and the variety of noise types that accompany the operation of the thermal power equipment that complicate the online measurements. Tests of the device were carried out in locations of oil drain from supporting bearings. The test results have demonstrated the possibility of applying the device directly in the oil system of a turbine and provided a practical basis for development of a system of multipoint control of the technological scheme in real time.

Thermal Engineering. 2016;63(8):544-550
pages 544-550 views

Estimation of lifespan and economy parameters of steam-turbine power units in thermal power plants using varying regimes

Aminov R.Z., Shkret A.F., Garievskii M.V.

Abstract

The use of potent power units in thermal and nuclear power plants in order to regulate the loads results in intense wear of power generating equipment and reduction in cost efficiency of their operation. We review the methodology of a quantitative assessment of the lifespan and wear of steam-turbine power units and estimate the effect of various operation regimes upon their efficiency. To assess the power units’ equipment wear, we suggest using the concept of a turbine’s equivalent lifespan. We give calculation formulae and an example of calculation of the lifespan of a steam-turbine power unit for supercritical parameters of steam for different options of its loading. The equivalent lifespan exceeds the turbine’s assigned lifespan only provided daily shutdown of the power unit during the night off-peak time. We obtained the engineering and economical indices of the power unit operation for different loading regulation options in daily and weekly diagrams. We proved the change in the prime cost of electric power depending on the operation regimes and annual daily number of unloading (non-use) of the power unit’s installed capacity. According to the calculation results, the prime cost of electric power for the assumed initial data varies from 11.3 cents/(kW h) in the basic regime of power unit operation (with an equivalent operation time of 166700 hours) to 15.5 cents/(kW h) in the regime with night and holiday shutdowns. The reduction of using the installed capacity of power unit at varying regimes from 3.5 to 11.9 hours per day can increase the prime cost of energy from 4.2 to 37.4%. Furthermore, repair and maintenance costs grow by 4.5% and by 3 times, respectively, in comparison with the basic regime. These results indicate the need to create special maneuverable equipment for working in the varying section of the electric load diagram.

Thermal Engineering. 2016;63(8):551-557
pages 551-557 views

Electrical Part of Thermal and Nuclear Power Plants

Diagnostics of the power oil-filled transformer equipment of thermal power plants

Eltyshev D.K., Khoroshev N.I.

Abstract

Problems concerning improvement of the diagnostics efficiency of the electrical facilities and functioning of the generation and distribution systems through the examples of the power oil-filled transformers, as the responsible elements referring to the electrical part of thermal power plants (TPP), were considered. Research activity is based on the fuzzy logic system allowing working both with statistical and expert information presented in the form of knowledge accumulated during operation of the power oil-filled transformer facilities. The diagnostic algorithm for various types of transformers, with the use of the intellectual estimation model of its thermal state on the basis of the key diagnostic parameters and fuzzy inference hierarchy, was developed. Criteria for taking measures allowing preventing emergencies in the electric power systems were developed. The fuzzy hierarchical model for the state assessment of the power oil-filled transformers of 110 kV, possessing high degree of credibility and setting quite strict requirements to the limits of variables of the equipment diagnostic parameters, was developed. The most frequent defects of the transformer standard elements, related with the disturbance of the isolation properties and instrumentation operation, were revealed after model testing on the real object. Presented results may be used both for the express diagnostics of the transformers state without disconnection from the power line and for more detailed analysis of the defects causes on the basis of the advanced list of the diagnostic parameters; information on those parameters may be received only after complete or partial disconnection.

Thermal Engineering. 2016;63(8):558-566
pages 558-566 views

Nuclear Power Stations

Experimental studies of local coolant hydrodynamics using a scaled model of cassette-type fuel assembly of a KLT-40S reactor

Dmitriev S.M., Barinov A.A., Varentsov A.V., Doronkov D.V., Solntsev D.N., Khrobostov A.E.

Abstract

The results of experimental studies of local hydrodynamic and mass exchange characteristics of the coolant flow behind the spacer grid in the fuel assembly of a KLT-40S reactor are presented. The experiments were aimed at the investigation of representative domains of the fuel assembly with three tracer injection regions. The studies were performed at the aerodynamic test facility using the tracer gas diffusion method. According to the theory of hydrodynamic similarity, the obtained experimental results can be transferred to full-scale coolant flow conditions in standard fuel assemblies. The analysis of the tracer concentration propagation made it possible to determine in detail the flow pattern and find the main regularities and specific features of the coolant flow behind the plate spacer grid of KLT-40S fuel assembly. The hydraulic resistance coefficient of the spacer grid was experimentally determined. The coefficients of mass exchange between cells for representative cells of the displacer region in the KLT-40S fuel assembly were calculated for the first time; these results are presented in the form of the “mixing matrix.” The results of studies of local coolant flow hydrodynamics in the KLT-40S fuel assembly are used at AO Afrikantov OKBM for estimation of thermotechnical reliability of active cores for reactors of floating nuclear power stations. The experimental data on hydrodynamic and mass exchange characteristics are included in the database for verification of CDF codes and detailed cell-wise calculation of the active core for KLT-40S reactor installation. The results of these studies can be used at FSUE RFNC-VNIIEF for testing and verification of domestic three-dimensional hydrodynamic CFD codes (“Logos”) that are applied for substantiation of newly designed reactor installations. Practical recommendations on the application of the obtained results in thermohydraulic calculations of the active core for the KLT-40S reactor will be worked out. Proposals on further improvement of structural elements of active cores in the considered nuclear power installations will also be presented.

Thermal Engineering. 2016;63(8):567-574
pages 567-574 views

Procedure of calculation of the spatial distribution of temperatures and heat fluxes in the steam generator of a nuclear power installation with an RBEC fast-neutron reactor

Frolov A.A., Sedov A.A.

Abstract

A method for combined 3D/1D-modeling of thermohydraulics of a once-through steam generator (SG) based on the joint analysis of three-dimensional thermo- and hydrodynamics of a single-phase heating coolant in the intertube space and one-dimensional thermohydraulics of steam-generating channels (tubes) with the use of well-known friction and heat-transfer correlations under various boiling conditions is discussed. This method allows one to determine the spatial distribution of temperatures and heat fluxes of heat-exchange surfaces of SGs with a single-phase heating coolant in the intertube space and with steam generation within tubes. The method was applied in the analytical investigation of typical operation of a once-through SG of a nuclear power installation with an RBEC fast-neutron heavy-metal reactor that is being designed by Kurchatov Institute in collaboration with OKB GIDROPRESS and Leipunsky Institute of Physics and Power Engineering. Flow pattern and temperature fields were obtained for the heavy-metal heating coolant in the intertube space. Nonuniformities of heating of the steam–water coolant in different heat-exchange tubes and nonuniformities in the distribution of heat fluxes at SG heat-exchange surfaces were revealed.

Thermal Engineering. 2016;63(8):575-580
pages 575-580 views

Environmental Protection

Current state of nuclear fuel cycles in nuclear engineering and trends in their development according to the environmental safety requirements

Vislov I.S., Pischulin V.P., Kladiev S.N., Slobodyan S.M.

Abstract

The state and trends in the development of nuclear fuel cycles in nuclear engineering, taking into account the ecological aspects of using nuclear power plants, are considered. An analysis of advantages and disadvantages of nuclear engineering, compared with thermal engineering based on organic fuel types, was carried out. Spent nuclear fuel (SNF) reprocessing is an important task in the nuclear industry, since fuel unloaded from modern reactors of any type contains a large amount of radioactive elements that are harmful to the environment. On the other hand, the newly generated isotopes of uranium and plutonium should be reused to fabricate new nuclear fuel. The spent nuclear fuel also includes other types of fission products. Conditions for SNF handling are determined by ecological and economic factors. When choosing a certain handling method, one should assess these factors at all stages of its implementation. There are two main methods of SNF handling: open nuclear fuel cycle, with spent nuclear fuel assemblies (NFAs) that are held in storage facilities with their consequent disposal, and closed nuclear fuel cycle, with separation of uranium and plutonium, their purification from fission products, and use for producing new fuel batches. The development of effective closed fuel cycles using mixed uranium–plutonium fuel can provide a successful development of the nuclear industry only under the conditions of implementation of novel effective technological treatment processes that meet strict requirements of environmental safety and reliability of process equipment being applied. The diversity of technological processes is determined by different types of NFA devices and construction materials being used, as well as by the composition that depends on nuclear fuel components and operational conditions for assemblies in the nuclear power reactor. This work provides an overview of technological processes of SNF treatment and methods of handling of nuclear fuel assemblies. Based on analysis of modern engineering solutions on SNF regeneration, it has been concluded that new reprocessing technologies should meet the ecological safety requirements, provide a more extensive use of the resource base of nuclear engineering, allow the production of valuable and trace elements on an industrial scale, and decrease radioactive waste release.

Thermal Engineering. 2016;63(8):581-586
pages 581-586 views

Steam Boilers, Power-Plant Fuel, Burner Facilities, and Boiler Accessories

Thermal gain of CHP steam generator plants and heat supply systems

Ziganshina S.K., Kudinov A.A.

Abstract

Heating calculation of the surface condensate heat recovery unit (HRU) installed behind the BKZ-420-140 NGM boiler resulting in determination of HRU heat output according to fire gas value parameters at the heat recovery unit inlet and its outlet, heated water quantity, combustion efficiency per boiler as a result of installation of HRU, and steam condensate discharge from combustion products at its cooling below condensing point and HRU heat exchange area has been performed. Inspection results of Samara CHP BKZ-420-140 NGM power boilers and field tests of the surface condensate heat recovery unit (HRU) made on the bimetal calorifier base КСк-4-11 (KSk-4-11) installed behind station no. 2 Ulyanovsk CHP-3 DE-10-14 GM boiler were the basis of calculation. Integration of the surface condensation heat recovery unit behind a steam boiler rendered it possible to increase combustion efficiency and simultaneously decrease nitrogen oxide content in exit gases. Influence of the blowing air moisture content, the excess-air coefficient in exit gases, and exit gases temperature at the HRU outlet on steam condensate amount discharge from combustion products at its cooling below condensing point has been analyzed. The steam condensate from HRU gases is offered as heat system make-up water after degasification. The cost-effectiveness analysis of HRU installation behind the Samara CHP BKZ-420-140 NGM steam boiler with consideration of heat energy and chemically purified water economy has been performed. Calculation data for boilers with different heat output has been generalized.

Thermal Engineering. 2016;63(8):587-591
pages 587-591 views

District Heating Cogeneration and Heat Networks

Definition of hydraulic stability of KVGM-100 hot-water boiler and minimum water flow rate

Belov A.A., Ozerov A.N., Usikov N.V., Shkondin I.A.

Abstract

In domestic power engineering, the methods of quantitative and qualitative-quantitative adjusting the load of the heat supply systems are widely distributed; furthermore, during the greater part of the heating period, the actual discharge of network water is less than estimated values when changing to quantitative adjustment. Hence, the hydraulic circuits of hot-water boilers should ensure the water velocities, minimizing the scale formation and excluding the formation of stagnant zones. The results of the calculations of hot-water KVGM-100 boiler and minimum water flow rate for the basic and peak modes at the fulfillment of condition of the lack of surface boil are presented in the article. The minimal flow rates of water at its underheating to the saturation state and the thermal flows in the furnace chamber were defined. The boiler hydraulic calculation was performed using the “Hydraulic” program, and the analysis of permissible and actual velocities of the water movement in the pipes of the heating surfaces was carried out. Based on the thermal calculations of furnace chamber and thermal- hydraulic calculations of heating surfaces, the following conclusions were drawn: the minimum velocity of water movement (by condition of boiling surface) at lifting movement of environment increases from 0.64 to 0.79 m/s; it increases from 1.14 to 1.38 m/s at down movement of environmental; the minimum water flow rate by the boiler in the basic mode (by condition of the surface boiling) increased from 887 t/h at the load of 20% up to 1074 t/h at the load of 100%. The minimum flow rate is 1074 t/h at nominal load and is achieved at the pressure at the boiler outlet equal to 1.1 MPa; the minimum water flow rate by the boiler in the peak mode by condition of surface boiling increases from 1669 t/h at the load of 20% up to 2021 t/h at the load of 100%.

Thermal Engineering. 2016;63(8):592-600
pages 592-600 views

Energy Saving, New, and Renewal Sources of Energy

World Geothermal Congress WGC-2015

Tomarov G.V., Shipkov A.A.

Abstract

This article discusses materials and results of the World Geothermal Congress that was held in Melbourne (Australia) from April 19 to April 25, 2015. Information on the extent and technological features of utilization of geothermal resources for heat supply and power production, as well as in other economic areas, is given. A stable growth in the capacity and number of geothermal power systems that is determined by ecological cleanliness, economic efficiency, and the highest (among renewable energy sources) indicators of installed capacity utilization is shown. It was noted that combined schemes of geothermal power plants (GPPs), such as turbine units of different type (binary units, units with one or two separation pressures, etc.), have become more frequently used to increase the efficiency of utilization of geothermal heat carrier. Actual data determining room heating systems with the total worldwide capacity of nearly 50000 MW thermal (MWt) as the most currently significant segment of consumption of geothermal waters are given. In addition, geothermal resources are also utilized in soil pumps, balneological and sports basins, greenhouse complexes, and other manufactures. It was noted that geological studies were carried out in more than 40 countries, with the development of methods of simulation of tanks for the existing and new geothermal fields. Trends of development and the role of geothermal power engineering in the energy supply of many countries are shown. It was shown that prospects for the development of geothermal power generation are significantly associated with utilization of low-temperature geothermal sources in binary power generating units, as well as with the increase in installed capacity of operating geothermal power plants (GPPs) without drilling additional wells, i.e., by using waste geothermal heat carrier in binary-cycle or combined-cycle power plants. The article provides data on a pilot binary power unit at Pauzhetka GPP and on a promising Russian geothermal project to increase the installed capacity of Mutnovsk GPP (whose current capacity is 50.0 (2 × 25.0) MW of electric power) by 25% by constructing a combined binary-cycle power generating unit on the basis of waste separate utilization.

Thermal Engineering. 2016;63(8):601-604
pages 601-604 views