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`Alexander INOZEMTSEV `Mikhail KHAIRULLIN

iameter of present-day Russian oil trunk pipelines is up to 1220 mm. Pumping stations are spaced at 50...150 km intervals. They are equipped with elec-trically actuated rotary pumps. Pump capacity is up to 12 500 m3/h, power consumption is up to 8 MW. Oper-ating pressure in a pipe is produced by two or three se-quential pumps the total power of which may be as high as 25 MW.

The GOST state standard for oil pumping packages de-veloped as far back as in the times of the Soviet Union stipulates the use of no other oil pump actuation system but electrical which was quite reasonable from the eco-nomic point of view with a highly reliable and well-devel-oped centralized power supply system in place. How-

ever, the studies undertaken show that with the gas supply system available, oil pumping sets with gas tur-bine drives may successfully compete with electric drive even in the regions with cheap electricity. Whereas in the regions with no centralized power supply there is practically no alternative to gas turbine driven pumps.

It should be noted that in other countries of the world the use of gas turbines at major oil pipelines in remote ar-eas and regions with adverse climatic conditions is fairly wide, though one can’t say that the gas turbine drive is dominating there. Oil pumping packages with gas tur-bine drives rated at 1…10 MW per unit are operated in Algeria, Saudi Arabia, Iran, Iraq, Canada, USA (Alaska). Major suppliers: GE, Siemens, R-R, Solar.

A broad range of new generation gas turbines rated from 2500 to 25 000 kW has been developed to date in Perm based on D-30 and PS-90А engines.Offering a variety of gas turbine power ratings, power turbines of various speed (3000…9000 rpm) in combination with reducing and multiplying gear-boxes both developed inhouse and outsourced, Aviadvigatel is able to satisfy a wide range of re-quirements with respect to natural and associated oil gas compressor and electric generator drives with both variable and constant speed. Company’s experience and best practices in gas turbine development allowed Aviadvigatel to promptly respond to emerging market demand and develop and supply to the customer a product that was quite new for Russian oil and gas equip-ment market – Ural-6000 gas turbine pumping set for crude oil pumping – in a very short period of time. The gas turbine pumping set was specially made for Sakhalin-2 project – the major source of energy resources for Asian-Pacifi c Region coun-tries.

PERSONAL PROFILE

Alexander INOZEMTSEVGeneral Designer, Aviadvigatel

Doctor of Engineering Professor

Head of Aviation Engines and Power Generation Gas

Turbines DepartmentPerm State Technical

University

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URAL-6000 GAS TURBINE PUMPING SET GENERAL LAYOUT

Legend:1. Engine section ventilation system air duct. 2. Engine oil air cooler. 3. Air filtration module. 4. Noise suppression module. 5. Oil pump section ventilation system air duct. 6. Oil pump and gearbox oil air cooler. 7. Control system section. 8. Oil pump and gearbox oil system. 9. Oil pump. 10. Gearbox. 11. Engine cycle air inlet chamber. 12. Engine. 13. Blast shield. 14. Engine section. 15. Exhaust with expansion joint. 16. Exhaust stack.

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4

5 6

7910 8111213141516

Fuels that may be used are natural gas, kerosene, diesel oil, treated crude oil. Choice of fuel is a matter of cost effectiveness. Natural gas is used when avail-able. For instance, in 1974 they put into operation 750 km oil pipeline with gas turbine driven pumps in Iran, and laid 114 mm gas pipeline in parallel to the oil pipe-line to support gas turbines operation.

The most cost effective fuel of all liquid fuels is pumped crude oil that is used after special treatment or as product of distillation performed at small crack-ing plants located on site. However, operation with crude oil requires frequent flowpath washing, nozzles cleaning and hot section repairs.

The presence of parallel oil and gas lines and lack of centralized power supply system in Sakhalin project determined the choice in favor of gas turbine drive as the most cost effective; and experience and capabili-ties of Aviadvigatel made it possible to win a tender for equipment supply.

n 2008–2009, Aviadvigatel developed and manufac tured two Ural-6000 gas turbine pumping sets to the order of Sakhalin Energy Investment Com-pany Ltd. (SEIC) within the framework of Sakhalin-2 project. These machines will be operated at SEIC’s DNKS-2 boost pumping compressor station that is situated about 1 km to the north of Gastello village and 20 km to the south-west of Poronaisk town at Sakhalin island.

The major requirements made by the Customer to the manufacturer of equipment for this project were as follows:• vendors shall have certificates and licenses for

equipment and materials;• gas turbine pumping set shall be made in com-

pliance with Russian and international standards, project specific technical requirements and speci-fications of SEIC and FLUOR.

All equipment was designed considering that pump-ing sets would be installed outdoors and therefore they must be suitable for climatic conditions typical for Sakhalin island.

ral-6000 gas turbine pumping set developed and made by Aviadvigatel is an integrated technological system intended to pump crude oil by the long dis-tance pipeline. The pipeline begins at production plat-forms near the northeast end of Sakhalin island and runs to the LNG plant and oil shipment terminal at the south of the island in Aniva Bay.

The main module of the GT pumping set is a turboma-chinery compartment including:• GTU-6P gas turbine based on D-30EU-6 engine

with R-45-01 gearbox (made by Perm Engine Com-pany);

• rotary oil pump with bearing compartment sealing system (made by Ruhr Pumpen (Germany);

• GT pumping set automatic control system based on multiprocessor integrated control system made with Siemens hardware components (made by Systema-Service).

On the roof of the turbomachinery compartment there is a dedicated cyclone type air filtration system with a silencer; engine section and pump and gearbox sec-tion ventilation modules; engine, gearbox and pump oil systems air oil coolers. Exhaust gas is withdrawn to the system equipped with a silencer and an exhaust stack

PERSONAL PROFILE

Mikhail KHAIRULLINDeputy General Designer –

Chief Designer, Gas Turbines for Gas Compressor Packages

Winner of P.A.Soloviev 2nd Degree prize.

Has 13 certificates of authorship and patents for

inventions.

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URAL-6000 GT PUMPING SET PERFORMANCE (in site conditions)

that is 15 m high from the basement. The Customer’s design requirements contained no requirement for heat recovery. The GT pumping set also includes equipment of lighting, electrical heating and ventila-tion systems. Besides, the pumping set is equipped with an automatic fire fighting and gas detection sys-tem.

It should be noted that the specialty of Ural-6000 gas turbine pumping set is that it is mainly made with Rus-sian equipment. The exception is a crude oil pump and that was the choice of the Customer. Use of an electri-cal starting system was also dictated by the Customer.

Ural-6000 gas turbine pumping set is connected to DNKS-2 boost pumping compressor station pip-ing. Fuel used is natural gas. The pumping set noise suppression system ensures compliance with SN 2.2.4/2.1.8.562 sanitary requirements for noise. Noise reduction is achieved by using silencers in en-gine and pump ventilation systems, air intake suction duct and exhaust system.

The GT pumping set processes are completely au-tomatic. Its automatic control system communicates with DNKS-2 station process control system by the approved MODBUS interconnect protocol. High de-gree of automation and robust control system provide for unattended operation of the machines.

Analysis of Ural-6000 gas turbine pumping set tur-bomachinery compartment and exhaust system load-carrying structure components strength under seismic and wind loads was conducted in the process of development. GT pumping set has been proved ro-bust in wind load conditions – for Region III [0.38 kPa (38 kgf/m2)] and snow load conditions – for Region VI [2.5 kPa (250 kgf/m2)] as per SNiP 2.01.07 Construc-tion Norms and Regulations.

Ural-6000 gas turbine pumping set was delivered and transported to the site in factory preassembled mod-ules that reduced the period of on-site assembly. Di-mensions of all modules allow for their transportation by road or railway.

A number of Ural-6000 gas turbine pumping set improve-ment measures were introduced at the Customer’s re-quest. The basic design and technical solutions are de-scribed below:

1. The turbomachinery compartment is divided into three sections: engine section, rotary pump and gearbox section and control system section. This is the way the explosion safety of the equipment used is achieved. The control system section is a non-explosive zone. The engine section and rotary pump and gearbox section are equipped with an in-duced draft ventilation system. The control system section is equipped with an air conditioning system.

2. Use of explosion-proof control system compo-nents including two SKV isolation valves, DGV gas metering unit and KA-30GE-VI command unit.

3. Use of an automatic GT pumping set control system based on MSKU-5000 multiproces-sor integrated control system. The multiproces-sor integrated control system is supplied with a workstation for process equipment monitor-ing and control from the control system section.

4. The automatic gas fire extinguishing system (designed and made by Aviadvigatel) provides

for total saturation extinguishing by means of gas (СО2) fire control units. Control is ac-complished with Rosa-2SL security and fire alarm control unit (one per all sections – en-gine, pump and control system section). Gas fire extinguishing modules are placed in a special heated container which is installed in close vicin-ity to the turbomachinery compartment. Fire ex-tinguishing module equipment is explosion-proof.

5. The gas detection system provides for control of gas content in the air intake flowpath, engine section, engine section ventilation module in-let, pump section ventilation module inlet, control system section. SGOES-TG/115 gas analyzing system consists of gas analyzers, UPES-30/116

Parameter

Pump capacity, m3/hPump head, mPower consumed at pump shaft, kWPump speed, rpmPT speed, rpmPT exit gas pressure, ОСPT exit gas flow, kg/sLife, hrsto overhaultotal assigned

Max

2 245925

5 3923 6507 088530

29.99

Nominal

1 4241 0453 9283 5326 859500

29.93

25 000100 000

Min

800294650

1 8863 66340016.5

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D-30EU-6 GAS TURBINE ENGINE GENERAL LAYOUT

Legend:

1. Air intake. 2. Intermediate case with towershaft drive. 3. Upper accessory drive gearbox. 4. Gearbox with coupling. 5. Compressor. 6. Combustor. 7.

Turbine. 8. Turbine exhaust case. 9. Engine mount. 10. Lower accessory drive gearbox.

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threshold device, sound-and-light annunciators in-stalled outside the turbomachinery compartment.

6. Information from GT pumping set control sys-tem, fire extinguishing system and gas de-tection system is transmitted to DNKS-2 sta-tion control and emergency protection sys-tems using MODBUS interconnect protocol.

7. GT pumping set scheduled maintenance inter-val is increased to 4 000 hours.

actory testing of the entire gas turbine pumping set under a special test program developed by Avia dvigatel and approved by the Customer was a very important milestone in the project implementation pro-cess.

Supervision of GT pumping set manufacturing, assem-bly, testing and dispatch was carried out by the repre-sentatives of Moody International. Representatives of SEIC and Moody International supervisors performed acceptance of both individual parts and components and the entire GT pumping set.

GT pumping set project design was submitted to HAZOP commission to review the process flow sheets and the documentation pertaining thereto and analyze project design safety in the event of equipment failure or systems malfunction.

In April 2010, two Ural-6000 gas turbine pumping sets made within the framework of Sakhalin-2 project successfully passed 72-hr tests and were transferred to commercial operation.

OPINION

Serguei MENSHIKOVGeneral Director,

Gazprom Dobytcha Nadym

«Development and designers’ supervision of gas turbine

engines for civil and military aviation, as well as industrial gas turbines and generator

packages – these are the major tasks which have been

successfully completed by Aviadvigatel over many years

for many applications including industrial facilities of Gazprom

Dobytcha Nadym».