GAS TURBINES FOR POWER GENERATIONS

AND
GAS TURBINE POWER PLANTS
50 years for marine gas turbine manufacturing

The State Gas Turbine Research & Production

Complex “Zorya-Mashproekt” since 2001 has
combined with R&D production enterprise
“Mashproekt” and mass production line “Zorya”
one of the world leading manufacturer of gas
turbine engines and gearboxes. Since 1954 more
than 30 types of marine propulsion units have
been delivered and proven on successful
operation.
The ships powered by propulsion units operate
Navies of Ukraine, Russia, Bulgaria, Romania,
Poland, Germany, India, Vietnam, China, USA,
and other countries.
In the middle of 60th “Zorya-Mashproekt”
began conversion of naval production for civil
application. Gas turbines designed for severe
marine conditions possess high reliability,
durability and compact design; they are
economically attractive in comparison with
industrial gas turbine engines.
Application of “Zorya-Mashproekt” engines
was performed parallel in two parallel directions
for power generation and the gas pipeline
industry.
Spurt construction of transcontinental gas
pipelines from European part of the former Soviet
Union to Western Europe required a large number
of gas pumping units fueled by natural gas. The
first gas pumping unit of “Zorya-Mashproekt”
GPA-10 of rated 10MW power was derived from
marine gas turbine engine of M8 type.
Near 500 of such gas pumping units have been
delivered to gas pipelines.
The leading engines have accumulated more
than 100,000 firing hours with no overhaul and are
still under operation. Later on other marine gas
turbines were also powered gas pipeline industry.
Nowadays gas turbine movers rated at 3, 6, 10,
15, 16 and 25MW are offered for application in gas
pipeline industry. At present gas turbines
manufactured by “Zorya-Mashproekt” are widely
used to drive gas superchargers on gas pipelines
of Russia, Ukraine, Kazakhstan and Belarus, at
compressor stations in Iran, underground gas
storage in Czech Republic.
To meet customer's specific requirements
concerning rotational speed “Zorya-Mashproekt”
has its own gearbox manufacturing facility and got
wide experience in the development variety of
reduction gears.

2
 35 years - industrial gas turbines manufacturing

In 1969 the first floating co-generating power

plant “Severnoie Siyanie” ( “Northern Lights”)
rated 24MW was equpped by “Zorya-
Mashproekt” gas turbines. Since then for more
than 30 years several such power plants have
provided heat and power in distant regions of
Siberia and the Far East.
In 70th mobile power trains were developed for
power supply to constructed “Baikal-Amur” rail
road, operating until now.
In 90th third and the fourth generation gas
turbines were introduced to the power market of
CIS countries and abroad.
At the beginning of 21 century, gas turbine
engines energize more than 50 power plants from
Turkmenistan in the East to Canada in the West.
“Zorya Mashproekt” turbines operate in various
climatic conditions from cold upper Arctic zones
down to hot central Asian deserts.
Present time “Zorya-Mashproekt” offers a wide
choice of turbo generating sets and gas turbine
plants ranged from 2.5 to 325MW of:
-simple cycle plants;
-cogeneration plants;
-steam injection plants including “Aquarius”
type units;
-combined cycle plants;
-cogeneration plants with distilling desalting
units (DDU).

3
 Gas Turbines For Power Generations

(D049)

Efficiency, %
Power, MW

о о
Ambiet air temperature, С Ambiet air temperature, С

Rated power, kW 2850 Exhaust gas temperature, оC 460

Efficiency, % 28,5 Dimensions (L x W x H), m 3,51х2,52х1,93
3
Fuel gas consumption, nm /kW .h 0,353 Weight, t 4,25
Exhaust gas mass flow, kg/sec 16,5

Features
1 - Рower flange
2 - Gearbox
3 - Electric starter
4 - Compressor
5 - Combustion chamber (CC)
6 - Turbine
7 - Frame

1 2 3 4 5 6 7

Gas turbine generating set UGT 2500

4
 Gas Turbines For Power Generations

UGT 6000, UGT 10000, UGT 15000, UGT 25000

Gas Turbine Design Features
56 7

1 2 3 4

Features

1 - Variable geometry inlet guide vane

2 - Low pressure compressor
3 - High pressure compressor
4 - Combustion chamber
5 - High pressure turbine
6 - Low pressure turbine
7 - Power turbine
8 - Auxiliary drive gearbox
9 - Electric starter
10 - Frame

8 9 10

(DV71)
Efficiency, %
Power, MW

о о
Ambiet air temperature, С Ambiet air temperature, С

Rated power, kW 6360 Exhaust gas temperature, оC 428

Efficiency, % 31,5 Dimensions (L x W x H), m 4,6х1,8х1,8
3
Fuel gas consumption, nm /kW .h 0,319 Weight, t 4,5
Exhaust gas mass flow, kg/sec 30,5

5
 Gas Turbines For Power Generations

(DN70)

Efficiency, %
Power, MW

о о
Ambiet air temperature, С Ambiet air temperature, С

Rated power, kW 10500 Exhaust gas temperature, оC 490

Efficiency, % 36,0 Dimensions (L x W x H), m 4,0х1,8х1,7
3
Fuel gas consumption, nm /kW .h 0,279 Weight, t 5
Exhaust gas mass flow, kg/sec 36,0

UGT 15000
(DB90)
Efficiency, %
Power, MW

18

о о
Ambiet air temperature, С Ambiet air temperature, С

Rated power, kW 17500 Exhaust gas temperature, оC 414

Efficiency, % 35 Dimensions (L x W x H), m 4,7x2,1x2,2
3
Fuel gas consumption, nm /kW .h 0,287 Weight, t 9
Exhaust gas mass flow, kg/sec 72,2

6
Газотурбинные
Gasдвигатели для привода
Turbines For Power Generationsгенераторов

UGT 16000
(DJ59)

Efficiency, %
Power, MW

о о
Ambiet air temperature, С Ambiet air temperature, С

Rated power, kW 15900 Exhaust gas temperature, оC

Efficiency, % 31,4 Dimensions (L x W x H), m
3
Fuel gas consumption, nm /kW .h 0,324 Weight, t
Exhaust gas mass flow, kg/sec 96,0

UGT 25000
(DG80)
Efficiency, %
Power, MW

о о
Ambiet air temperature, С Ambiet air temperature, С

Rated power, kW 26200 Exhaust gas temperature, оC 485

Efficiency, % 36,3 Dimensions (L x W x H), m 6,4х2,5х2,7
3
Fuel gas consumption, nm /kW .h 0,277 Weight, t 16
Exhaust gas mass flow, kg/sec 87,5

7
 Gas Turbines For Power Generations

UGT 110000
(GTD110)

Efficiency, %
Power, MW

о о
Ambiet air temperature, С Ambiet air temperature, С

Rated power, kW 114500 Exhaust gas temperature, оC

Efficiency, % 36,0 Dimensions (L x W x H), m
3
Fuel gas consumption, nm /kW .h 0,279 Weight, t
Exhaust gas mass flow, kg/sec 365

1 2 3 4 5

Features

1 - Variable geometry inlet guide vane

2 - Compressor
3 - Combustion chamber
4 - Turbine
5 - Frame

8
 1
Waste heat recovery boiler Control system
Starting Generator
Air inlet and contact condenser
frequency converter
device

Gas turbine
exhaust

6
2
3 4
7

5 14

9
10
9
13
11
Lub oil tank
8

12
15
“Zorya-Mashproekt” Complete Power Plants

Gas turbine
 Gas Turbine Power Plants
“Zorya-Mashproekt” offers a wide choice of
gas turbine based combined heat and power
plants:
-simple cycle plants;
-cogeneration plants;
-steam injection plants including
“Aquarius” type units;
-combined cycle plants;
-cogeneration plants with distilling
desalting units (DDU).
Every type of plants has its own
advantages for operation under certain
conditions. What the Customer has to know
for optimal selection of the plant type?
All the plants can operate using liquid or
gaseous fuel; they also have dual-fuel
capability or can use alternative types of fuel
(biofuel, gas oil etc.)
Simple cycle installations feature small
dimensions, low weight, high maneuverability
and fast start up; they can be used at mobile
platforms. Such units have an advantage of
being used as an emergency or peak power
plants as well as stationary power plants in
areas where cheep fuel is available and when
a consumer needs only electric power.
Cogeneration plants are designed for
simultaneous production of electric and heat
power as steam or hot water. Electric power is
directly related to the mechanical power of the
gas turbine. As for heat it significantly varies in
a wide range depending on the selected
waste heat recovery configuration (steam or
water type, or combined steam and water
type, or use of supplemental firing). Such
plants are most effective for manufacturing
enterprises and public utilities with stable
demand for electric power and heat as steam
or hot water.
Steam injection plants (STIG) utilizing
steam injection into the gas turbine hot gas
path are also designed for power generation.
Steam produced in a waste heat recovery
boiler is supplied to a gas turbine as additional
working media. STIG type plants feature:
-the most increase of electric power up to
90%;
-cost effective low NOx, CO emission
levels;
-cost effective level of capitals $/kW
10
installed electric power.
Steam injection plants can be produced as
gas turbine based of non-covered (S1) and
converted (S2) gas path versions. Such
plants have advantages when used as power
plants for industrial enterprises and as small
regional power plants where maximum
electric power is required and a source of
fresh water is available.
“Aquarius” type units also operate
according to STIG cycle. They have a contact
water condenser installed over the waste
heat recovery boiler to return water
condensed into the cycle. Their main
application is implementation in regions
suffering from fresh water shortage or in
areas where are difficulties in treatment of
boiler water large amounts. This type of units
also has the ability to generate surplus of
distilled water. At ambient air temperature the
unit can increase the power of the electric
power plant due to water injection at the
engine inlet.
Combined cycle power plants are
designed for the highest possible
effectiveness of power generation. Steam
generated in waste heat recovery boiler is
supplied to separate gas turbine. Electric
power is the total power of gas turbine engine
and a steam turbine. The plants are offered
with two basic configurations: CC1 - one gas
turbine with waste heat recovery boiler plus
one steam turbine; CC2 - two gas turbines
with two waste heat recovery boilers and one
steam turbine operating for its own
generator. The power plants have
advantages when used as regional power
stations and also as power stations for big
industrial enterprises in areas with the high
prices power resources.
Cogeneration with distillation-
desalinating plants are introduced for the
countries with the fresh water shortage.
Certain quantity of distillate when used for
water injection to gas turbine inlet, allows
providing nominal power output at high
ambient temperatures.
 Gas Turbine Power Plants Thermal Diagrams

Simple cycle Steam-in-gas (stig)

Exhaust
Exhaust gas
Fuel gas

Feed water
Air

Fuel

1 - Gas turbine.
Air
2 - Generator.

1 - Gas turbine. 2 - Generator.

3 - Waste heat recovery boiler.
Co-generation 4 - Feed water tank. 5 - Pump.

Exhaust
“Aquarius” gas
Exhaust
gas

Condensate
Feed Feed water
Steam water
Steam
Fuel
Fuel Steam-gas
mix

Air Air

1 - Gas turbine. 2 - Generator.

3 - Steam contact condenser.
1 - Gas turbine. 2 - Generator. 4 - Steam condensate collector.
3 - Waste heat recovery boiler. 5 - Steam condensate cleaning unit.
4 - Feed water tank. 5 - Pump. 6 - Feed water tank. 7 - Water cooler. 8 - Pump.
6 - Heat energy consumer. 9 - Waste heat recovery boiler.

Co-generation with sea water distillation Combined cycle CC1

5
Exhaust
Exhaust
gas
6 gas

Distilled Feed
water water Feed
Steam water
Steam

Sea water Fuel Fuel

Air
Air

1 - Gas turbine. 2 - Generator.

3 - Distillation unit.
1 - Gas turbine.
4 - Waste heat recovery boiler. 2 - Generator. 3 - Steam turbine.
5 - Feed water tank. 6 - Pump. 4 - Waste heat recovery boiler. 5 - Condenser.
6 - Feed water pump. 7 - Pump.

11
 Power Plants With UGT 2500

Power, Efficiency Fuel consumption

MW
Cycle Installation
Electr. T
Therm.
herm. % ВТU/kW.h gas (m3 /h) liquid (kg/h)

Simple UGT 2500 2,5 26,0 11975 1010 840

Co-generation UGT 2500C 2,5 4,7 26,0 12411 1010 840

Steam-in-gas UGT 2500S1 4,15 33,1 9614 1225 1020

STIG

“Aquarius” UGT 2500S1A 4,0 33,1 9922 1225 1020

All data according to the ISO 3410

Gas turbine engine UGT 2500 is specially designed

to drive the electric generators. The engine has an Gas turbine power plant UGT 2500C in Rybinsk, Russia.
integrated gearbox and can be applied to generators
with 50 and 60 Hz frequencies.
According to the order from Canadian company
“ORENDA Aerospace Corporation” such engine is
adapted to work on biofuel (liquid wood) operates
since 1995.

Gas turbine power plant UGT 2500C in Toronto, Canada. Gas turbine power plant UGT 2500C in Brno, Czechia.

12
 Power Plants With UGT 6000

Power, Efficiency Fuel consumption

MW
Cycle Installation
Electr. T
Therm.
herm. % ВТU/kW.h gas (m3 /h) liquid (kg/h)
Эл. % газ (м3/ч)
Simple UGT 6000 6 31.5 10835 газ
2130 1790

Co-generation UGT 6000C 6 11.1 73,2 11339 1990 1680

Steam-in-gas UGT 6000S1

STIG 8 36.3 9402 2210 1860

UGT 6000 generating set

Co-genereting power plant UGT 6000C at Yablunevka Co-generating power plant in Zapolyarie (Nother
refinery, Poltavskaya oblast, Ukraine Russia) with 4 UGT 6000 gas turbines

Gas turbine engines of UGT 6000 type are in serial production since 1978 and have 6
modifications with different rotational speed and power take-off (from compressor side, from
power turbine side and simultaneously from both sides).
This class engines combine considerable specific power and high efficiency with reliable
operation and simplicity in maintenance. More than 300 engines of UGT 6000 type are in
operation all over the world. They are used at Naval ships of different classes and also as
supercharges and electric generator drives of power stations.

13 5
 Power Plants With UGT 10000

Power, Efficiency Fuel consumption

MW
Cycle Installation
Electr. T
Therm.
herm. % ВТU/kW.h gas (m3 /h) liquid (kg/h)

Simple UGT 10000 10,5 36 9481 2950 2460

Co-generation UGT 10000C 10,0 15,04 85,6 9980 2960 2470

Steam-in-gas UGT 10000S2 16,0 43 7937 3760 3140

STIG

“Aquarius” UGT 10000S2A 15,7 42,2 8146 3760 3140

Combined UGT 10000CC1 13,5 45,8 7452 2980 2500

UGT 10000CC2 27,5 46,3 7371 5960 4940

UGT 10000 engine has several modifications

including flow path modification for STIG cycle which
increases the engine power and reduces NOx
emissions level to 25 ppm.
UGT 10000S2A engine of “Aquarius” power plant
was tested as electric generator drive at “Zorya”-
“Mashproekt” test facilities.
The power plant “Aquarius-16K” with UGT 10000S2A
engine was set into experimental and commercial
operation in 2003 at Stavishchenskaya compressor
station (Kiev region, Ukraine).
UGT 10000S2A (DU70) Gas turbine engine

Exhaust

Waste heat Contact

recovery boiler condenser

Condensate
return
Steam pipe
Separator
Air inlet device

Generator
Gas turbine

Thermal and sound insulating container

“Aquarius” installation layout “Aquarius-16K” installation at Stavishchy

compressor station
14
 Power Plants With UGT 16000

Power, Efficiency Fuel consumption

MW
Cycle Installation
Electr. T
Therm.
herm. % ВТU/kW.h gas (m3 /h) liquid (kg/h)

Simple
UGT 16000 16 300 31,0 11010 5320 4430

Co-generation UGT 16000C 14 500 27, 04 79,9 4270 5260 4380

UGT16000CC1 18 400 36,2 9430 5260 4280

Combined

Three UGT 16000C units at Kzyll-Orda, Kazakhstan Two UGT 16000C power units at Mozyr petroleum
refinery, Belarus

Floating power station “Aurora borealis” with two Power station at Salekhard, Russia with one DC59
UGT 16000C power units and two UGT 16000 gas turbines

UGT 16000 is the modernized engine of the 2nd generation. Still it remains popular
among the Customers due to its high reliability, easy maintenance and optimal relation
between price and quality. Some of the engines have accumulated 80-100 thousand hours
without overhaul. Dual fuel version engine is able to switch over from gas to diesel fuel
was implemented at Salekhard power station.

15
 Power Plants With UGT 15000

Power,
Мощность, Efficiency
Эффективность Fuel consumption
Расход топлива
MW
МВт
Cycle
Цикл Installation
Установка
3 3
Electr.
Эл. T тепл.
Therm.
herm. %
% ВТU/kW.h.h
ВТU/kW gas(м
газ (m/ч)/h) liquid (kg/h)
жидкое (кг/ч)

UGT 15000 16.0 33.5 9740 5020 4215

Simple

UGT 15000C 16.0 23,9 32.5 10490 4940 4150

Co-generation

Steam-in-gas UGT 15000S2 25.0 42.0 8120 5960 5020

STIG

“Aquarius” UGT 15000S2 25.0 42.0 8120 5960 5020

Combined UGT 15000CC1 22.7 45.3 7530 4940 4150

UGT 15000CC2 45.8 45.9 7430 9880 8300

Assembling of UGT 15000 gas turbine engine UGT 15000C power unit at Kostyukovichy cement
works, Belarus

UGT 15000 in the container “Aquarius” power station with UGT 15000S2 gas
turbine at “Zorya-Mashproekt” testbed

Gas turbine engines of UGT 15000 type are in serial production since 1991. They are used at Navy ships,
as gas supercharges drives and electric generators drives for power stations. The serial engine of DG90
modification with operation on natural gas reached NOx emissions level of 37.5 ppm and CO emissions
level of 26 ppm. While operating on diesel fuel the decrease of NOx and CO emissions to 25 ppm is
achieved by means of steam injection into combustion zone.
GTRPC “Zorya-Mashproekt” manufactures and supplies container power stations with UGT 15000 engine.

16 5
 Power Plants With UGT 25000

Power, Efficiency Fuel consumption

MW
Cycle Installation
Electr. T
Therm.
herm. % ВТU/kW.h gas (m3 /h) liquid (kg/h)

Simple UGT 25000 25 35,0 9402 7330 6170

Co-generation UGT 25000C 25 35,5 34.8 9807 7220 6060

UGT 25000S1 30.8 40 8533 7720 6490

Steam-in-gas
STIG UGT 25000S2 40.7 42.8 7974 9570 8020
UGT 25000S1 30.8 40 8533 7720 6490
“Aquarius”
UGT 25000S2 40.7 42.8 7974 9570 8020

Combined UGT 25000CC1 34.7 47.5 7185 7220 6060

UGT 25000CC2 70.6 48.5 7037 14440 12120

Gas turbine engine UGT 25000 (DG80) Engine cover during assembling

UGT 25000C power unit during assembling at UGT 25000C power unit at Beryozovskaya power
Beryozovskaya power station, Belarus. station, Belarus.

UGT 25000 is the most powerful from the unified series of engines. It belongs to the forth generation
of engines and is in serial production since 1995. It successfully combines the newest attainments of
modern design ideas, advanced technologies and many years of experience in operation, which
allows produce the high maneuverability and efficiency.

17
 Power Plants With UGT 110000

Power, Efficiency Fuel consumption

MW
Cycle Installation
Electrical % ВТU/kW.h gas (m3 /h) liquid (kg/h)

Simple cycle UGT 110000 110 35,5 9610 31100 26100

UGT 110000CC1 160 51,5 6758 31810 26700

Combined cycle UGT 110000CC2 325 52,5 6563 63620 53400

UGT 110000 at Ivanovskaya power station

(Komsomolsk city, Ivanovskaya oblast, Rossia)

1 - Ga turbine engine UGT 110000

2 - Generator TVG-110-2
3 - Air inlet device
4 - Waste heat recovery boiler
5 - Steam turbine
6 - Transformers room

UGT 110000CC2 for Ivanovskaya power station

(under construction, Komsomolsk city,
Ivanovskaya oblast, Rossia)
UGT 11000CC1 (PGU-160) power units during
construction in Kaborga village, Nikolaevskaya
oblast, Ukraine

UGT 110000 is a new engine of the fourth generation

designed according to single shaft configuration
especially to drive the electric generator. The engine
favorably differs from foreign analogues in weight -
which is only 50 tons and overall dimensions:
5.7x3.7x4.0 m. Engine #2 is under trial-commercial
operation at Ivanovo power station in Russia. Engine
#1 is being mounted now as a part of 160 MW-
combined cycle power plant at the company's test
plant in Kaborga for further commercial power
generation.

UGT 110000 at “Zorya-Mashproekt” test bed

18 5
 Power generation applications

TYPE POWER APPLICATION LOCATION NUMBER OF BEGINNING OF REMARKS

MW GAS TURBINES OPERATION
YAKUTIYA
GTD-1 FLOATING POWER RUSSIA
PLANT CHUKOTKA

RAILROAD POWER RUSSIA YAKUTIYA

TRAIN TUMEN REGION
BURYATIYA
DO12 KOMI
STATIONARY RUSSIA KHABAROVSKY KRAY
AMUR REGION
YAKUTIYA
KHABAROVSKY KRAY
FLOATING POWER RUSSIA PRIMORSRY KRAY 2 1971-75
PLANT YAKUTIYA
CHUKOTKA
RAILROAD POWER RUSSIA TUMEN REGION
DO14
TRAIN YAKUTIYA
KHABAROVSKY KRAY
KAZAKHSTAN YUZHNAYA
STATIONARY RUSSIA YAKUTIYA
KHABAROVSKY KRAY
FLOATING POWER RUSSIA YAKUTIYA 2 1970-74
DА14 PLANT TUMEN REGION 2 1978-2000
RAILROAD POWER RUSSIA
YAKUTIYA 6 1986
TRAIN
STATIONARY RUSSIA SOVETSKAYA GAVAN 3 1976
FLOATING POWER RUSSIA TUMEN REGION 17 1980
PLANT KAZAKHSTAN TENGIZ 27 1990
RAILROAD POWER 4 1998
RUSSIA TUMEN REGION
TRAIN
DC59 AZERBAIJAN 13 1990
NEFTYANYE KAMNI
STATIONARY RUSSIA 12 1986
TUMEN REGION
53 1982
YAKUTIYA
21 1986
TURKMENIYA NEBIT-DAG
9 1980
KAZAKHSTAN JANAJOL
2 1998
RUSSIA TUMEN REGION 2 2002
RUSSIA RYBINSK 10 1995-2003 Licence

STATIONARY UKRAINE KHARKOV REGION 1 1997 manufacturing by

UGT 2500 “NPO SATURN” not
CZECH BRNO, OLOMOUC 2 1994
completely included
CANADA TORONTO 2 1995

RUSSIA TUMEN REGION 4 2002-2003

UGT 6000 STATIONARY
UKRAINE POLTAVA REGION 1 1999

UKRAINE NIKOLAEV REGION

UGT 10000 STATIONARY

UKRAINE NIKOLAEV REGION 1 1996

UGT 15000 15 STATIONARY
BELARUS 2 2003-2005

UGT 15000 STATIONARY UKRAINE NIKOLAEV REGION

FLOATING POWER RUSSIA CHUKOTKA 5 1992

PLANT YAKUTIYA 11 1993
RAILROAD POWER YAKUTIYA 4 1993
RUSSIA
TRAIN
RUSSIA KHABAROVSKY KRAY 2 1992
UGT 16000 STATIONARY
STATIONARY BYELORUSSIA MOZYR 2 1991
RUSSIA TUMEN REGION 1 1995
ROSTOV REGION 3 1997
KRASNODARSKY KRAY 3 1992
UKRAINE SEVASTOPOL 3 1992
RUBEJNOYE 1 2003

UGT 25000 STATIONARY UKRAINE NIKOLAEV REGION 1 1996

BELARUS BREST REGION 4 2003-2005
UGT 110000 110 STATIONARY UKRAINE NIKOLAEV REGION 1 2004
RUSSIA IVANOVO REGION 3 2001-2005

19
 Nikolaev at night

GTR&PC
“Zorya”-“Mashproekt”
Oktyabrsky prospekt 42a
Nikolaev, 54018, Ukraine.
Phone +38 0512 50-25-61, 55-69-92
Fax +38 0512 50-90-50, 55-68-68

E-mail: spe@mashpoekt.nikolaev.ua, omito1@zorya.com.ua

http:// www.zmturbines.com

2006