ALSTOM

Experience from Alstoms TPP-26 Project in Moscow: District Heating with the KA26 Combined Cycle Power Plant
Conference Paper
POWER
Experience from Alstoms TPP-26 Project in Moscow: District Heating with the KA26 Combined Cycle Power Plant Christian Bohtz, Stefan Jeken, Thomas
Experience from Alstoms TPP-26 Project in Moscow: District Heating with the KA26 Combined Cycle Power Plant Christian Bohtz, Stefan Jeken, Thomas Wunsch - Alstom Power - Baden, Switzerland Russia Power 24-26 March 2010, Moscow, Russia Alstom 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose.
Christian Bohtz, Stefan Jeken, Thomas Wunsch - Alstom Power - Baden, Switzerland
1 Abstract .........................................................................................................................................2 The TPP-26 project .......................................................................................................................3 1.1 - TTP-26 Plant in Detail ................................................................................................................3 1.2 - Set-up of the Project ..................................................................................................................4 1.3 - Specialties of Joint Plant Engineering in Russia and Switzerland ........................................................5 1.3.1 - Different Norms for Piping ...............................................................................................5 1.3.2 - Engineering Processes ......................................................................................................5 1.3.3 - Steel Work and Plant Arrangement ....................................................................................5 1.3.4 - Documentation and Certification ........................................................................................5 1.4 - Transportation of Gas Turbine and Generator .................................................................................6 Market situation in Russia ............................................................................................................7 2.1 - Use of District Heating ................................................................................................................7 2.2 - Alstoms EPC Capability in Russia .................................................................................................7 Alstom KA26 technology: Extraordinary high operational flexibility ............................................8 3.1 - Sequential Combustion ...............................................................................................................8 3.2 - Start-up Behaviour ....................................................................................................................9 3.3 - Large Operation Range and High Part-Load Efficiency .....................................................................9 3.4 - Low Load Operation Capability ...................................................................................................10 3.5 - KA26 for District Heating ..........................................................................................................10 3.6 - Alstom CCPP References in District Heating Applications ...............................................................10 3.7 - OEM, Plant Integrator and EPC capability ....................................................................................11 Major Components and Systems ................................................................................................12 4.1 - Gas Turbine.............................................................................................................................12 4.2 - Steam Turbine .........................................................................................................................13 4.3- Generators ...............................................................................................................................14 4.4 - Heat Recovery Steam Generator.................................................................................................14 4.5 - Main Steam System ................................................................................................................15 4.6 - Condensing System ..................................................................................................................16 4.7 - District Heating System ...........................................................................................................16 4.8 - Fuel Gas Supply System ............................................................................................................16 4.9 - Instrumentation & Control (I&C) .................................................................................................16 TTP-26 Operation Modes ............................................................................................................17 5.1 - Condensing Mode for Power Production .....................................................................................17 5.2 - District Heating Mode for combined Heat and Power Production ....................................................17 Summary .....................................................................................................................................17
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Experience from Alstoms TPP-26 Project in Moscow: District Heating with the KA26 Combined Cycle Power Plant Christian Bohtz, Stefan Jeken, Thomas Wunsch - Alstom Power - Baden, Switzerland Russia Power 24-26 March 2010, Moscow, Russia Alstom 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose.
Abstract
TPP-26 Unit 8 is a combined-cycle power plant (CCPP), which is also used for district heating and is currently being constructed in Moscow, the capital and economical centre of Russia. The power plant is being built by Alstom and its consortium partner EM Alliance. It is the first Russian power plant to be built on the basis of a turnkey engineering, procurement and construction (EPC) contract by a non-Russian company. The customer is OJSC Mosenergo, a public-joint stock company and the biggest utility provider in the Moscow region. Notice to Proceed was given in 2007 and erection works is coming to full swing. The plant is based on Alstoms KA26 combined cycle power plant in a oneon-one multi-shaft arrangement for high operational flexibility, comprising a GT26 gas turbine (GT), heat recovery steam generator (HRSG), steam turbine (ST) and two turbogenerators, whereas Alstom is supplying the key components. With the high operational flexibility and the operation range from 100% combined cycle load down to less than 40% load, the KA26 is ideally suited for district heating, producing either 420 MW electrical power in full-condensing mode or up to 265 MWth heat in the highly-efficient district heating mode with a fuel utilisation above 85%. This flexibility as well as the superior partload efficiency is achieved with the unique sequential combustion and 3 variable compressor guide vanes of the GT26 gas turbine. The new CCPP will be installed as unit 8 of the existing TPP-26 plant, increasing the total installed capacity from 1400 to 1820 MW. Synchronisation to the grid of the new power plant is planned in the second half of 2010. Utilising its Plant Integrator approach for designing and constructing turnkey EPC power plants and its experience gained from the engineering of TPP-26, Alstom is able to offer optimised, tailor-made district heating power plants utilising its in-house core components (GT, Generator, ST, HRSG, condenser, control system, ...). Alstom is therefore in a good position to support Russia, which has a demand to modernize its district heating power plants, by both, brownfield and greenfield installations or repowering of existing steam power plants, reducing domestic fuel gas consumption to foster export by increasing the efficiency of Russias district heating power plants.
Experience from Alstoms TPP-26 Project in Moscow: District Heating with the KA26 Combined Cycle Power Plant Christian Bohtz, Stefan Jeken, Thomas Wunsch - Alstom Power - Baden, Switzerland Russia Power 24-26 March 2010, Moscow, Russia Alstom 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. 2
1 - The TPP-26 project

1.1 - TTP-26 Plant in Detail
The TTP-26 combined-cycle power plant is providing power and heat for district heating. It uses Alstoms proven and mature combined-cycle technology based on the advanced class GT26 gas turbine, with more than 1.5 million hours operating experience mainly in combined-cycle plants, including Co-Generation and also Repowering applications. The gas turbine and steam turbine are arranged in a multi-shaft configuration, each turbine provided with its own air-cooled TOPAIR turbogenerator. In addition the block features one HRSG, one water-cooled condenser, two steam/water heat exchangers for district heating, and the auxiliaries required to operate the plant. The units control system is based on Alstoms ALSPA DCS technology. It is anticipated that the plant will need to accommodate daily load variations in the range between 50-100 per cent relative load. However, daily start-up and shut-down cycles are also envisaged, as is short-term plant operation at gas turbine loads down to 30 per cent. District heat extraction will be possible between 30-100 per cent of gas turbine load. The facility will be capable of operating at baseload without any restrictions in an ambient temperature range of -42C to 35C. Design ambient conditions are ambient temperature (-3.1C), ambient pressure (995 mbar) and relative humidity (77%). The plant is designed to operate principally with natural gas and oil as the back-up fuel. It complies with strict near-field and far-field noise guarantees which are considerable more onerous than the industry norm and below those stipulated in the contract for the plants metropolitan location.
The cutaway schematic clearly shows both the generator block and the district heating system of the high-efficiency TPP-26 CHP plant
1.2 - Set-up of the Project
The TPP-26 turnkey project is a consortium comprising Alstom Switzerland, Alstom Russia and EM Alliance: Alstom Switzerland is doing conceptual engineering, supplying key equipment (GT26 and steam turbine, each with generator and auxiliary systems and the ALSPA Distributed Control System (DCS), basic overall engineering and detail engineering for the GT and ST. In addition, it is also assigning technical consultants during engineering, construction and commissioning. Alstom Russia is the consortium leader with the key management functions, assigning technical supervisors for erection supervision and commissioning. Alstom Russia is supplying the Heat Recovery Steam Generator (HRSG), designed according to Russian norms and regulations. EM Alliance is providing detail-engineering, supplies the Balance of Plant (BoP) equipment and electrical equipment (step-up transformer, auxiliary transformer and switchboard), as well as all commodities. EM Alliance is executing the civil and erection works, pre-commissioning and commissioning together with Alstom. OJSC TEK-Mosenergo as a sub-contractor to EM Alliance for detail engineering is providing necessary engineering resources, knowing the situation in Mosenergos existing plants as well as country-specific Russian expertise to perform detail engineering according to Russian norms and regulations.
View of the TPP-26 turbine hall
Compact arrangement inside the turbine hall: ST turbogenerator and lateral ST exhaust at the front, GT at the back (with air intake on the right side)
1.3 - Specialties of Joint Plant Engineering in Russia and Switzerland
With specific parts of the power plant being engineered in Russia, it was possible to benefit from local engineering experience. Alstom in Switzerland cal sourcing, GOST standard piping was used for the majority of the piping (For the main steam pipe work, ASME was used as no technical equivalent GOST piping was available). The use of GOST piping facilitated the certification of the piping, as it was possible to use well-introduced engineering tools familiar to the Russian authorities. On the other hand, the installation of numerous transition pieces between the different pipe norms and European-supplied equipment was necessary. In particular, the conversion of plant design according to ASME standards to a plant with Russian GOST standards needed to be considered. With some of the plant engineering performed in Russia and the benefit from local sourcing, GOST standard piping was used for the majority of the piping (For the main steam pipe work, ASME was used as no technical equivalent GOST piping was available). The use of GOST piping facilitated the certification of the piping, as it was possible to use well-introduced engineering tools familiar to the Russian authorities. On the other hand, the installation of numerous transition pieces between the different pipe norms and European-supplied equipment was necessary. For Alstom, so called fast-track engineering, the parallel work on interconnected systems and final consolidation has proven to be a time effective approach. However with a more step-wise approach in Russia, requiring more design data for a start of the detailed engineering, accelerated engineering schedules are difficult to follow for tailor-made projects. In particular the steelwork needed to be planned prior to the engineering of the piping, requiring additional time. The use of 3D piping and arrangement planning was not yet widely introduced in Russia and Russian designers partly do not use the benefits from 3D modelling in order to achieve an optimised plant arrangement. Missing resources were compensated by Alstom, performing overall engineering management, integration of the different engineering disciplines and review of all process relevant design by own staff, significant lowering the number of modifications during construction. The steelwork was planned based on Russian norms, that typically are heavier built than European design, requiring smaller margins due to continuously improved design tools. Deviating design concepts in Russia require additional supports to the steelwork resulting in numerous adaptations of pipe work against Alstoms standard.
1.3.1 - Different Norms for Piping
1.3.2 - Engineering Processes
1.3.3 - Steel Work and Plant Arrangement
1.3.4 - Documentation and Certification
Having a long-time experience as EPC provider in many countries, Alstom was also able to consider the specialties of the Russian legislation for the documentation and certification of the plant. With the experience from the TPP-26 project, Alstom can now benefit for future projects in Russia.
1.4 - Transportation of Gas Turbine and Generator
Alstom already evaluated the transportation of the heavy plant components prior to the start of the project: The generators and the gas turbine were too large for rail transport. Due limited navigability of the Volga channel system between November and April, even airfreight was considered at the beginning. Weight limitations for road transportation in Moscow posed an additional challenge. The GT had to be transported in disassembled condition and also the rotor of the GT generator needed to be removed and reassembled on site. Finally the GT was shipped from the factory in Mannheim via the river Rhine to Rotterdam and loaded on a heavy lift vessel to St. Petersburg. From St. Petersburg the equipment was shipped on barges through the Volga channel system to Moscow with a transit time of 20 days for 1542 km! In Moscow, the bearing weight capacity of two bridges needed to be investigated in order to get permission for the 20 km heavy lift transport from the South River Port to site.
Transportation of GT thermal block in disassembled condition on a barge
2 - Market situation in Russia

2.1 - Use of District Heating
Russia has the largest district heating system in the world. District heating plants as TPP-26 provide more than 70% of the heat supply. In large cities between 70% to 95% of the homes are connected to district heating systems, whose total length amounts to 200000 km. Around 30% of the supplied heat is produced in close to 500 Combined Heat and Power (CHP) plants. The rest is produced in more than 65000 mainly gas-fired boiler houses. With an average lifetime above 20 years, mainly using natural gas at lower efficiency (< 38%), there is a large potential for new CHP plants that offer fuel utilisation factors up to 90% and above. Also re-powering is an attractive option for such plants: With the installation of a new GT and a new HRSG, the existing steam turbine and its foundation and auxiliary equipment can be maintained.
2.2 - Alstoms EPC Capability in Russia
Alstom is building the TPP-26 combined-cycle power plant (CCPP) on turnkey-basis, and as an Original Equipment Manufacturer (OEM), Alstom is also providing all main plant components. Alstom has fully established the required local organisation and resources to execute such projects, including a Russian legal entity. Alstoms organisational setup, having his headquarter in the centre of Moscow, is taking care of the full product range, from consulting and service up to EPC plant delivery. For any required technical expertise, Alstom can benefit from the know-how of over 50000 employees in its Power Sector to provide any support required. Depending on customer requirements, Alstom can provide power plant equipment, full turnkey combined-cycle power plants or repowering of existing steam plants with a new GT and HRSG, maintaining the steam turbine or including an upgrade of the steam turbine. Alstom is therefore in a good position to support the modernisation and expansion of the large Russian power generation fleet.
3 - Alstom KA26 technology: Extraordinary high operational flexibility
For the TPP-26 project, Alstom was offering the most effective combined-cycle power plant technology in its class. Alstom as designer, manufacturer and supplier is providing the key equipment from a single source. One of the key project drivers of the Unit 8 contract was a large reduction in gas consumption. In the first year of operation alone this translates into a $55 million saving (based on 2011 expected gas prices). Alstom has integrated its heavy-duty GT26 gas turbines into an optimized single-shaft or multi-shaft combined-cycle generating block the KA26 Reference Plants. In the mid-1990s, Alstom introduced two similar sequential combustion gas turbines, the GT24 for the 60 Hz market and the GT26 for the 50 Hz market. Since their launch, these advanced class GT24/GT26 units have demonstrated that this technology platform offers significant advantages to plant operators superior operating flexibility, low emissions, high part-load efficiency and world class levels of reliability being amongst them. These benefits are brought about by utilizing the concept of sequential combustion: The GT26 combustion system is based on the well-proven Alstom combustion concept using the EV (EnVironmental) burner in a first annular combustor followed by the SEV (Sequential EnVironmental) burner in the second combustor. The dry, low NOx EV burner has a long operating history and is used across the whole range of Alstom gas turbines. About 50 per cent of the total fuel (at baseload) is burned in the first combustion chamber. After this the combustion gas expands through the single stage, high-pressure (HP) turbine, which reduces the pressure by approximately a factor of two. The remaining fuel is then added in the second combustion chamber, where the combustion gas is heated a second time and finally expanded in the four-stage low-pressure (LP) turbine. Utilizing sequential combustion, the GT24/GT26 design is able to achieve a high power density in a compact unit with a small footprint. TPP-26 Unit 8 will burn either natural gas or, as a back-up, liquid fuel. With a rated output of 266 MW at an ambient temperature of 15C, the unit will have an exhaust gas flow rate of 620 kg/s, leaving the turbine at a temperature of 625C. At that point it will enter a three-pressure reheat, horizontal type HRSG, which is capable of generating steam in any operation state of the gas turbine. From there the steam enters the three casing steam turbine.
3.1 - Sequential Combustion
The advanced KA26 combined cycle power plant technology and the sequential combustion of the GT26 gas turbine offer a number of key advantages: I excellent start-up characteristics for hot, warm and cold starts I operational flexibility from 100 per cent down to 40 per cent combined-cycle power plant (CCPP) load and below I high part-load efficiency I low NOx emissions down to 40 per cent CCPP load and below I extremely low parking load during off-peak periods at about 20 per cent CCPP load I a very good fuel flexibility capability with regard to varying natural gas compositions.
3.2 - Start-up Behaviour
The start-up behaviour of a power plant is determined both by the startup time and the reliability. With the optimal plant concept it has been shown that the KA26 combined-cycle baseload can achieve a hot start within 50 minutes (i.e. after about an eight hour shut-down). This is achieved without an auxiliary boiler or other special steam conditioning equipment. Such short start-up time means the plant is able to supply power sooner and therefore earn money for its owner. This ability is an important advantage in a market environment with a volatile electricity price. It allows the operator to take opportunities with minimal time delay. Secondly, Alstoms monitoring of its KA24/KA26 fleet has demonstrated a start-up reliability of more than 95 per cent. This is again important because a missed start can be extremely expensive in terms of buying in the previously committed power. There may also be further benefits such as revenues from non-spinning reserve payments. The short start-up times and high start-up reliability thus have the ability to boost revenue for customers, compared to CCPPs using other technologies.
3.3 - Large Operation Range and High Part-Load Efficiency
The KA26 power plant has a large operation range from 100% down to less that 40% CCPP load. Superior part-load efficiency is achieved with the combination of the sequential combustion system (2 combustion chambers) and three rows of variable compressor guide vanes to maintain a high GT exhaust temperature with partially closed compressor inlet guide vanes. High part-load efficiency is important to achieve high operational flexibility: Even in case of lower power demand or low electricity prices, the plant operator can continue to operate the plant at reduced power output without sacrificing substantial efficiency.
Therefore the number of starts is reduced, decreasing the associated starting costs.
3.4 - Low Load Operation Capability
Alstoms KA26 plant has the unique Low Load Operation Capability (LLOC): The plant can be operated at approx. 20% CCPP load, with the steam turbine remaining in operation. With only the first combustion chamber in operation, low NOx can be maintained. From the LLOC mode, plant baseload can be reached in less than 30 minutes as the steam turbine remains in operation. With the low fuel gas consumption of the LLOC, the plant can remain in operation at even lower electricity prices ready to load up immediately. Therefore the lifetime consumption that is related to the number of starts of the gas turbine can be controlled by freely choosing whether the gas turbine is shut-down during low price periods, or not. This offers an important advantage, which significantly increases the flexibility in outage planning. Furthermore, the high part-load efficiency indirectly allows control of the starts reduces the absolute emissions produced during start-up.
3.5 - KA26 for District Heating
In particular for district heating plants, Alstoms plant integration capability based on the Plant Integrator approach brings a big advantage for a customer, as the plant is fully optimized and tailor-made based on Alstoms engineering capabilities and experience with district heating plants. As an OEM, Alstom can even adapt the main plant components and offer customised steam turbine and district heater designs in order to supply the optimum district heating plant solution. In particular the GT24 and GT26 are very well suited for Co-Generation, as they have been designed for combined-cycle applications in KA24 and KA26 plants. The large load range from 100% down to less than 40% plant load is a big advantage for Co-Generation and with sequential combustion and 3 variable compressor guide vanes, superior efficiency can be achieved even in part-load operation.
3.6 - Alstom CCPP References in District Heating Applications
Beside of the large number of conventional CCPP, Alstom has built over the last 30 years a dozen plants in district heating applications. These plants were based on the entire Alstom gas turbine portfolio, both for 50 Hz and 60 Hz, including the GT8, GT11, GT13E2 and most recently the GT26 at TTP-26. An example for the KA13E2 is the Diemen plant in the Netherlands that went into operation in 1995. Same as the TTP-26 plant, this plant was built on turnkey-basis.
In power production mode, it is providing 253 MWe at an efficiency of 55.5%. In district heating mode, it is providing 193 MWth heat and 228 MWe power with a fuel utilization of 87%.
3.7 - OEM, Plant Integrator and EPC capability
Alstom is one of the few OEMs in the market able to offer all the major power generation technologies in-house; bringing together the knowledge and expertise of the architect-engineer, or EPC contractor with those of an OEM. With the in-depth knowledge of the main power plant components, Alstom can integrate them into a fully optimized plant. With this approach, Alstom has the appropriate capabilities, the required skills and credentials to contribute significantly to power expansion and replacement capacity needs in precisely the way currently being undertaken in Moscow. Moreover, this approach is highly conducive to meeting the increasing demand globally for EPC turnkey solutions. This comprehensive approach to turnkey EPC includes performance and schedule guarantees, warranties and assurances encompassing the entire scope of the plant, rather than being limited to individual components or packages, reducing the end-user risk significantly.
Bird view of the TPP-26 plant-layout: Full indoor arrangement includes HRSG and water pumps
4 - Major Components and Systems

4.1 - Gas Turbine
The GT26 type gas turbine consists of a solid welded rotor with 22 compressor stages, one HP turbine stage and four LP turbine stages. Heat input is performed by two annular combustion chambers (EV & SEV burners). The rotor is rigidly coupled to the generator shaft. The airflow through the gas turbine is controlled by the angular position of three variable guide vane (VGV) rows. During part-load above the 25 per cent gas turbine load, the turbine controller maintains the exhaust gas temperature at the maximum partload temperature by opening the VGV and increasing fuel injection to both combustors.
GT26 thermal block
For cooling and sealing purposes, air is drawn off the compressor at a number of stages. Two airflows are cooled external to the gas turbine one flow by an HP and the other by a LP air cooler referred to as a once through cooler. These coolers are producing additional steam, which result in additional power produced by the steam turbine. An anti-icing and air prewarming system based on a heat exchanger is provided in order to preheat the air during icing conditions, enabling the normal operation of the gas turbine.
GT filter house with integrated anti-icing and air prewarming system based on a heat exchanger
4.2 - Steam Turbine
For the steam turbines, Alstom can select from a large portfolio of steam turbines optimised for use in combined cycle power plants and ranging up to 400 MW. Several configurations in singe and two casing turbines, for backpressure and condensing-extracting operation are available. The Alstom STF15C used at the TPP-26 plant consists of one reheat type single flow HP chamber, one single flow IP (intermediate pressure) chamber and one double flow LP chamber. The turbines are rigidly coupled. HP live steam enters the HP turbine through a single valve block, consisting of one stop and one control valve, and is expanded to reheat pressure. The cold reheat steam is mixed with the IP steam, generated in the HRSG, and reheated. The hot reheat steam enters the IP turbine via two intercept valve blocks, each equipped with a one stop and one control flap, where it is mixed with the IP steam before entering the LP turbine. The outlet steam of the LP turbine is discharged to the water-cooled condenser.
HRSG
FEEDWATER TANK
Steam Water Cooling water Fuel
LP HRSG
IP HRSG TO GT COOLING AIR COOLERS
COLD REHEAT FUEL OIL HOT REHEAT NATURAL GAS FROM GT COOLING AIR COOLERS HP HRSG STEAM TURBINE
G
GT26 GAS TURBINE FORCE COOLED COOLING SYSTEM CITY HEATER DEMIN WATER FROM DISTRICT HEATING RETURN
G
LP STEAM HRSG STEAM TPP 26 AUX. NETWORK AIR INLET
TO DISTRICT HEATING NETWORK
CONDENSER CLOSED COOLING WATER LOOP
ANTI ICING AIR PRE-WARMING SYSTEM
COOLING TOWER BLOWDOWN WATER
A simplified flow diagram of the TPP-26 combined-cycle CHP plant
The IP steam turbine is equipped with extractions for district heating operation. Steam for the district heater DH1 is drawn off from the IP exhaust. District heater DH2 receives steam from the IP steam turbine at an intermediate stage. During pure condensing mode, a minimum amount of steam is flowing through the last stages of the IP turbine in order to prevent ventilation, and discharged into an intermediate state of the LP steam turbine. The GT26 is driving an Alstom TOPAIR generator producing electricity at 19 kV, while the steam generator drives a TOPAIR generator at 15 kV. The generators are of a two-pole, three-phase synchronous design. The hot air is re-cooled in heat exchangers located in the generator housing. The heat is transferred into cooling water and rejected to atmosphere through a remote cooling system. The gas turbine-generator is equipped with a static frequency converter for using the generator as a synchronous motor. During start-up, the starting energy is provided via redundant connection from the station service transformers by the high voltage (HV) grid across the generator step-up unit transformer.
4.3- Generators
4.4 - Heat Recovery Steam Generator
In the HRSG, the exhaust energy from the Gas Turbine is used to produce steam. At TPP-26, a single, horizontal type HRSG, triple pressure reheat unit operates in natural circulation mode for the LP, IP and HP systems.
Heat discharged from the gas turbine as hot exhaust gas serves as the heat source to produce superheated HP, IP and reheat steam and superheated LP steam. The HP/IP feedwater pumps feed the HRSG, which the LP feedwater is extracted downstream of the second row of IP/LP economizers. The feedwater flows are pre-heated in the respective economizers and admitted via control valves into the HP, IP and LP drums. Saturated steam is generated at the HP, IP and LP evaporator. The HP steam is led to the multi-stage HP super-heater, the IP steam to the IP super-heater and subsequently to the re-heater. The LP steam is super-heated also. At the outlet of the HRSG, the HP and re-heat steam are attemperated with feedwater extracted from the HP economizer feedwater line and IP economizer section. This mixing line is equipped with a manual valve, which can be adjusted during commissioning. A blow down tank collects the drains of the HRSG and the drains of the steam turbine external steam system, which are located near the HRSG. After separation, steam is discharged to atmosphere and condensate is discharged to the wastewater system. Alstom produces a broad range of HRSG technologies and designs, for medium, large and very large gas turbines, designed to any standard code (ASME, EN, GOST, IBR, etc.), based on natural circulation, controlled circulation or once-through technologies. Alstoms HRSGs are optimised for cyclic operation, as required for Co-Generation. Improved features include single row harps, stepped component thickness, an optimized drain system and a high level of pre-fabrication in Alstom workshops requiring minimal site welding. All together, this leads to less leakages and higher availability.
4.5 - Main Steam System
The main steam system consists of the HP steam line, the cold re-heat steam line, the IP steam line and the LP steam line. The HP steam line transfers the HP steam produced in the HRSG to the HP section of the steam turbine.
The HP steam is expanded in the steam turbine and released into the cold reheat steam line. When the steam turbine is not in operation, the HP bypass guides the HP steam into the cold reheat steam line. The cold reheat steam line transfers the cold reheat steam back to the HRSG, where it is re-heated and mixed with the IP steam. Steam is taken from the cold reheat steam line for the supply of the air removal system and the gland steam system. It also supplies the auxiliary steam header with steam and acts as a secondary supply of the high temperature cogeneration heater.
4.6 - Condensing System
This is a horizontally arranged two-pass condenser, cooled directly using water from the cooling tower. Non-condensable gases on the steam side are extracted at a defined point of every tube bundle with the lowest pressure the so-called air coolers. The district heaters (DHs) consist of surface heat exchangers. District heating water enters the inlet water box of the first heater, flows through the tubes and leaves the heater via the outlet water box. Then it passes through the second district heater in much the same way. Condensing heater DH2 is fed with steam turbine extraction steam, while the condensate from it drains into DH1 through an expansion device. The condensing and sub-cooling heater DH1 is fed with cascade condensate from DH2, steam turbine extraction steam and with hot feedwater from the HRSG. The hot water from the HRSG drains into the heater through its expansion device. Cooled condensate from the heater DH1 leaves the heater via the heater condensate extraction pumps, of which there are four. Fuel gas is delivered to the plant by a pipeline. Because of the high variability in supply pressure and quality of the feed gas, it has to be treated or conditioned before it can be fed to the gas turbine fuel gas blocks. The fuel gas enters the plant via the main gas inlet valve and passes the redundant gas scrubber units. Separated condensate is collected in a skid and returned to the client systems. A redundant fuel gas compressor system increases the gas pressure from a minimum of only 10 bar to the needs of the gas turbine. In this way, gas pressure is controlled by a dedicated system of recirculation. The I&C system permits the safe running and supervision of the whole CHP plant. The units control system is based on Alstoms ALSPA DCS technology. Alstoms scope of work covers the control and monitoring of the gas turbines, water and steam cycle, HRSG, steam turbine, all the auxiliaries, and steam turbine generator, including the electrical equipment.
4.7 - District Heating System
4.8 - Fuel Gas Supply System
4.9 - Instrumentation & Control (I&C)
5 - TTP-26 Operation Modes

5.1 - Condensing Mode for Power Production
These are loosely divided into Condensing Mode and District Heating modes. Both are considered in the plant automation and are designed to be selectable by the plant operator through a human machine interface module. In this operating mode the exhaust steam from the HP steam turbine is re-heated in the HRSG and directed into the IP steam turbine, passing a crossover line into the LP steam turbine, and finally condensed. In this mode, the steam extraction control and check valves are closed, hot circulated feedwater is returned to the feedwater tank, the DH water control valve is closed and the DH condensate pumps are out of operation. The load of the power plant is controlled according to the grid requirements (i.e. electric load/frequency). In this operational mode, the plant is providing both power and heat for district heating. The steam turbine is in operation, with the steam extraction control and check valves open, hot circulated feedwater is being fed into the DH1, the DH water control valve is open and the DH condensate pumps are in operation. District heating network operators will determine the water flow and heater outlet temperature in accordance with the required heat load. The DH flow controller will throttle the DH water control flap according to requirements.
5.2 - District Heating Mode for combined Heat and Power Production
6 - Summary
The KA26 combined cycle power plant currently under construction at the TPP-26 project in Moscow is the ideal plant for district heating: It provides a large operational flexibility with an operation range from 100% combined cycle load down to less than 40% load at superior partload efficiency. The plant can either provide 420 MWe power or up to 265 MWth heat for the district heating system. With this project, Alstom has gained experience in the execution of turnkey-power plants in Russia. Utilising its Plant Integrator approach for designing and constructing turnkey power plants, Alstom is able to offer optimised, tailor-made district heating power plants based on its in-house core components (GT, generator, ST, HRSG, condenser, control system, ...). The necessary local organisation, combined with the long-term experience in power generation puts Alstom in a good position to support Russia, which has a demand to modernize its district heating power plants, by new greenfield and brownfield installations or repowering of existing steam plants.
Alstom Power
- Alstom 2010. Alstom, the Alstom logo and any alternative version thereof are trademarks and service marks of Alstom. The other names mentioned, registered or not, are the property of their respective companies. The technical and other data contained in this document is provided for information only. Neither Alstom, nor its officers and employees accept responsibility for or should be taken as making any representation or warranty (whether expressed or implied) as to the accuracy or completeness of such data or the achievement of any projected performance criteria where these are indicated. Alstom reserves the right to revise or change this data at any time without further notice. Photo credit: Alstom
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Experience from Alstoms TPP-26 Project in Moscow: District Heating with the KA26 Combined Cycle Power Plant

1 - The TPP-26 project

1.2 - Set-up of the Project

View of the TPP-26 turbine hall

1.3 - Specialties of Joint Plant Engineering in Russia and Switzerland

1.3.1 - Different Norms for Piping

1.3.2 - Engineering Processes

1.3.3 - Steel Work and Plant Arrangement

1.3.4 - Documentation and Certification

1.4 - Transportation of Gas Turbine and Generator

Transportation of GT thermal block in disassembled condition on a barge

2 - Market situation in Russia

2.2 - Alstoms EPC Capability in Russia

3 - Alstom KA26 technology: Extraordinary high operational flexibility

3.1 - Sequential Combustion

3.2 - Start-up Behaviour

3.3 - Large Operation Range and High Part-Load Efficiency

3.4 - Low Load Operation Capability

3.5 - KA26 for District Heating

3.6 - Alstom CCPP References in District Heating Applications

3.7 - OEM, Plant Integrator and EPC capability

4 - Major Components and Systems

GT26 thermal block

4.2 - Steam Turbine

Steam Water Cooling water Fuel

IP HRSG TO GT COOLING AIR COOLERS

TO DISTRICT HEATING NETWORK

CONDENSER CLOSED COOLING WATER LOOP

ANTI ICING AIR PRE-WARMING SYSTEM

COOLING TOWER BLOWDOWN WATER

A simplified flow diagram of the TPP-26 combined-cycle CHP plant

4.4 - Heat Recovery Steam Generator

4.5 - Main Steam System

4.6 - Condensing System

4.7 - District Heating System

4.8 - Fuel Gas Supply System

4.9 - Instrumentation & Control (I&C)

5 - TTP-26 Operation Modes

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