Advanced combined-cycle technology
Advanced combined-cycle technology makes Shatura one of Russia most efficient power plants

The Shatura combined-cycle power plant, in operation for almost two years, represents one of the most important developments in Russia’s battle to modernise its old and inefficient power generation fleet, writes GE Energy.

One of Russia’s most efficient and modern combined-cycle power plants, located at Shatura about 150 km east of Moscow, has completed close to two years of operation – since commissioning in November 2010 – and, more importantly, has set new output and efficiency standards for the site.

Owned by Russian power producer E.ON Russia and utilising GE technology, the Shatura site is one of the first combined-cycle blocks of its kind in Russia.

The new combined-cycle gas turbine (CCGT) Shaturskaya GRES (Shatura) plant is an upgrade of an existing facility at the site, which has been producing electricity since the mid-1920s. E.ON Russia estimates that site output has been increased by an impressive 115 GWh because of the extension of the generating capacities of the station. Also, the plant has lower carbon dioxide (CO2) emissions than older and less efficient plants with a similar capacity.

With this power station alone, CO2 emissions are expected to be cut by over a million tonnes by the end of 2012. The project was recognised by the United Nations as the first Russian carbon reduction Joint Implementation (JI) project under the Kyoto protocol. E.ON and GE also received a state award from Russia’s Ministry of Energy for the best technology used in implementing the Shatura project.

At the commissioning of the new CCGT plant, Bernhard Reutersberg, a member of the E.ON Board of Management, stated that this project “makes it quite clear what E.ON actually means with its new cleaner and better energy strategy. At Shatura, we are setting up one of the most efficient and modern power stations in Russia based on the state-of-the-art technology.

“With thermal efficiency of [close to] 56 per cent, E.ON is setting new standards here in terms of the efficiency and climate compatibility of power production. Shatura is the first project we are implementing as part of our investments in Russia. In this manner we want to modernise [the country’s] power industry and make energy supplies to Russian residential and industrial customers more reliable, efficient and climate-friendly.”

A long and distinguished history

The original Shatura plant was one of the first power stations commissioned as part of the former Soviet Union’s electrification plan for the country. The first plant, with a capacity of 5 MW, was commissioned on 25 July 1920.

The head of construction was Alexander Vasilievich Vinter, a distinguished Russian electric energy engineer. At that time, the plant operated on lignite, taken from rich lignite fields in the Shatura district, and it served as the experimental base to develop advanced solutions for burning lignite.

In 1933, the power station was expanded to 180 MW and became one of the largest and most economically efficient electric power stations in the world. Fifty years later, in the mid-1980s, the plant was revamped to allow it to burn gas. Currently, the Shatura plant can operate on four types of fuel – gas, coal, fuel oil and lignite. The capacity generated by the site plays an important role in providing a reliable supply of electricity for the Moscow region.

In 2006, the Shatura plant, along with four other Russian power plants, became part of OAO OGK-4, and the following year OGK-4 was acquired by E.ON and renamed E.ON Russia. The construction of the new 400 MW plant, incorporating today’s advanced technologies, started in 2008 and continued for 31 months.

Advanced combined-cycle tech

The upgraded Shatura plant features the advanced 109FA combined-cycle technology, including the high-efficiency Frame 9FA gas turbine and the D-series combined-cycle steam turbine, as well as the 390 class generator specially designed for power generators requiring large blocks of reliable power.

GE has been providing customers with reliable power generation equipment for more than 100 years, and has over 2300 gas turbines installed in combined-cycle plants around the world in addition to a total steam turbine fleet of nearly 6000 units.

The scope of GE’s contract for Shatura also included a heat recovery steam generator and a distributed plant control system.

The main features of GE’s combined-cycle technology include:

  • An enhanced gas turbine compressor design, increasing reliability and availability, and reducing periodic inspections and maintenance costs.
  • Dry Low NOx (DLN) 2.6+ combustion system providing low nitrogen oxides (NOx) level emissions, increased emissions compliant turndown capability, and longer combustion inspection intervals.
  • A blade health monitoring system providing real-time measurements of key static and dynamic deflection features to help determine blade deterioration.
  • Cooling optimisation providing improved 9FA gas turbine power output and baseload efficiency through better management of turbine section clearances and cooling air flows.
  • Fast start features, which reduce the start time of the gas turbine across the entire start sequence. For simple cycle, this product option delivers a 15-minute start to full load. For combined-cycle power plants, this production option reduces the start time of the power plant by as much as 20 minutes.
  • A Mark* VIe control system increasing overall performance, operability and reliability, which can be expanded to provide a common platform for power station control.
  • Three-pressure level D-series steam turbine with technologies optimising the bottoming cycle for this combined-cycle application.

In addition to the equipment contract, E.ON also signed a 12-year contractual service agreement (CSA) with GE, which covers the supply of parts, repairs and field services for maintenance outages of gas turbines and generators.

A long-term agreement such as this provides customers with predictable maintenance costs while ensuring a steady flow of revenue from power plant operations. To date, GE has long-term service agreements in place, including CSAs, at more than 700 sites worldwide.

Russia’s power fleet modernisation

In addition to the Shatura power station, E.ON is implementing modern and efficient new-build projects at three additional sites in Russia, as part of its investment programme totalling €2.8 billion ($3.5 billion).

In total, E.ON will increase its installed capacity in Russia by 2500 MW to reach 11,100 MW, thus helping to meet the growing demand for power in the country.

E.ON also gained recognition of its Joint Implementation projects for the three other CCGT plants, which were launched in 2011.Cristiano Tortelli, president and CEO, GE Energy, Central and Eastern Europe, Russia and CIS, said, “Shatura is one of several key projects that GE won in Russia. It demonstrates the clear progress of [our] localisation initiative in Russia. We are here to support the modernisation of the Russian energy industry by providing some of the most advanced and efficient technologies available today.”

Serving the Russia power market

While the new Shatura project marked the first installation of a GE 109FA combined-cycle system in Russia, the same technology has been applied at the Surgutskaya GRES-2 plant in Surgut, the largest power generation facility in Russia and the largest gas fuelled power plant in the world.

9FA gas turbine
9FA gas turbine is known for its high performance in output, efficiency and emissions control

Two new blocks of Surgutskaya GRES-2, inaugurated in July 2011, have two GE Frame 9FA gas turbines, which also are achieving high performance in output, efficiency and emissions control.

The Nizhnevartovsk plant in Russia also features GE 9FA technology.

GE Energy has been active in Russia since the early 1900s, supplying equipment and services to develop the country’s energy infrastructure. Today, more than 400 gas turbines, 65 steam turbines, 700 compressors and over 600 units of other equipment including air coolers, condensers, gas separators and pumps produced by GE Energy and GE Oil & Gas have been installed in Russia and the Commonwealth of Independent States (CIS).

In 2010, GE opened the Energy Technology Centre, a service centre in the Kaluga region in the east of the country that is dedicated to supporting the company’s installed base of equipment.

In September of 2011, GE signed a joint venture agreement with Inter RAO UES, one of Russia’s largest public energy companies, and UEC (United Engine Corporation) to localise production of GE’s 6FA gas turbines in Rybinsk, in the Yaroslavl region.

Since March 2008, GE’s MS5002E gas turbines have been manufactured, tested and sold in Russia as ‘LADOGA 32’ units, under a technology transfer and localisation licensing agreement between GE and REP Holding, a power engineering company.