AVIADVIGATEL MAKES BUSINESS PERFECTLY!
VICTOR AND OLGA OSIPOV
GPA-12 Ural gas compressor plants based on GTU-12P gas turbines
Under Ural-Gazprom program by Gazprom Order No. 27 dated July 10th, 1993 Permskaya CS was shifted to pilot operation to perform full-scale testing of PS-90 aircraft engine commercial prototype on the test benches located on the station's territory. Compressor station specifics and results of the tests performed on gas turbine equipment designed by Aviadvigatel are discussed with Dmitry YAGANOV, Director of Permskaya CS, and Igor PYANKOV, Shift Engineer for gas compressor equipment operation.
- Before reconstruction, the compressor station for some 20 years had been using GPA-TS-6.3/56 gas compressor plants, legendary machines from Sumy based on NK-12ST aircraft engines made in Samara Motorostroitel Plant. How the idea of reconstruction was born?
Dmitry Yaganov:
- GPA-TS-6.3/56 plants became time-worn, outdated and rather fire hazardous. By the beginning of '90 they fully depleted their life cycle. Their design was quite simple and did not require high-skilled maintenance personnel. Low capacity and productivity could no longer satisfy the growing demands of gas industry.
Igor Pyankov:
- I've been working at Permskaya CS for eighteen years, so I got to know PS-90A engines from the very moment they were installed here. In comparison with NK-12ST, the PS-90A engine is much more serviceable, reliable, and unpretentious. It's worth mentioning that the old engines were uncomfortable for conducting maintenance and repair - both the engine section and the gas compressor section. Not every gas turbine could work for the declared 20,000...25,000 hours without serious faults. Time itself demanded the Compressor Station to be retrofitted with new equipment.
- Why gas turbines of Aviadvigatel's design were chosen?
Dmitry Yaganov:
- I think that the tandem of the famous Pavel SolovIev's engine design school and of serial Perm Engine Company (PMZ) with great experience in gas turbine equipment manufacture for aviation is the best recommendation in selecting a designer and supplier. Surely not insignificant is vicinity of all the manufacturers: the Design Bureau, the full-scale production plant, and NPO Iskra - the gas compressor unit manufacturer. It meant prompt interaction and low-cost service. These are, in my opinion, the main reasons that influenced the choice made by Gazprom's top management.
Aviadvigatel's testing bench No.184 at Igrinskaya CS of Gazprom Transgaz Chaikovsky Ltd
- In these years it was the first experience of Perm engine builders in producing equipment for industrial purposes. It could have brought many problems, many «childhood diseases» of the product. Wasn't there any fear? The station should have provided gas transportation by all means.
Dmitry Yaganov:
There was not fear but confidence in my fellow countrymen. Some concern arose due to transformation of a common transportation station into some kind of a testing area: being a pilot facility is rather disquieting. Now our CS is equipped with two power plants - of 12 MW and 16 MW - gas turbines of which are being constantly reworked, updated, and tested. On one side, the machines work for gas transportation, and we want to use them as «our» machines. On the other hand, these machines are Aviadvigatel's test benches.
Igor Pyankov:
- I cannot say that adaptation of PS-90A-based machines brought concern: we were young and venturous, with much interest for work. After switching to more powerful GPA-12 gas compressor plants, the control system was fundamentally changed. It was computer-aided to the greatest possible extent and fitted with most up-to-date equipment for those times. Naturally, we had to learn how to work with PS-90A-based gas turbines. Aviadvigatel's specialists gave us methodological aid.
- When operation of Perm-built gas turbines began, surely you had problems. How they were solved? How contacts with the designer (Aviadvigatel) were established?
Dmitry Yaganov:
-The initial period in new technology assimilation is always associated with problems and difficulties, this is quite natural. During pre-commissioning the equipment was checked out and adjusted. I can remember a problem with the electric drive of the inlet guide vanes. It was resolved by equipping the gas turbine with a hydraulic control system of compressor mechanization. I can name no more shortcomings of the engine or the gas turbine.
- Mr. Yaganov, gas turbines have been operated at your compressor station for over fifteen years. Did you, as the operating company, bring any recommendation to improve the design of the engine or of the gas turbine in this period?
Dmitry Yaganov:
- The engine was designed by true professionals. I can say in the most responsible manner that the engines work flawlessly. As for the gas turbine, we put forward some recommendations which were all implemented. In particular, there was a necessity to move the tubes transmitting parameter values to the instrumentation cabinet. Input/output openings on the engine were transposed accordingly. This is, perhaps, the only example of a serious recommendation for GTU-12P improvement.
As for updated GPA-TS-16 our recommendations were conditioned by the changed transmission. It became longer, and a new lubrication and cooling system was introduced. It was rather uncomfortable for maintenance. That is why we proposed to develop a separate lubrication and cooling system to be integrated into the machine. This is Aviadvigatel's solution made after our initiative. At present this innovation is implemented, and operation of the machine has become easier.
- Does the presence of Aviadvigatel's designers and test bench at the CS influence your work anyhow?
Dmitry Yaganov:
- From the point of view of technical support, it's an advantage. Very competent specialists who know the engine and the gas turbine thoroughly come to the CS. We have a unique possibility of communication and constant consultations with them. I think you agree with me that a possibility to put a question to a true professional is a great help in your work. If not for Aviadvigatel's people, we will probably have more problems. We have good cooperative relationships with Yuri Goldin , Igor Korotayev, Vladimir Boyarshinov, Pavel Nikolayev, Vladimir Poleshov, and many others.
- Mr. Yaganov, you work in cooperation not only with Aviadvigatel, but with other machine building companies. What is cooperation with Perm Design Bureau noted for?
Dmitry Yaganov:
- The main criterion for someone's work is professionalism. We are very pleased to work with Aviadvigatel's specialists. They are people with a high level of technical training, true patriots of their company, giving all their efforts to their work. In fifteen years of team work we achieved full reciprocal understanding, and this is the most important thing.
- Reconstruction of Permskaya CS is completed. How can you describe the present-day condition of the station, its particularities?
Control console of Permskaya compressor station Gazprom Transgaz Chaikovsky Ltd
Dmitry Yaganov:
Our station is a line station for gas compression and transportation to the Central Russia and to industrial enterprises in Perm. Besides, it is a pilot station. All the machines installed are based on converted PS-90A engines. Two of them are equipped with a modern hydraulic compressor mechanization system.
All the gas compressor units installed at the station are different not only in capacity but in design. They are based on gas turbines of different configuration: different transmissions, different compressor vanes and valves control systems, different gas compressors. All this creates versatility with overall unanimity. Not every compressor station is unique to this extent. At that, all the gas turbines are characterized by flawless operation of the engines, comfortable configuration of assemblies, good maintenance conditions. The amount of the occasions when some components failed was limited, and they were not related to flaws in design.
- What machines, in your opinion, will be in demand on the gas compression market in the future?
Dmitry Yaganov:
- In my opinion, the best choice is 12 MW gas turbine. Let them be more in number in one station, but the unit capacity should be this. I think at present these machines are absolutely tried-and-true. The designers and the operators have passed through all «childhood diseases» of this equipment and they know much if not everything about GTU-12P particularities. Gas turbines with capacity of 16 MW and more are not inferior to 12 MW units in their qualities but they need time for rework and upgrading. Though one cannot deny that high capacity gas pipelines require high capacity gas turbines: 25 MW and more.
I know that Perm designers gorge ahead, they have already created and put into full-scale production GTU-25P gas turbine which, by the way, was tested at our compressor station, too. I am sure that Aviadvigatel has other projects and promising developments.
