Comprehensive supply of pumping equipment for an energy facility — Novolenskaya TPP

Customer: Inter RAO – Electric Power Generation JSC.

Facility: Novolenskaya TPP is a 550 MW plant under construction in the Republic of Sakha-Yakutia.

Client: Inter RAO JSC is one of the largest Russian energy companies that manages assets in Russia as well as in Europe and the CIS. Its activities include the production and sale of electric and thermal energy, international energy trading, engineering, design and construction of energy facilities.

Project objectives:

1. 1. Ensure the company's active and effective participation in a strategically important national-scale infrastructure project.

2. 2. Demonstrate the professional potential of the company by using a full range of engineering and management resources to perform high-level tasks.

3. 3. It is guaranteed to fulfill all contractual conditions, including strict compliance with the deadlines for commissioning the power facility set by the customer.

4. 4. Provide the power plant with modern technological equipment for the uninterrupted operation of an important technological link.

Project objectives:

1. 1. Definition of the production and technological task that needed to be solved as part of the construction of a new power facility.

2. 2. Determination and coordination with the customer of the technical parameters and characteristics of the necessary equipment.

3. 3. Execution of design of layout solutions.

4. 4. Choosing reliable suppliers to solve the technological problem.

5. 5. Development of technical requirements for equipment for placing orders at manufacturing plants.

6. 6. Monitoring the execution of orders by the company's leading engineers directly at the partners' production sites.

7. 7. Completion of the working documentation in order to improve the design to increase the convenience of subsequent operation and maintenance.

8. 8. Development of a unique comprehensive testing program for the entire supply volume and provision of complex logistics for the delivery of equipment.

The key task was to provide the power plant under construction in one of the most remote and extreme regions of Russia with highly reliable and energy-efficient pumping equipment, which is very important for its operation. The result of our interaction with the Customer, designers and contracting companies was an agreed technological task, which defined the requirements for the process, equipment and necessary parameters for the effective implementation of production tasks.

In the current international situation and restrictions on the supply of traditional equipment, it has become particularly difficult to find and integrate alternative solutions from trusted manufacturers that guarantee uninterrupted operation of thermal power plants throughout their entire life cycle.

Detailed description of the work performed

1. Technological audit and engineering

The work of our company's specialists began with an in-depth analysis of the technical specifications and project documentation of the Customer. The specialists of EnergoFront conducted

• Analysis of operating modes. All planned technological modes of operation of thermal power plants were studied in detail to accurately select pump characteristics.

• Comparative analysis of manufacturers. In the context of new market realities, a large-scale international audit of potential suppliers was conducted. In the process, it became necessary to deeply adjust the standard equipment, from the dimensions and connection dimensions for integration into the specified design solutions to the technical characteristics of the unit. Our specialists from the Foreign economic activity department carried out a comprehensive analysis of the production capacities, experience and reference projects of each manufacturer. The key selection criteria, in addition to strict compliance with technical parameters, were the long-term reliability of the partner, his readiness for close operational and engineering cooperation, and the ability to provide full-fledged service support for the entire life cycle of the equipment.

• Development of complex solutions. Not just equipment was designed for each type of pump, but a complete system including control cabinets, frequency converters, and control systems.

2. Design and selection of equipment

The selected technological equipment must be optimally placed in the machine room under construction, connected to technological systems and workshop infrastructure. Optimal technical solutions were proposed and agreed with the Customer.

• For the heating system

Task: to ensure the supply of up to 1500 m³/h of mains water with a head of 80 m. It required the operation of three main and one backup pump (500 m³/h each) with the possibility of smooth regulation of productivity for significant energy savings.

Solution: two-way inlet pumps XS150-605 manufactured by Hunan M&W Energy Saving — the largest manufacturer in this segment, have been selected. Frequency converters from the Russian company «VEDA MK», integrated into control cabinets, were used for speed control and control.

• To power the boiler (feed pumps)

Task: supply of six high-pressure (H = 2145 m), high-temperature (up to 160 °C) feeding units with a smooth and reliable control system for operation in extreme conditions of Yakutia. An error in the choice or reliability of the equipment was unacceptable due to the remoteness of the facility and the importance of pumps for the operation of thermal power plants.

Solution: we selected the TDG670-215x10 series pump manufactured by Shanghai Kaiquan Pump - оone of the largest and most technologically advanced manufacturers in China with experience in nuclear and thermal energy, with which our company is developing strategic business relations.

Technical parameters of the equipment

General drawing of the TDG pump

EFP layout for Novolenskaya TPP

Drawing of the EFP unit

Features of the solution

• Double-hull design: external power housing and internal flow-through for maximum safety.

• Modern materials: the use of high-alloy steels and wear-resistant alloys to combat cavitation and erosion.

• Drive solution:

- the electric motor is a time–tested electric motor of the AZM series.

- hydraulic coupling: the most important element of the drive is a smooth control system based on a hydraulic coupling, which has proven significant operational advantages in the technology of supplying feed water to power boilers.

Hydraulic coupling drawing

- connecting plate couplings: provide compensation for misalignment. The presence of a detachable spacer provides access for maintenance of bearing assemblies.

• Adaptation to the facility: during the design process, an adjustment of the overall and connecting dimensions of the equipment was required to integrate into the existing layout of the technological sections.
• The unit is equipped with a hydraulic coupling control system and primary sensors for measuring temperature, vibration, and axial displacement.
• Ensuring efficiency: work has been carried out to ensure the technical characteristics of the units in order to achieve the specified parameters of the thermal power plant's production efficiency.
• Deep refinement of structures: interaction was carried out with equipment manufacturers at the level of changing the design and manufacturing technology of parts and assemblies to meet the requirements of the project.
• Extended equipment: increased up to 3 years of stock of wear-resistant items and spare parts due to the complexity of logistics. The construction of the Novolenskaya TPP is underway in an extremely inaccessible region — the Republic of Sakha, which creates large-scale logistical challenges. The remoteness of the facility, the extreme climate and the lack of year-round highways force the use of a complex delivery scheme for specialized pumping equipment. The supply route consists of road transportation, a ferry crossing along the Lena River (taking into account the short navigation period), as well as numerous overloads between modes of transport.
• Development of a set of operational documentation for each type of equipment: within the framework of the project, a special set of operational documentation is being developed and prepared for shipment with the first batch of shipments, necessary for the organization of installation work, the commissioning stage of preparation for commissioning into warranty operation and subsequent engineering support for the operation of units.

3. Production control and testing

To minimize project risks, EnergoFront specialists are implementing a program for operational control of the production process at enterprises.

• Production and technological planning: having in-depth knowledge and practical skills in the machine-building industry, in the context of strategic business relationships with owners and key leading managers of manufacturing plants, production schedules for each piece of equipment have been formed in a single format, on the basis of which operational management of the production process is implemented.
• Stage control: monitoring of key production stages at manufacturing plants. Supply chain tracking is provided for all materials and components.
• Testing: all pumps will be tested at the factory stand in the presence of Customer representatives. The feed pumps will be tested as part of the supplied assembly arrangements and will include confirmation of the actual parameters (pressure, flow rate, cavitation reserve), vibration diagnostics and monitoring of bench parameters for the entire pressure and flow characteristics.

4. Delivery and upcoming work

• Mains pumps: the equipment has been successfully manufactured, tested and shipped to the Customer. Despite all the logistical difficulties, the first batch of pumping equipment was successfully delivered to the construction site, which confirms the effectiveness of the proven route.
• Feed pumps (EFP): the equipment is at the manufacturing stage. Delivery to the facility is scheduled for 2026.

Results:

As part of an integrated approach to the project, EnergeFront performed a full range of services from in-depth project analysis to implementation process management.

Special attention was paid to completing the facility with detailed documentation, which is extremely important to comply with the manufacturer's regulations, especially at remote sites.

As a result, not just equipment was offered, but a ready-made technological solution that ensures the energy security of a responsible facility. The full engineering cycle also included the search and evaluation of new manufacturers in the changed market conditions, production control and supply management.

Key results for the Customer

• Ensuring the energy security of the region: the plant will receive highly reliable equipment necessary for launch and stable operation.
• Energy efficiency: the use of CHP for network pumps will provide significant energy savings.
• Risk reduction: careful selection of manufacturers, multi-level control and advanced equipment minimize the risks of downtime in the difficult conditions of Yakutia.
• Meeting deadlines: all stages of the project are carried out in strict accordance with the TPP construction schedule.

This project confirms EnergoFront's ability to act as a reliable strategic partner, capable of solving problems of any level of complexity and responsibility, ensuring the development of its own technologies and energy stability.

Project achievements