Supply of boiler feed pump unit APE-270-150-3 and hydrodynamic coupling Premium 580 PST, for Ufimskaya CHPP-3 LLC Bashkir Generating Company

Ufimskaya CHPP-3 is a combined heat and power plant located in the city of Ufa, Republic of Bashkortostan, put into operation in 1954 and is part of the Limited Liability Company Bashkir Generating Company (PJSC Inter-RAO).

Ufa CHPP-3 releases thermal energy in steam and hot water for heating needs, as well as electrical energy. The main consumers of steam are oil refining industry enterprises - PJSC Ufaorgsintez and the branch of PJSC ANK Bashneft - Bashneft-Novoil. Installed electrical capacity is 95 MW, thermal capacity is 992.8 Gcal/h. The main fuel is natural gas, the backup fuel is fuel oil.

Currently, 6 boiler feed pumps are in operation at Ufimskaya CHPP-3. The management of BGK LLC was tasked with implementing a program to replace outdated boiler feed pumps to ensure reliable operation of the station and, accordingly, uninterrupted heat supply to the facilities of PJSC Bashneft. Under this program, from 2019 to 2021, we supplied and commissioned three APE270 boiler feed pumps at Ufimskaya CHPP-3, which significantly increased the reliability and performance characteristics of the equipment. The next task for the station employees was to increase the energy efficiency and maneuverability of the boiler feed pump.

In collaboration with specialists from Ufa CHPP-3, our engineers in 2021 worked on the APE270 boiler feed pump complete with a variable-fill fluid coupling manufactured by Voith (Germany). The project was successfully agreed upon and accepted for implementation, with commissioning in 2024.

But in 2022-2023, the energy equipment market has changed and many brands have become unavailable. In the current situation, it was necessary to quickly make a decision to replace the fluid coupling in order to avoid delays in the implementation of the project. EnergoFront specialists were tasked with tasks analyze suppliers from India and China, conduct production audits, in the format of personal visits by specialists, as well as via video communication. As a result, a fluid coupling manufactured by Premium (India) was selected, which best corresponds to the technical specifications.

The complete range of constant and variable fluid dynamic couplings offered by Premium India covers transmission power from 4 to 5200 kW. 3000 rpm Thanks to more than fifty years of development experience, the company has achieved the highest quality standards for its products and has created a wide application market covering almost all continents. Premium has 26 representative offices in various countries of America (North and South), Europe, Asia, Africa and Australia. The company meets 90% of the domestic demand for fluid couplings in India and supplies €10 million worth of products annually to various countries around the world through its representative offices.

The main technical solutions were:

• proposal for a boiler feed pump APE-270-150-3 manufactured in Russia by JSC GMS Livgidromash (Livny, Oryol region) with a modernized flow part;

• modernized pump flow part;

• increased efficiency;

• variable-fill fluid coupling Premium 580 PST, the fluid coupling oil system provides oil supply to the engine and pump;

• as a pump drive, instead of the existing 2AZM 2000/6000 UHL4 electric motor, a 4AZM 2000/6000 UHL4 electric motor manufactured by NPO ELSIB PJSC Novosibirsk was selected. Modern reliable technology “Monolit-4” is used as insulation of the stator winding of this motor, providing a working life of up to 30 years.

After implementation of the project, Ufa CHPP-3 will receive the following benefits:

• automatic control of feed water supply to the boiler;

• smooth start of the unit, which will eliminate starting shocks and increased vibration.

We provide a complete set of the unit, including fittings, vibration and axial displacement sensors, a set of spare parts and couplings, and are also responsible for the installation supervision of the project.

Delivery of pumping equipment is scheduled for March 2024.

Project achievements