Supply of APE-270-150-3 feed pump unit for Ufimskaya CHPP-3 Bashkir Generation Company LLC

Ufimskaya CHPP-3 is a combined heat and power plant which was commissioned in 1954 and located in the city of Ufa of the Republic of Bashkortostan, and is a part of the Bashkir Generation Company LLC (PJSC Inter-RAO).

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

Currently, Ufimskaya CHPP-3 operates 6 feed pumps. The management of BGK LLC set the task of implementing a program to replace obsolete feed pumps to ensure the reliability of the station and, accordingly, uninterrupted heat supply to Bashneft PJSC facilities. Under this program, in the period from 2019 to 2021, we delivered and put into operation three APE270 feed pumps at Ufimskaya CHPP-3, which significantly improved the reliability and performance of the equipment.The next task for the station staff was to increase the energy efficiency and agility of the feed pump.

In 2021 our engineers worked on the APE270 feed pump complete with a variable filling fluid coupling manufactured by Voith (Germany) cooperation with the Ufimskaya CHPP-3 specialists. The project was successfully agreed 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 this situation, it was necessary to quickly make a decision to replace the fluid coupling in order to avoid disrupting the project deadlines. EnergoFront specialists were tasked to analyze suppliers from India and China and to conduct the production audits in the format of personal visits of specialists, as well as via video communication. As a result, a fluid coupling manufactured by Premium (India) was chosen, which is the most consistent with the technical specifications.

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

The main technical solutions were:

• offer of a feed pump APE-270-150-3 produced in Russia by HMS Livgidromash JSC (Livny, Oryol region) with a modernized flow path;

• modernized flow part of the pump;

• increased efficiency;

• Premium 580 PST Variable Fill Hydraulic Coupling, hydraulic 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, the 4AZM 2000/6000 UHL4 electric motor manufactured by NPO ELSIB PAO Novosibirsk was selected. As the insulation of the stator winding of this motor, modern reliable technology "Monolith-4" is used, which provides a working life of up to 30 years.

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

• automatic regulation of feed water supply to the boiler;

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

We carry out a complete set of the unit, including fittings, vibration and axial shift sensors, a set of spare parts and accessories and couplings, and we are also responsible for the installation supervision in the project.

The delivery of pumping equipment is scheduled for March 2024.

Project achievements