Supply of oil supply units for electric boiler feed pumps for project 10510 icebreaker “Leader”

Our company, together with JSC HMS Livgidromash, continues its active participation in the construction of the country’s nuclear icebreaker fleet. At the beginning of 2023, a contract was signed with PJSC Kaluga Turbine Plant (part of JSC Power Machines), manufacturer of the PTU-74 steam turbine unit, for the supply of main feed and circulation electric pumps complete with an electric drive for the nuclear icebreaker under construction, project 10510 “Leader” LK-120Ya.

The design of the nuclear icebreaker pr. 10510 “Leader” LK-120Ya started several years ago and was carried out by many organizations: the lead developer was the Iceberg Central Design Bureau, OKBM im. I.I. Afrikantova was responsible for the development of a nuclear power plant, and part of the research and design work was taken over by the Krylov State Scientific Center. This is not the first time these organizations have teamed up to create a new vessel, but this time they had to develop a particularly large-scale project - the largest icebreaker in the world.

In accordance with Decree of the Government of the Russian Federation No. 11 of January 15, 2020, the state corporation Rosatom was appointed as the state customer for the new construction. FSUE Atomflot, which is responsible for the operation of the entire Russian fleet of nuclear icebreakers, has been appointed as the developer. The ship was laid down at the Zvezda shipbuilding complex in Bolshoy Kamen.

The task of the “Leader” will be year-round work on the Northern Sea Route in order to ensure navigation and escort of merchant and scientific vessels. Associated with this is a number of characteristic technical requirements, the fulfillment of which must be achieved using modern and promising technologies. In accordance with the technical specifications, the icebreaker Project 10510 must overcome ice with a thickness of at least 4 m while constantly moving at a minimum speed. For ice 2 m thick, the constant speed is set at 12 knots. The need to pilot large-capacity vessels led to an increase in the width of the icebreaker's hull. It was also required to ensure high autonomy in terms of power reserve and service life of 40 years.

According to the project, the new nuclear icebreaker has a length of 209 m with a maximum width of 48 m. The total displacement is more than 71 thousand tons.

The power plant for Project 10510 is built on the basis of two RITM-400 water-cooled reactors with a thermal power of 315 MW each with a service life of 40 years and the need to replace fuel after 5-7 years.

The correct choice of equipment included in the STP and its completeness directly affect the production and technological capabilities, meeting the high requirements for reliability and service life of the STP.

One of such elements for the main electric boiler feed pumps used in this project is the oil supply unit (BMS EPN), which must provide lubrication and heat removal from the pump bearings in all operating modes. BMS EPN must comply with the Rules for the classification and construction of sea vessels, the Rules for the classification and construction of nuclear ships and floating structures and the Rules for technical supervision of the construction of ships and the manufacture of materials and products for ships.

The main criteria for selecting a manufacturer for a given tasks were:

• many years of experience in the development and supply of similar equipment;

• a modern production site equipped with high-precision production equipment;

• availability of a test bench;

• availability of quality management certificates and experience in working with RMRS.

Based on the results of an analysis of possible manufacturing plants, taking into account all the above criteria, EnergoFront employees selected the Pneumax LLC plant, located in the city of Khimki, Moscow region. The manufacturing plant has been a leader in the production of hydraulic systems for various purposes on the domestic market for more than 25 years. Using the results of many years of development by the research team, the use of high-precision processing machines, coordinate measuring centers allows us to obtain the highest quality products that meet the latest world standards.

In the process of close collaboration between the technical services of our company and Pneumax LLC, taking into account the requirements of the technical specifications of PJSC Kaluga Turbine Plant, the optimal solution for the BMS EPN was selected for this installation.

The EPN BMS includes:

• oil tank EPN (BM EPN) assembly;

• counter flanges, sealing gaskets and fasteners BM EPN;

• two (main and backup) oil pumps (MN EPN);

• single-chamber suction filters MN EPN;

• switchable oil filter on the pressure manifold;

• two oil coolers (MO) on the pressure manifold;

• two low oil pressure reducing valves;

• two direct-acting oil temperature regulators;

• two non-return shut-off valves (one each at the MN ESP discharge);

• fittings and pipelines within the BM EPN;

• magnetic level indicator;

• high and low level alarm;

• release bolts on supporting surfaces;

• a set of mounting parts;

• spare parts kit.

The proposed oil installation is compact in size, while ensuring stable operation and lubrication of bearings throughout the entire range of ESP operation.

Supervised installation and commissioning work on the icebreaker will be carried out by the chief engineers of our service department, which guarantees that these works are carried out in strict accordance with the requirements of the operational documentation for the supplied equipment. This allows you to be confident in the long-term and trouble-free operation of the entire ship system.

Project achievements