Complex supply of pumping equipment for an energy facility - Novolenskaya TPP

Customer: JSC Inter RAO – Electric Power Plants.

Object: Novolenskaya TPP is a station under construction in the Republic of Sakha-Yakutia with a capacity of 550 MW.

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

Project goals:

1. 1. Ensure the company’s active and effective participation in a strategically important infrastructure project of a national scale.
2. 2. Demonstrate the company's professional capabilities by deploying the full range of engineering and management resources to perform high-level tasks.
3. 3. Guaranteed to fulfill all contractual conditions, including strict adherence to the deadlines for commissioning of the power facility established by the customer.
4. 4. Provide the power station with modern technological equipment for the uninterrupted operation of an important technological link.

Project objectives:

1. 1. Determination of the production and technological problem 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. Design of layout solutions.
4. 4. Selecting reliable suppliers to solve a technological problem.
5. 5. Development of technical requirements for equipment for placing orders at manufacturing plants.
6. 6. Monitoring the fulfillment of orders by the company’s leading engineers directly at the partners’ production sites.
7. 7. Refinement of working documentation in order to improve the design to improve the convenience of subsequent operation and maintenance.
8. 8. Development of a unique comprehensive testing program for the entire scope of delivery and provision of complex logistics for the delivery of equipment.

The key task was providing a 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 upon technological specification, which determined 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, the search and integration of alternative solutions from trusted manufacturers that guarantee uninterrupted operation of thermal power plants throughout the entire life cycle has become particularly difficult.

Detailed description of work performed

1. Technology audit and engineering

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

• Analysis of operating modes. All planned technological operating modes of thermal power plants were studied in detail to accurately select the characteristics of the pumps.
• Comparative analysis of manufacturers. In the context of new market realities, a large-scale international audit of potential suppliers was carried out. In the process, it became necessary to deeply adjust the standard equipment - from dimensions and connection dimensions for integration into given design solutions to the technical characteristics of the unit. Our foreign trade department specialists carried out comprehensive work to analyze the production capacity, 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 interaction and the ability to provide full service support for the entire life cycle of the equipment.
• Development of complex solutions. For each type of pump, not just equipment was designed, 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 upon with the Customer.

• For heating system

Task: to ensure the supply of up to 1500 m³/h of district heating water with a pressure of 80 m. The operation of three main and one backup pumps (500 m³/h each) was required with the ability to smoothly regulate productivity for significant energy savings.

Solution: double entry pumps selected XS150-605 production Hunan M&W Energy Saving is the largest manufacturer in this segment. Frequency converters from a Russian company are used to regulate speed and control "VEDA MK"integrated into control cabinets.

• To feed the boiler (boiler feed pumps)

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

Solution: series pump selected TDG670-215x10 production Shanghai Kaiquan Pump - one 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.

Equipment technical parameters

General drawing of the TDG pump

PEN layout for Novolenskaya TPP

Drawing of the PEN unit

Solution Features

• Double-body version: external power housing and internal flow housing for maximum safety.

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

• Drive Solution:

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

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

Fluid coupling drawing

- plate couplings: provide misalignment compensation. The presence of a split spacer provides access for servicing the bearing units.

• Adaptation to the object: during the design process, for integration into the existing layout of technological sections, it was necessary to adjust the overall and connection dimensions of the equipment.
• The unit is equipped with a fluid 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 to achieve the specified parameters of the production efficiency of thermal power plants.
• Deep modification of designs: 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 configuration: increased supply of wearable items and spare parts to 3 years due to the complexity of logistics. The construction of the Novolenskaya TPP is being carried out in an extremely inaccessible region - the Republic of Sakha, which creates large-scale logistics challenges. The remoteness of the site, extreme climate and lack of year-round roads force the use of a complex scheme for the delivery of specialized pumping equipment. The supply route consists of road transportation, ferry crossing on the Lena River (taking into account the short navigation period), as well as numerous transshipments 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 necessary for organizing installation work, the commissioning stage of preparation for launching into warranty operation and subsequent engineering support for the operation of the units is being developed and prepared for shipment with the first shipment.

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: possessing in-depth knowledge and practical skills in the mechanical engineering industry in the context of strategic business relationships with the owners and key leading managers of manufacturing plants, production schedules for each piece of equipment have been generated in a unified format, on the basis of which operational management of the production process is implemented.
• Stage control: monitoring key production stages at manufacturing plants. Supply chain tracking is provided for all materials and components.
• Tests: all pumps will be tested at the factory stand in the presence of Customer representatives. Testing of boiler feed pumps will be carried out as part of the supplied aggregate assemblies and will include confirmation of real parameters (pressure, flow, cavitation reserve), vibration diagnostics and monitoring of bench parameters throughout the entire pressure-flow characteristic.

4. Delivery and upcoming work

• Network pumps: the equipment was 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 established route.
• Feed pumps (FEN): The equipment is at the manufacturing stage. Delivery to the site is scheduled for 2026.

Results:

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

Particular attention was paid to complete the facility with detailed documentation, which is extremely important for compliance with the manufacturer's instructions, especially at remote sites.

As a result, not just equipment was proposed, but a ready-made technological solution that ensures the energy security of a critical facility. The full engineering cycle also included the search and assessment of new manufacturers in changing market conditions, production control and delivery organization.

Key results for the Customer

• Ensuring energy security of the region: the station will receive highly reliable equipment necessary for launch and stable operation.
• Energy efficiency: the use of VFDs for district heating pumps will provide significant energy savings.
• Risk Reduction: careful selection of manufacturers, multi-level control and expanded 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