Supply of three 1KsV125-140-4 condensate electric pump units for the needs of the project: technical re-equipment of the PT-60-130/13 turbine of the Branch of JSC "TGC-16" - Nizhnekamsk Thermal Power Plant (PTK-1)

Nizhnekamsk CHPP (PTK-1), a branch of OJSC TGC-16, is the largest industrial heating CHPP in the Republic of Tatarstan. Installed electrical capacity is 880 MW. Installed thermal power – 3,746 Gcal/h.

Nizhnekamsk CHPP (PTK-1) provides electrical and thermal energy to the largest petrochemical enterprises, tire industry, and construction industry. The station is a link in a single industrial and economic complex for the production, transmission, distribution of electrical and thermal energy.

In accordance with the terms of the agreement, Power Machines will carry out technical re-equipment of the PT-60-130/13 turbine with generator No. 2 for the Nizhnekamsk CHPP (PTK-1) with the replacement of the HPC and regenerative heaters with the organization of the selection of 30 ata.

This project will also require the supply and replacement of existing condensate pumps KsV125-140 in the amount of 3 pcs. for new ones.

During the competition announced by OJSC TGC-16, several companies competed for the right to supply 3 condensate electric pump units for the needs of the PT-60-130/13 steam turbines. The EnergoFront company managed to win the competition by thoroughly working out the technical and commercial aspects of the project, and as a result, offering the optimal solution. During the decision tasks Our company’s specialists selected a solution for the supply of 1KsV125-140-4 condensate electric pump units in the amount of 3 pcs. produced by JSC HMS Livgidromash.

Electric pump unit 1KsV125-140-4 (for parameters Q=125m3/h, H=140m) is designed for pumping clean or aggressive liquids that do not destroy pump materials by chemical or mechanical properties.

Characteristics 1KsV125-140-4

Dimensional drawing of the pumping unit 1KsV125-140-4

Pump cross-section

1 – low-speed part; 2 – fasteners; 3 – high-speed part; 4 – coupling pins; 5 – screw securing the electric coupling half. engine; 6 - electrical fasteners engine; 7 - el. engine; 8 – bolt for centering; 9 – bar; 10 ÷ 17 – rubber rings.

The pump unit consists of a pump (consisting of a low-speed part 1 and a high-speed part) and an electric motor connected to it using a sleeve-pin coupling.

The high-speed part of the pump has two impellers mounted on a high-speed shaft, the supports of which are a rolling bearing and a plain bearing. A double mechanical seal and a pin-type coupling are mounted on the shaft. The hydraulic seal of the mechanical seal (as well as its cooling) when pumping a medium with a temperature of more than 313K (+40°C) is ensured by supplying barrier and cooling fluid to the seal zone from an independent source.

One of the main technical requirements for the supply of the pump unit was to ensure a minimum cavitation reserve of up to 1 meter, due to the vacuum at the pump suction. This can be achieved through the use of a two-shaft design in the flow part of the pump: the booster wheel of the low-speed part receives rotation from the turbine wheel located in the flow of the pumped liquid behind the impeller of the high-speed part. The booster stage rotates in its own sliding bearings, combined with a hydrostatic heel. The support unit for fastening to the foundation is made integral with the pump casing.

Advantages of 1KsV125-140-4 pumping units:

• cavitation reserve at the operating point: 1 meter - less support under the condenser collector is required;

• Efficiency at the operating point: 66% - higher efficiency than the pumps being replaced, reducing energy costs for own needs;

• smoother flow-pressure characteristic - less wear of control valves when the pump operates in underloaded mode;

• stainless steel flow part – for long-term trouble-free operation of the pump.

5AM250M2 electric motors (for parameters N=90kW, ω=300rpm, U=380kV) with high technical and operational characteristics were chosen as the electric drive of the 1KsV125-140-4 pump.

High degree of protection (IP54), low noise level (76 dBA at a distance of 1 m), efficiency of 96% at full load, mean time between failures of 40 thousand hours allow us to classify 5AM250M2 electric motors as one of the best in the 380 kV voltage class on the Russian market.

Electric motors are equipped with grease lubricated rolling bearings. They are easy to use, reliable and durable. All this will save financial and labor resources during the operation and repair of electric motors.

One of the distinctive features of these asynchronous motors is the presence of a significant reserve in the active parts of the motor and its electromagnetic core. This made it possible to withstand short-term overloads of up to 10-15%. Also, such an engine will be able to operate in long-term mode with supply voltage drops within ±10%.

In addition, it is worth noting the presence of increased starting torque and the mandatory implementation of a full testing program for equipment at idle. The use of class F insulation, which can withstand temperatures up to +155 °C, provides a margin of 25 °C even for the hottest point of the operating mode. As a result, it was possible to eliminate the problem of reducing engine life by 50% if during operation the temperature exceeds the norm by 10%.

Factory testing, assembly and commissioning

Before delivery of pumping equipment to the customer, the HMS Livgidromash JSC enterprise will carry out a set of works on assembling (installing an electric motor on the pump with shaft alignment) of pumping units with carrying out factory hydraulic tests to confirm the declared parameters.

After delivery of the equipment, EnergoFront service specialists will provide services for supervising installation and supervising adjustment of pumping units on site.

Case summary

• period of work on reconstruction of the turbine: 1-2 quarters. 2025;

• place of work: branch of JSC "TGC-16" Nizhnekamsk CHPP (PTK-1);

• equipment/services: supply, installation supervision, commissioning of three 1KsV125-140-4 condensate pumping units for the PT-60-130/13 turbines manufactured by Power Machines JSC as part of the project: steam turbine PT-60-130/13 with generator No. 2. Technical re-equipment of the turbine with replacement of the HPC and regenerative heaters with the organization of the selection of 30 ata" for the branch of JSC "TGK-16" Nizhnekamsk Thermal Power Plant (PTK-1).

Project achievements