Supply of boiler feed pumps brand DG270-140Cx10 (Q=270 m3/h, 1650 m) manufactured by Shanghai Kaiquan Pump Industry (Group) Co., Ltd. (China) for the needs of PJSC RusHydro

Customer: PJSC RusHydro (JSC DGK)
Object: JV "Artemovskaya CHPP"

Project goal
Ensuring reliable and uninterrupted operation of a strategically important power plant by urgently replacing exhausted Ukrainian-made boiler feed pumps with modern analogues adapted to the existing infrastructure.

Due dates
Delivery of a set of 4 pumps was carried out in record time - 180 calendar days.

Introduction
EnergoFront successfully completed an urgent project to replace critical equipment for the Artyomovskaya Thermal Power Plant, one of the oldest power plants in the Far East, commissioned in 1936. In the context of a changing geopolitical situation and the lack of Russian-made boiler feed pumps, EnergoFront was faced with the task of replacing, adapting and supplying a reliable alternative to outdated Ukrainian pumps in the shortest possible time. The key features of the project were in-depth engineering to ensure full compatibility with existing infrastructure, multi-level quality control and advanced equipment to minimize future risks. The project was implemented in full accordance with the established deadlines, the first pump is undergoing installation supervision.

Goals and tasks project

1. Urgent replacement of obsolete equipment: replacement of worn-out boiler feed pumps PE270-150-3 with modern and reliable analogues.

2. Minimizing integration costs: development of a new pump design that is maximally compatible in size and connection dimensions with the existing foundation and communications to reduce the volume and cost of installation work.

3. Improving operational reliability: equipping new equipment with modern systems (block oil station) and supplying with an expanded set of spare parts.

4. Creating a universal solution: development of an engineering, technical and documentary package aimed at application at other energy facilities operating pumps of a similar series.

Technical parameters of the supplied equipment

The supplied DG270-140Cx10 pumps fully meet process requirements and exceed the performance of older equipment.

Detailed description of work performed

1. Technology audit and engineering
EnergoFront specialists conducted a detailed analysis

● Customer Requirements: studied the operating conditions, parameters and design features of the replaced PE270-150-3 pumps.

● Alternative solutions: in the absence of Russian analogues, a proven global manufacturer was chosen - the Shanghai Kaiquan Pump (SKP) concern, one of the leaders in energy pump manufacturing.

● Design compatibility: together with SKP engineers, a unique job was carried out to adapt the design of the new DG270-140C×10 pump. This made it possible to install on existing foundations with minimal modifications, which significantly reduced installation time and cost.

2. Design and adaptation of equipment

● Documentation development: a complete set of design and operational documentation has been provided, developed in accordance with Russian standards, for seamless integration of the pump into the existing feedwater supply system.

● Design Improvements: Unlike the outdated oil system of the PE270-150-3 pump, the new unit is equipped with a modern block oil station with main and reserve sections, an automation system and a highly efficient heat exchanger, which increases reliability and ease of maintenance.

3. Production control and testing
To ensure high quality, EnergoFront has implemented a strict inspection program

● Step-by-step production control: company specialists controlled the key stages of pump manufacturing at the SKP plant.

● Test bench: the pumps were tested in accordance with the volumetric Program at the factory stand in the presence of representatives of the EnergoFront company. Tests confirmed the specifications of the machines (flow 270 m³/h, head 1650 m) over the entire operating range.

4. Delivery, installation and service

● Meeting deadlines: a set of 4 pumps was delivered to the site within the agreed 180 calendar days.

● Extended configuration: to eliminate the risk of downtime due to logistics in a remote region, the pumps are equipped with an expanded range of spare parts, including impellers.

● Installation supervision and commissioning: EnergoFront service engineers carry out supervision of installation of the first pump followed by commissioning. It is planned to commission two more units by the end of 2025.

● Warranty support: EnergoFront, as the official service partner of SKP in Russia, provides full warranty and post-warranty support.

Reliability indicators

The supplied equipment meets the customer’s high requirements for durability and reliability.

Results achieved

1. Operational result

• The task of urgently replacing critical equipment was completed in a short time (180 days).

• The first pump is being prepared for commissioning, which will ensure reliable operation of the thermal power plant.

2. Technical result

• The reliability of the boiler power system has been increased through the use of modern equipment from the world leader.

• An improved and more reliable lubrication system (block oil station) has been introduced.

• The equipment is highly adaptable, reducing installation costs and future replacements.

3. Economic and strategic result

• Capital costs are reduced by minimizing installation work.

• A ready-made standard project has been created for replacing PE270-150 pumps at other stations in Russia.

• The risks of downtime are minimized thanks to an expanded set of spare parts.

Conclusion

EnergoFront has confirmed its status as a reliable partner capable of solving complex problems of import substitution in a short time. The successful implementation of the project at the Artyomovskaya CHPP demonstrates an integrated approach: from engineering adaptation of equipment to the needs of a specific facility to the organization of a full cycle of supply, installation and service support. The project not only eliminated the Customer's current problem, but also created a valuable solution for the entire industry, contributing to the energy security of the Far Eastern region.

Project achievements