Summary case. Comprehensive replacement of PE series boiler feed pumps with modern TDG units at energy facilities in the Russian Federation

Project / Customers

Project: Replacement of worn-out PE series boiler feed pumps with modern highly efficient TDG pumping units produced by SHANGHAI KAIQUAN PUMP (GROUP) Co., Ltd. (PRC)
Customers: PJSC "T Plus" (branch "Nizhegorodsky", Samara CHPP), JSC "TGK-16", JSC "Kuzbassenergo" (SGK)
Objects: Sormovskaya CHPP, Nizhnekamskaya CHPP, Samara CHPP, Tom-Usinskaya GRES

Introduction

EnergoFront LLC is successfully implementing a large-scale program to replace worn-out PE series boiler feed pumps with modern highly efficient TDG pumping units produced by SHANGHAI KAIQUAN PUMP (GROUP) Co., Ltd. (PRC). In the context of a changing geopolitical situation, critical deadlines for the production of Russian analogues, the EnergoFront company was faced with the task of quickly replacing, adapting and supplying a reliable alternative to outdated equipment at key generation facilities in Russia.

Projects are being implemented at four large energy facilities:

• Sormovskaya CHPP (Nizhegorodsky branch of PJSC T Plus)
• Nizhnekamsk CHPP (JSC TGC-16)
• Samara CHPP (PJSC T Plus)
• Tom-Usinskaya GRES (JSC Kuzbassenergo)

All projects are united by a single task - replacing boiler feed pumps of the PE series with modern analogues without changing overall dimensions and preserving existing foundations and pipelines.

The key features of the projects were:

• deep engineering work to ensure full compatibility with existing infrastructure;
• adaptation of equipment to the specific conditions of each facility;
• multi-level quality control at all stages of production and delivery;
• advanced packaging to minimize future downtime risks.

General information on objects

Characteristics of objects and problems

3.1. Branch "Nizhegorodsky" PJSC "T Plus" (Sormovskaya CHPP)

Object: The Nizhegorodsky branch unites generating and heating network assets in Nizhny Novgorod, Dzerzhinsk and Kstovo. The branch includes three power plants: Dzerzhinskaya CHPP, Sormovskaya CHPP and Novogorkovskaya CHPP, as well as heating networks. The installed electrical capacity of the branch is 1472 MW, thermal capacity is 2565 Gcal/h.

Problem: Replacement of the old “Sumy” boiler feed pump PE580-185, which has expired, with modern, more efficient equipment.

Technical parameters of the supplied equipment:

Key requirement: Maintaining overall and connecting dimensions - the new pump must be installed on an existing foundation and connected to standard pipelines without overcooking or modifications.

3.2. Nizhnekamsk CHPP (JSC TGC-16)

Object: Thermal power plant in Nizhnekamsk, Republic of Tatarstan. Property of TGC-16 JSC, part of the TAIF group of companies. Provides thermal energy to most of the industry in Nizhnekamsk. The key consumer is Nizhnekamskneftekhim, one of the largest petrochemical enterprises in Russia.

Problem: Wear of boiler feed pumps of the PE580-185 series, developed back in the 70s. In current conditions, the production time for new pumps of this type is critically high, which makes it difficult to implement investment programs in a timely manner. Long production and delivery times for PE pumps create risks of disruption to technical re-equipment schedules.

Modernization goals:

• increasing the efficiency and reliability of the pumping unit;
• ensuring compliance with new equipment operating parameters;
• import substitution - switching to an alternative supplier without losing compatibility with the existing infrastructure.

3.3. Samara Thermal Power Plant (PJSC T Plus)

Object: Samara CHPP is one of the key and most modern combined heat and power plants in the Samara region. Since 2019, the facility has been participating in the federal program “DPM-2” (Agreements for the provision of capacity of modernized generating facilities), aimed at increasing the efficiency and reliability of existing facilities.

As part of the modernization of unit No. 4, the boiler unit, turbine, generator and key auxiliary equipment are being replaced.

Problem: The existing APE 580-185-3 boiler feed pump has expired, has reduced efficiency and does not meet the requirements of unit No. 4 being modernized. The PE series pumps were produced at the Nasosenergomash plant (Sumy, Ukraine), the production and delivery times of which became unacceptable under the new conditions, which creates the risk of violating the DPM-2 schedule.

Key requirement: Strict compatibility requirements - the new unit must comply with the parameters and dimensions of PE 580-185-5 without large-scale construction and installation modifications.

3.4. Tom-Usinskaya GRES (JSC Kuzbassenergo / SGK)

Object: Tom-Usinskaya GRES is the largest thermal power plant in the south of Western Siberia, includes 9 power units with a total installed capacity of 1345.4 MW. Located in the town of Myski, Kemerovo region, 25 km from Novokuznetsk. Designed to cover base loads of the Kuzbass energy system. Part of the Siberian Generating Company Group (SGK).

Problem: Replacement of the PE-580-195-5 boiler feed pump (flow 580 m³/h, head 2150 m) with a modern analogue while maintaining the existing infrastructure.

Project Feature: The delivery was carried out without an electric motor and an oil station - the customer planned to use the existing 4AZM-5000/6000UHL4 engine and a standard oil station. It was necessary to manufacture a non-standard coupling for the existing electric motor and confirm full compatibility.

Difficulty: During the on-site inspection, numerous inconsistencies with design solutions and hidden defects were identified that required mandatory modifications before installation.

Technical parameters of the supplied equipment:

Electric Motors (included in delivery for three out of four projects):

• Type: 4АЗМ4000/6000УХЛ4 (manufactured by NPO "ELSIB" PJSC, Russian Federation)
• Power: 4000 kW
• Voltage: 6000 V
• Speed: 3000 rpm

Individual engineering solutions for objects

For the Nizhegorodsky branch of PJSC T Plus (Sormovskaya CHPP):

• The TDG600-200×10 pump was selected as a complete analogue of the PE580-185 in all key parameters.
• Parametric identity is ensured: flow 580 m³/h, head 2030 m.
• High efficiency of 82% provides lower operating costs compared to worn-out equipment.
• The delivery includes a Russian-made electric motor 4АЗМ4000/6000УХЛ4, which reduces dependence on import suppliers.

For Nizhnekamsk CHPP (JSC TGC-16):

• It is proposed to use TDG double-casing pumps, adapted to Russian operating conditions.
• Full technical adaptation to the parameters of the original PE580-185.
• The unit is equipped with an electric motor, a block oil station, fittings and a fire extinguishing system.
• Preliminary factory load tests were carried out on certified stands with the participation of Customer representatives.

For Samara Thermal Power Plant (PJSC T Plus):

• A detailed comparison of the parameters of TDG with the original PE 580-185-5 was carried out.
• The dimensions were adapted to the existing foundation and layout of block No. 4.
• Connections to the existing pipeline system have been worked out.
• A complete set of design and technical documentation for implementation has been prepared (ESKD format).
• The delivery is made in the form of a complete unit: a pump, an electric motor 4AZM-4000/6000UHL4, a block oil station, a set of instrumentation and pipeline fittings.

For Tom-Usinskaya GRES (JSC Kuzbassenergo / SGK):

• A comprehensive inspection of the installation site was carried out with a visit to the station.
• Inconsistencies with design solutions and hidden defects were identified:

• Non-designed insertion of the recirculation line (insertion directly into the pressure pipe instead of the section between the pipe and the check valve) - the check valve had to be moved.
• Absence of an electrified valve on the recirculation line (a manual one is installed) - replacement is recommended.
• Electric motor defect: instead of the standard oil sump ring, a flange of the coupling housing is installed - restoration is required.
• Center distance error 35 mm - accurate measurements taken, custom coupling ordered.

• Two new oil pumps NMSh 12-25-10/4 (Q=10 m³/h, P=4 kgf/cm², N=4 kW) are recommended.
• The standard Chinese-made instrumentation has been replaced with Russian devices (agreed with the CTAI workshop).

Summary of results achieved

1. 1. Operating results:

• Four pumping units have been manufactured and delivered to Customers' sites.
• All projects were implemented in compliance with the requirements for deadlines and quality.
• Factory tests of the equipment under load were carried out on certified stands.

2. Technical results:

• A universal engineering solution has been created for replacing PE series pumps with modern TDG analogs without changing foundations and pipelines.
• A two-hull design ("barrel" type) has been introduced - increased rigidity, durability and reliability.
• Provides high efficiency (up to 82%) and resistance to cavitation.
• At the Tom-Usinskaya GRES facility, in-depth engineering diagnostics were performed, hidden defects in the existing piping and components were identified and eliminated.

3. Economic and strategic results:

• Reducing capital costs by preserving existing foundations, pipelines and central nervous system buildings (excluding costs for reconstruction of construction parts).
• Import substitution: transition to an alternative supplier (China) without loss of compatibility with the existing infrastructure.
• Localization: replacement of Chinese instrumentation with Russian devices (Tom-Usinskaya GRES project), supply of Russian ELSIB electric motors in three projects.
• A standard package of engineering solutions and documentation has been created for scaling to other Russian facilities operating PE series pumps.

Reliability indicators of supplied equipment

Conclusion

EnergoFront LLC has confirmed its status as a reliable engineering partner capable of solving complex problems of import substitution in a short time at key Russian energy facilities. The successful implementation of projects at the Sormovskaya CHPP, Nizhnekamskaya CHPP, Samara CHPP and Tom-Usinskaya GRES demonstrates the company’s systematic approach:

• Technical expertise - selection and adaptation of equipment for the specific conditions of each facility, including complex cases (preserving a standard engine, identifying hidden defects).
• Full cycle of work - from pre-design survey and design to delivery, installation supervision and commissioning supervision (where this is provided for in the contract).
• Multi-level quality control - step-by-step production control and factory load testing.
• Localization - equipping equipment with Russian electric motors and instrumentation, reducing dependence on imports.
• Creating a standard solution - the developed package of engineering and technical documentation is applicable to other Russian Federation facilities operating PE series pumps.

The projects not only eliminated the current problems of the Customers, but also created a valuable industry solution that contributes to the energy security and technological independence of the Russian energy sector.