Equipment supply for Chelyabinskaya GRES

Chelyabinskaya GRES, built in 1930, is the first power station in the region. It is one of the main sources of heat supply in Chelyabinsk. Start-up of the station allowed the construction and start-up of the following works to be accelerated: Chelyabinsk Tractor Works, Chelyabinsk Electro Metal works, electrolytic, Chelyabinsk Zinc Plant, Paints and Lacquers, Abrasive and other large plants in Chelyabinsk and Chelyabinsk region.

Capacity: electric-82 MW, heat-946,7MW.

 

Drawing. 1 Chelyabinskaya GRES

 

Due to growing needs in electric energy in industries of the South Urals under the contract of power supply it was decided to realize investment project of construction of two energy units 247,5 MW each at Chelyabinskaya GRES in 2011. The town will getnecessary volume of heat from generation source of combined cycle that is corresponding to Russian energy policy aimed to saving natural resources and implementation of energy saving technologies into all industries.

 

 

Drawing 2.Construction of two energy units 247,5 MW each at Chelyabinskaya GRES

 

 

Design project of construction of two gas and steam units was made by JSC “KOTES” in cooperation with strategic partner, a Finnish company Pöyry. Together with the Finnish colleagues the conceptual design and main technical solutions of the new units were prepared. Application of modern foreign experience of Pöyry allowed making the project on a high technical level including modern equipment and technologies.

Producer of the main power equipment-Alstom company.

JSC “EnergoFront” has worked out solution to supply main line pumps for auxiliary supply and cooling water pumps of BCS on the basis of leading European pump producer- KSB Company. To achieve the highest effectiveness from the equipment the pump sets are completed with VFD by LS Industrial Systems.

Specialists of the company selected producers and solutions basing on the analysis of the current situation, modern technical solutions and requirements of JSC “Fortum”.

Specialists of JSC “Fortum” in cooperation with design institute examined some variants to realize the above mentioned projects on pump units and selected our solutions as the most effective and suitable for these tasks.

Finally to construct two energy units 247,5MW at Chelyabinsk GRES JSC “EnergoFront” supplied the following equipment:

1. Main line pump for auxiliary supply Omega 250-480 A GC GF (Q=1100 m3/h, Н=60 m) produced by   KSB in the amount of 4 pcs. in set with electric motors ABB (250 kW, 6 кV, 1500 rpm, 50 Hz, IP 55)  and VFD type LSMV 1000-060F 060 400  (250 кW, 6 кV) produced by  LS Industrial Systems.

2. Cooling water pump BCS   Omega 200-320 B GB GF (Q=600 m3/h, Н=20 m)   produced by KSB in the amount of 3 pcs. in set with electric motor ABB (45 kW, 1500 rpm, IP 55, 0,4 kV).

 

One-stage pump with scroll case and direct-axis split type Omega are multifunctional and guarantee essential energy saving. Besides they have the following advantages:

- high efficiency

- low positive suction head NPSH

- reliable bearing assembly

- innovative case (in-line design, close clearance between bearings, high leak resistance, etc.)

- high-performance impeller

- simple shaft service ( the shaft is enclosed and dry so its free from corrosion ,changeable shaft protection sleeves, absence of thread connections in flow part, etc.)

 

Electric motors produced by ABB Concern and used as drives have high characteristics of reliability and effectiveness.

Drawing 4.Induction electric motor produced by ABB

 

Used as regulation system VFD LSMV provides modern effective control over electric motor. Range of frequency from 0 to 120 Hz.

U/f and vector sensorless control allows optimizing operation of electric motor on low speed and reduce losses for heating and magnification increasing efficiency of the drive on the whole. Advanced distribution control system master-controller is responsible for the forming of modulation of output signal. Each power cell has its processor and text display. Powerful PLC provides service functions and connection with out devices. Adaptive cooling system provides increasing of service life of fans and period of cleaning (replacement) of filters. Only tested components IGBT Siemens, power condensers PANASONIC are used for production.

 

Drawing. 5 VFD LS Industrial Systems type LSMV

 

According to tight period of construction of new units at Chelyabinskaya GRES specialists from JSC “EnergoFront” faced the necessity to speed up the terms of delivery of the pumps. In cooperation with KSB and LS Industrial Systems our specialists optimized the schedule of production of the equipment, logistics routs, hereupon all equipment was supplied on time due to the schedule of construction of the energy units.

Specialists of service department of JSC “EnergoFront” will make commissioning and start-up of the pump sets.