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Supply of three condensate electric pump units 1KcB125-140-4 for the project’s needs: technical re-equipment of the turbine PT-60-130/13 of the branch of JSC TGK-16 - Nizhnekamsk CHP (IBH-1)

22 августа 2024

Nizhnekamsk CHP (IBH-1), a branch of JSC TGK-16, is the largest industrial heating CHP in the Tatarstan Republic. Installed electric power is 880 Mw. Installed thermal power is 3746 Gcal/h.

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

Нижнекамская ТЭЦ (ПТК-1)

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 Nizhnekamsk CHP (IBH-1) with the replacement of central heating elements and regenerative heaters with the organization of selection of 30 atm.

As part of this project, a stand will also be required with the replacement of existing condensate pumps КсВ125-140 in the amount of 3 pcs. with new ones.

During the competition announced by TGC-16, several companies competed for the right to supply 3 condensate electric pump units for the needs of PT-60-130/13 steam turbines. EnergoFront managed to win the competition, having thoroughly worked out the technical and commercial side of the project, and as a result, offering the optimal solution. In the course of solving the task, our company's specialists selected a solution for the supply of condensate electric pumping units 1KcB125-140-4 in the amount of 3 pcs. produced by JSC HMS Livgidromash.

The electric pump unit 1KcB125-140-4 (for parameters Q =125 m3/h, H=140m) is designed for pumping clean or aggressive liquids that do not destroy the pump materials by chemical or mechanical properties.

Характеристика 1КсВ125-140-4
Characteristics 1KsV125-140-4


Габаритный чертеж насосного агрегата 1КсВ125-140-4
Dimensional drawing of the pump unit 1KsV125-140-4


Разрез насоса
Pump section


1 – low–speed part; 2 – fasteners; 3 – high–speed part; 4 - clutch fingers; 5 - screw for fixing the half coupling of the electric motor; 6 – fasteners of the electric motor; 7 – electric motor; 8 - bolt for centering; 9 - bar; 10 -17 – rubber rings.

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

The high-speed part of the pump has two impellers mounted on a high-speed shaft, supported by a rolling bearing and a sliding bearing. A double mechanical seal and a sleeve-finger coupling are mounted on the shaft. Hydraulic closure of the mechanical seal (as well as its cooling) when pumping a medium with a temperature of more than 313 K (+40°(C) is provided by supplying the sealing zone with a shut-off and coolant from an autonomous source.

One of the main technical requirements for the supply of the pumping unit was to ensure a minimum cavitation margin of up to 1 meter, due to the vacuum at the pump suction. This is possible due to the use of a two-shaft design in the flow part of the pump: the booster wheel of the slow-moving part receives rotation from the turbine wheel located in the flow of pumped liquid behind the impeller of the high-speed part. The booster stage rotates in its own sliding supports combined with a hydrostatic haunching. The support unit for mounting to the foundation is made at the same time as the pump body.

    Advantages of pumping units 1KcB125-140-4:

  • cavitation reserve at the working point: 1 meter - requires a smaller backstop under the condenser;

  • efficiency at the operating point: 66% - higher efficiency than that of replaceable pumps, reduced energy costs for own needs;

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

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

Electric motors 5AM250M2 (for parameters N=90kW, ω=300ob/min, U=380kV) with high technical and operational characteristics were selected as the electric drive of the 1KcB125-140- pump.

Electric motor 5AM250M2

WattagVoltageRevolutionsNoise levelLevel of protection KPI

A high degree of protection (IP54), low noise level (76 dBA at a distance of 1 m), an efficiency of 96% at full load, time to failure of 40 thousand hours make it possible to classify 5AM250M2 electric motors as one of the best in the 380kV voltage class on the Russian market.

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

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

In addition, it is worth noting the presence of an increased starting torque and the mandatory implementation of a full program of equipment testing at no-load. The use of Class F insulation, which can withstand heating 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 the engine life by 50% if the temperature exceeds the norm by 10% during operation.

Factory testing, aggregation and commissioning

Before the delivery of pumping equipment to the customer, a complex of works on the assembly (installation of an electric motor on a pump with shaft alignment) of pumping units with factory hydraulic tests to confirm the declared parameters will be carried out at the enterprise of JSC HMS Livgidromash.

After the equipment is delivered, EnergoFront service specialists will provide services for installation supervision and commissioning of pumping units at the place of operation.

    Summary of the case

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

  • place of work: branch of JSC TGC-16 Nizhnekamsk CHP (IBH-1);

  • equipment/services: supply, installation supervision, commissioning of three condensate pumping units 1KcB125-140 for turbines "PT-60-130/13" produced by JSC "Power Machines" within the framework of the project: steam turbine PT-60-130/13 with generator No.2. Technical re-equipment of the turbine with the replacement of central heating elements and regenerative heaters with the organization of selection of 30 atm" for the branch of JSC TGK-16 Nizhnekamsk CHP (IBH-1).

Project achievements

Modern highly effective equipment is appliedIncrease in reliability of the equipmentAchievement of the maximum unification


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