Upgrade Your Pump

R e h a b i l i t a t i o n m e a s u r e s f o r p o w e r s t a t i o n p u m p s

21 32

R e h a b i l i t a t i o n – t h e m o r e c o s t - e f f e c t i v e s o l u t i o n

I N C R E A S E E F F I C I E N C Y

New hydraulic systems and targeted engineering optimize pump performance

I N C R E A S E O P E R A T I N GR E L I A B I L I T Y A N D P L A N TA V A I L A B I L I T Y

New designs and new materialsminimize wear.

E X T E N D M E A N T I M E B E T W E E N M A I N T E N A N C E

Parts ”made by KSB” and preci-sion matching of componentsreduce the need for maintenance

U p g r a d e Y o u r P u m p –

M a k e p o w e r g e n e r a t i o n m o r e e f f i c i e n t

Supplying power reliably, cost-effectively and with economical use of resources is and will continue to be

a global challenge – and something we must all work to achieve.

”Upgrade Your Pump” is our economical concept for the rehabilitation of installed pumps. This extensive

action plan includes all the necessary measures to bring your pumps up to the state of the art. Customized

rehabilitation also saves you money, since fully functional old components, such as for example founda-

tions, barrels and piping, can be re-used.

The starting point is a detailed on-site pump diagnosis by our team of experts. After that, everything hap-

pens very quickly: engineering, design, production of the upgrade components, installation, the test run and

start-up – experienced KSB specialists ensure that the project is completed conscientiously and on time.

And once your installation is up and running again, all work performed and all upgrade components are

covered by the comprehensive KSB warranty. Go for rehabilitation now – with the assurance of KSB.

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E X T E N D R E M A I N I N G S E R V I C E L I F E

The extensive diagnosis and systematic elimination of weakpoints increase the service life ofthe entire machine

Power stations

Rehabilitated pumps

P E R M -S K A Y A G R E S

S U R G U T -S K A J A G R E S

N I S H N E V A R T O W S K -S K A J A G R E S

S Y R D A R I N S K -S K A J A G R E S

R E D U C E M A I N T E N A N C EC O S T S

Longer service lives of componentsextend the mean time betweenmaintenance

S A F E G U A R D S P A R EP A R T S S U P P L Y

Standard components are availableoff the shelf. CAD archiving allowsrapid production at any time

P o w e r w i t h K S B s a f e t y

” R e h a b i l i t a t e d ” p u m p s f o r P e r m

Power generation at Perm is reliable and efficient again.

The three units of the gas-fired Perm power station at the foot of the

Urals are now working at full capacity again, each with an output of

800MW.

The situation used to be different. Antiquated boiler feed pumps badly

affected operation of the plant. Modernization was absolutely essential.

Following an extensive on-site diagnosis by a KSB team of experts at

the power station, a comprehensive rehabilitation programme was

drawn up for the installed pumps.

The scope of supply comprised six cartridges for barrel casing pumps,

two reserve cartridges and six new booster pumps. All measures, from

engineering and new design through dismantling, transport, conversion

and the test run at KSB right up to installation and acceptance testing

at the power station were carried out or supervised by KSB specialists.

Back in top form:

Rehabilitated boiler feed pumpwith booster pump at the gas-firedPerm power station

Boiler feed pumpperformance data:

Q 6000 m3/h

H 322 bar

T 165 °C

n 4665 rpm

P 17150kW (turbine drive rating)

4

R e h a b i l i t a t i o n a t t h e P e r m p o w e r s t a t i o n

Vibrations, specified values

Vibrations, measured values

5

V i b r a t i o n s , r e t u r n o n i n v e s t m e n t

Vibrationmeasurementsdemonstrate theexcellent vibra-tion behaviour of the rehabili-tated pump

100 %

75%

50%

25%

0%

0% 25% 50% 75% 100%

Veff when operating at characteristic boiler values

Veff

Q/Qopt [m**3/h]

Veff [%]

R e t u r n o n i n v e s t m e n t –

C o s t s f u l l y u n d e r c o n t r o l

Rehabilitation yes – but not at any price.

Perm shows that all the modernization and optimization measures for power station pumps can pay for them-

selves after a short time. In other words: rehabilitation makes economic sense. At Perm, investment costs were

recovered after less than two years.

Do you want to know how this would pay off for you too? Just ask us. We’ll prepare a customized return-on-

investment analysis for you, taking into account all the cost-relevant data. To provide a sound basis for this,

our specialists will meet with you to identify all the factors we need to know for proper analysis.

In this way, rehabilitation remains clearly in focus at all times, and you keep a firm grip on costs.

I n v e s t m e n t

P r o f i t

Life cycle

Return on Investment

P [kW]

eta [%]

CHTD8/7 (KSB)

PN-1500-350/7

T e c h n i c a l d a t a i n c o m p a r i s o n

6

19000

17000

15000

13000

11000

9000

7000

0 200 400 600 800 1000 1200 1400 1600

0 200 400 600 800 1000 1200 1400 1600

Q [m**3/h]

Q [m**3/h]

0 200 400 600 800 1000 1200 1400 1600 Q [m**3/h]

100

80

60

40

20

0

H [m]

The steeper H/Q curve meansstable parallel operation of thefeed pumps

Duty point

Enormous improvement inefficiency means cost-effectiveoperation

Lower power input meanshigh energy savings

Month 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

7

P e r m b o i l e r f e e d p u m p s – d i a g n o s i s a n d s o l u t i o n s

C o n d i t i o n o f t h e p u m p s

b e f o r e r e h a b i l i t a t i o n

The old pumps had the following problems:

• Unstable operating conditions caused thermal deforma-

tions which, in turn, affected the pump’s balancing system

and shaft seal.

• Thermal, mechanical and hydraulic influences led to high

vibration amplitudes and wear.

• High barrier fluid consumption of the shaft seal

(inflexible throttles).

C o n s e q u e n c e s

• High wear and high repair costs

• Unplanned downtimes

• Unsatisfactory plant availability

• Shorter mean time between maintenance

• High energy consumption

Design safety: new balancing system

Avoid barrier fluid losses: efficient shaft seals

This is how fast it can be: rehabilitation time management for Perm

Inspection visit and diagnosis by KSB

at the power station*

Conclusion of contract

Design / engineering

Materials procurement

Production

Pump assembly

Trial run on KSB test rig witnessed by customer

Piping, final assembly of cartridge

Transport to the destination (ex works)

Barrel casing: adaptation at the power station

Installation of the cartridge, pressure test

Tests and start-up

*The diagnosis need not be done immediately prior to conclusion of contract. The actual timetable begins with conclusion of contract.

8

R e h a b i l i t a t i o n m e a s u r e s f o r b o i l e r f e e d p u m p s

B A L A N C I N G S Y S T E M

Double drum:

• Maximum operating reliability

• Fail-safe mechanism prevents total failure

• Minimizes thrust bearing loading even when there is internal wear

• Stable performance under transient operating conditions

E X T E N D S E R V I C E L I F E

Main assembly studs with special tensioner:

• Minimizes stud loading by tighten-ing without exerting any torque

• No special design – can also be used on existing mainassembly studs

• No special tool required

E N S U R E I N T E G R I T Y

Casing seal:

• No bolting forces required to achieve the sealing effect

• High elasticity makes for good adjustment even to transient operatingconditions

G R E A T E R S A F E T Y

Thrust bearing:

Defined axial clearance of the drum

• Additional safeguards under transient operatingconditions

P R E V E N T O V E R L O A D *

*Additional measure

Thrust ring:

• Ensures uniform, concentricthrust bearing loading

• Extends service life

• Well-adjusted elasticity protects thrust bearingagainst overloading

I N C R E A S E R E L I A B I L I T Y

Efficient shaft seal:

• High reliability

• Low losses thanks to cartridge design

• Easy to maintain

• Optimized protection prevents thermal deformations

9

P R E V E N T C A V I T A T I O N *

*Additional measure

Inlet casing:

• Hydraulically optimized geometries ensure uniform, concentric inflow

• High level of cavitation prevention

• Smooth running, low vibration

O P T I M I Z E D L I N E S O F A C T I O N O F F O R C E S

(Green markings)

• High rigidity

• Excellent vibration behaviour

• Minimized deforma-tions under load

R E D U C E V I B R A T I O N S

Modern coupling:

• Precise and lightweight

• Compensates for misalignment

• Long service life

• Suitable for all types of drive

• Simple assembly

Conventional casing wear ring

O P T I M I Z E D A M P I N G

Cellular surface wear rings:

• Smooth running

• Good damping behaviour

• High efficiency

• Good anti-seizure properties

Cellular surface wear ring

10

Lippendorf power station

R e h a b i l i t a t i o n m e a s u r e s f o r c o o l i n g w a t e r p u m p s

C U T C O S T S

Back pull-out coolingwater pumps:

• Rotor assembly can bereplaced

• New hydraulic systemimproves efficiency

O P T I M I Z E I N T A K E C H A M B E R S

Vortex-free conditions by:

• Fitting pre-swirl control equipment

• Structural changes in the intake chamber

R E D U C E W E A R

Impeller, elbow, shaft protectingsleeve etc. are replaced by new,more wear-resistant components

R E S I D U R ® S H A F TG U I D E B E A R I N G

• Medium-lubricated

• Maintenance-free and low-wearing

• No need for additionallubricating and coolingsystems

• Resistance to hydroabra-sive wear

S A V E C O S T S

3 impeller types permit selection of a cost-efficient,optimized pump for any operating point

• Pump control by bladepitch adjustment /control

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R e h a b i l i t a t i o n m e a s u r e s f o r c o n d e n s a t e p u m p s

I M P R O V E R E S I S T A N C EP R O P E R T I E S

Replace first-stage impeller by model of higher-gradematerial:

• Copes better with cavitation

• Lower maintenance cost

I N T E G R A T E D T H R U S T B E A R I N G

Fitting monitoring instrumen-tation for oil lubrication andcooling systems:

• Longer service life

E X T E N D S E R V I C EL I F E

Hydrodynamic bearings:

• Medium-lubricated

• Replaceable casing wear rings

C U T C O S T S

New pump cartridge withnew hydraulics:

• Improved efficiency

A D D S A F E T Y A N DR E L I A B I L I T Y

Shaft seal:

Replace gland packing bymechanical seal

• Greater reliability

• Safe operation

Heilbronn power station

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E n g i n e e r i n g s e r v i c e s

M o r e t h a n j u s t a p u m p . . .

What we have to offer you is a complete engineering package

comprising everything from customized inspection of your pump,

through upgrade component manufacture, re-assembly and test

run, up to and including re-installation and commissioning

on site:

• Efficient pump and upgrade component selection

• Selection of accessories, e.g., instrumentation,

minimum-flow system, oil supply, cooling water supply, etc.

• Engineering of the complete pump set, incl. drive, couplings,

gearing, variable-speed couplings and booster pumps

• Calculation of, say, foundation loads, strength analyses

(finite-element method), seismic tie-downs

• Sensor equipment design, e.g., for pump diagnostic systems

• Tests and analyses, e.g., of vibrations and noise

KSB engineering teamFrankenthal, Germany

Engineering services Boiler feed pump Cooling water pump Condensate pump

Minimum flow system •Drives • • •Gear / geared variable-speed coupling • •Pump diagnostic system •Remaining lifetime calculation •Payback analysis • • •Vibration analysis •Cycle calculation • • •Optimization of process parameters • • •Optimization of intake structure •

Engineering services at a glance

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W i t h K S B y o u c a n r e s t a s s u r e d

R e s p o n s i b i l i t y a w a r e n e s s

Your task as a power station operator is to continue to provide

power safely and cost-effectively. The decisions you make and action

you take today pave the way for power supply tomorrow.

We are there to help you in this task.

So why not rely on over 125 years of experience and know-how in

pump and valve engineering for fossil-fired and nuclear power sta-

tions. Why not benefit from the manpower of the world’s leading

manufacturer – more than 12,800 specialists cater to your needs –

wherever you are.

Our ongoing product research and development, systematic quality

management and global service network provide you with the neces-

sary certainty – for today and the future.

Feed pumps being tested under operat-ing conditions on KSB’s own test rigs(top photo)

Research sets standards:

Only continuous research enables us tokeep improving our products

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KSB Aktiengesellschaft67225 Frankenthal (Germany)Tel. +49 (6233) 86 - 2135 • Fax +49 (6233) 86 - 3462 • www.ksb-energy.com

Y o u c a n r e l y o n s u p p o r t f r o m K S B –

a r o u n d t h e w o r l d

As a global player, we feel at home anywhere in the world. Our inter-

national presence enables us to provide intensive local customer service.

More than 1000 KSB service employees worldwide are there to make

sure that your pumps, systems and facilities keep working reliably and

efficiently.

Responsibility for the future – assured by KSB.