U p g r a d e Yo u r P u m p
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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 G R E L I A B I L I T Y A N D P L A N T A V A I L A B I L I T Y
New designs and new materials minimize 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 components reduce 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 G6
S E R V I C E L I F EThe extensive diagnosis and systematic elimination of weak points increase the service life of the 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 E C O S T S
Longer service lives of components extend the mean time between maintenance
S A F E G U A R D S P A R E P A R T S S U P P L Y
Standard components are available off the shelf. CAD archiving allows rapid 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 800 MW.
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 pump with booster pump at the gas-fired Perm power station
Boiler feed pump performance data: Q 6000 m3/h H 322 bar T 165 °C n 4665 rpm P 17 150 kW
(turbine drive rating)
Vibrations, specified values Vibrations, measured values
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
Vibration measurements demonstrate the excellent 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
P [kW] eta [%] CHTD 8/7 (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
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 means stable parallel operation of the feed pumps
Duty point
Enormous improvement in efficiency means cost-effective operation
Lower power input means high energy savings
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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
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 exerttighten-ing any torque • No special design –
can also be used on existing main assembly 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 operating conditions
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 operating conditions
P R E V E N T O V E R L O A D *
*Additional measure
Thrust ring:
• Ensures uniform, concentric thrust bearing loading • Extends service life • Well-adjusted elasticity
protects thrust bearing against 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
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
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 cooling water pumps:
• Rotor assembly can be replaced
• New hydraulic system improves 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 protecting sleeve etc. are replaced by new, more wear-resistant components
R E S I D U R® S H A F T
G U I D E B E A R I N G
• Medium-lubricated • Maintenance-free and
low-wearing
• No need for additional lubricating and cooling systems
• 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 blade pitch adjustment /control
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 E P R O P E R T I E S
Replace first-stage impeller by model of higher-grade material:
• 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 and cooling systems:
• Longer service life
E X T E N D S E R V I C E L I F E Hydrodynamic bearings: • Medium-lubricated • Replaceable casing wear rings C U T C O S T S
New pump cartridge with new hydraulics:
• Improved efficiency A D D S A F E T Y A N D
R E L I A B I L I T Y
Shaft seal:
Replace gland packing by mechanical seal
• Greater reliability • Safe operation
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 team Frankenthal, Germany
Engineering services Boiler feed pump Cooling water pump Condensate pump
Minimum flow system
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Drives
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Gear / geared variable-speed coupling
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Pump diagnostic system
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Remaining lifetime calculation
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Payback analysis
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Vibration analysis
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Cycle calculation
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Optimization of process parameters
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Optimization of intake structure
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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 to keep improving our products
artwork: www
.sti-werbeagentur
.de
Subject to technical modification without notice.
0361.035 /2 – 10 7/ 00 bdf
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.
