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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.
4 5 63
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. Well 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 pumps 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.
8R 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
9P 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
11
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
12
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
13
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 worlds 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 KSBs 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.