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In Kaliningrad, the Pregolskaya TPP began operation - one of four power plants designed to provide autonomous energy supply to the region. GRUNDFOS equipment was installed at the TPP. It provides the operation of a combined-cycle plant unit, hot water supply, cooling, air heating systems, as well as fire extinguishing, drainage and water treatment systems.
The Pregolskaya TPP with a capacity of 455.2 MW was fully commissioned in March 2019. It is part of the project for ensuring the region’s energy security, which is being implemented by Kaliningrad Generation LLC. The general contractor for the construction is Inter RAO - Engineering LLC, a subsidiary of Inter RAO PJSC. The project involves the construction in the Kaliningrad region of four new stations with a total capacity of 1 GW. The remaining three are the already launched Mayakovskaya and Talakhovskaya, as well as Primorskaya TPPs, the commissioning of which is scheduled for 2020.
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The goal of the project is to provide autonomous power supply to the Kaliningrad region. Recall that the region is included in the BRELL electric ring (Belarus Russia, Estonia, Latvia, Lithuania), its energy is supplied through European energy systems. By 2025, it is expected that the Baltic countries will leave the ring, which could greatly affect the energy security of the Russian enclave. New TPPs will ensure the safe functioning of the energy system of the Kaliningrad region in the event of termination of the agreements on BREL.
Pregolskaya TPP includes four combined cycle plants (CCGT). The capacity of each power unit is 113.8 MW. This is the largest facility of the new Kaliningrad generation. More than 70 pumps have been installed here, which ensure the operation of water and wastewater treatment systems in domestic, drinking, fire-fighting water supply and drainage networks.
Vertical closed-loop pumps GRUNDFOS KPV 1015 are installed in the closed cooling system of the auxiliary unit of CCPP. GRUNDFOS KP 2832 units are used as the main circulation pumps. The equipment is specially designed taking into account the requirements for reducing the cost of the pump life cycle. High efficiency and reliability are achieved thanks to preliminary CFD and FEA analyzes - computer simulation methods that allow reproducing the work of equipment and the associated physicochemical processes in real conditions. The double-sided impeller reduces the load on the shaft and minimizes noise and vibration. The pumps have an in-line design: the discharge and suction nozzles are aligned, making the pumps easy to install. The frequency converters supplied with the units allow automatic and manual operation to change the rotation speed of electric motors. Thus, the optimal operating conditions of auxiliary CCGT systems are supported.
For household water supply, console pumps GRUNDFOS NKG 200-150-500 with one-way suction are used, as well as console-monoblock pumps GRUNDFOS NB 100-250. NKG pumps are designed specifically for pumping liquids and increasing pressure in demanding industrial environments. They have cast iron impellers protected against corrosion by cataphoresis coating. Optimized flow-through hydraulics help reduce losses by providing up to 77% pump efficiency at a nominal flow rate of 495 m3 / h.
NB 100-250 - single-stage pumps that develop a head up to 92 m. At the optimum operating point, the pumps operate with an efficiency of up to 78% and a capacity of 345 m3 / h. The equipment is equipped with electric motors with fan cooling. During repair, the electric motor and impeller can be dismantled as a single unit. This greatly facilitates the maintenance of pumps: work can be performed by one person using a crane.
In the air heating system of a gas turbine installation, metering pumps GRUNDFOS DMH 175-10 operate. Pumps provide dosing accuracy within +/- 1% of the calculated flow rate and have proven themselves when integrated into technological processes. The equipment is equipped with a diaphragm protection system, which protects the pump and the dosing system from sudden pressure surges.
The constant pressure of the heat carrier - the propylene glycol mixture - in the GTU air heating system is supported by the GRUNDFOS Hydro MPC-E unit based on two GRUNDFOS CRE 45-2 pumps with built-in frequency converters. They are part of the anti-icing system of a comprehensive air-cleaning device. The installation is capable of supplying a coolant up to 140 m3 / h and increasing the pressure to 7.2 atm. The MGE electric motor provides high energy efficiency of the equipment.
In the gas turbine heating system, vertical single-stage pumps GRUNDFOS CRN 64-1 with electric motors GRUNDFOS MG are installed. They provide a nominal flow of 64 m3 / h with an efficiency of 80% and a maximum head of up to 30 m. The robust construction of the hydraulic part made of high-quality stainless steel guarantees CRN 64 long-term operation even when pumping process liquids in thermal power plants.
The TPP drainage and sewage system includes GRUNDFOS equipment for pumping process and domestic water. The station uses two types of pumps: as standard, submersible sewage pumps with a single-channel impeller - GRUNDFOS SL1.50.65 and pumps with a cutting mechanism - GRUNDFOS SEG.40.40.2.50BZ The latter are installed in drainage systems for floor pits.
SL1.50.65 is designed for transporting liquids with a maximum size of solids up to 50 mm. The smooth surfaces of the single-channel impeller and the entire hydraulic part contribute to the self-cleaning of the pump and reduce the risk of jamming. The engine is equipped with a humidity switch, which provides power off in case of leakage, and is protected from overheating by two thermal switches.
SEG.40.40 can be operated in intermittent operation with partial immersion or in continuous operation with complete immersion of the motor housing. The cutting mechanism of the pump and the discharge pipe with a diameter of 40 mm allow pumping industrial effluents with the content of fibrous inclusions through pipes of small diameter.
“Pregolskaya TPP is a key stage in a large-scale project, the implementation of which not only ensures the energy security of the Kaliningrad region, but also gives impetus to the further socio-economic development of the region. Compared with other power plants of the previous generation, the Pregolskaya production cycle is more environmentally friendly and more efficient. High quality characteristics of the station are provided, inter alia, by GRUNDFOS equipment. Modern and reliable, it is well adapted to modern automated control systems and allows you to achieve minimal energy consumption for your own needs, increasing the overall efficiency of the unit,” says Mikhail Lychagin, head of the Grundfos energy facilities department.
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