Consolidated Case Study: Comprehensive Replacement of PE-Series Boiler Feed Pumps with Modern TDG Units at Power Generation Facilities of the Russian Federation

Project / Customers

Project: Replacement of end-of-life PE-series boiler feed pumps with modern high-efficiency TDG pumping units manufactured by SHANGHAI KAIQUAN PUMP (GROUP) Co., Ltd. (China)
Customers: PJSC T Plus (Nizhegorodsky Branch, Samara CHP), JSC TGK-16, JSC Kuzbassenergo (SGK)
Facilities: Sormovskaya CHP, Nizhnekamskaya CHP, Samara CHP, Tom-Usinskaya GRES

Introduction

LLC EnergoFront is successfully implementing a large-scale program to replace end-of-life PE-series boiler feed pumps with modern high-efficiency TDG pumping units manufactured by SHANGHAI KAIQUAN PUMP (GROUP) Co., Ltd. (China). Amid the changing geopolitical landscape and critically long lead times for Russian-made equivalents, EnergoFront was tasked with promptly replacing, adapting, and delivering a reliable alternative to obsolete equipment at key power generation facilities across Russia.

The projects are being implemented at four major energy facilities:

• Sormovskaya CHP (Nizhegorodsky Branch, PJSC T Plus)
• Nizhnekamskaya CHP (JSC TGK-16)
• Samara CHP (PJSC T Plus)
• Tom-Usinskaya GRES (JSC Kuzbassenergo)

All projects share a common objective — replacing PE-series boiler feed pumps with modern equivalents without altering overall dimensions and connection sizes, while preserving existing foundations and piping.

Key features of the projects include:

• In-depth engineering design to ensure full compatibility with existing infrastructure;
• Adaptation of equipment to the specific conditions of each facility;
• Multi-level quality control at all stages of production and delivery;
• Extended equipment packages to minimize future downtime risks.

General Information on Facilities

Facility Characteristics and Challenges

3.1. Nizhegorodsky Branch, PJSC T Plus (Sormovskaya CHP)

Facility: The Nizhegorodsky Branch combines generation and heat network assets in Nizhny Novgorod, Dzerzhinsk, and Kstovo. The branch comprises three power plants — Dzerzhinskaya CHP, Sormovskaya CHP, and Novogorkovskaya CHP — as well as heat networks. The installed electrical capacity of the branch is 1,472 MW, and thermal capacity is 2,565 Gcal/h.

Challenge: Replacement of the old Sumy-made PE 580-185 boiler feed pump, which had reached the end of its service life, with modern, more efficient equipment.

Technical parameters of the supplied equipment:

Key requirement: Preservation of overall dimensions and connection sizes — the new pump must be installed on the existing foundation and connected to standard piping without re-welding or modifications.

3.2. Nizhnekamskaya CHP (JSC TGK-16)

Facility: A combined heat and power plant located in Nizhnekamsk, Republic of Tatarstan. Owned by JSC TGK-16, part of the TAIF Group of Companies. It supplies thermal energy to the majority of Nizhnekamsk's industrial enterprises. The key consumer is Nizhnekamskneftekhim, one of the largest petrochemical companies in Russia.

Challenge: Wear of PE 580-185 series feed pumps designed back in the 1970s. Under current conditions, lead times for manufacturing new pumps of this type have become critically long, making it difficult to meet investment program deadlines. Extended manufacturing and delivery times for PE pumps pose risks of disrupting technical re-equipment schedules.

Modernization objectives:

• Improving the efficiency and reliability of the pumping unit;
• Ensuring compliance with new equipment operating parameters;
• Import substitution — switching to an alternative supplier without losing compatibility with existing infrastructure.

3.3. Samara CHP (PJSC T Plus)

Facility: Samara CHP is one of the key and most modern combined heat and power plants in the Samara Region. Since 2019, the facility has been participating in the federal DPM-2 program (Capacity Supply Agreements for Modernized Generation Facilities), aimed at improving the efficiency and reliability of existing generating capacity.

As part of the modernization of Unit No. 4, the boiler unit, turbine, generator, and key auxiliary equipment are being replaced.

Challenge: The existing APE 580-185-3 feed pump had reached the end of its service life, had reduced efficiency, and did not meet the requirements of the modernized Unit No. 4. PE-series pumps were manufactured at the Nasosenergomash plant (Sumy, Ukraine), whose production and delivery lead times became unacceptable under the new conditions, creating a risk of disrupting the DPM-2 schedule.

Key requirement: Strict compatibility requirements — the new unit must match the parameters and dimensions of the PE 580-185-5 without major construction and installation modifications.

3.4. Tom-Usinskaya GRES (JSC Kuzbassenergo / SGK)

Facility: Tom-Usinskaya GRES is the largest thermal power plant in the south of Western Siberia, comprising 9 power units with a total installed capacity of 1,345.4 MW. Located in the city of Myski, Kemerovo Region, 25 km from Novokuznetsk. It is designed to cover the base load of the Kuzbass power system. Part of the Siberian Generating Company (SGK) Group.

Challenge: Replacement of the PE-580-195-5 feed pump (flow rate 580 m³/h, head 2,150 m) with a modern equivalent while preserving existing infrastructure.

Project specifics: Delivery was carried out without an electric motor and oil station — the customer planned to use the existing 4AZM-5000/6000UKhL4 motor and the standard oil station. A non-standard coupling had to be manufactured to fit the existing electric motor, and full compatibility had to be confirmed.

Complexity: During the on-site survey, numerous deviations from design documentation and hidden defects were identified, requiring mandatory corrective work before installation.

Technical parameters of the supplied equipment:

Electric motors (included in the supply package for three out of four projects):

• Type: 4AZM4000/6000UKhL4 (manufactured by NPO ELSIB PJSC, Russia)
• Power: 4,000 kW
• Voltage: 6,000 V
• Rotation speed: 3,000 rpm

Individual Engineering Solutions by Facility

For Nizhegorodsky Branch, PJSC T Plus (Sormovskaya CHP):

• The TDG 600-200×10 pump was selected as a complete equivalent of the PE 580-185 in all key parameters.
• Parametric identity was ensured: flow rate 580 m³/h, head 2,030 m.
• High efficiency of 82% ensures reduced operating costs compared to worn-out equipment.
• The supply package includes a Russian-made 4AZM4000/6000UKhL4 electric motor, reducing dependence on foreign suppliers.

For Nizhnekamskaya CHP (JSC TGK-16):

• Double-casing TDG pumps adapted to Russian operating conditions were proposed.
• Full technical adaptation to the parameters of the original PE 580-185.
• The unit is equipped with an electric motor, modular oil station, valves, and fire suppression system.
• Preliminary factory load tests were conducted on certified test stands with customer representatives in attendance.

For Samara CHP (PJSC T Plus):

• A detailed comparison of TDG parameters with the original PE 580-185-5 was conducted.
• Dimensions were adapted to the existing foundation and Unit No. 4 layout.
• Connection points to the existing piping system were designed.
• A complete set of design and technical documentation was prepared for implementation (ESKD format).
• Delivery was made as a fully equipped unit: pump, 4AZM-4000/6000UKhL4 electric motor, modular oil station, instrumentation package, and pipeline valves.

For Tom-Usinskaya GRES (JSC Kuzbassenergo / SGK):

• A comprehensive survey of the installation area was conducted with an on-site visit to the station.
• Deviations from design documentation and hidden defects were identified:

• Non-standard tie-in of the recirculation line (directly into the discharge nozzle instead of the section between the nozzle and the check valve) — relocation of the check valve was required.
• Absence of a motorized gate valve on the recirculation line (a manual one was installed) — replacement was recommended.
• Electric motor defect: a coupling housing flange was installed instead of the standard oil slinger ring — restoration is required.
• Center distance deviation of 35 mm — precise measurements were taken, and a non-standard coupling was ordered.

• Two new NMSH 12-25-10/4 oil pumps were recommended (Q=10 m³/h, P=4 kgf/cm², N=4 kW).
• Standard Chinese-made instrumentation was replaced with Russian instruments (agreed with the CTAI department).

Summary of Achieved Results

1. 1. Operational results:
• Four pumping units were manufactured and delivered to customer facilities.
• All projects were completed in compliance with schedule and quality requirements.
• Factory load tests of the equipment were conducted on certified test stands.
2. 2. Technical results:
• A universal engineering solution was created for replacing PE-series pumps with modern TDG equivalents without modifying foundations or piping.
• Double-casing construction (barrel type) was implemented — providing increased rigidity, durability, and reliability.
• High efficiency (up to 82%) and cavitation resistance were ensured.
• At Tom-Usinskaya GRES, in-depth engineering diagnostics were performed, and hidden defects in existing piping and components were identified and eliminated.
3. 3. Economic and strategic results:
• Capital cost reduction by preserving existing foundations, piping, and pump station buildings (eliminating civil reconstruction costs).
• Import substitution: switching to an alternative supplier (China) without losing compatibility with existing infrastructure.
• Localization: replacement of Chinese-made instrumentation with Russian instruments (Tom-Usinskaya GRES project), delivery of Russian-made ELSIB electric motors in three projects.
• A standard package of engineering and technical solutions and documentation was created for scaling to other Russian facilities operating PE-series pumps.

Reliability Indicators of the Supplied Equipment

Conclusion

LLC EnergoFront has confirmed its status as a reliable engineering partner capable of solving complex import substitution challenges within tight deadlines at key Russian energy facilities. The successful implementation of projects at Sormovskaya CHP, Nizhnekamskaya CHP, Samara CHP, and Tom-Usinskaya GRES demonstrates the company's systematic approach:

• Technical expertise — selection and adaptation of equipment to the specific conditions of each facility, including complex cases (retaining the existing motor, identifying hidden defects).
• Full project cycle — from pre-project survey and design to delivery, installation supervision, and commissioning supervision (where provided by the contract).
• Multi-level quality control — stage-by-stage production control and factory load tests.
• Localization — equipping units with Russian-made electric motors and instrumentation, reducing import dependence.
• Creation of a standard solution — the developed package of engineering and technical documentation is applicable to other Russian facilities operating PE-series pumps.

The projects have not only resolved the customers' immediate issues but have also created a valuable industry-wide solution contributing to energy security and technological independence of the Russian power sector.