Refurbishment of Atlas Copco compressor for Kazan TPP-1: Globaltechexport Ltd. successfully implements a complex reengineering project

The project implementation ensured reliable operation of backup equipment of a strategically important combined heat and power plant.

In 2024, Globaltechexport Ltd. completed comprehensive refurbishment of Atlas Copco GT032T4D1 centrifugal compressor for Kazan TPP-1, branch of Tatenergo JSC.
This project was aimed at restoring one of the three operating compressors to ensure uninterrupted power and heat generation for the central and southern parts of Kazan.

Challenge: Major damage and need for reengineering

The work was prompted by a serious accident associated with foreign objects entering the compressor's flow path during its operation. This resulted in unstable equipment operation, a significant drop in performance, and a high risk of component wear.

After a complete equipment disassembly and inspection, our engineers determined the extent of the damage: the first-stage impeller was damaged beyond repair, and components of subsequent stages had sustained significant damage. Conventional repairs were impossible, so a strategic decision was made in collaboration with the customer to reengineer the impeller of Atlas Copco GT032T4D1 centrifugal compressor, followed by manufacture of new parts and repair of the damaged ones.

Comprehensive solution: from 3D model to load tests

Globaltechexport Ltd. implemented a turnkey project that included a range of services unique to the services market:

1. Full reengineering cycle of the 1st stage impeller:

3D scanning of the flow path components and sketching.
New impeller aerodynamics engineering design.
Development of design documentation and working drawings.
Engineering studies and writing programs for a 5-axis CNC machine.
Manufacture of a new impeller with a Hirth coupling.
Performance of acceleration tests to verify strength and reliability.

2. Refurbishment of other parts and assemblies:

Refurbishment of the 2nd, 3rd, and 4th stage impellers with cleaning of damaged tips.
Balancing of rotor assemblies.
Cleaning and straightening of diffusers and repair of inlet guide vane (IGV) damages.
Refurbishment of John Crane dry gas seals and Eagle Burgmann groove barrier seals.

3. Final assembly and commissioning:

Compressor unit assembly.
Commissioning, testing, and adjustment of control circuits.
Surge tests, adjusting the surge detection and surge control system.
Valve adjustment and load tests.

Result

Following the successful project completion, Atlas Copco GT032T4D1 compressor unit was fully restored to service. The compressor was commissioned and is currently operating normally without any issues. It should be noted that all work was performed without shutting down of any operating equipment of the thermal power plant.

Project significance

This project has proved Globaltechexport Ltd.’s expertise in solving non-standard problems related to refurbishment of complex process equipment. Our ability to perform full cycles of reengineering of critical components enables the Company to provide its customers with effective solutions even in the most challenging situations.

The reliable operation of Kazan TPP-1 is crucial for the city's infrastructure, as the plant provides heat for the central and southern parts of Kazan and steam to major industrial enterprises in the Southern Industrial District, such as KZSK, KVART, and Nefis Cosmetics.

Kazan TPP-1 info

Kazan TPP-1 is located in Privolzhsky District of Kazan on the shore of Lake Sredniy Kaban. It is part of JSC Tatenergo and is a strategic power engineering facility of Tatarstan providing heat and steam to a significant portion of the city's infrastructure and industry.

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