Methodology

• Our experienced pump specialists meticulously assessed the entire power plant’s pumping systems, including:
  • Condenser water pumps, boiler feedwater pumps, and cooling water pumps.
  • Flow rates, pressures, and energy consumption of each pump system.
  • Pump efficiency curves and operating points.
  • System design, piping configurations, and control systems.
• We utilized advanced flow meters and data loggers to capture real-time performance data of each pump system.
• We analyzed the data to identify inefficiencies, such as off-peak operation, oversized pumps, and improper controls.
• We performed hydraulic modeling and pump system simulations to evaluate various optimization scenarios.

Unveiling Inefficiencies and Saving Opportunities:

The pump energy audit revealed several crucial findings:

• Oversized pumps: Certain pumps were significantly larger than required for their designated tasks, leading to excessive energy consumption even during partial load conditions.
• Inefficient operating points: Improper control settings and throttling valves resulted in pumps operating away from their peak efficiency point, wasting energy.
• System friction losses: Old piping configurations and poorly maintained valves contributed to increased friction losses and reduced pump performance.
• Lack of automation: Manual control of pumps led to inconsistencies and opportunities for optimizing operational schedules.

Tailored Solutions for a Streamlined Pumping System:

Based on these findings, we provided a detailed report with prioritized recommendations, including:

• Downsizing or replacing oversized pumps with right-sized options.
• Implementing variable speed drives (VSDs) to adjust pump speed based on real-time demand.
• Optimizing control settings and eliminating throttling losses.
• Upgrading piping configurations and replacing worn-out valves.
• Automating pump operations through intelligent control systems.

Results:

By diligently implementing our recommendations, the Bawana thermal power plant achieved remarkable results:

• Significant energy savings: Reduced pump energy consumption by up to 20%, translating to substantial cost savings and minimized environmental impact.
• Improved operational efficiency: Optimized pumping system performance minimized downtime and enhanced overall plant reliability.
• Enhanced environmental footprint: Lower energy consumption contributed to a reduced carbon footprint, aligning with the power plant’s sustainability goals.
• Demonstrable leadership in efficiency: Implementing comprehensive pump optimization measures positioned the power plant as a leader in industrial efficiency, garnering industry recognition and trust.