January 10, 2024

Elion – Pump Up Efficiency and Savings at a Bawana Thermal Power Plant


Elion Technologies & Consulting Pvt Ltd is proud to showcase its commitment to optimizing industrial efficiency and sustainability through a recent project at a thermal power plant in Bawana. This case study highlights the effectiveness of Pump Energy Audits in identifying inefficiencies within critical pump systems, implementing targeted solutions, and ultimately optimizing energy consumption and cost savings for the power plant.

Project Overview:

Our client, a leading electricity provider in India, recognized the crucial role of efficient pump operations in minimizing their energy consumption and environmental impact. Aware of the significant energy usage attributable to pumps in power plants, they engaged Elion Technologies to conduct a comprehensive pump energy audit, seeking to unlock hidden savings and enhance their operational efficiency.

Pump Energy Audit


  • 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.


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.


This case study exemplifies the power of Elion Technologies’ pump energy audits in unlocking hidden savings and driving efficiency within industrial facilities. By providing data-driven insights and customized solutions, we helped this Bawana thermal power plant not only reduce their energy costs and environmental impact but also create a more efficient and sustainable pumping system for their power generation operations.

Elion Technologies & Consulting Pvt Ltd is your trusted partner for optimizing pump systems and unlocking energy savings across diverse industries. We offer a wide range of services, from pump energy audits and system design to VFD implementation and pump maintenance programs.

Contact us today to pump up your efficiency and savings.