The original high pressure water pump system for the Unit 5 ash plant was oversized, operating inefficiently during dry mode operation. To save energy, ash plant engineers from GSECL modified the system by installing two new smaller capacity air washer pumps. This reduced the operating hours and load on the original high pressure pump, cutting annual energy consumption by over 1 million kWh and saving Rs. 3.3 million per year. The payback period for the modification was 49 days due to the significant energy savings.

1. MODIFICATION OF PUMPINGMODIFICATION OF PUMPING
SYSTEM OF UNIT- 5 ASH PLANTSYSTEM OF UNIT- 5 ASH PLANT
FOR ENERGY SAVINGFOR ENERGY SAVING
BY ASH PLANTS ENGINEERSBY ASH PLANTS ENGINEERS
GSECL, TPS, GANDHINAGARGSECL, TPS, GANDHINAGAR

2. ORIGINAL DESIGN BY OEM
(1) As Per OEM, M/s. DCIPS Ltd. The Originally designed
HP Water Pump was running for Wet Mode Fly Ash
System & Dry Mode Fly Ash System of Ash Plant #5,
since commissioning of the Unit in the Year 1998.
(2) The Capacity of HP Water Pump was 600 Cubic metre
Per Hour with 80 MWC Head & having 190 KW Motor.
(3) For Wet Mode Fly Ash System Running, the HP Water
Pump caters water Requirement to Wetting Heads &
Air Washer Tanks both simultaneously.

3. Why Small Capacity of Pump Required ?
(1) During Running of Dry Mode Fly Ash system, Water required by Air
Washer Tanks only. Wetting Heads are not required to be kept in
Service.
(2) By the Time, Demand for Dry Fly Ash increased, hence, mostly Dry
Mode Fly Ash System is in Running Condition.
(3) During Dry Mode System Running for Dry Ash Collection into Silo of(3) During Dry Mode System Running for Dry Ash Collection into Silo of
Unit-5, the HP Pump having 600 m3/hr capacity with 190 KW motor isUnit-5, the HP Pump having 600 m3/hr capacity with 190 KW motor is
to be kept running with Recirculation Valve in open condition toto be kept running with Recirculation Valve in open condition to
cater the requirement of HP Water to Air Washer System of all Fourcater the requirement of HP Water to Air Washer System of all Four
Streams of Fly Ash System. This leads to operation of pump at veryStreams of Fly Ash System. This leads to operation of pump at very
high pressure & to maintain the header pressure around 8.0 Kg/cm2,high pressure & to maintain the header pressure around 8.0 Kg/cm2,
Re - circulation Valve is to be kept Open & thereby there is energyRe - circulation Valve is to be kept Open & thereby there is energy
loss in re-circulation. In order to avoid this energy loss, the smallloss in re-circulation. In order to avoid this energy loss, the small
capacity Pumps (one running + one stand by) are required to becapacity Pumps (one running + one stand by) are required to be
installed.installed.

4. Schematic Diagram of Modification

5. AIR WASHER PUMPS DATA SHEETAIR WASHER PUMPS DATA SHEET
Pump Data Rated For Motor Details
Make – Maxflow Total Head – 60 Meter Make - ABB
Type - 100 HH2 Discharge–125 M3/HR. Rating – 37 KW
Pump Sr. No. 12052117
& 12052116.
Efficiency – 70% Motor Sr.No. 794901 &
792587.
Suction Size – 125 MM BKW Abs. – 29.10 Frame – HX+225SMB4
Delivery Size – 100 MM Speed – 1450 RPM FL.RPM - 1470

6. AIR WASHER PUMPS SUPPLY DETAILS
OEM OF THE PUMP S Maxflow Pumps India Pvt. Limited, 1/5, Khandsa
Road, Gurgaon. HARYANA.
Ref. No. 7816
Pump Type 100HH2 (Horizontal Split Casing Pump)
Machine Nos. 12052116 (Installed as Pump No. 2) &
12052117 (Installed as Pump No. 1)
Quantity 2 Nos.
Customer M/S. Xama Traders, Vidyanagar. (Supplier to GSECL)
Customer Order Ref. XT / PO-07 / 2141 Date : 17.02.2012
Consignee M/S. GSECL, Gandhinagar.
GSECL Order Ref. A/T. No. GPS/Tech/Supply/ASH/ET-145/315/01361,
06.02.2012 & EPO No. 37494.
Description of Order Item Centrifugal Pumps with Motor for Air Washery
System for Ash Plant having Head – 60M, Flow – 125
M3/HR, Motor – 37.0 KW, Quantity – 02 Sets.
Order Value Rs. 465000/-
Total End Cost Rs. 474300/-
Pumps Received Ref. STSR 1778, 11.06.2012
Installed & Commissioned of both pumps at Unit-5
Ash Plant.
JULY – 2012.

7. ENERGY SAVING BY PROVIDING NEW 37 KW, 415V
AIR WASHER PUMPS: 02 NOS. (1 R +1 SB) for 2012
- 2013
Sr.No Description
FULL LOAD
AMP.
RUNNING
HRS.
Before/
After
Root 3 V I CosQ
ENERGY
CONS. IN
KWH
ENERGY
CONSUMPTI
ON IN
KWH / day
ENERGY
CONSUMPTI
ON IN
KWH / day
1 6.6 KV, 190 KW HP PUMP 18 24 / 4 1.732 6.6 18 0.95 195 4680 780
2
NEW 415 V, 37 KW AIR
WASHER PUMP 50 0 / 24 1.732 0.415 50 0.95 34 0 816
3
TOTAL CONSUMPTION
Kwh 4680 1596
4 SAVING IN KWH PER DAY 0 3084
5
ANNUAL SAVING KWH
(Considering 330 Days
Running) 1017720
6
ANNUAL SAVING IN RS.
( 3.25 RS./Kwh) 3307590.00
7
COST OF NEW PUMP (1+1)
INCLUDING INSTALLATION
CHARGES 487447.00
8 NET SAVING FOR THE YEAR 2012-13 2820143.00
9
PAY BACK PERIOD 49 Days

8. Water Saving by ModificationWater Saving by Modification
Sl.
No.
Parameters Before
Improvement
(HP Pump in
Service & RC
Valve Open)
After
Improvement
(Air Washer
Pump in Service)
Water Flow Requirement / Calculation :
(1) Design Flow rate (M3/Hr)
& Head in MWC
600, 80 MWC 125, 60 MWC
(2) Flow rate (M3/Hr) to Air
Washer Tanks
450 125
(3) Reduction in Flow Rate after Improvement = 325 M3/Hr.

9. THANKS

10. Presented byPresented by
 MM Modi,MM Modi, SE(TS)SE(TS)
 DV Pandya,DV Pandya, DE(Ash plant)DE(Ash plant)