Grasim Industries Limited

Grasim Industries, part of the Aditya Birla Group, operates a captive power plant where efficient cooling water systems are essential for maintaining stable power generation. The existing system relied on two low-capacity pumps operating simultaneously, resulting in inefficiencies, higher maintenance efforts, and increased power consumption.

Managing multiple pumps also introduced operational complexity and higher chances of system imbalance. The client required a simplified, energy-efficient solution that could maintain required performance while reducing system complexity and operating costs.

Wilo identified an opportunity to optimize the system rather than simply replacing existing pumps. By leveraging its engineering expertise, Wilo proposed a solution that improved efficiency while reducing equipment footprint. The goal was to enhance system performance, reduce energy consumption, and provide a long-term reliable solution tailored to the plant’s operational needs.

Wilo replaced the dual-pump configuration with a single high-capacity horizontal split case pump designed to handle the entire load efficiently. This redesign simplified system architecture and improved operational efficiency.

The upgraded system ensured stable hydraulic performance and consistent cooling water supply, eliminating the inefficiencies associated with running multiple pumps. Maintenance requirements were significantly reduced, and system reliability improved.

The solution achieved energy savings of approximately 30 kW per pump, leading to reduced operational costs and improved efficiency. By optimizing the pumping system, Wilo delivered both technical and economic benefits, showcasing its ability to provide value-driven engineering solutions.