Gujarat Mineral Development Corporation

Gujarat Mineral Development Corporation (GMDC) operates a 250 MW thermal power plant that relies on high-pressure pumping systems for reverse osmosis (RO) feed and energy recovery applications. These systems are critical for maintaining water treatment efficiency and ensuring uninterrupted plant operation. However, the existing Ingersoll-Rand pumps were facing significant challenges, including frequent failures, high maintenance costs, and extended downtime due to limited service support and spare part availability.

The inefficiencies in the existing system not only impacted operational reliability but also led to increased energy consumption and reduced overall plant performance. GMDC required a solution that could enhance system efficiency while utilizing existing infrastructure, particularly the motors, to minimize capital expenditure.

Wilo was engaged to develop a technically advanced and cost-effective retrofit solution that could address these challenges. This project also presented a unique opportunity to introduce innovative energy recovery concepts within the system. The goal was to improve pump performance, reduce operational costs, and ensure long-term reliability, while maintaining compatibility with existing plant configurations.

Wilo implemented a customized retrofit solution by replacing the existing pumps with high-performance ring section pumps while retaining the existing motor setup. A key innovation in this project was the development of a new hydraulic design tailored specifically for energy recovery applications, enabling efficient utilization of outlet pressure from the RO system.

The system was engineered to recover energy from the high-pressure discharge and transfer it back into the system, thereby reducing the load on the motor and improving overall efficiency. This approach not only optimized performance but also introduced a sustainable energy-saving mechanism within the plant’s operations.

The upgraded pumps demonstrated improved reliability, significantly reducing failure rates and maintenance requirements. Additionally, the solution delivered energy savings of approximately 25 kW per pump, contributing to reduced operating costs and improved plant efficiency. The success of this installation has strengthened customer confidence and created opportunities for further pump replacements within the facility, positioning Wilo as a preferred partner for advanced industrial applications.