The high-pressure cooling pumps play a very critical role in the manufacturing of TMT bars. They are used for quenching the red-hot TMT bars to get the required microstructure as per standards. The TMT cooling pumps help to maintain the essential cooling effects by maintaining accurate water pressure.

However, different sizes and grades of TMT bars require distinct water pressures.

The accurate working of cooling pumps and maintaining the desired water pressure is essential for maintaining the quality of the TMT bar, else it may cause complete batch rejection and heavy losses.

The high-pressure cooling pump rating varies from 75 KW to 220KW. In the quenching process, pumps are the major contributor to energy consumption.

Since this application is critical, the power consumption aspect has been neglected, and the maintenance team does not take any risk of modification/Change in the operation.

To improve energy efficiency at the factory, the company looked at the energy consumption of its TMT manufacturing plant and invited L&T Electrical & Automation Team (E&A) to offer a solution.

To address the above challenges, the Drives & Automation team from E&A conducted an energy audit of the TMT Bar manufacturing process. The

high-pressure cooling pumps, being one of the major power consumers, were targeted first. The team monitored the water pressure at many different points of the cooling water pipeline. As per the grade and size of the TMT rod, the required pressure at the final cooling point was achieved by valve control. The team found out that valve control led to major power wastage.

The team critically analyzed the process and identified potential opportunities in areas of automation and energy saving. The solution was designed and implemented using a Variable Frequency Drive (VFD) to monitor the final pressure and also control the water flow as per requirement, without compromising the required process parameters.

The Fx2000 Series AC drives with inbuilt PLC control helped in achieving process optimization and eliminating power wastage.

The Drive solution helped the customer to achieve power savings of 2,66,400 KWH annually for one 125KW TMT cooling pump. It resulted in a cost savings of approximately. 20L rupees and an environmental benefit of 200 tons of CO2 emission. To absorb 200 tons of CO2, approximately 7500 trees would be required in a year, which the Drive could do in less than 4 months.

As consumers of electricity, we all need an uninterrupted power supply to continuously run the operations of buildings, industries, and other infrastructure. At the same time, we cannot ignore the quality of power, which is impacted by the use of switching electronic devices like variable speed drives (VFDs), uninterruptible power supplies (UPS), switched-mode power supplies (SMPS), light-emitting diode (LEDs), etc. The poor quality of power leads to premature failure or degrades the performance of equipment and has a negative impact on the overall electrical system.

E&A’s Power Quality Solution helps run all your electrical systems efficiently and reliably by improving the quality of power in its distribution network.

Consult with the E&A team to know how you can consistently maintain Unity True-Power Factor and mitigate current harmonics as per IEEE 519, or about a special solution for high voltage harmonics.

E&A’s offerings include Type Tested APFC Panel as per IEC 61439 & IEC 61921, a wide range of Active Harmonic Filters, Hybrid Harmonic Filters, and many others.

Every energy unit is charged, and it is thus essential to know where it is being used. E&A helps you to measure your energy spend.

Know more about

How our SmartComm EMS

(Energy Management Software) helps you to monitor energy consumption in real-time, take corrective actions in areas of energy wastage, and improve energy efficiency.

The Fx2000 Series AC drives with inbuilt PLC control helped in achieving process optimization and eliminating power wastage.

Benefits

The Drive solution helped the customer to achieve power savings of 2,66,400 KWH annually for one 125KW TMT cooling pump. It resulted in a cost savings of approx. 20L rupees and an environmental benefit of 200 tons of CO2 emission. To absorb 200 tons of CO2, approximately 7500 trees would be required in a year, which the Drive could do in less than 4 months.

Product improvement is a continuous process. For the latest information and special application, please contact any of our offices listed here. Product photographs shown for representative purposes only.