CASE28 · Power generation · Auxiliary pumps and fans
Benchmarking auxiliary electricity across seven by-product-gas generating units
Generation-normalized auxiliary indicators identify differences between feedwater, condensate and seawater pumps and forced/induced-draft fans. The proposal connects benchmarking to dispatch and setpoint guidance.
01 · CASE ANALYSIS
Why auxiliary performance matters
Existing systems emphasized condition monitoring and fault diagnosis rather than energy-efficiency guidance. Comparable generating units showed different auxiliary-power ratios and equipment intensities.
Pump/fan control and operating-unit counts needed to be interpreted alongside generating load, condenser conditions and service requirements.
02 · CASE ANALYSIS
Equipment and performance diagnosis
The scope included 14 feedwater pumps and 14 condensate pumps, normally seven of each operating; 17 seawater pumps with approximately 7–14 operating; and seven FDF and seven IDF units.
The reported equipment-intensity ranges use source-specific denominators. Their numerical values should not be compared across different equipment types without confirming definitions.
| Indicator | Reported range | Relative spread |
|---|---|---|
| Auxiliary-power ratio | 3.2–4.3% | Up to 34% versus best unit |
| Feedwater-pump intensity | 6.3–7.7 | Approximately 22% |
| FDF intensity | 0.665–1.576 | Up to 137% |
| IDF intensity | 0.019–0.038 | Up to 100% |
03 · CASE ANALYSIS
Integrated operating improvements
Select efficient pumps, review variable-speed control and valve settings, and balance seawater-pump power against condenser vacuum and generation performance.
For fans, evaluate airflow, furnace pressure, dampers and VFD control while maintaining combustion and process requirements. Performance gaps identify investigation priorities, not directly attainable savings.
04 · CASE ANALYSIS
System proposal and M&V
Estimated auxiliary load was approximately 28 MW and annual electricity cost KRW 23.1 billion. The proposal targeted approximately 2%, or KRW 460 million/year.
The proposed data scope comprised 320 points: 278 existing points and 42 additional points, including 28 power-related points and 14 current-meter communication points.
| Item | Source estimate |
|---|---|
| Auxiliary load | 28 MW |
| Annual electricity cost | KRW 23.1 billion |
| Annual expected savings | KRW 460 million; approximately 2% |
| Proposed investment | KRW 443 million |
| Program duration | 12 months |
05 · CASE ANALYSIS
Verification framework
Baseline UPI is auxiliary electricity divided by generation. Reporting-period UPI applies a pre-agreed correction for generation and climate conditions; saving rate is (baseline UPI − corrected reporting UPI) / baseline UPI.
The source proposed approximately KRW 443 million investment and roughly one-year payback. These are historical proposal economics requiring actual scope and M&V to confirm.
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