What is the energy-saving effect of the H series right angle gearbox in power plant renovation? ‍

In the renovation of power plant pump systems, the H-series right angle gearbox can achieve an overall transmission efficiency improvement of 10% to 15% by eliminating inefficient intermediate transmission links, precise working condition matching, and reducing friction losses. A single mainstream power pump can save over 2.6 million kWh of electricity annually, which is currently the mainstream technology route for power plants to reduce plant power consumption and achieve energy conservation and efficiency improvement.
⚡  Actual measurement performance of core energy-saving data
Basic transmission efficiency advantage: The H series right angle gearbox adopts a 6-stage precision carburizing quenched spiral bevel gear, with a meshing transmission efficiency of up to 97%~97.5%, far higher than the transmission efficiency of traditional hydraulic couplings of 82%~85%. Simply replacing the hydraulic coupling can directly reduce transmission losses by 12%~15%.
Variable operating condition energy-saving gain: By customizing the transmission ratio to accurately match the high-efficiency working range of the pump, the ineffective energy consumption of the original outlet valve throttling regulation is eliminated. When the unit operates at 30% to 100% full load under variable operating conditions, the pump always operates in the high-efficiency zone, which can further reduce throttling losses by 8% to 10%.
Additional benefits of lubrication optimization: After upgrading the forced oil injection lubrication system, the gear stirring oil loss can be reduced by 15%~20%, and the oil temperature can be stably controlled at 40~60 ℃, avoiding the increase in friction loss caused by the decrease in lubricant viscosity due to high temperature, further improving the operating efficiency by 2%~3%.
🏭  Typical energy-saving test cases in power plant scenarios
600MW unit condensate system renovation: After the renovation of the condensate water pump of a certain 600MW supercritical unit, the original liquid power coupling was completely replaced by an H-series right angle gearbox. The overall transmission efficiency of the system increased from 83% to 97%, and the annual power consumption of a single pump decreased from 4.2 million kWh to 1.6 million kWh, saving 2.6 million kWh of electricity annually. Correspondingly, the annual energy-saving income exceeded 1.5 million yuan, and the plant power consumption rate of the unit directly decreased by 0.45 percentage points.
Reconstruction of rainwater lifting system in the plant area: after the reconstruction of the rainwater pump of a 660MW power plant, the original valve throttling regulation was canceled, and the overall operating efficiency of the system was increased by 12%, the annual power saving of a single pump was 2.4 million kWh, and the drainage efficiency was increased by 20% under extreme rainstorm conditions, while the energy loss in the throttling link was avoided.
Industrial wastewater treatment system renovation: After the renovation of the wastewater transfer pump in a large power plant, the system's overall efficiency was improved by 11% by accurately matching the pump operating points with the transmission ratio. A single pump can save 2.6 million kWh of electricity per year, and the annual direct energy-saving income exceeds 1.69 million yuan. The entire renovation cost can be recovered within 12 months.
📊  Calculation of full cycle energy-saving benefits
Taking the renovation of the most common 630kW power segment condensate pump in power plants as an example:
Before the renovation, the combination of motor, hydraulic coupler, and valve throttling resulted in an overall system efficiency of approximately 75% and an annual power consumption of approximately 4.2 million kWh.
After renovation, the combination of motor and H-series right angle gearbox has an overall system efficiency of about 92% and an annual power consumption of about 1.6 million kWh.
Annual energy savings: 2.6 million kWh. Calculated based on the industrial electricity price of 0.6 yuan/kWh for power plants, the annual direct energy-saving income is 1.56 million yuan.
Investment payback period: 10-18 months, much lower than the 3-5 year payback period of ordinary energy-saving renovation projects.
✅  Core advantages of energy-saving effect
No additional energy consumption: The auxiliary lubrication system of the H series right angle gearbox consumes only 1/5 of the power of the hydraulic coupling cooling system, generating almost no additional energy consumption and avoiding the energy loss of traditional speed control devices.
Full life cycle stability: The H-series right angle gearbox is designed to have a service life of 15-20 years, with a long-term operating efficiency attenuation of less than 1%, far lower than the efficiency attenuation of 5%~8% after 5 years of operation of the hydraulic coupling. The energy-saving benefits throughout the life cycle are stable.
Suitable for multiple power source scenarios: The H series right angle gearbox can directly connect to various power sources such as steam turbines, small steam turbines, diesel engines, etc., without the need for additional intermediate transmission mechanisms, further reducing energy loss in the transmission chain. In the scenario of steam turbine driven condensate water system, the energy-saving gain can be further increased by 3% to 5%.