tips for thermal energy conservation_12

8/6/2019 Tips for Thermal Energy Conservation_12

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ENERGY CONSERVATIONTECHNIQUES


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ENERGY CONSERVATION TECHNIQUES Page 2

Tips for Thermal Energy Conserva t ion

Generaly Undertake regular energy audits.y P lug all oil leakage. Leakage of one drop of oil per second

amounts to a loss of over 2000 liters/year.y F ilter oil in stages. Impurities in oil affect combustion.y P re-heat the oil. F or proper combustion, oil should be at

right viscosity at the burner tip. P rovide adequate P re-heatcapacity.

y Incomplete combustion leads to wastage of fuel. Observethe colour of smoke emitted from chimney. Black smokeindicates improper combustion and fuel wastage. Whitesmoke indicates excess air & hence loss of heat. Hazy brownsmoke indicates proper combustion.

y Use of Low air pressure film burners helps save oil upto15% in furnaces.

Fu rnacey Recover & utilize waste heat from furnace flue gase for

preheating of combustion air. Every 210C rise in combustionair temperature results in 1% fuel oil savings.

y Control excess air in furnaces. A 10% drop in excess airamounts to 1% saving of fuel in furnaces. F or an annualconsumption of 3000 kl. of furnace oil. This means a savingof Rs 3 Lacs. (Cost of furnace oil- Rs. 10 per litre).

y Reduce heat losses through furnace openings. Observationsshow that a furnace operating at a temperature of 10000Chaving an open door (1500mm*750mm) results in a fuel lossof 10 lit/hr. F or a 4000 hrs. furnace operation this translatesinto a loss of approx. Rs. 4 Lacs per year.

y Improve insulation if the surface temperature exceeds 200Cabove ambient. Studies have revealed that heat loss form afurnace wall 115mm thick at 6500C amounting to 2650Kcal/m2/hr can be cut down to 850 kcal/m2/he by using 65mm thick insulation on the 115 mm wall.

y P roper design of lids of melting furnaces and training ofoperators to close lids helps reduce losses by 10-20% infoundries.


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Top Boi ler

y Remove soot deposits when flue gas temperature raises 400Cabove the normal. A coating of 3mm thick soot on the heattransfer surface can cause an increase in fuel consumption

of as much as 2.5%.y Recover heat from steam condense. F or every 60C rise inboiler feed water temperature through condense return,there is 1% saving in fuel.

y Improve boiler efficiency. Boilers should be monitored forflue gas losses, radiation losses, incomplete combustion,blow down losses, excess air etc. P roper control candecrease the consumption upto 20%.

y Use only treated water in boilers. A scale formation of 1mmthickness on the waterside would increase fuel consumptionby 5-8%.

y Stop steam leakage. Steam leakage from a 3 mm-diameterhole on a pipeline carrying steam at 7kg/cm2 would waste

32 kl of fuel oil per year amounting to a loss ofR

s. 3 Lacs.y Maintain steam pipe insulation. It has been estimated that abare steam pipe, 150 mm in diameter and 100m in length,carrying saturated steam at 8kg/cm2 would waste 25 kl offurnace oil in a year amounting to an annual loss of Rs. 2.5Lacs.

D G Setsy Maintain diesel engines regularly.y A poorly maintained injection pump increases fuel

consumption by 4Gms/KWH.y A faulty nozzle increases fuel consumption by 2Gms/KWH.y Blocked filters increase fuel consumption by 2Gms/KWH.y A continuously running DG set can generate 0.5 Ton/Hr of

steam at 10 to 12 bars from the residual heat of the engineexhaust per MW of the generator capacity.

y Measure fuel consumption per KWH of electricity generatedregularly. Take corrective action in case this shows a risingtrend.


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Tips for Elec t r ica l Energy Conserva t ion

Generaly Improve power factor by installing capacitors to reduce KVA

demand charges and also line losses within plant.y Improvement of power factor from 0.85 to 0.96 will give

11.5% reduction of peak KVA and 21.6% reduction in peaklosses. This corresponds to 14.5% reduction in average lossesfor a load factor of 0.8.

y Avoid repeated rewinding of motors. Observations show thatrewound motors practically have an efficiency loss of upto5%. This is mainly due to increase in no load losses. Henceuse such rewound motors on low duty cycle applicationsonly.

y Use of variable frequency drives, slip power recoverysystems and fluid couplings for variable speed applicationssuch as fans, pumps etc. helps in minimizing consumption.

Illum inat iony Use of electronic ballast in place of conventional choke

saves energy upto 20%.y Use of C FL lamp in place of GLS lamp can save energy upto

70%.y Clean the lamps & fixtures regularly. Illumination levels fall

by 20-30% due to collection of dust.y Use of 36W tubelight instead of 40 W tubelight saves

electricity by 8 to 10%.y Use of sodium vapour lamps for area lighting in place of

Mercury vapour lamps saves electricity upto 40%.

C omp ressed A iry Compressed air is very energy intensive. Only 5% of

electrical energy are converted to useful energy. Use ofcompressed air for cleaning is rarely justified.

y Ensure low temperature of inlet air. Increase in inlet airtemperature by 30C increases power consumption by 1%.

y It should be examined whether air at lower pressure can beused in the process. Reduction in discharge pressure by 10%saves energy consumption upto 5%.

y A leakage from a diameter hole from a compressed airline working at a pressure of 7kg/cm 2 can drain almost Rs.2500 per day.

y Air output of compressors per unit of electricity input mustbe measured at regular intervals. Efficiency of compressorstends to deteriorate with time.


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R efr igerat io n & A ir C ond it io n in g y Use of double doors, automatic door closers, air curtains,

double glazed windows, polyester sun films etc. reducesheat ingress and air-conditioning load of buildings.

y Maintain condensers for proper heat exchange. A 50Cdecrease in evaporator temperature increases the specific

power consumption by 15%.y Utillisation of air-conditioned/refrigerated space should be

examined and efforts made to reduce cooling load as far aspossible.

y Utillise waste heat of excess steam or flue gases to changeover from gas compression systems to absorption chillingsystems and save energy costs in the range of 50-70%.

y Specific power consumption of compressors should bemeasured at regular intervals. The most efficientcompressors to be used for continuous duty and others onstandby.

C oo ling Tow ersy Replacement of inefficient aluminum or fabricated steel

fans by moulded FRP fans with aerofoil designs results inelectricity savings in the range of 15-0%.

y A study on a typical 20ft. diameter fan revealed thatreplacing wooden blade drift eliminators with newlydeveloped cellular P VC drift eliminators reduces the driftlosses from 0.01-0.02% with a fan power energy saving of10%.

y Install automatic ON-O FF switching of cooling tower fans and

save upto 40% on electricity costs.y Use of P VC fills in place of wooden bars results in a saving in

pumping power of upto 20%.

P ump sy Improper selection of pumps can lead to large wastage of

energy. A pump with 85% efficiency at rated flow may haveonly 65% efficiency at half the flow.

y Use of throttling valves instead of variable speed drives tochange flow of fluids is a wasteful practice. Throttling cancause wastage of power to the tune of 50 to 60%.

y It is advisable to use a number of pumps in series andparallel to cope with variations in operating conditions byswitching on or off pumps rather than running one largepump with partial load.

y Drive transmission between pumps & motors is veryimportant. Loose belts can cause energy loss upto 1-20%.

y Modern synthetic flat belts in place of conventional V-beltscan save 5% to 10% of energy.

y P roperly organized maintenance is very important.Efficiency of worn out pumps can drop by 10-15% unless


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maintained properly.

P rom o t io nal Sche m esy Energy Auditors empanelment schemey Energy Audit subsidy schemey Soft loan for purchase of energy audit equipment's & instruments.

Besides these, P CRA also conducts Energy audits, F uel Oil diagnostic studies, Studies in small scaleindustries, Follow-ups; Organizes technical meets, Consumer meets, Seminars, Institutionaltraining programmers, Workshops, Clinics; helps in organizing Action Group meetings and puts upstalls in exhibitions on conservation of petroleum products

G ood Dr iv ing Habi t s

How to make every drop last longer

D r ive bet ween 45-55 K m/H

Drive slow and steady. The faster you go, the more wind resistanceyour vehicle will face. If you go at speeds above 60 Km/H, you willwaste petrol. Tests on Indian cars prove that you can get up to 40 %extra mileage at 45-55 Km/H as against 80 Km/H.

Remember Avoid accelerating or decelerating unnecessarily.Avoid banking by anticipating stops and curves well in advance.Tests show that a reduction in speed leads to no appreciable rise incommuting time. Much less than what most people think.

Kee p you r en gine healthy

Tests on a large number of cars prove that you can save as much as6% by tuning your car regularly. If your engine emits black smoke,has poor pulling power or consumes large quantities of oil, get itchecked immediately at a reputed garage. A delay, may prove more


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expensive in terms of petrol and oil as compared to the cost of anoverhaul.

Remember Use of bi-metallic spark plugs saves over 1.5% fuel and reducesexhaust emissions too. Get your car serviced at every 5000 kms.

D r ive in the C orrect Gear

Incorrect gear shifting can lead to as much as 20% increase in fuelconsumption. Start your car in the 1st gear only, except if you are ina muddy patch or going downhill then engage the 2nd gear.

Remember F or city driving, change to a higher gear when you are sure theengine will not struggle. Get into top gear as soon as possible.Use same gear for uphill and downhill journey.It is advisable to follow the manufacturer's recommendation.

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D ont wa it f or y ou r car t o war m up

Instead, drive in low gear till the engine warms up. Use choke

briefly only when necessary.

Remember At 10C and below, your fuel consumption per kilometer doubles


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when you make trips of 5 kms or less. So combine trips.Do not park a car so that you have to reverse with a cold engineThis will consume more fuel.Install engine-heating system (in cold regions) in your car if itdoes not have one.

Goo d Brak ing Hab its

Stop-and-go driving wastes fuel. When you slam on the brakes, a lotof useful energy is wasted in the form of heat. A good driver alwaysanticipates stops.

Remember Test wheels for free rotation when your car is being serviced.Binding of brakes restricts free wheel movement and the engineconsumes more petrol in order to overcome resistance.Check wheel alignment at regular intervals.

Kee p you r Foo t off the C lu tch

Use clutch only when you change gears. R iding the clutch causes lossof energy and damages clutch-linings.

Remember Use your handbrake when stopped on an upgrade and dont forget torelease it when restarting.Dont manipulate the clutch and accelerator to stay stationary


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because it wastes fuel.

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C lean A ir Filter R e gu larly

Air filter prevents dust from F ouling the engine. Dust causes rapidwear of engine components and increases fuel consumption.

Remember Cylinder bores wear out 45 times faster in engines without air-cleanersClean air filters at every time-up.

W atch Y ou r Tyre P ress u re

Under inflated tyres increase rolling resistance, which leads tohigher petrol consumption.

Remember Tests show that a 25% decrease in tyre pressure can cost you 5-10%more on petrol and 25% on tyre life.

Use radial tyres for 3-7% fuel economy, longer tyre life and greaterriding comfort.


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W hen y ou st op you r car, st op en gine

Always keep your car ready to start. Keep the battery, dynamo, self-starter and fan-belt in good condition. This will ensure a quick startwhenever you need it.

Remember

Switch off the engine at stops of over 2 minutes.

U se the R ec omm ended grade of oi l

Check the car manual and oil manufacturers recommendations,before using any particular grade of oil. Always use multi-gradeoil equivalent to S P CC/SGCC type for added benefits.

Remember Engine oil that is thicker than the recommended oil can cause2% increase in fuel consumption.Change oil filter along with engine oil.


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Plan Y ou r

R ou te

Rush hour, or stop-and-go traffic, can waste fuel excessively. Youwill get more mileage from each litre if you take a less congestedroute, even though it is slightly longer.

Remember F uel consumption in a highly congested road can be double thenormal.

R ed u ce L oads

Unnecessary loads increase fuel consumption. Do you really need tocarry the luggage rack?

Remember A reduction of weight by 50 kg can lead up to 2% saving in fuel,when driving in the city. Remember that overhead racks increasewind resistance leading to higher fuel consumption.

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Share Y ou r car-f or car poo ls

Look for people who go in the same direction as you. You can shareyour car and the costs.


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P lan Y ou r Tr ip s

Before you start on a trip, ask yourself two questions:Is this trip really essential?Can I combine this trip with other trips in the same direction?

tips for thermal energy conservation_12

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