USEFUL TIPS FOR SAVING ENERGY IN INDUSTRIAL SECTOR

Read our Energy Efficiency tips on National Energy Conservation Day, our effort to make industries more energy efficient.

ELECTRICITY

• Optimize the tariff structure with Distribution company
• Schedule your operation to maintain high load factor
• Minimize maximum demands by tripping unessential loads through demand controller
• Use APFC panel to correct power factor to unity under rated load conditions
• Disconnect primary power to transformers that do not serve active loads
• Use stand by electric generation equipment for on-peak high loads
• Check utility meter with your own meter

MOTORS

• Use properly sized motors matching with the load for optimum efficiency
• Use energy-efficient motors where economical (High efficiency motors provide 4-5 % higher efficiency than standard motors).
• Use synchronous motors to improve power factor
• Check for under voltage or over voltage conditions
• Provide proper ventilation (for every 10 c rise in temperature over recommended, motor life is estimated to be halved)
• Demand efficiency restoration after motor rewinding (If rewinding not done properly, the efficiency can reduced by 5-8%)

DRIVES

• Use variable speed drives for large variable loads
• Use high efficiency gear sets
• Use precision alignment
• Check belt tension regularly
• Eliminate variable pitch pulleys
• Use flat belts as alternatives to V belts
• Use synthetic lubricants for large gear box
• Eliminate eddy current couplings

FANS & BLOWERS

• Use smooth well rounded cones for air intakes
• Avoid poor air flow distribution at the air inlet
• Minimize fan inlet and outlet obstructions
• Clean screens, filters, and fan blades regularly
• Use aero foil shaped fan blades
• Eliminate leaks in air ducts
• Minimize bends in air ducts
• Turn fan and blower off when not needed

PUMPS

• Operate pump near best efficiency points
• Modify pumps to minimize throttling
• Adapt to wide load variations with variable speed drives or sequenced control of smaller units
• Stop running both pumps – add an auto start for online spare or add a booster pump for a problem area
• Ensure proper seals and packing to minimize water waste
• Increase fluid temperature differentials to reduce pumping rates in case of heat exchangers
• Avoid pumping head with free fall return ; use siphon affect to advantage

COMPRESSORS

• Consider variable speed drive for variable load on positive displacement compressors
• Use a synthetic lubricant if compressor manufacturer permits it
• Be sure lubricating oil temperature is not too high ( oil degradation and lowered viscosity) and not too low ( condensation contamination )
• Change the oil filter regularly
• Periodically inspect compressor inter coolers for proper functioning
• Use waste heats from a very large compressor to power am absorption chiller or preheat process or utility feeds
• Establish a compressor efficiency maintenance program. Start with an energy audit and follow up , then make a compressor efficiency maintenance program a part of your continuous energy management program