Useful tips for saving energy in Industrial Sector

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