Empanelled As ESCO With BEE
Awarded First as ESCO BY MEDA
Opel Energy Systems Private Limited
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Energy Conservation Tips

GENERAL
 
Undertake regular Energy Audits.
Plug all oil leakage. Leakage of one drop of oil per second amounts to a loss of over 2000 litres/year.
Filter oil in stages. Impurities in oil affect combustion.
Pre-heat the Oil. For proper combustion, oil should be at right viscosity at the burner tip. Provide heat capacity.
Incomplete combustion leads to wastage of fuel. Observe the colour of smoke emitted from chimney. Black smoke indicates improper combustion and fuel wastage. White smoke indicates excess air & hence loss of heat. Hazy brown smoke indicates proper combustion.
Use of low air pressure "film burners" helps save oil upto 15% in furnaces.
 
FURNACE
 
Control excess air in furnaces. A 10% drop in excess air amounts to 1% saving of fuel in furnaces. For an annual consumption of 3000 kilo litres of furnace oil, means a saving of Rs. 3 lakhs.
Reduce heat losses through furnace openings. Observation shows that a furnace operating at a temperature of 1000 °C having an open door Results in a fuel loss of 10 lit/hr. For a 4000 hrs. Furnace operation this translates into a loss of approx. Rs. 4 lakhs per year.
Improve insulation if the surface temperature exceeds 20°C above ambient. Studies have revealed that heat loss from a furnace wall 115 mm thick at 650°C amounting to 2650 Kcal/m² /hr can be cut down to 850 kcal/m²/hr by using 65 mm thick insulation on the 115 mm wall.
Proper design of lids of melting furnaces and training of operators to close lids helps reduce losses by 10-20% in foundries.
Improve insulation if the surface temperature exceeds 20°C above ambient. Studies have revealed that heat loss from a furnace wall 115 mm thick at 650°C amounting to 2650 Kcal/m²/hr can be cut down to 850 kcal/m²/hr by using 65 mm thick insulation on the 115 mm wall.
Proper design of lids of melting furnaces and training of operators to close lids helps reduce losses by 10-20% in foundries.
 
BOILER
 
Remove soot deposits when flue gas temperature rises 40°C above the normal. A coating of 3 mm thick soot on the heat transfer surface can cause an increase in fuel consumption of as much as 2.5%.
Recover heat from steam condensate. For every 6°C rise in boiler feed water temperature through condensate return, there is 1% saving in fuel.
Improve boiler efficiency. Boilers should be monitored for flue gas losses, radiation losses, incomplete combustion, blow down losses, excess air etc. Proper control can decrease the consumption upto 20%.
Use only treated water in boilers. A scale formation of 1-mm thickness on the waterside would increase fuel consumption by 5-8%.
Stop steam leakage. Steam leakage from a 3mm-diameter hole on a pipeline carrying steam at 7 kg/cm² would waste 32 kilo litresl of fuel oil per year amounting to a loss of Rs. 3 lakhs.
 
DG SETS
 
A poorly maintained injection pump increases fuel consumption by 4gm/kwh.
A faulty nozzle increases fuel consumption by 2gm/kwh.
Blocked filters increase fuel consumption by 2gm/kwh.
A continuously running DG set can generate 0.5Ton/Hr of steam at 10 to 12 bar from the residual heat of the engine exhaust per MW of the generator capacity.
Measure fuel consumption per kWh of electricity generated regularly. Take corrective action in case this shows a rising trend.
 
COMPRESSED AIR
 
Compressed air is very energy intensive. Only 5% of electrical energy is converted to useful energy. Use of compressed air for cleaning is rarely justified.
Increase in inlet air temperature by 3°C-increase power consumption by 1%. Ensure low temperature of inlet air.
Reduction in discharge pressure by 10% saves energy consumption upto 5%. It should be examined whether air at lower pressure can be used in the process.
A leakage from a ½" diameter hole from a compressed air line working at a pressure of 7 kg/cm
Air output of compressors per unit of electricity input must be measured at regular intervals. Efficiency of compressors tends to deteriorate with time.
 
REFRIGERATION & AIR CONDITIONING
 
Use of double doors, automatic door closures, air curtains, double glazed windows, polyester sun films etc. reduces heat ingress and air-conditioning load of buildings.
Maintain condensers for proper heat exchange. A 5°C decrease in evaporator temperature increases specific power consumption by 15%.
Utilization of air conditioned/ refrigerated space should be examined and efforts made to reduce cooling load as far as possible.
Utilize waste heat of excess steam or flue gases to change over from gas compression systems to absorption chilling systems and save energy costs in the range of 50-70%.
Specific power consumption of compressors should be measured at regular intervals. The most efficient compressors to be used for continuous duty and others on standby.
 
PUMPS
 
Improper selection of pumps can lead to large wastage of energy. A pump with 85% efficiency at rated flow may have only 65% efficiency at half the flow.
Use of throttling valves instead of variable speed drives to change flow of fluids is a wasteful practice. Throttling can cause wastage of power to the tune of 50 to 60%.
Drive transmission between pumps & motors is very important. Loose belts can cause energy loss upto 15-20%.
Modern synthetic flat belts in place of conventional V belts can save 5% to 10% of energy.
 
 

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