Training Manual on Energy Efficiency - APO Asian Productivity ...

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<strong>Training</strong> <strong>Manual</strong> on Energy Efficiency for Small and Medium Enterprises • All pneumatic equipment should be properly lubricated, which will reduce friction and prevent wear of seals and other rubber parts, thus preventing energy wastage due to excessive air consumption or leakage. • Misuse of compressed air, such as for body cleaning, agitation, general floor cleaning, and other similar applications, must be discouraged in order to save compressed air and energy. • Pneumatic equipment should not be operated above the recommended operating pressure as this not only wastes energy but can also lead to excessive wear of equipment components which leads to further energy wastage. • Pneumatic transport can be replaced by a mechanical system as the former consumes about 8 times more energy than the latter. • Pneumatic tools such as drill and grinders consume about 20 times more energy than motor-driven tools. Hence, they have to be used efficiently. Wherever possible, they should be replaced with electrically operated tools. • Where possible, welding is a good practice and should be preferred over threaded connections. • On account of high pressure drop, ball or plug or gate valves are preferable to globe valves in compressed air lines. 9.7 GENERIC TIPS FOR EFFICIENT USE OF COMPRESSORS • Install a control system to coordinate multiple air compressors. • Study part–load characteristics and cycling costs to determine the most efficient mode for operating multiple air compressors. • Avoid over-sizing: match the connected load. • Avoid partial loading on modulation-controlled air compressors. (They use almost as much power at partial load as at full load.) • Turn off the back-up air compressor until it is needed. • Reduce air compressor discharge pressure to the lowest acceptable setting. (Reduction of 1 kg/cm • Use the highest reasonable dryer dew point settings. • Turn off refrigerated and heated air dryers when the air compressors are off. • Use a control system to minimize heatless desiccant dryer purging. • Minimize purges, leaks, excessive pressure drops, and condensation accumulation. 2 air pressure (8 kg/cm2 to 7 kg/cm2 ) would result in 9% input power savings. This will also reduce compressed air leakage rates by 10%.) - 96 -
Energy Efficiency in Compressed Air Systems (Every 5 • Use an air-cooled after-cooler to heat building makeup air in winter. • Be sure that heat exchangers are not fouled (e.g. with oil). • Be sure that air/oil separators are not fouled. • Monitor pressure drops across suction and discharge filters, and clean or replace filters promptly upon increase in pressure drop. • Use a properly sized compressed air storage receiver. Minimize disposal costs by using lubricant that is fully demulsible and an effective oil–water separator. • Consider alternatives to compressed air such as blowers for cooling, hydraulic rather than air cylinders, electric rather than air actuators, and electronic rather than pneumatic controls. • Use nozzles or Venturi-type devices rather than blowing with open compressed air lines. º (Compressed air leak from 1mm hole size at 7 kg/cm • Use drain controls instead of continuous air bleeds through the drains. • Consider engine-driven or steam-driven air compression to reduce electrical demand charges. • Replace standard V-belts with high-efficiency flat belts as the old V-belts wear out. • Take air compressor intake air from the coolest (but not air-conditioned) location. C reduction in intake air temperature will result in a 1% reduction in compressor power consumption.) 2 pressure would mean power loss equivalent to 0.5 kW.) • Check for leaking drain valves on compressed air filter/regulator sets. Certain rubber-type valves may leak continuously after they age and crack. Replacement is the best choice. • In dusty environments, control packaging lines with high-intensity photocell units instead of standard units with continuous air purging of lenses and reflectors. • Establish a compressed air efficiency-maintenance program. Start with an energy audit and follow-up, then make a compressed air efficiencymaintenance program a part of your continuous energy management program. - 97 -
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2.5 Boiler water treatment 14 2.6 E
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7. ENERGY EFFICIENCY IN PUMPS 64 7.
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LIST OF TABLES 1-1 Gross calorific
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6-1 Induction motor 56 6-2 Boosting
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FOREWORD With the rising costs of e
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