TIPS FOR ENERGY CONSERVATION

By Ashok R Parikh, Engineering Consultant 1.0 1.1 General tips for Energy Saving
Unnecessary operation: One of the greatest causes of energy wastage is unnecessary operation of electric power consuming equipments. The most energy-efficient equipment will consume excess energy, if it runs when it is not needed. Hence, suitable system, manual or auto, may be devised to turn off the equipment immediately on completion of its need. 1.2 Maintenance: Likewise, lack of preventive maintenance of electrical equipments according to the specified schedule is another great cause of energy wastage. It is essential to adhere to the maintenance schedule under any worst circumstances. For example, if dust is not removed from surface of the motor, reduction in heat transfer effectiveness results into more electric power consumption. For getting desired performance from any equipment, the effective maintenance plays vital role to optimise the power consumption.

1.3

Capacity utilisation: For the equipments and systems operating round the clock or for longer durations, normal operation at point nearer to respective full load capacity is vital to optimise the efficiency and save energy. In selecting the equipment and system, every effort should be made to match the load requirement and equipment or system capacity for optimised operation. 1.4 Use of VFD: Significant electrical energy can be saved by operating large number of motors driving pumps/fans/compressors through variable frequency drives (VFD). If these drives are working continuously with variable load, then VFD must be installed to change the speed according to load, which will result into saving of good amount of energy.

1.5

Phantom load: The appliances such as TV, computer VDU, electrical clocks, remote controlled appliances, etc. continue to consume small amount of power even in switched off condition, which is called phantom load. One would get a big surprise if overall power consumption is estimated. Hence, power supply switch in the board should be switched off along with the switch on individual appliance to save phantom power consumption. 1.6 Awareness and habit: Inculcate the habit in the employees to use electric power as per need only and switch off light and fans in change rooms when not occupied. Unless awareness for energy saving is developed, the efforts made in direction may not result in achievement of desired goal. Any equipment operated on electric energy should be shutdown immediately when not required for the process.

1.7

Metering: Various load intensive panels, lighting boards, etc. should be provided with calibrated meters to monitor energy consumption pattern and trend so that reasons for major deviations form the anticipated consumption can be tracked down and to supplement corrective action accordingly. 1.8 Pressure drops: Straight pipelines with just required numbers of valves having low pressure drop characteristics save substantial quantum of pumping and fan power requirements.

1.9

Automatic controls: In order to efficiently control and coordinate multiple air compressors, chillers, cooling tower cells/fans, boilers, pumps, area/street lighting, etc., a suitable automatic control should be incorporated in the circuit so that switching operations as per load requirement can be established to avoid unnecessary operation and reduce energy consumption. 1.10 Efficiency maintenance schedule for all equipments consuming energy in any form: Start with initial energy audit and follow-up for each equipment and system as a whole, and prepare maintenance schedule as a part of energy management program.

2.0 2.1

Tips for Energy Saving in Electrical Power Distribution Systems

System power factor: Wherever possible, insert capacitors in the circuit of individual equipment like motor or connect on load bus for a group of equipments to reduce reactive power load on the system and to improve system power factor. The best option is to connect capacitor of suitable rating across the motor terminals.

2.2

Load Centre: As far as possible, locate the distribution transformer at the centre of the load to be supplied so as to reduce lengths of LT power distribution lines even at the cost of longer HT line. The losses in LT losses are more in LT line due to more current in comparison to HT lines and hence shorter length of LT line is desirable.

2.3

Plant operations: The plant operations may be scheduled in such a manner to attain optimum load factor as far as possible. 2.4 Demand side management: Install demand controller and set for tripping of non-essential loads automatically in the event of sudden rise in the demand from the plant side.

2.5

Captive power generation: Continuous process chemical industry in need of energy in forms of electric power, steam, chilling or direct heat should explore feasibility of setting up a captive power plant, which would prove a biggest measure of energy conservation coupled with very attractive economics.

3.0 3.1

Tips for Energy Saving in Transformers

Rationalisation of transformers: Where two or more transformers are installed to supply the load, effort should be made to rationalise the load on individual transformer. The load losses in the transformer are proportional to square of the load. Normally, transformers are designed to offer maximum efficiency in the range of 50% to 65% of its full load capacity. Hence, proper distribution of load between numbers of transformers may bring loading on each unit within this range to reduce overall load losses and to save energy thereby. 3.2 Switching off transformer: Where numbers of transformers are working, even one of the transformers can be switched off to further reduce energy wastage due to transformer no load losses. (It is recommended to change over the transformers one by one for switching ON/OFF operation, as prolonged shutdown may adversely affect the insulation and oil property).

3.3

Core material in transformer: In selecting the material for core, the amorphous metal core provides excellent opportunity for reducing the no-load losses. This can summate immense economic savings to the electric utilities since they are one of the highest energy efficient transformers rated so far. Use of best quality core material like amorphous magnetic alloy offers great advantage not only at fundamental frequency but, the advantage increase manifold as the distortion in both load current and supply voltage increases due to harmonics. There is increase in total loss and decrease in efficiency with higher distortions, but this phenomenon affects this core material much less as compared to transformer with silicon steel core.

4.0

Tips for Energy Saving in Electric Motors

4.1 Motor sizing: Avoid mismatch between the motor rating and load to be driven by all means, as under capacity utilisation the motor results into enormous energy wastage due to lower efficiency and poor power factor. Never operate, particularly, the standard motor at less than 75% of its rated capacity, as input power to the motor steeply increases with respect to power output. 4.2 Rewound motor: The motor, rewound often, should be replaced by a new motor, as rewound motor never offers the performance offered by the new motor. Efficiency of a motor rated 30 kW and above reduces approximately by 1 percentage point with each rewinding as a thumb rule, which results into more input power with respect to power output. If difference between cost of motor rewinding and cost of a new motor is considered vis--vis cost saving due to reduced input power, the additional cost of new motor pays back within no time. 4.3 Cable size: If length of cable supplying power to the motor is long, cable of next higher size than normal recommended size may be selected, even at marginally additional cost, to reduce voltage drop and energy losses in cable. 4.4 Replacement of old motors: Whenever an old motor for the drive, operated for more than 12 hours per day, is to be replaced for any reason, it should be replaced with an energy efficient motor. Though the cost of energy efficient motor will be about 20-25%

higher than that of a standard motor, but the difference in cost will be paid back within short duration due to energy saving. 4.5 Power supply: Maintaining of 3-phase balanced voltage power supply to the motor is very vital for getting desired performance from the motor. Average voltage unbalance of 1% causes about 6% current unbalance and undue heating resulting into more losses. 4.6 Operation delta connected motor in star connection: An oversized delta connected motor, if loaded below 30% of its rated shaft load, can be connected in star and permanently operated in that mode. This method of operations can save energy, as the motor provides significantly better efficiency in star. 4.7 Proper ventilation: When a motor is installed indoor, provide proper ventilation to meet its cooling needs.
Remember that for every 100C increase in the motor operating temperature over recommended peak, the motor life is reduced approximately by half.

4.8 Maintenance: Most important maintenance for the motor is regular blowing of dust from surfaces, as dust deposited on the body reduces heat transfer are and effectiveness of cooling resulting into more losses. Other aspects of maintenance are greasing of bearings as recommended by the manufacturers, checking of parameters and cable connections. These small measures results into considerable saving of energy coupled with increased motor life. 5.0 5.1 Tips for Energy Saving in Illumination Systems

High efficacy: Always make efforts to use the lamps with high efficacy, i.e. lamps giving light output at least power consumption even at higher initial cost. Compact fluorescent lamps and Metal halide lamps are such type of lamps consuming less power giving equivalent or better light output.

5.2

Daylighting: Feasibility of using sunlight during daytime should be explored so as to switch off artificial lighting to reduce energy consumption. The working areas in most of the industries provide biggest opportunity to implement the measure of using day light by installing acrylic roof sheets. 5.3 Replacement: Replace old lamps with energy efficient lamps with due consideration to luminaire, colour rendering index, illumination levels required to be maintained, etc. as well as expected life of new lamps.

5.4

Electronic ballasts: Replace conventional electro-magnetic ballasts with more energy efficient electronic ballasts considering life expectancy, watt loss, and effect on power factor. 5.5 Interior painting: Instead of dark colours, light colours for interior and ceiling may be selected for better light reflection and thereby reducing the number of lights.

5.6

Controls: One or more of the following controls may be provided in individual/group to increase the lighting efficiency. On/off voltage regulation for illuminance controls.

Group control switches to control switching as per requirement such as photocells for road lighting and area flood lighting. Occupancy sensors in infrequently occupied rooms, such as conference rooms. Timer operated controls, particularly in road lighting and area flood lighting. Computerised lighting controls, which switches on and off the lights in accordance with the sunrise and sunset as per day. Lighting layout: Explore feasibility of revising the lighting layout for more efficient lighting.

5.7 5.8

Voltage regulation: Incorporating isolating transformer / voltage regulator / controller in lighting system inputs significantly improve lighting efficiency as well as increase life of lamps. 5.9 LED lamps: Using LED type lamps in place of normal FTL or incandescent lamps is feasible to improve lighting efficiency. LED can also be used in signboards.

6.0

Tips for Energy Saving in Chillers

6.1

Replacing chilled water by cooling water in process cooling: Wherever found feasible in process cooling applications, circulate cooling water instead of chilled water at higher flows and increased heat transfer area in heat exchanger. With running of one cooling circuit and stoppage of secondary circuit, energy saving would be possible.

6.2

Chilled water temperature: Increase chilled water temperature set point whenever possible due to system conditions, which would reduce load on the motor driving the chiller compressor due to reduction of chilling load. 6.3 Old chiller units: Replace old chiller or compressor in old chiller with more efficient latest generation models, which would result into saving of good amount of energy.

6.4

Multiple chiller running: Where multiple chillers are installed, the most-efficient mode for operating the multiple units can be determined with study of part-load characteristics and cycling costs. 6.5 Optimisation of chilled water flow rates: Optimisation of condenser water flow and chilled water flow may be carried out to maintain the design temperature difference across the condensers and chillers. Speed reduction by a suitable method like variable frequency speed drive would modify the higher flow rate to match the operating load by maintaining a constant temperature drop or pick-up across the evaporator and condenser at all times.

6.6

Type of condensers: As far as possible, use water-cooled condenser rather than air-cooled condensers, as the fan motors in air-cooled condenser would consume more power than the pumps in the water-cooled condenser.

6.7

Maintaining higher evaporator temperature: At higher refrigerant gas temperature in evaporator, more refrigeration capacity is available with higher overall power consumption, but lower specific power consumption. Thus, the cooling effect increases in greater proportion than the power consumption at higher evaporator temperature. The refrigeration system would cool faster and either shut down or unload saving of electric power. Remember that every 10C increase in the evaporator temperature reduces the specific power consumption by about 2% to 3%.

6.8

Condenser water temperature: Use the lowest temperature condenser water available that the chiller can handle as per design. Remember that reducing the condensing temperature by every 10C, results in 4 - 5% decrease in compressor power consumption. 6.9 Removal of scale from heat exchangers: The fouled condensers are found usual culprit for inefficient performance of refrigeration machines. Scale deposition inside the condenser tubes takes place due to continuous water circulation. Scaling reduces the heat transfer efficacy; increases the refrigerant temperature and pressure in the condenser; reduces cooling capacity; increases the compressor power consumption. Appropriate fouling factors should be specified at system design and procurement stage. Remember that even 1 mm scale build-up on condenser tubes can increase energy consumption by about 40%.

6.10

Overcharging of oil in compressor: Maintain oil level in the compressor according to the level mark on sight glass. Excessive oil level may result into oil carry over along with refrigerant vapour and subsequent formation of film in the condenser thereby reducing the heat transfer efficacy very significantly. Finally, the operating time of compressor would increase along with more power consumption. 6.11 Chiller load and machine capacity at normal operating stage: At part load operations, the effective system Coefficient of Performance (COP) increases due to rise in evaporator temperature and fall in condenser temperature. However, part load running increases mechanical losses in greater proportion due to shift from the design operating point, which nullifies the effect of improved COP and decreases the part load efficiency.

6.12

Control system: It is preferable to install electronic controls due to more accuracy of settings, reliability and long lasting performance than conventional knobs and switches. Initial cost of electronic controls may be found marginally high, the additional expenditure proves well worth it in

the long run due to continuous saving of power and its cost. Control systems play a prominent role for energy conservation potential in multiple systems. 6.13 Pipelines and insulation: The location of a chiller plant may be selected to ensure minimum heat loss in piping due to optimised length. The key properties of the insulating material should be considered for its suitability for operating temperature, thermal conductivity, water vapour permeability and moisture absorption. Selection of right type of insulating material of appropriate economical thickness is vital consideration at design stage of system. For pipeline fitting, valves, pumps, etc., flexible type of insulation or pre-fabricated box-up insulation should be used. All the equipments, pipelines, fittings, etc. should be well insulated as far as possible. Regular maintenance of insulation is a must for consistent energy saving.

7.0 7.1

Tips for Energy Saving in Refrigeration Systems

Use pre-fabricated modular cold storage units: The heat load generated by the evaporator fans is the major load in the cold storages remaining shut for longer durations. Once temperature is attained in such cold storages, refrigerant flow in evaporator coils and running of fans can be operated in on and off cycles using a programmable controller. This will reduce the heat load due to fans to save energy.

7.2

Brine/Glycol concentration: Check brine or glycol concentration in the system and correct inappropriate brine or glycol concentration that adversely affects the heat transfer and/or pumping energy. If it sweats, insulate it, but if it is corroding, replace it first. 7.3 Defrosting: This happens in the cold storages, where accumulation of frost on the evaporator tubes decreases the air flow rate and in turn the heat transfer rate in significant manner. Suitable method for defrosting, like switching off refrigeration compressor, use of outside warm air, temporary condenser bypass, etc. may be implemented to improve heat transfer efficacy of the evaporator. Provide moisture/liquid indicators and inspect regularly.

7.4

Over sizing: Thoroughly check requirement of refrigeration load at the engineering stage and match the refrigeration system capacity that with the load and avoid over sizing under all circumstances.

7.5

Type of condensers: As far as possible, use water-cooled condenser rather than air-cooled condensers, as the fan motors in air-cooled condenser would consume more power than the watercooled condenser.

7.6

Control system: It is preferable to install electronic controls due to more accuracy of settings, reliability and long lasting performance than conventional knobs and switches. Initial cost of electronic controls may be found marginally high, the additional expenditure proves well worth it in the long run due to continuous saving of power and its cost. Control systems play a prominent role for energy conservation potential in refrigeration systems. 7.7 Optimisation of chilled water/brine/air flow rates: Optimisation of condenser water flow and chilled water/brine flow may be carried out to maintain the design temperature difference across the condensers and chillers. Speed reduction by a suitable method like variable frequency speed drive would modify the higher flow rate to match the operating load by maintaining a constant temperature drop or pick-up across the evaporator and condenser at all times.

7.8

Pipelines and insulation: The location of a refrigeration plant may be selected to ensure minimum heat loss in piping due to optimised length. The key properties of the insulating material should be considered for its suitability for operating temperature, thermal conductivity, water vapour permeability and moisture absorption. Selection of right type of insulating material of appropriate economical thickness is vital consideration at design stage of system. For pipeline fitting, valves, pumps, etc., flexible type of insulation or pre-fabricated box-up insulation should be used. All the equipments, pipelines, fittings, etc. should be well insulated as far as possible. Regular maintenance of insulation is a must for consistent energy saving.

8.0

Tips for Energy Saving in Heat, Ventilation & Air-conditioning (HVAC) Systems

8.1

Evaporative cooling for comfort cooling in dry areas: In the areas predominantly having dry climate, it is feasible to achieve reasonable comfort temperatures adopting evaporative cooling, i.e. using of desert coolers for humidification of dry air or by installing central humidification plants instead of conventional air-conditioning systems. The energy consumption in evaporative cooling is about 10% to 20% of a conventional air-conditioning system, i.e. substantial saving of 80% to 90% electrical energy.

8.2

Seasonal temperatures: In winter during unoccupied periods, allow temperatures to fall as low as possible without freezing water lines or damaging stored materials. Similarly in summer during unoccupied periods, allow temperatures to rise as high as possible without damaging stored materials. 8.3 Reducing cooling loads and heat loads in buildings as follows.

Unnecessary heat loads: As far as possible, heat generating loads such as laboratory ovens should not be installed in the air-conditioned room and should be removed and located at other suitable place so as to reduce air-conditioning load. False ceiling: Wastage of energy in the empty spaces in rooms with very high ceiling can be significantly reduced by providing false ceiling with return air ducts due to reduced airconditioning load. Relocating air-diffusers: At many places, even relocation of air-diffusers would result into near uniform distribution of air, which would reduce the heat load and saving of energy due to reduced air-conditioning load.

Glass walls: Wastage of air-conditioning energy is high through glass walls than through brick walls, even worst from the wall facing west. Hence, every effort should be made to avoid total glass walls, unless absolutely necessary and construct brick walls. 8.4 Outside air utilisation: Control and utilisation of outside air may be improved so as to reduce load on the air-conditioning system to the extent feasible.

8.5

Heat exchangers: Use air-to-air heat exchangers for heating and cooling of outside air would result into reduction of energy requirements of air-conditioning system. 8.6 Operating hours: The operating hours for HVAC system should be reduced by not operating the system during night and during weekend holidays. Use morning pre-cooling in summer and preheating in winter, i.e. before starting of electrical peak hours with commencement of office working. Possibility of building thermal lag may also be checked to minimise air-conditioning load.

8.7

Control system: In room air-conditioning, install occupancy sensor so that AC unit would be switched ON/OFF automatically as per occupancy in the room. As an alternate, AC units can be provided with timer control. 8.8 System balancing: Balance the system to minimize flows and reduce blower/fan/pump power requirements.

8.9

Ventilate when necessary: Allow air to be ventilated only when necessary. Provide shutoff dampers at strategic points in ducting so as to isolate the areas whenever not occupied for longer durations and reduce air-conditioning load. Where continuous requirement of air-conditioning is envisaged, such as control rooms, install a dedicated AC system, which may run continuously permitting shutdown of AC systems of other areas, such as administrative offices, occupied for 8-10 hours. 8.10 Fan speed variation: The fan motor can be operated through variable sped drive to vary speed of fan as per the load requirement and save energy.

8.11

Air ducts and insulation: The location of a AC plant may be selected to ensure minimum heat loss in air distribution duct work due to optimised length. The key properties of the insulating material should be considered for its suitability for operating temperature, thermal conductivity and moisture absorption. Selection of right type of insulating material of appropriate economical thickness is vital consideration at design stage of system. The duct work and fittings, dampers should be well insulated as far as possible. Regular maintenance of damaged insulation is a must for consistent energy saving. 8.12 Maintenance: Clean HVAC unit coils periodically and comb mashed fins. Seal leaky HVAC ductwork. Seal all leaks around coils. Repair loose or damaged flexible connections (including those under air handling units). Inspect, clean, lubricate, and adjust damper blades and linkages. Check

HVAC filters at least once a month and clean or change if appropriate. Carry out preventive maintenance for motors, fans and compressors as specified by the manufacturer. 8.13 Energy efficient models: Bureau of Energy Efficiency has been identifying energy efficient air-conditioning units after rigorous testing and providing labels showing level of energy efficiency with 1 star for minimum to 5 stars for maximum. Hence, it is preferred to install appliance with 5 star label even at marginally higher capital cost to save energy and cost till its life cycle.

9.0 9.1

Tips for Energy Saving in Air Compressors & Compressed Air Systems

Compressor testing: It is essential to conduct Pump up Test periodically to know the performance for free air delivery (FAD) output and specific power consumption. The test results show whether the compressor requires maintenance to bring the performance as specified.

9.2

Air intake: The intake air to the compressor should be cool, as hot air reduces capacity of the compressor. Air suction should be preferred outside the compressor room. The dirty air at intake can choke suction filter and subsequent line and may cause excessive wear and tear of moving parts. Air suction should be kept away from dusty and humid areas such as boilers, coal storage, chemical vapours, cooling towers, etc. The suction may be provided with a coarse air filter. 9.3 Compressor discharge pressure: The compressor should be operated maintaining discharge pressure minimum required for the air consumers. The compressor capacity varies inversely with discharge pressure increasing the specific power consumption. Remember that increase in discharge pressure by 1 kg/cm2 can increase energy consumption by about 4% and can also increase air leakage rate by 6%.

9.4

Capacity Control: Normally, the compressors are designed to deliver variable air volume at a fixed pressure. Most of the compressors work at part loads, which results into increased specific power consumption. Hence, some capacity control mechanism may be installed to reduce the compressor output according to system demand. Capacity control has a significant effect on energy consumption. Running of compressor through a variable speed drive for variable load on positive displacement compressors offers good opportunity to save energy. 9.5 Lube-oil temperature: Ensure that lubricating oil temperature does not reach too high to rapidly cause oil degradation and lower viscosity and does not reach too low to cause condensation and contamination. Regular replacement of oil filter is a must.

9.6

Modulated control: If modulation-controlled air compressors are installed, make them operating always at full loads, as they use almost as much power at partial load as at full load. 9.7 Drain control: Use drain controls instead of continuous air bleeds through the drains to avoid air leakage which is uncalled for.

9.8

Belt drives: Wherever possible, replace standard v-belts with high-efficiency flat belts. This would be possible whenever the old v-belts would wear out and would be replaced.

9.9

Air distribution: For efficient air distribution system, design should take care of proper pipe sizing, minimum pressure drops and minimum leakages. It is not possible to totally prevent air leakages, but it should not increase beyond 5-10% of total air generated by the compressors. As far as possible, pipes may be joined by welding with few flanged joints with proper gaskets to minimise leakages. Pipeline layout should ensure minimum pressure drop during transmission.

9.10

Leakage test: It is recommended that entire air distribution system be tested for leakage to find out quantity of leakage. The method of testing can be found in any of the reference books on the compressed air system. Every effort should be made to minimise purges, leaks, excessive pressure drops, and condensation accumulation. Remember that compressed air leak from 1 mm hole size at 7 kg/cm2 pressure results into mean power loss equivalent to about 0.5 kW. 9.11 Air header: Install a separate service air header with an isolation valve for cleaning air requirement in large quantity, so that the valve is opened only when required and immediately closed after use of air. No tapping should be taken from process air or equipment air lines.

9.12

Air usage: Use of air for direct cleaning by open blowing, personnel cooling, vacuum generation, padding, dilute phase/dense phase transport, etc. should be discouraged as far as

possible, as maximum loss of air occurs during such applications. Alternating means to supply air for such applications should be explored. In case of absolute necessity, compressed air should be used only with blow guns to keep the air pressure below 2 bar to reduce loss of air and save energy. 9.13 Maintenance: Periodic preventive maintenance as recommended by the manufacturer should be judiciously implemented, as it provides for need of repairs/replacement of moving parts such as piston rings, if required, to improve efficiency. Check for leaking pipe joints, drain valves, etc. and set right. Pressure drops across suction and discharge filters should be monitored and cleaning or replacement of filters be promptly arranged upon alarm. Maintenance of heat exchangers as mentioned elsewhere is also required to be adhered to.

10.0 10.1

Tips for Energy Saving in Cooling Tower and Cooling Water Systems

Rationalisation of cooling water pumping system: Efforts should be made to rationalise the pumping system, where number of cooling towers are in service, depending on the process cooling load. Load transfer from one tower to another will result into considerable overall saving of power due to better utilisation of respective capacities.

10.2

Cooling tower fans: Use of two speed motor is one way to save energy. As the fan is operated at low speed at low load and low WBT condition, the power consumption reduces. During winter, even total stoppage of CT fan for energy saving can also be considered for sometime depending on the ambient conditions. Thus, control of cooling tower fans based on leaving water temperatures saves a good amount of electric power. Temperature sensor can be introduced in cold water line to start/stop operation of fans in sequence as per cold water temperature requirement of process. 10.3 Sequential running of fans: In a large capacity cooling tower consisting of number of cells and fans, the running of fans can be sequenced through automatic switching devices based on increase or decrease in cooling load to maintain the approach temperature difference to save energy.

10.4

Pump speed variation: To avoid unnecessarily pumping of excess cooling water across the condenser during off-load conditions, variable frequency drive may be installed in such circuit. The temperature difference is measured continuously and VFD will change the speed of the pump to vary flow of cooling water across the condenser and maintain the difference at design levels. It is possible to achieve energy saving of around 25%. 10.5 Fan blade material and design: Conventional aluminium fan blades may be replaced with fibre reinforced plastic (FRP) fan blades. FRP blades are wider at tip with a higher degree of twist to provide better efficiency and are lighter by weight than aluminium blades. Use of FRP blades reduces power consumption by fans. Provide device to vary fan blade angle on a seasonal and/or load basis to optimize fan and cooling tower performance. Use a velocity pressure recovery fan ring.

10.6

Fill material: Instead of conventional wooden splash bars, PVC honeycomb fills, PVC V-bars and PVC slats may be used to reduce water circulation rate for same heat load and to reduce the pumping power requirements by about 15 to 20%.

10.7 10.8

Drift eliminators: Old slat-type drift eliminators should be replaced with new highefficiency, low-pressure-drop, self-extinguishing, PVC cellular units to reduce drift losses. Blowdown: Blowdown flow rate may be optimized and automatic control may be introduced to minimise the blowdown as per requirement. Blowdown water should be taken from the return water line only so as not to load the pump sending cold water to the system and also not to loose cold water. Blowdown water can be used for other purposes like cleaning of floors, toiler water, gardening, etc. 10.9 Maintenance: Periodic cleaning of plugged cooling tower distribution nozzles and fills is a must to maintain cooling tower efficiency and reduce power consumption.

11.0 11.1

Tips for Energy Saving in Pumping Systems

Rationalisation of pumping system: Efforts should be made to rationalise the pumping system, where number of pumps are in service, depending on the process load. Load transfer from

one pump to another will result into considerable overall saving of power due to better utilisation of respective pump capacities. 11.2 Capacity Utilisation: Make every effort to operate the pump as near as possible to its specified duty point referring to the performance curves.

11.3

Unrealistic head: Reduce the pump head to the extent feasible by changing pipe diameter to higher side; by reducing pipe length; by changing pipe material and by reducing number of pipe bends and valves. As cost for new pipeline and fittings would be substantial, when deciding to modify, a trade-off between the initial cost of pipeline and energy cost is to be considered. 11.4 Impeller replacement: Changing of existing impeller with smaller size is another way to suit the system requirement will result into energy saving. The pump casing is generally designed to accommodate different impeller sizes.

11.5

Trimming impeller: Where mismatch between system and pump is small, trimming of impeller can shift the pump characteristic downward to match the system head. Trimming will reduce flow and discharge pressure and the efficiency also generally goes down. Due to avoidance of throttling losses and higher flow, energy is saved. The pump manufacturer is to be consulted while deciding to go for trimming. 11.6 Replacement of pump: Replace existing pump by a high-efficiency pump of required head if mismatch between the pumps and the system is large. Energy saving potential is very good.

11.7

Speed changing - Use of VFD: Modify the pump speed to match the pump characteristics with the system characteristics. As the power consumed is directly proportional to cube-root of speed, reducing the speed would save good amount of power. Tip for energy saving with use of variable frequency drive in case of fluctuating flow is already provided elsewhere.