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Youth Section How to make every drop last longer
R& D
Drive between 45-55 Km/H
Training
Schemes For You
Drive slow and steady. The faster you go, the more wind resistance
Tenders your vehicle will face. If you go at speeds above 60 Km/H, you will
Walk through PCRA waste petrol. Tests on Indian cars prove that you can get up to 40 %
Education Campaign extra mileage at 45-55 Km/H as against 80 Km/H.
Online Litreature
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ACT Remember
Latest In PCRA Avoid accelerating or decelerating unnecessarily.
Literatures & Films Avoid banking by anticipating stops and curves well in advance.
Tests show that a reduction in speed leads to no appreciable rise in
commuting time. Much less than what most people think.

Keep your engine healthy

Tests on a large number of cars prove that you can save as much as
6% by tuning your car regularly. If your engine emits black smoke, has
poor pulling power or consumes large quantities of oil, get it checked
immediately at a reputed garage. A delay, may prove more expensive
in terms of petrol and oil as compared to the cost of an overhaul.

Remember
Use of bi-metallic spark plugs saves over 1.5% fuel and reduces
exhaust emissions too. Get your car serviced at every 5000 kms.

Drive in the Correct Gear

Incorrect gear shifting can lead to as much as 20% increase in fuel

consumption. Start your car in the 1st gear only, except if you are in
a muddy patch or going downhill then engage the 2nd gear.

Remember
For city driving, change to a higher gear when you are sure the engine
will not struggle. Get into top gear as soon as possible.

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Use same gear for uphill and downhill journey.

It is advisable to follow the manufacturer's recommendation.
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Don’t wait for your car to warm up

Instead, drive in low gear till the engine warms up. Use choke
briefly only when necessary.

Remember
At 10°C and below, your fuel consumption per kilometer doubles
when you make trips of 5 kms or less. So combine trips.
Do not park a car so that you have to reverse with a cold engine
This will consume more fuel.
Install engine-heating system (in cold regions) in your car if it does
not have one.

Good Braking Habits

Stop-and-go driving wastes fuel. When you slam on the brakes, a lot
of useful energy is wasted in the form of heat. A good driver always
anticipates stops.

Remember
Test wheels for free rotation when your car is being serviced. Binding
of brakes restricts free wheel movement and the engine consumes
more petrol in order to overcome resistance.
Check wheel alignment at regular intervals.

Keep your Foot off the Clutch

Use clutch only when you change gears. Riding the clutch causes loss
of energy and damages clutch-linings.

Remember
Use your handbrake when stopped on an upgrade and don’t forget to
release it when restarting.
Don’t manipulate the clutch and accelerator to stay stationary
because it wastes fuel.
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Clean Air Filter Regularly

Air filter prevents dust from Fouling the engine. Dust causes rapid
wear of engine components and increases fuel consumption.

Remember
Cylinder bores wear out 45 times faster in engines without
air-cleaners
Clean air filters at every time-up.

Watch Your Tyre Pressure

Under inflated tyres increase rolling resistance, which leads to higher

petrol consumption.

Remember
Tests show that a 25% decrease in tyre pressure can cost you 5-10%
more on petrol and 25% on tyre life.
Use radial tyres for 3-7% fuel economy, longer tyre life and greater
riding comfort.

When you stop your car, stop engine

Always keep your car ready to start. Keep the battery, dynamo,
self-starter and fan-belt in good condition. This will ensure a quick
start whenever you need it.

Remember
Switch off the engine at stops of over 2 minutes.
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Use the Recommended grade of oil

Check the car manual and oil manufacturer’s recommendations,

before using any particular grade of oil. Always use multi-grade oil
equivalent to SPCC/SGCC type for added benefits.

Remember
Engine oil that is thicker than the recommended oil can cause 2%
increase in fuel consumption.
Change oil filter along with engine oil.

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Plan Your Route

Rush hour, or stop-and-go traffic, can waste fuel excessively. You will
get more mileage from each litre if you take a less congested route,
even though it is slightly longer.

Remember
Fuel consumption in a highly congested road can be double the
normal.

Reduce Loads

Unnecessary loads increase fuel consumption. Do you really need to

carry the luggage rack?

Remember
A reduction of weight by 50 kg can lead up to 2% saving in fuel, when
driving in the city. Remember that overhead racks increase wind
resistance leading to higher fuel consumption.
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Share Your car-for car pools

Look for people who go in the same direction as you. You can share
your car and the costs.

Plan Your Trips

Before you start on a trip, ask yourself two questions:

Is this trip really essential?
Can I combine this trip with other trips in the same direction?

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Best Fuel Saving T ip s f o r T h erm a l En erg y Co n serva t io n
Case Studies
Activities General
Youth Section Undertake regular energy audits.
R& D Plug all oil leakage. Leakage of one drop of oil per second
Training
amounts to a loss of over 2000 liters/year.
Filter oil in stages. Impurities in oil affect combustion.
Schemes For You
Pre-heat the oil. For proper combustion, oil should be at right
Tenders
viscosity at the burner tip. Provide adequate Pre-heat
Walk through PCRA capacity.
Education Campaign Incomplete combustion leads to wastage of fuel. Observe the
Online Litreature colour of smoke emitted from chimney. Black smoke indicates
Online TVspots improper combustion and fuel wastage. White smoke indicates
ACT excess air & hence loss of heat. Hazy brown smoke indicates
proper combustion.
Latest In PCRA
Use of Low air pressure “film burners” helps save oil upto 15%
Literatures & Films
in furnaces.

Furnace

Recover & utilize waste heat from furnace flue gase for
preheating of combustion air. Every 210C rise in combustion air
temperature results in 1% fuel oil savings.
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 kl. of furnace oil. This means a saving of Rs 3 Lacs. (Cost
of furnace oil-Rs. 10 per litre).
Reduce heat losses through furnace openings. Observations
show that a furnace operating at a temperature of 10000C
having an open door (1500mm*750mm) results in a fuel loss of
10 lit/hr. For a 4000 hrs. furnace operation this translates into
a loss of approx. Rs. 4 Lacs per year.
Improve insulation if the surface temperature exceeds 200C
above ambient. Studies have revealed that heat loss form a
furnace wall 115mm thick at 6500C amounting to 2650
Kcal/m2/hr can be cut down to 850 kcal/m2/he 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.

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Boiler

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Remove soot deposits when flue gas temperature raises 400C

above the normal. A coating of 3mm thick soot on the heat
transfer surface can cause an increase in fuel consumption of
as much as 2.5%.
Recover heat from steam condense. For every 60C rise in boiler
feed water temperature through condense 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 1mm
thickness on the waterside would increase fuel consumption by
5-8%.
Stop steam leakage. Steam leakage from a 3 mm-diameter hole
on a pipeline carrying steam at 7kg/cm2 would waste 32 kl of
fuel oil per year amounting to a loss of Rs. 3 Lacs.
Maintain steam pipe insulation. It has been estimated that a
bare steam pipe, 150 mm in diameter and 100m in length,
carrying saturated steam at 8kg/cm2 would waste 25 kl of
furnace oil in a year amounting to an annual loss of Rs. 2.5
Lacs.

DG Sets
Maintain diesel engines regularly.
A poorly maintained injection pump increases fuel consumption
by 4Gms/KWH.
A faulty nozzle increases fuel consumption by 2Gms/KWH.
Blocked filters increase fuel consumption by 2Gms/KWH.
A continuously running DG set can generate 0.5 Ton/Hr of
steam at 10 to 12 bars 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.

T ip s f o r El ec t ric a l En erg y C o n serva t io n

General
Improve power factor by installing capacitors to reduce KVA
demand charges and also line losses within plant.
Improvement of power factor from 0.85 to 0.96 will give 11.5%
reduction of peak KVA and 21.6% reduction in peak losses. This
corresponds to 14.5% reduction in average losses for a load
factor of 0.8.
Avoid repeated rewinding of motors. Observations show that
rewound motors practically have an efficiency loss of upto 5%.
This is mainly due to increase in no load losses. Hence use such
rewound motors on low duty cycle applications only.
Use of variable frequency drives, slip power recovery systems
and fluid couplings for variable speed applications such as fans,
pumps etc. helps in minimizing consumption.

Illumination

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Use of electronic ballast in place of conventional choke saves

energy upto 20%.
Use of CFL lamp in place of GLS lamp can save energy upto
70%.
Clean the lamps & fixtures regularly. Illumination levels fall by
20-30% due to collection of dust.
Use of 36W tubelight instead of 40 W tubelight saves electricity
by 8 to 10%.
Use of sodium vapour lamps for area lighting in place of
Mercury vapour lamps saves electricity upto 40%.

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Compressed Air
Compressed air is very energy intensive. Only 5% of electrical
energy are converted to useful energy. Use of compressed air
for cleaning is rarely justified.
Ensure low temperature of inlet air. Increase in inlet air
temperature by 30C increases power consumption by 1%.
It should be examined whether air at lower pressure can be
used in the process. Reduction in discharge pressure by 10%
saves energy consumption upto 5%.
A leakage from a ½” diameter hole from a compressed air line
working at a pressure of 7kg/cm2 can drain almost Rs. 2500 per
day.
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 closers, 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 50C decrease
in evaporator temperature increases the specific power
consumption by 15%.
Utillisation of air-conditioned/refrigerated space should be
examined and efforts made to reduce cooling load as far as
possible.
Utillise 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.

Cooling Towers
Replacement of inefficient aluminum or fabricated steel fans
by moulded FRP fans with aerofoil designs results in electricity
savings in the range of 15-0%.
A study on a typical 20ft. diameter fan revealed that replacing
wooden blade drift eliminators with newly developed cellular
PVC drift eliminators reduces the drift losses from 0.01-0.02%
with a fan power energy saving of 10%.
Install automatic ON-OFF switching of cooling tower fans and
save upto 40% on electricity costs.

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Use of PVC fills in place of wooden bars results in a saving in

pumping power of upto 20%.

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%.
It is advisable to use a number of pumps in series and parallel
to cope with variations in operating conditions by switching on
or off pumps rather than running one large pump with partial
load.
Drive transmission between pumps & motors is very important.
Loose belts can cause energy loss upto 1-20%.
Modern synthetic flat belts in place of conventional V-belts can
save 5% to 10% of energy.
Properly organized maintenance is very important. Efficiency
of worn out pumps can drop by 10-15% unless maintained
properly.

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Besides these, PCRA also conducts Energy audits, Fuel Oil diagnostic studies, Studies in small scale
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programmers, Workshops, Clinics; helps in organizing Action Group meetings and puts up stalls in
exhibitions on conservation of petroleum products

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