Improve efficiency of power transmission equipment

Happy New Year'2008 to All!

Power transmission equipment e.g. gears or couplings are the most neglected areas where nobody (including good energy auditors also) focuses for energy saving opportunities.

However, a certain approach or simple steps can improve their efficiency by at least 2% which may result in total annual cost saving in power bill by more than 6%.

Comparative lubricant studies have shown that power inefficiencies result more often when mineral-based lubricants are employed. The drawbacks of using mineral lubes are fluid churning, friction wear, higher operating temperatures, increased need to re-lubricate components, or even outright component replacement. Over time, these issues not only increase the amount of energy being released, but drive down the efficiency rates of production, potentially diminishing profitability.

Here is the comparison of efficiency for a Worm Gear with mineral lube & synthetic lube oil.



Choosing a synthetic over a mineral-based oil maximizes energy efficiency as the initial investment proves to be far less than the cost of energy down the line. When synthetics are tested in controlled experiments, they have shown a 2% to 8% improvement in energy conservation over mineral oils. This is due to the fact that synthetics provide a proprietary chemical makeup that protects itself from formula depletion thus extending the effective life of the lubricant.



Due to the performance capabilities of synthetics, companies operating in extreme hot or cold environments also achieve increased energy efficiency. A recent trial of 12 pump jacks in Canada, at bitter temperatures down to -51°C/-60°F, gained a 14.4% reduction in energy consumption from the product’s low viscosity and Pour Point. Other benefits include, extended gear performance by the elimination of friction, reduced start-up torques, lower amperage draw and improved lubricant pumpability. Furthermore, the formulation minimizes downtime, prevents pre-mature wear and requires change-outs after five years, supporting decreased lubricant use

So it means that the efficiency depends on ambient condition also.

Here is one simple comparison of Synthetic Vs Mineral.



Cost of Lube can be paid back in a years time.

So check out in your plant that all rotary machines are using right kind of lubricant for better energy efficiency.