How to Save Fuel When Running a DG in a Manufacturing Unit

Diesel generators, or DGs, play a vital role in providing an uninterrupted power supply for manufacturing units. Running these generators in the long run is expensive because of the high fuel consumption. However, implementing fuel-saving methods can make a significant impact on operational costs and efficiency.

Here are some essential tips to help save fuel while running DGs at a manufacturing unit.

1. Use an Accurate Capacity DG

Choosing the correct DG capacity has a direct bearing on fuel efficiency. A DG set whose capacity is more or less than required can lead to excessive fuel consumption and increased maintenance costs. Therefore, the power requirement of the manufacturing unit needs to be assessed to select the DG that exactly caters to that demand.

2. Operate DGs at Right Load

Running a DG correctly at the right load ensures maximum efficiency. In a very low load, the DG has a tendency towards incomplete combustion and hence carbon deposition, while overloading increases wear and tear. An ideal load should be that where 70-80 percent of the capacity of a diesel generator is being utilized with respect to fuel consumption and durability.

3. Synchronize Units for Load-Dependent Start/Stop

Multiple DGs in a manufacturing unit may offer better fuel savings with synchronization and a load-dependent start/stop arrangement. Instead of operating several DGs in parallel at low loading, let the load be handled by fewer. Start/stop operation on others can then be activated based on evolving needs.

4. Use the Right Fuel

Using the right type of fuel is really important to save fuel when running a DG in a manufacturing unit. Using the fuel type recommended by the manufacturer will ensure efficiency and reduce wastage. High-grade fuel that meets the required specifications will minimize engine deposits, facilitate combustion, and improve performance.

5. Ensure Proper Air Circulation in the DG Room

The DG room must be equipped with air circulation of good quality and quantity for the efficient running of the machine. Poor ventilation is one of the causes of overheating and inefficiencies, which eventually lead to increased fuel cost and maintenance expenditure. Proper ventilation will ensure adequate ambient air intake and exhaust, thus promoting combustion and improved engine performance.

6. Maintain the DG Properly to Improve Performance

There is no shortcut in maintaining a DG, as servicing in time keeps the DG in good shape. The servicing should focus on oil levels, cooling systems, and belts, thereby keeping inefficiencies at bay that cause excessive fuel consumption. Well-maintained DGs will work smoothly and consume fuel efficiently.

7. Use High-Quality Spare Parts

Low-quality parts affect the operation of the engine, thus increasing the rate of fuel consumption due to the fact that they do not use oil and filters that are meaningful, impacting. It is advised to use manufacturer-prescribed filters, lubricants, and other spare parts in order to keep the engine healthy and efficient.

8. Install a High-Quality Air Filter

Air filters are critical to the combustion process in an engine, and a clogged or poor-quality air filter leads to airflow restrictions and, thus, incomplete combustion while increasing fuel consumption. This high-quality air filter ensures that the DG engine receives clean air, promoting good combustion and saving fuel.

9. Make Adjustments to the Valve Timings

Valve timing adjustment ensures proper fuel-air mixture and combustion efficiency. Incorrect valve timing causes power loss, a hike in emissions, and fuel overconsumption. Routine checks as well as regular modification according to the manufacturer allow the DG to operate efficiently.

10. Repairing as per the Manufacturer’s Specification

As time passes, the wear and tear caused by the various uses reduce the efficiency of a DG over time. The recommendations provided by the manufacturer regarding repair or overhauling required at specific intervals ensure that the engine is functioning at its peak level of efficiency. The timely overhauls completely restore engine performance and prevent excessive fuel consumption.