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PERFORMANCE ASSESSMENT TRIALS OF NEWLY DEVELOPED ENERGY EFFICIENT PU SPINDLE TAPES PRESENTED BY

PERFORMANCE ASSESSMENT TRIALS OF NEWLY DEVELOPED ENERGY EFFICIENT PU SPINDLE TAPES PRESENTED BY A.K.JAIN & S.SAXENA. Features of the tapes: Polyurethane thermoplastic material Higher spindle RPM No change in jockey pulley centre distance Low power consumption Better yarn quality

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PERFORMANCE ASSESSMENT TRIALS OF NEWLY DEVELOPED ENERGY EFFICIENT PU SPINDLE TAPES PRESENTED BY

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  1. PERFORMANCE ASSESSMENT TRIALS OF NEWLY DEVELOPED ENERGY EFFICIENT PU SPINDLE TAPES PRESENTED BY A.K.JAIN & S.SAXENA

  2. Features of the tapes: • Polyurethane thermoplastic material • Higher spindle RPM • No change in jockey pulley centre distance • Low power consumption • Better yarn quality • Low speed variation among other spindles • No fluff accumulation- antistatic • Finger joint – no jerk • Instantaneous speed pickup • Uniform TPI

  3. TRIALS CONDUCTEDIN • M/S CHENAB TEXTILES, KATHUA • M/S WINSOME TEXTILES, BADDI • M/S AURO SPINNING MILLS, BADDI

  4. MAIN OBJECTIVE • TO OBSERVE THE GAINS IN SLIPPAGE • TO MEASURE THE POWER CONSUMPTION LEVEL AND COMPARE THE SAME WITH CONVENTIONAL TAPES • TO CHECK THE YARN QUALITY i.e. COUNT, STRENGTH, CSP, TPI, RKM, TENACITY

  5. CASE STUDY - 1

  6. METHODOLOGY • Experiment Set-up The trial was conducted in cotton section. M/C No. 22 was selected in shed No.3, • Machine particulars: LR-G5/1, 1008 spindles, 160 mm lift, 38 mm ring Dia., 27 mm. F.R. dia, 19.0mm spindle wharve dia. main motor - 45 kw, pneumafil fan motor was 5.5 kw.

  7. Process particulars: Count 60s Cotton, TPI 34.72, spindle speed -19000 (max), 280 FRS, slip 2.5%, speed up/down set at 100%. The detaile speed steps are as follows: Step no.Spindle speed Time 1 8000 3 Mints 2 9000 2 3 10000 2 4 11000 2 5 12000 2 6 13000 2 7 14000 2 8 15000 3 9 16000 3 10 17000 3 11 18000 3 12 18800 3 13 19000 3 14 19000 350 15 18860 3 16 18500` 2

  8. Instruments used: Three phase power analyzer which records all the electrical parameters,i.e. voltage, frequency, current, Kw, Kva, Power factor,kwh & harmonics, digital non-contact type tachometer for spindle speed and digital tachometer (contact type) for FRS.

  9. TRIAL SEQUENCE • TRIALS ON EXISTING OLD TAPES • NEW CONVENTIONAL TAPES • NEWLY DEVELOPED ENERGY EFFICIENT PU SPINDLE TAPES • POWER SAVING OBSERVATION • PRODUCTIVITY GAINS OBSERVATION

  10. RESULTS&DISCUSSION

  11. All the trials were undertaken in a similar and controlled condition. • The trial was conducted on R/F No. 22 (unit No.3). Machine was running with 60s count, spindle speed was 19000 (max.), FRS was 180 RPM, TPI was 34.72. • During trials, the power consumption has been measured only for main motor. • In existing old tapes the power consumption was around 139.893 units per doff. The specific power consumption (UKG) was 2.944.

  12. Then all the tapes replaced by new conventional tapes because comparison should always between new tapes V/S new tapes to avoid any aging factor of the tapes. • In new conventional tapes, spindle speed has slightly increased by 50-60 rpm. All the process parameters were kept constant as earlier one. The avg. power consumption was around 142.067 units/doff (two doffs avg.) and specific power consumption (UKG) was 2.957.

  13. After the above trials, all the conventional tapes have been replaced by newly developed energy efficient PU spindle tapes. • The new EE tapes have very low slippage and due to this, spindle speed has increased by around 1.75% (300-350 rpm) which is resulting in higher TPI in the yarn around 1.75% (0.60-0.65). • Full doff power consumption was measured for two doffs. All the process parameters were constant as previous one. • The avg. power consumption was 142.065 units per doff. The power consumption was more or less same as it was in the conventional tapes even in new PU tapes the actual spindle speed was higher around 1.75%. the overall specific power consumption (UKG) was 2.98.

  14. Then We want to reduce the TPI which has increased around 0.60 due to less slippage in energy efficient PU tapes to 34.05 by gear combination. • but it was not possible because min. possible TPI was 33.92 which was 0.80 lower than original one. • Then TPI has reduced by one step i.e. 33.92 and simultaneously reduced the spindle to keep the FRS same i.e 180 rpm. Then two full doffs trials have been undertaken to see the scope of power saving in newly developed PU tapes. • The avg. power consumption of energy efficient tapes has reduced to 134.592 from 142.067 per doff i.e. 5.26% and specific power consumption (UKG) has reduced from 2.957 to 2.783 i.e 5.88 %.

  15. After analyzing the scope of power saving, we wanted to see the gains in productivity also. So the spindle speed increased to 19,000, TPI was 33.92, and FRS has increased to 185.5 from 180 rpm. Two full doffs trials have been taken. • The avg. power consumption has further reduced to 137.026 units from 142.067 i.e. 3.55% over new conventional tapes and UKG has reduced around 4.56%. • The productivity gain comes around 3.0%. The overall doff time has reduced around 9 – 10 minutes i.e around 2.7%. in case of power saving, only main motor power is considered but if doff time reduces, the pneumafil power consumption also reduces which will further increase the overall savings.

  16. TENTATIVETECHNOECONOMICS • Conventional tape cost : Rs. 5.60 per meter • Cost of one tape (2382 x 11mm) : Rs. 14.67 • Total tape cost for one M/C (1008spdls.) : Rs. 3,696.84 • Cost of newly developed PU tape : Rs. 20.0 per meter • Total new tape cost for one M/C : Rs. 13,205.81 • Approx. higher investment in new tape : Rs. 9,508.97 per M/C • Approx. Power consumption per Hr. : 20 Kwh/Hr. • Approx power saving with new tapes : 5.0 % • Power saving per day (23.5 Hrs. operation) : 20 x .05 x 23.5 Hrs. = 23.5 units • Annual power saving (360 days working) : 23.5 x 360 days = 8460 units • Annual monetary saving @ Rs. 3.50/kwh : 8460 x 3.50 = Rs. 29,610/- • Total difference in tape cost per M/C : Rs. 9,508.97 • Total saving in power cost per M/C : Rs. 29,610/- per year • Pay back period : Rs.9509 / Rs.29610 = Approx. 0.3 year • Note: the above tape cost is tentative. After commercialization it may vary in the range of 5 – 10%

  17. CONCLUSIONS

  18. CONCLUSIONS • During trials, the newly developed energy efficient PU tapes have shown power saving of around 5.26% over new conventional tapes and on the basis of specific power consumption (UKG), the saving was around 5.88%. • in second case, the productivity gain was around 2.78%, power saving was around 3.55%, saving in UKG was around 4.46% and doff time reduction was around 2.78% in case of newly energy efficient PU tapes over new conventional tapes. • in the above case, the power saving is considered only for main motor but if pneumafil motor is also considered the power saving will be more as the pneuma motor operation time will also reduced as per reduction in doff time. • The tentative techno-economics is also given in the report and pay back period is quite attractive i.e. with in six months. • The yarn quality results have no significant difference in the colleted samples during trial.

  19. CASE - II

  20. CONCLUSION • Old tape v/s newly developed (energy efficient) tape, power saving was 9.79% while on UKG basis the savings was 10.43%. We have not considered this savings as real savings because of aging factor of old tapes. • New conventional tapes v/s newly developed (energy efficient) tape the power saving was 4.16% and on UKG basis the power savings was 5.03% in UKG. • In the third case the savings were on two ground i.e. productivity gains as well as power saving. New conventional tapes v/s newly developed (energy efficient) tapes the productivity gain was around 2.15% and power saving was 2.46%.

  21. CASE - III

  22. CONCLUSION • Old tape v/s newly developed (energy efficient) tape, power saving was 4.1% while on UKG basis the savings was 5.15%. We normally do not consider this savings as real savings because of aging factor of old tapes. • New conventional tapes v/s newly developed (energy efficient) tape the power saving was 4.50% and on the basis of specific power consumption (UKG), the power savings was 4.90% in UKG. • In the third case the savings were on two ground i.e. productivity gains as well as power saving. New conventional tapes v/s newly developed (energy efficient) tapes the productivity gain was around 2.87% and power saving was 2.20% even the spindle speed is higher due to low slippage.

  23. THANK YOU

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