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Before Units per Kg, Now Kg per Unit!

Implement energy-efficient strategies in textile mills to maximize production, reduce losses, and improve motor performance. This case study explores voltage regulation, power factor correction, motor efficiency, and more.

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Before Units per Kg, Now Kg per Unit!

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  1. Before Units per Kg, Now Kg per Unit! • Previously textile manager talked often the UKG. To produce more Kgs, how much they needed more units. • Now, the same manager talks how much more Kg of yarn can be produced for given Half quota of electricity • A blessing in disguise in a way, this quota crisis makes us “Lesser we get, More we become wise now”. • Many mills responded to wakeup call. They have maximized production and they reduced internal losses.

  2. Energy Intake by Textile Mill • Energy Losses (Between the Cup & Lip in industry) • Voltage Regulation in Stages upto Load End • Power Factor Regulation in Stages • Compressed Air – Cool Dry Air in Stages • Energy Measured Digitally & Accurately • Measure Energy from Entrance to Load End .

  3. ELECTRICAL DISTRIBUTION SYSTEM -- SINGLE LINE DIAGRAM EB POWER M DG SET TRIVEATOR METER Metering 11 KV/440V Transformer Effi.95-98% M Dist. loss 4 - 8% Feeders, Capacitors M M M M C MECHANICAL ELECTRICAL Distribution Panels C C Motors Effi.85-96% FANS & BLOWERS PUMPS R & AC COMPRESSORS LIGHTING, HEATING

  4. Textile mill in Lean mode working • Improve the individual efficiency of machine, say frame to frame. • find the optimum speed of ring frames at this half load quota. • Improve utilization of the frames & utility • Tune down utilities like AC plant, compressor etc. • Mainly reduce waste evacuation system sizing • Motor takes power based on load only. So reduce Load • Give more thrust to KVA instead of KW now. • Make use of Maximum Demand Controller fully using Auto mode. • Slightly Compensate major motors at load ends.

  5. Case study of high efficiency motorsDifferent makes of motors are compared for 20 hp rating ring frame motor in textile industry10 % difference between high effy & low effy motors

  6. Are we loading our motors efficiently ?

  7. Motors – range of Losses

  8. Motor 15 KW-Good Vs Bad - in work

  9. Motor is a Consumable = 7.5 hp replaced by 5 hp new

  10. Do we give right volts to our mill now ? • In the mill having Transformer with OLTC, we can now reduce the voltage settings from 420 to 400 volts. • when mill having transformer without OLTC operated at 400 volt instead of 440 volt especially at night, • A standard motor operated at an average half the load – its efficiency increases around 4 % • The same standard motor at average half the load - its power factor improves around 10% • This is applicable to standard motors and the above change is not that much in Energy Efficient motors.

  11. Running ring frame motors in star mode • Running ring frame main motors on Automatic Delta to Star mode gives savings around 5 to 10 %. • Now the conditions are that instead of 18000 rpm now only 12000 rpm running say and the loading is around 30 to 40 % level only. • First fool proof protection to motor and then think of change over from delta to star mode • To protect whole circuits by providing Fool proof Electronic Overload & winding protection relays.

  12. The table below Compares the behavior of 5 H.P motor at Higher than 400 voltscourtesy – Muskan Servo OEM study

  13. Motor derates at higher ambient temperature

  14. Improved Power Factor Correction on typical 50HP Motor gives significant results.

  15. Study -Capacitor bank at load end Connectedload 970 KW at 200 meters from power house capacitor OFF – 0.8 pf & cap ON – 0.97 pf

  16. Ring frame motor is a Bullock Cart • greasing the motor bearing is not to protect the bearing only, it should catalyze the smooth working of motor • Existing motor is like a bullock cart climbing up the hill. Please make motor to drive like cart smooth down the hill. • Right Quality & Quantity Lubrication at Frequent intervals • Active & Forced Ventilation surrounding the motor • Motor shaft loses 10 rpm, spindle speed loses by 100 rpm. • The more the motor heat, more losses & less Spindle speed.

  17. Thermal Imaging – Tool to Predictive Maintenance – Management

  18. Effect of Voltage Unbalanceon the performance of 5 HP motor :- is more detrimental to motor performance and motor life than voltage variation.Increased temp. rise is 40 *C for unbalance of 5 %Say motor temp is 60 * , then this raises to 100 * C.

  19. Hot spots motor bearing DE & NDE

  20. Humidification effect on mill • Less water, more air yields more humidity to mill • Nozzles to operate at rated Pressure and Flow • Hour meter on water pump,water meter online. • High Efficiency Aerofoil designed Aluminum Pressure die cast alloy fan Exhaust fan to suit to air changes • Nozzles not to jetting / pissing /oozing but Fogging but spray dwell time of water in air must be more for mill. • Ring main type water distribution to the nozzles in water circuit, instead of the present Radial system

  21. Are our buildings under Umbrella ?

  22. Pumping system – savingsparameters existing’ new pump • Motor rating hp 7.5 5 • Suction pipe mm 65 75 • Delivery pipe mm 50 75 • Piping material GI White PVC • Foot valve local ISI • Discharge LPS 3.68 5.03 • Input power KW 6.18 4.35 • Increase in discharge -- 36 % • Input power reduction 30 % -- • Saving in Energy -- 48 %

  23. Compressed air what supplied & what used ?

  24. CA system Air intake –Rupee wise, Paisa Foolish • Compr. Air intake Temp. 3*C raise, Power Up 1 % • 100 scfm @ 7 bar Annual Comp Air use Rs. 6 Lacs • Daily clean Pre Air Filter before Air intake Filter • 160 Scfm Compr. @ 7 bar at 45*C air outlet pumps 1 Litre more water in air per hour than at 35 * C

  25. Compressed Air system pressure drop? • Pressure loss/drop is a function of a compressed air system’s dynamics • the interaction of airflow with the inherent resistance of the pipeline and air system components. • Pressure drop also causes a system’s pressure to fluctuate & leads to inconsistent pressure at end-use. • Air receivers at compressor house, load –incoming point and Air Bottles at the consumption point.

  26. Your Genset gives maximum efficiency? • The genset sub systems like air, fuel, cooling and lubrication to be individually cared for better maintenance. • Because we get around only one third of Kcal output as Electricity for 1 liter of Diesel. Efficiency from genset is poor, definitely there is  more scope for better UPL. •  The maximum Demand Controller fitted to DG set will help us to set & get max units per liter of diesel. • Care is taken on genset air intake temperature, pressure drop, exhaust temperature & pressure to optimum level. • Ducting out air intake with nylon pre filter, and ducting out heat exchanger exhaust is done to keep house cool.

  27. DG set Air intake & Exhaust system Healthy ? • - Early choking of air intake filter leads to : - • - Low power • - Black smoke • - Turbocharger failure • Higher back pressure leads to : • - Lower fuel economy • - High exhaust temperatures and related failures • - Poor performance of the engine • - Less durability of the engine • - Exhaust system must create minimum back press.

  28. Why Less Units per Liter now? • Ageing • Inadequate maintenance • Inadequate operation practices. • Low capacity utilisation • Fluctuating load • Derating effect • Exhaust temperature limit the loading & KVA • Lagging of exhaust pipe is required.

  29. Allow DG set to Breathe • DG Set building should be cross ventilated. • Increase in air intake temperature from 25°C to 40°C, the air fuel ratio decreases by about 5% resulting in increase in fuel consumption in the range of 0.5 to 2% depending on engine design. • WATER TEMPERATURE = 75°C to 93°C • The cooling system should be so designed that difference between inlet and outlet water temperature = 6 to 10°C

  30. “ we must know what we consume where ” Preliminary energy audit is a relatively quick exercise • to Establish energy consumption in the organization • Estimate the scope for saving • Identify the most likely ( & easiest areas for attention.) • Identify early ( no-/ low-cost) improvement & savings • Set a reference point / Bench mark within the machine • Identify areas for more detailed study/measurement • Preliminary audit uses existing, and easily obtained data.

  31. Energy Audit shows where we stand • What to do, • where to start, • at what cost and • for what benefits • First step is start with Preliminary Audit with existing Datas. • Second step is Detailed Audit & Generate more Parameters. • Indicative saving potential to achieve • Good House-keeping yields 5 - 10% • Minor Investment gives 10 - 15% • Reasonable Investment pays back 20 - 25%

  32. Shock, Relief & Delight • The three stages of accepting results of an energy study or audit of process & utility are • Shock, Relief and, finally, Delight ! • The general wrong opinions about Maintenance has been • "Maintenance is a necessary evil" • "Nothing can be done to improve maintenance costs” • Please remove the opinions & now Remember: • Where Safety (Conservation) Fails, Pollution Starts. • Maintenance is a Tool to Productivity • Utility to process is like Medicine in bottle to our body. • Shake bottle before use & shake our body after intake for quick & better results of medicine.

  33. FIVE COST REDUCTION MEASURES OF ENERGY CONSERVATION • Identify inefficient energy use • Upgrade machinery & process in context of energy efficiency • Improve maintenance practice • Promote employee awareness and • Conservation in domestic consumption.

  34. Lighting – Lumens per watt

  35. Lighting purpose – General or Visual tasking ?

  36. Tube light– variation in Light output & Power output • Particulars at 10% low-360 volt - at10% high – 450 volt • Light output Decreases by 9 % - Increases by 8 % • Power input Decreases by 15 % - Increases by 8 % • Take the case of your transformer without OLTC • Low & High voltages are 400 to 450 volts in day & night • Lighting wants safe regulated working 360 volts only • Priority is towards Energy Savings in Lighting • More priority is in Safety in lighting voltages • Tube light life increases and inventory comes down • Not only for tube lights but also for ballasts also.

  37. Conserve Energy & Serve Nation • Thanks for your kind attention • to our SIMA textile mill seminar program by • South India Mills Association. • Thank You S.ASHOK, Energy Advisor, BEE certified Energy Auditor COIMBATORE – 05. cell : - 9 4 4 3 7 - 2 0 2 2 0 ID :ashok.anbesivam@gmail.com Please visit my site www.energymeasuretosave.com

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