Before Units per Kg Now Kg per Unit

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.

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.

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

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.

Case study of high efficiency motors Different makes of motors are compared for 20 hp rating ring frame motor in textile industry 10 % difference between high effy & low effy motors Making of motor Running hours A B C D E 8 8 8 Kwh consumed 92 101 89 98 96

Are we loading our motors efficiently ?

Motors – range of Losses

Motor 15 KW-Good Vs Bad - in work Motor status Rated current Rewound motor Motor loss / year 12600 units Efficient motor 28 A 26 A Speed Rpm 1445 rpm 1450 rpm No load current 24 A ( 85 %) 6. 6 A ( 25 %) No load power 2. 3 KW ( 15 %) 0. 87 KW ( 6 %) No load Power 1. 46 KW increase nil Efficiency 76 % 91 % Motor loss / day 35 units Nil Motor loss/ month 1050 units nil

Motor is a Consumable = 7. 5 hp replaced by 5 hp new Motor particulars Motor rating Input voltage Volts Full load speed rpm Power factor Measured current amps Energy consumed / hr Units consumed MORE Units lost per day Units lost per month 7. 5 hp std motor 5 hp E E motor 5. 5 KW 400 1430 0. 84 8. 6 5. 0 units 0. 6 unit / hr 14 units 430 units 3. 7 KW 400 1450 0. 89 7. 16 4. 4 units nil

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.

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.

The table below Compares the behavior of 5 H. P motor at Higher than 400 volts courtesy – Muskan Servo OEM study Input Voltage Current KVA PF 400 7. 5 A 5. 2 0. 8 425 11% More 18% More 0. 7 435 19% More 28% More 0. 61 445 26% More 38% More 0. 57

Motor derates at higher ambient temperature

Improved Power Factor Correction on typical 50 HP Motor gives significant results. 50 HP motor Without Cap 37. 3 KW 50 HP motor ( with Cap ) 36. 2 KW % Change in parameters 3% Decrease 28 KVAR 15. 1 KVAR 46% Decrease 46. 6 KVA 38. 4 KVA 17% Decrease 0. 8 PF 0. 92 PF 15% improvement

Study -Capacitor bank at load end Connected load 970 KW at 200 meters from power house capacitor OFF – 0. 8 pf & cap ON – 0. 97 pf Description Capacitor at powerhouse Capacitor at load end Rating 1211 KVA 1000 KVA Line current 1715 amps 1443 amps Cables in I I 5 runs 343 mps 289 amps Cable losses 35 kw 25 kw cable loss pm 21000 units 15000 units(for 600 hrs) nil 6000 units per month Current /cable Net savings

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.

Thermal Imaging – Tool to Predictive Maintenance – Management

Parameter Unbalance in current in % Increased Temp Rise *C in motor Percent unbalance in voltage 0. 3 = 2 volt 2. 3 = 10 volts 5. 4 = 20 volts 0. 4 17. 7 40 0* 30* 40* Say 60 * C 60 + 30 = 90* 60 + 40= 100* Effect of Voltage Unbalance on 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.

Hot spots motor bearing DE & NDE

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

Are our buildings under Umbrella ?

Pumping system – savings parameters • • • existing’ Motor rating hp 7. 5 Suction pipe mm 65 Delivery pipe mm 50 Piping material GI Foot valve local Discharge LPS 3. 68 Input power KW 6. 18 Increase in discharge -Input power reduction 30 % Saving in Energy -- new pump 5 75 75 White PVC ISI 5. 03 4. 35 36 % -48 %

Compressed air what supplied & what used ?

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

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.

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.

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.

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.

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

“ 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.

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 • Minor Investment gives • Reasonable Investment pays back 5 - 10% 10 - 15% 20 - 25%

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.

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.

Lighting – Lumens per watt Lamp type Incandescent bulbs CFL Fluorescent tube HPSV Metal Halide lamps LPSV Light intensity from sun Diffused light near window Lumens per watt 15 60 60 - 100 – 150 120 183 1, 20, 000 lumen/m 2 500 – 600 lumens / m 2

Lighting purpose – General or Visual tasking ?

Tube light– variation in Light output & Power output • Particulars at 10% low-360 volt - at 10% 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.

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