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
• Measure Energy
Digitally & Accurately
from Entrance to Load End .
ELECTRICAL DISTRIBUTION SYSTEM --
SINGLE LINE DIAGRAM
EB POWER
TRIVEATOR METER
Metering
11 KV/440V
Transformer
Effi.95-98%
M
ELECTRICAL
M
DG SET
Dist. loss
4 - 8%
M
M
M
M
Feeders,
Capacitors
C
C
Distribution
Panels
Motors
Effi.85-96%
FANS & BLOWERS
PUMPS
R & AC COMPRESSORS
LIGHTING, HEATING
MECHANICAL
C
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
Kwh consumed
A
8
92
B
C
D
E
8
8
8
8
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
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 loss / year
12600
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
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
7.5A
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
50HP 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
15.1KVAR
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
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
•
•
•
•
•
•
•
•
•
•
Motor rating hp
Suction pipe mm
Delivery pipe mm
Piping material
Foot valve
Discharge LPS
Input power KW
Increase in discharge
Input power reduction
Saving in Energy
existing’
7.5
65
50
GI
local
3.68
6.18
-30 %
--
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
100 – 150
120
183
1, 20,000 lumen/m2
500 –600 lumens / m2
Lighting purpose – General or Visual tasking ?
Tube light– variation in Light output & Power output
• Particulars
• Light output
• Power input
•
•
•
•
•
•
•
at 10% low-360 volt - at10% high – 450 volt
Decreases by 9 % - Increases by 8 %
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