Guidelines for Energy saving for Textile Mills

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Guidelines for Energy saving for Textile Mills

• S.ASHOK,
• PCRA FACULTY,
• ENERGY CONSULTANT
• COIMBATORE .
• 0422 2580472, 94437 20220.
• ID ashoksvs_at_eth.net

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ENERGY BALANCE in India

• Energy used more
• 1unit of electricity

• Decreasing Fuels Industry Consuming More
• Thermal plants generate _at_ 35 Efficiency
• Transmission Distribution Losses at 33
• 4 units of Primary Fuel gives one EB unit

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Energy Efficiency Benefits

• Reduced Energy bills Your Visible Gains !
• Please Look Not for Visible Gains, But for
• Hidden long term profits after payback period !
• Increased Productivity Invisible Benefits !!
• Improved Quality in product Increased Profits

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Pillars of Successful Energy Management

• Key ingredient- top management support is First
• Well chartered strategy plan
• Effective Monitoring system
• Adequate technical capability for
• Analyzing and Implementing Energy Saving options
• Good communication downwards from senior
  management is the first vital step

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Energy Intake by Textile Mill Energy Stages
Between Cup Lip in industry

• Voltage Regulation in Stages upto Load End
• Power Factor correction Improve in Stages
• Compressed Air - Cool Dry Air in Stages
• Steam - Dry Saturated state at load
• Lighting - Regulated voltage for soft load
• Regulated, Balanced, Filtered, slightly Lagging,
• Metered and Sustain-released in stages to the
  loads.

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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 5
unbalance .
Percentage Of Unbalance voltage in
Effect 0.3 2.3 5.4
Unbalance in current in 0.4 17.7 40
Increased Temp Rise C 0 30 40
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Motor check points in maintenance

• condition based lubrication - Scheduling
• quality quantity of Greasing
• check active ventilation by fan
• casing temperature, Keep clean.
• remove cooling off passages blockage
• alignment of motor and load

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Case study of high efficiency motorsDifferent
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 8 101
C 8 89
D 8 98
E 8 96
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MLM MLA is Important

• Condition based monitoring than Breakdowns
• Predictive Preventive Maintenance
• MLM micro level monitoring of parameters
• MLA macro level Analysis of altering parameters

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CA system Air intake Rupee wise, Paisa Foolish

• Compr. Air intake Temp. 3C raise, Power Up 1
• 100 scfm _at_ 7 bar Annual Comp Air use Rs. 6 Lacs
• Daily clean Pre Air Filter before Air intake
  Filter
• 160 Scfm Compr. _at_ 7 bar at 45C air outlet pumps
• 1 Litre more water in air per hour than at 35
  C

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Compressed Air loss - Examples

• Leakage _at_ ½dia hole in CA line _at_ 7 Kgsc can
  drain almost Rs.2500/- per day
• Hour meter on Compressor Load/ Unload Status
• Compressor works like Submersible pump in air.
• Cool Compressor delivers more air.
• Continuously run Compressor delivers less than an
  intermittently run Compressor.

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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 GRP fan on Supply Exhaust fans
• nozzles jetting, plugged, pissing or oozing
• Ring main method instead of the present Radial
  system

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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

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Boiler efficiency improves by

• 22 C reduction in flue gas temp gt effy UP by 1
  
• 6 C raise in feed water temp leads to 1 fuel
  saving
• 20 C raise in pre-heated combustion air gt1
  fuel saving
• 5 excess air reduction improves boiler Effy by
  1
• 1TPH of steam _at_ 7000 hrs pa cost Rs. 35 lakhs pa
• One inch steam trap failed ( open) cost Rs. 8
  lakhs pa

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MINUTE STEAM PARAMETERS

• A few Air vents reduce cycle time in start up.
• A separator directly increases machine output by
  removing condensate and so boosting heat
  transfer.
• A sight glass helps one to daily monitor Trap
  and directly increases drying machine speed.
• Invest in Pressure Reduction valve PRV at the
  load ends and it pays back in few months.

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STEAM HOUSE KEEPING VALUES

• A weekly brushing of boiler tubes save 2 fuel
  bill.
• A Deaerator head reduces dissolved oxygen and so
  reduces corrosion (leaks!) of pipes and
  fittings.
• Wet steam is highly corrosive please avoid
• Automatic Blow down Control costs lt Rs.1 lakh
  pays for itself in months improves steam
  quality.
• Float traps the payback is days.

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Steam Pressure Vs Latent Heat

• Steam has high Latent Heat at low pressure.
• Latent heat at 1 kg/cm2 526 Kcal/Kg.
• Latent Heat at 7 kg/cm2 490 Kcal/Kg.
• Latent Heat is 7.5 less at Higher pressure
• OR
• 7.5 more steam is used at higher pressure.
• Always advisable to reduce steam pressure near
  equipment and not in Boiler House.

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ENERGY AUDIT WHY ?

• To reduce cost of production and overheads.
• To identify areas of excess consumption of
  energy in Production Utilities - ref Industry
  standards
• To suggest ways for minimizing waste energy
  consumption using good maintenance practices
• To increase levels of efficiency of energy
  consumption with good operating parameter,
  retrofit

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Energy Auditing
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Energy Audit Indicates you

• What to do,
• where to start,
• at what cost and
• for what benefits
• Indicative saving potential to achieve
• Good House-keeping yields 5-10
• Minor Investment gives 10-15
• Reasonable Investment pays back 20-25