Process Based Approach for Project Execution

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Role of IT in Textile Industry
A Tool for PROFIT in Textile Industry
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Beginning with IT
- Website - Learning / knowledge - Fast
communication - Interaction with industry
members - Access of data bases - Technology - Soft
ware - Hardware - Energy conservation norms
- Information about textile mills
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Website Background
Bureau of Energy Efficiency (BEE), Ministry of
Power, Govt. of India, in coordination with
Indo-German Energy Programme (IGEN), sponsored by
German Technical Cooperation (GTZ), is
institutionalizing energy efficiency services and
promote energy efficiency delivery mechanisms in
all sectors of the economy. This website is
operated and managed by IGEN for BEE.
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Broad Sections of the website
Contd., Learning Overview of EC Act, general
information on energy management and large number
of technical learning material for all sectors of
industries, equipments, case studies, industries
experiences, success stories. Industry overview/
process, equipment design/types, maintenance
tips, case studies, best practices, books
journals on energy management. Roles
responsibilities of energy manager and energy
auditors, energy audit guidelines. Specialists
Information about energy managers, energy
auditors, industry specialists, consultants,
temporarily accredited energy audit firms,
Industry associations and state level designated
agencies. Details of certified energy managers /
energy auditors also provided.
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Broad Sections of the website
Equipments Technical information on energy
consuming equipments - electrical systems,
boilers, steam systems, furnaces, insulation
refractors, electric motors, compressors,
compressed air system, HVAC and refrigeration,
cooling towers, fans pumps, lighting systems,
diesel generating systems, maintenance tips, OM
manuals, dos donts and much more. The
equipment manufacturer/ suppliers contact
details. Events All important energy
management events such as awarding industry for
their best practices, celebrations of National
Energy Conservation Day, energy management
promotional activities, awareness training
programmes / workshops / seminars
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Major information on website

•   Contd.,
• Energy Conservation Act, 2001
• Energy manager/ energy auditor accreditation,
• Course material, exam updates and results
• Certified energy managers, energy auditors and
• temporarily accredited energy audit firms.
• Sector-wise specialists details
• Sector-wise user group interaction
• Energy audit guidelines energy audit equipments
• Sector-wise overview / process technical reading
• Equipment - design, types, tips, manufacturers
  details.
• Energy management software with suppliers

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Major information on website

• Major events, seminars, workshops on energy
  management, sector-wise task force meetings, and
  their proceedings.
• Users technical papers, success stories
  technical papers for issues quizzes
• Industry best practices on energy conservation
• National Campaign on Energy Conservation
• Books, journals on energy management.
• Kaupps corner a thought provocative discussion
  forum
• Energy management related tenders
• Job requirements - Energy management specialists

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Support to Textiles sector
Textile manufacturing processDescribes textile
manufacturing process i.e. spinning, Weaving/
Knitting/ Stitching, Dyeing, Quality Fibre to
fabric Testing Equipments for Textile Industry.
Basic Principles of Rayon Fiber
Production.Definitions of textiles, linen,
wool, cotton, silk etc.Synthetic and
cellulosic fiber formation technologyConservatio
n of lubricants by modified dispensing
equipmentsA study report on Conservation of
Lubricants by Modified Dispensing Equipments and
Through RecyclingImproved performance and
eliminate fibre ball formationPublication on
Measure to Achieve Improved Performance and
Eliminate Fibre Ball Formation in Weaving of
Heavy Reed Sorts on Shuttleless Weaving Machines
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Assessment of compressed air requirement for
spinningPublication on Assessment of Compressed
Air Requirement for Spinning and Weaving
Machines.Estimation monitoring and control of
energy consumptionBTRA Powerspin System, a
microprocessor based instrument system to monitor
and control the actual energy consumption pattern
in textile mills.Compressed air system
Introduction to the compressed air system and
Compressed Air Consumption StudyOptimisation of
compressed air costMinimising wasteful
consumption of compressed and by improving the
efficiency of compressors.Heat economy in
textile millsSome general suggestions for heat
economy in this article.
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Effect of processing conditions at ginning on
fibre propertiesThe moisture role in processing
at ginning. Energy balance and accounting for
boilers and process houseIt is a matter of great
concern to all that boiler should run at its
maximum efficiency with minimum indirect losses.
Fuel saving in decentralised process house
unitsThermal efficiency values for different
fuels for boilers and thermic fluid heaters,
areas of steam and fuel savings identified, with
recommendations for the fuel savings.Preparatio
n of fuel oils storage, handling. IT based
sewing room data for improved performancemicro-co
ntroller based single system working to transmit
the machine performance and production data to a
computer system to store, process and generate
reports, to increase productivity.
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Cyclic activated sludge technologyA detailed
technical description, salient features
advantages of the cyclic activated sludge
technology.Energy saving in textile
processingPractical tips and a ready reckoner
for making investment decisions related to energy
saving.Avenues for cost reductionsalient
findings of the some mills making 100 cotton,
polyester/cotton, worsted, polyester/wool
blended, woven/knitted fabrics, the measures
suggested/implemented/followed up for water
conservation and accrued benefits.Energy
savings audit in textile industryProvides
major power consuming areas in textile mill and
its optimization. SITRA energy audit reports
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Website role in Textile industry

• Various database accesses have been provided in
  this website viz.
• energy managers, energy specialists, energy
  auditors to facilitate
• the users to choose the desired professionals as
  per their
• requirement.
• We propose to make available following to the
  textile industry
• Brief details of the equipments used in textile
  industry, equipment tips, OM information.
• Supplier details of the textile machinery with
  their specifications.
• Energy efficient equipments details along with
  their suppliers details
• Energy audit equipments required for energy audit.

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Industry user group Textiles Few technical
problems posted by users
1. What are the key factors for achieving good
quality of raw material in textile industry? 2.
Which are responsible for dust generation in
textile industry? 3. Is it advisable to run the
turbine with 49Hz instead of 50Hz? Will this give
any fuel saving? Any harm to the turbine? 4. How
to pre-cool the Utility compressor suction air
economically? The compressor in industry utility
functions like a submersible pump in air. Like
the submersible pump which needs water to be
sucked in as well water to be surrounded by the
pump to keep the pump cool and efficient the
compressor too needs clean dry cool 5. Energy
conservation solutions for applications in
textile industry located at Coimbatore and
knit-wear industry at Tirrupur. Specific problem
areas are 1. Dyeing processes and chemical
effluents recovery and waste disposal 2.
Electrical energy saving for textile machineries
6. COMPRESSORS--There are many cases when
pressure required for say 20 equipment is 6 kg/
sq.cm and for remaining about 5 kg/sq.cm. For
meeting requirement of 20 equipment, total
pressure has to be kept higher. Has any body come
across any manufacturer who manufactures booster
compressors for such eventualities?
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Detailed technical information on equipment
design / types and Tips

•   Electrical systems
• Boilers
• Furnaces
• Insulation refractories
• Electric motors
• Compressors and compressed air system
• HVAC and refrigeration
• Cooling towers
• Fans pumps
• Lighting system
• Testing equipment

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Typical problems that cause higher energy costs

• Process operations Incorrect set points, fouled
  heat exchangers, advanced control switched off,
  poor control timing.
• Boilers Poor air-fuel ratio, fouled exchanges,
  excessive blow-down, incorrect boiler selection.
• Refrigeration Fouled condenser, air in
  condenser, incorrect superheat settings, high
  head pressure settings, incorrect compressor
  selection.
• Compressed Air Leaks, poor compressor control,
  incorrect pressure
• Steam Leaks, failed traps, poor isolation,
  incorrect set-points, low condensate return.
• Space Heating / Cooling Excessive space
  temperature, excessive fan power use,
  overcooling, heating and cooling, high chilled
  water temperature
• Power Generation Poor engine performance,
  incorrect control settings, poor cooling tower
  operation, fouled heat exchangers

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Role of IT in energy management

• Track energy usage, identify wastage and generate
  reports.
• Energy monitoring, verification on Performance
  Contracting.
• Plan, process, monitor and compare activities.

Advantages The major advantages of the softwares
for energy management is to store the data in a
usable format, the calculations of effective
targets for energy use, and comparison of actual
consumption with the targets, early detection of
poor performance, effective performance
reporting.
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Proposed software for assessment of energy
consumption in Textile industry
19 20 March 2006
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Software objective

• Assess the energy consumption (Thermal,
  Electrical, Water) of textile mills.?
  Generate identification code for proper
  classification of textile mills for comparative
  analysis.
  ? Compare the
  textile mills energy consumption with the
  Industry average? Bringing Awareness about
  standards of energy consumption? Self
  assessment for improvements in the textile mills
  energy consumption.? Classification
  of textile mills into gold/ silver/ bronze/ tin

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Login Page
Web page http//www.energymanagertraining.com/ecs
ectors.php
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Brief description of the mill
Web page http//www.energymanagertraining.com/ecs
ectors.php
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Mill details and status
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Statistics Summary
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Electrical Rating
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Thermal Rating
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Water Rating
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Extract from Dr. Kaupps Corner
Article 23 Become Energy Efficient. Change
Colours Like a Chameleon
A recommended rating for efforts under step 6
could be 1 point for having a designated and
certified energy manager appointed 1 point for
having conducted an energy audit through an
accredited energy auditor and validation of
self declared energy consumption data 1 point
for having submitted the energy audit report to
BEE in electronic form 1 point for having
prepared a three year business plan 1 point for
submitting the business plan in electronic form
to BEE or designated State Agency The
remaining 5 points could be distributed based on
the degree of implementation and documentary
evidence of verified energy savings and costs.
Satisfying the formal requirements of the Act
will already result in a 5 point effort level,
while any Gold or Silver standard in efforts
depends on the level of successful implementation
of energy conservation measures.
Web page http//www.energymanagertraining.com/new
_kaupp.php
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Benefits to the registered members

• The registration to the website is FREE.
• Registered member will be entitled to the
  following
• Complete access to the website
• Recent development in energy management.
• Receive regular updates on the website
• View the technical problems posted by the
  industry members along with the answers from the
  specialists. Any registered member can post any
  technical queries on the website
• Upload profile on the website

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Users Contribution

• Submit technical papers best practices
• Submit live case studies
• Useful softwares, calculating tools
• Submit information on energy efficient equipment
  manufacturer /supplier
• Become member of industry user group and submit
  querry
• Post energy management related event details
• Send feedback to improve the site
• Submit your profile
• SURF PROMOTE THE SITE REGULARLY

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Contact ASHOK KUMAR Advisor
Information Indo-German Energy Programme
(IGEN) Hall No.4, 2nd Floor, NBCC Tower 15,
Bhikaji Cama Place, New Delhi 110 066 Phone
011-26179699 Fax [phone] Email
akumar_at_emt.in akumar_at_energymanager
training.com