Energy Conservation case study in a Textile

Processing Unit
By
K. Narayanan,
Chief Coordinator KEC IIPC,
Prof. EEE Department,
Kongu Engineering College,
Perundurai, Erode-638052

knarayanan@kongu.ac.in

Energy Conservation- a Case Study

Agenda of the presentation :
Energy conservation act 2001/ Energy Manager training/ Energy
audit
Energy audit- a typical methodology; power analyzer
Introduction to the textile processing industry and various
opportunities of energy savings.
Variable speed drives for variable torque loads for energy saving ;
affinity laws of pumps and fans;
Energy saving in an oversized energy inefficient Compressor
Energy saving in a typical process pump
Energy saving in a boiler combustion control through ID and FD
fans
Energy saving in motor load coupling
Appropriate selection of motors
Energy efficiency in lighting controls
Summary of energy saving in the process industry.

Energy Conservation- a Case Study

The Industry- Institute Partnership Cell ( IIPC )
of Kongu Engineering college is undertaking
Energy Auditing assignments in industries.
The energy auditing team of the college is
approved by TNEB for the conduct of energy
audit in HT industries as per the conditions and
norms fixed by the Bureau of energy Efficiency (
BEE ).
BEE ( under the Ministry of Power ) is formed
under the act of the Parliament (
Energy conservation Act 2001 ) to take up various
activities to bring about the awareness as well
as to implement the energy conservation
measures in the country .

Energy Conservation- a Case Study

BEE is conducting a training programme for developing

Energy managers and auditors and is conducting a
national level certification examinations every six months
and is awarding the certificates to the successful
Energy managers and auditors.
Refer site www.energymanagertraining.com
The EC act mandates all the designated energy
intensive industries to have an energy manager reporting
directly to CEO.
They are required to conduct an yearly external audit
and based on the feedback of the external auditor take
corrective actions and report back to BEE. The energy
manager has the responsibility for the same.
The presenter has undergone the course and is a
certified energy auditor.
As a part of the energy audit team of Kongu
engineering college, the presenter had conducted energy
audits and this presentation is regarding a textile
processing industry.

Energy Conservation- a Case Study

Power Analyzer used and its

connections

Energy Conservation- a Case Study

Features of Power Quality Analyzer CA 8332

Measurement of AC voltages up to 960V RMS between phases.
Measurement of currents from 0.5A to 3000A RMS using current sensors that can
be clamped to the load circuit with out switching off the supply or load.
Measurement of the frequency 10 Hz to 70 Hz.
Calculation of neutral current by vector summing of phase current for star
configurations.
Measurement of RMS values and peak values for currents and voltages.
Calculation of the K factor for currents (transformers).
Calculation of short-term flicker for voltages.
Calculation of the phase unbalance for voltage and current (three-phase networks
only).
Measurement of harmonics for voltage, current or power, up to level 50.
Calculation of overall harmonic distortion factors.
Measurement of active, reactive and apparent power per phase and their aggregate.
Calculation of the total power factor , displacement factor , harmonic factor,
tangent factor.
Total amount of energy consumed during a set period chosen by the user.
Monitoring of the average value of any parameter, calculated over a period running
from 1 sec to 2 hours.
Recording, time stamping and characterization of any parameter against time as
well as disturbances like Swells, dips and interruptions, overrun of power and
harmonic thresholds...
Detection of transients in the waveforms.

Energy Conservation- a case study

XYZ Textiles ( name changed ) Tiruppur -is engaged in dying,
printing and curing of textile goods as job work. There are many
such industries in Tiruppur belt undertaking similar activities.
It is Processing approximately 6 lac meters of cloth weighing
about 1 lac kg per month(26 working days)
The following machinery are used:
Slit open machine for opening up the raw cloth reel and
stretching and reeling them again
Exposing Machine for preparation of printing screens
Colour kitchen for making appropriate colour shades
Rotary printing machine
Curing machine
Batching machine
The various energy and other inputs :
Electrical energy is received through 2 three phase LT feeders ;
Daily Consumption is 1300 units for both the feeders( Rs. 5.5
per unit ). They also have 140 kVA DG set.
Wood fired boiler with ID and FD fans for heating the thermic fluid.

Daily Consumption of wood 3000kg costing Rs.9000

Also 25 lac liters of water for washing etc.

Energy Conservation case study

The energy audit was conducted in the

plant as follows :
Study of the plant and the process by
the audit team
Taking measurements using power
analyzer for the various electrical loads
as per the following format :

1)
2)
1)

Format for Energy Audit for Motors

2)

Excel format for energy Conservation Study

3)

Collecting production data

Energy Conservation case study

Energy Consuming load categories:
Electrical energy for the various machinery- constant torque
loads( load torque remains constant for the full range of
speeds ) like conveyor of the cloth in the printing, curing and
batching machines etc.
Electrical energy for utilities - Variable torque loads ( load
torque varies as the square of the speed )- like fans,
blowers, pumps and compressors
Thermal energy produced by burning the wood in the boiler
is used for heating up the Thermic fluid which is used for
drying the processed cloth. The oil is getting re- circulated.
Oil circulation pump for the circulation of the fluid within the
plant.
Compressor for supplying the compressed air for exposing
and printing machine.
Effluent treatment Plant

Energy Conservation case study

Energy Conservation case study

Energy Saving Possibilities :
Energy saving in Compressor size, reduce the
unloading cycle, reduce the line leakages.
Energy saving in the thermal systems- reducing the
heat loss by controlling the combustion, optimum
boiler utilization depending upon the boiler loading.
Energy saving by energy efficient motors ;
optimum utilization of the motors .
Energy saving in the transmission system of the
motors to the loads - belt, gears etc.
Energy saving via speed control by variable speed
drives driving variable torque loads (
Variable speed drives , Pump / fan Basics ; affinity
law
).
Energy saving by energy efficient lamps .

Energy Conservation case study

Major energy saving Opportunities after the study :
It has been found that of the 1300 units of electrical
energy consumption in a day, the following four motors:

Compressor -30 HP,

oil circulation pump-15 HP
Boiler ID fan- 15 HP
and FD fan -5 HP

consume about 800 Units a day as compared to totally

500 units consumed by various other motors.
There are about 65 other motors for different
applications whose total capacity add up to about 300
HP ) .
Hence these four motors which run almost continuously
( except ID and FD fans ) are addressed predominantly
and energy saving proposals are carefully looked at.
Other motors are either intermittently run or they are
constant torque loads which do not contribute to
significant energy saving. They are not hence
considered.

Energy Conservation case study

1.Compressor ( 30 HP ) :
Compressor operates 24 hrs a day.
The compressor is feeding a reservoir of 1000
kg capacity and its pressure is maintained
between 8 to 9.5 kg/cm2
The maximum air requirement is 3.03 m3/ min
@ 9.5 kg/ cm2 .
Presently the loading time ratio is only 42 %
in a 2 minutes cycle under full utilization of
the plant. Thus the compressor is oversized.
Energy wastage due to the unloading = 70.6
units/day i.e. 1835.6 units / month
Reducing or replacing the existing compressor
is one option.

Energy Conservation case study

The other option is to switch off the compressor instead of
unloading. This will however require starting and stopping of the
compressor motor every 2 minutes. This can not be tolerated by
the motor ( DOL staring current is 6 times the 100% current )and
also the compressor mechanicals which specifies only 6 times
operation of the compressor. Life of compressor will be affected.
Other option to operate the same at lower capacity by
variable speed drive for the motor without changing the
compressor system.
Incorporate a VFD (22 kW CT- constant torque type Inverter)
instead of
the conventional loading and unloading arrangement (energy
inefficient).
switching ON/OFF the compressor is being done now . (large
number of switching cycles will affect the life of the motor
and compressor).
This corresponds to Rs.10095.80 / month ( for 1835.6 units).
The cost of Inverter (22 kW CT type ) is around Rs.40,000/- to
45,000/ In addition take action to eliminate all the leakages and
operate the compressor at the optimum pressure
The use of VFD facilitates operation at the optimum pressure.

Energy Conservation case study

2. Oil Circulation Pump ( 11 kW) :

Operates 24 hrs a day. Uninterrupted flow of the fluid heated

to 220 C is required.
Fuel Saving :
The pump circulates the heated thermic fluid at constant

flow rate.
The pump circulates at 67 m3/hr at 50 m head; The total

volume of oil is 5000 liters. Hence the oil is estimated to be

circulating at 13 times an hour irrespective of the plant
production rate .
Since the fluid is at high temperature the circulation can

not be stopped. Standby pump as well as diesel engine back

up is there to ensure uninterrupted flow.
During one recirculation cycle ,it is giving out heat at the

rate of an estimated 21250 kCal for the drying process and

the temperature of the 5000 liters of thermic fluid drops by
20 C to 200 C.
When the plant is running under capacity or during other

machine breakdowns, the availability of the VFD will ensure

slower recirculation which will reduce the heat losses which
will occur at full rate circulation.

Energy Conservation case study

2. Oil Circulation Pump contd. :
Incorporate a VFD (11 kW, VT variable torque type)
Consider operation of the pump at say 15% reduced
speed on the average per day.
The thermic liquid will then get re-circulated at 15%
less rate on the average per day depending on the
different plant load patterns including off peak
periods, lunch and other off times.
This will result in heat saving per day, which otherwise
get lost in the unnecessary circulation; This is
estimated about 5 % of the thermal energy input.
This will mean a saving of 5 % of the fuel ( wood )
and hence a saving of Rs. 450/- per day ( assuming Rs
9000/- is spent on fuel per day) .
This works out to Rs.11,700 per month of fuel
expenses.

Energy Conservation case study

2. Oil Circulation Pump contd. :
Additional Electrical Energy saving in the pump energy

Consumption:
By the affinity laws , 15% average speed reduction per
day the average power demand reduces by 39%.
The power drawn ( as measured ) with 350 V VLL = 9.7 kW

Estimated power drawn at 415 V, 50 HZ = 10.5 kW.

Reduced average power demand at 15% less speed is 6.4
kW ; ); ie saving of average power of 4.1 kW.
Total electrical energy saving per month is 2558.4 kW.
Saving is Rs.14071.20/month
Cost of 11 kw (VT type Inv) is around Rs.30,000/Saves both electrical power consumed by pump and the
fuel.

Energy Conservation case study

3. ID fan for Boiler (11 kW)

Saving due to reduced transmission losses:
It is suggested to connect the ID fan motor directly

onto the blower and control it through VFD for 50%

speed to take care of 50 % reduction in the fan
speed by the existing belt arrangement.
The expected energy saving due to reduced

transmission losses is 10%.

The actual power drawn when in operation = 6.8

kW
Hence the saving in power
= 0.68 kW

The ID fan operates only for 20 minutes in an

hour; when the thermic fluid temperature drops

below 200C.
Hence saving in energy in an hour = 0.23 kWhr

Hence saving in one month

= 143.52 kWhr

This corresponds to monthly saving =Rs. 789.36

Energy Conservation case study

3. ID fan for Boiler (11 kW) contd.

Saving due to reduced fan power losses

If the motor is direct coupled to the fan it needs to

operate at 50 % speed corresponding to the fan 100 % speed

of 750 RPM . This will require a VFD.
The power drawn by the motor at this condition will be same

as the present condition except for the reduction of

transmission losses.
The torque to be developed will be doubled. This was found to

be within the motor capability as the motor is presently loaded

less than 50%
The provision of VFD for ID fan have opened up the

possibility of supplying the air at optimum rate continuously for

the best combustion possible by continuously changing the motor
speed.
Assume that the fan be run at an optimum speed continuously

-say at 60% speed or 40 % reduction in speed when the boiler

is under loaded due to the plant loading becoming , say 60 %.
With this speed , the fan will operate continuously ( without

going OFF and ON ) controlling the combustion optimally by

supplying just the required quantity of air for full combustion of
the fuel.

Energy Conservation case study

3. ID fan for Boiler (11 kW) contd.
Additional electrical energy saving can be achieved by operating the
fan at lower speeds as per affinity laws.
Saving due to reduced fan power losses ( Contd.)
The expected fan/ motor speed = 450 RPM ( 60% of the fan
rated speed for optimum combustion )
= 1.468 kW
The reduced continuous power drawn
= 6,8 kW for 33 % time
The power drawn at rated fan speed
in an hour
= 5.3312 kW
Saving in power
= (6.8 x 1/3 1.468) x 1 = 0.8
Saving in energy in an hour
units / hour
and In a month saving of 498 kW hr/month
= Rs.3528.36 ( only the fan motor
Saving per month :
energy saving )
This is in addition to the transmission loss saving of Rs.789.36
per month
= Rs. 30,000
Cost of 11 kw Inverter
The above excludes possible fuel cost saving due to the better
combustion of the fuel ( wood ).

Energy Conservation case study

4. VFD

for the blowers for the Printing machine ( 4 x 11 kW)

It is proposed to supply the blowers of the printing machine through
VFD-s and control the drying rate .
There will be 49 % power saving and 36 % energy saving by
reducing the speed of the blowers by 20 % (Affinity Laws ).
20 % reduction in blower speed and hence 20 % reduced air
quantity will require reduction in material speed by 20 % to ensure
drying.
This will mean 20 % additional running time for the machine.
However it is seen that the energy to be spent for running the
machine for 20 % more time is not significant
Also 20 % additional time is available from the records of the
machine running time per month.
Total power input = 35.84 kW
Each blower is presently loaded to 8.47 kW. Such 4- blowers
are there
Hence total expected energy saving ( 36% ) in a day will be 292.7
kWhr and the saving per month will be 7610.8 kWhr.
The cost of the elec.energy saved will be Rs. 41,859.40 per month
This is a major saving.
Cost of 4 Nos of 11 kW inverters expected to be Rs. 1,20,000.00

Energy Conservation case study

5. Checking the loading of the electrical motors :
It is important that the motors are optimally loaded.
Motors operate at their maximum efficiency only at loads more
than 75 % to 80 %.
Less loaded motors exhibit poorer power factors and also operate
at lower efficiencies.
It is better to go for efficient motors which may be nominally
costlier rather than cheaper motors which are inefficient.
The running cost of the motors are more than 98% and hence it is
very clear that one should for the latest high efficiency motors
instead running with lower efficiency motors.
The field test for the motors can be done if they are available
for no load and load running. This was not done due lack of
availability of time.
Customers were advised to undertake the same and do the
needful.

Power factor
kW
Power Factor Cos
kVA
As the load on the motor is reduced, the magnitude of the active current ( I
Iactive= SQRT ( Istator2 - Im2 )

) reduces.

active

However, there is not a corresponding reduction in the magnetizing current, with the result
that the motor power factor reduces, or gets worse, with a reduction in applied load.
Similarly the power factor is poor during starting ( the current is predominantly reactive )

Life cycle cost of a motor

Comparison of motor efficiencies-Old and new

types

Comparison of motor efficiencies-Old and new

types

Energy Conservation case study

6. Energy saving in lighting system:

The various energy saving opportunities

with the lighting system were explained to
customer.

Energy Conservation case study

6. Energy saving in lighting system ( Contd.) :

1 ) There are 170 numbers of tube lights in the plant .
2 ) All the lamps are the normal 36 W lamps with ballast( assume
additional 10 W )
3) The total energy consumed per day assuming 10 hrs of
average On time for all the lamps is equal to 46 x 170 x 10 = 78.2
kWhr.
4) This corresponds to 2033.2 kwhr / month.
5) It is recommended that the lamps be changed T-5 series
lamps ( 28 W ) which has higher efficacy ( more light or lumens per watt
consumed ), longer life ( about 2 times ) ,better colour Rendering Index
etc.
6) The saving will be 795.6 kWhr per month and Rs.4375.8 per
month
7 ) The cost of the T5 series lamp is approximately Rs. 800 /and hence the
total
investment will be Rs. 1,36,000.00.
8) When working out the pay back period additional benefit of
longer life ( about 4-times maximum ) to be considered.
9) At 10 hrs / day average use, the existing lamps are
presumed to have a life of one year.
10)With T- 5 series lamps, it will be 4 years.

Energy Conservation case study

Summary :
S. No

Energy Saving

Amount Saved
per Month

Remarks /
Investment

Payback
Period

1.

Energy saving per month by 22 kW

VFD for the Compressor

Rs. 10,095.80

Rs.45,000.00

5 Months

2.

Energy saving per month

VFD for the oil pump

Rs. 30,000.00

3 Months

2.1

Estimated fuel

Rs.30,000.00

10 months

by 11 kW

saving
Rs..11,700.00

2.2

Estimated electrical energy saving of

the pump motor

3.

Energy saving per month

VFD for the ID fan

3.1

Estimated saving
mechanical losses

3.2

Estimated saving due to fan motor

operation at reduced speeds

Rs.3528.36

4.

Energy saving per month by 11 kW

VFD for 4-Nos of blowers of the
printing machine
Energy saving per month by changing
the existing tube lights by T-5 series

Rs. 41,859.40

Rs.1,20,000.00

4 months

Rs. 4375.80

Rs.1,36,000.00

30 months

5.

Rs. 14071.20

by 11 kW

due to reduced

Rs.789.36

Energy Conservation case study

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