“SITRA Energy Audit” – Implementation Strategy in Textile Mills

K.R. Chandran and P. Muthukumaraswamy

The South India Textile Research Association, Coimbatore-641 014

Abstract

The energy cost in increasing at a faster pace and is the largest conversion cost accounting for about
10% of the sales and almost 5 times the net profit margin a spinning mill can earn under normal trading
condition. Energy audit is the starting point of an energy management plan to reduce the overall cost of
production. SITRA is regularly conducting Energy Audit in textile mills and has so far covered 250 textile
mills within the country and abroad. While implementing the recommendations of the audit, the mills have
experienced certain problems in the area of electrical systems, energy efficient components and
ancillaries. An analysis has been made for 43 mills, where SITRA has audited during the past 3 years.
This paper provides the implementation strategy with solutions for each problem. The audited textile mills
have realised an energy saving of about saving of about 30% of the projected savings.

Keywords: Energy audit, implementation strategy, electrical system, and conservation measures.

Introduction

In Indian textile industry, energy has become the largest conversion cost at about 10% of sales and
almost 5 times the net profit margin the mill can earn under normal trading condition. In order to reduce
the overall energy cost, many government and non-government and non-government organisations are
involved in conducting energy audit in every industrial establishment in the Country. Moreover, the
government has made it as a mandatory requirement for almost all industries. Energy Audit is the starting
point of an energy management plan and it is an important process for taking stock of the available
system, so that it can highlight various issues for improvements. SITRA is regularly conducting Energy
Audits in textile mills and has so far covered 250 textile mills within the country. SITRA’s services have
also been retained by a number of mills located overseas such as Philippinnes, Thailand and Malaysia.
While implementing the recommendations of the audit, the mills have experienced certain problems in the
area of electrical system, energy efficient components and ancillaries. An analysis has been made for 43
mills, where SITRA has audited during the past 3 years. This paper highlights the implementation strategy
and provides practical solutions for each problem encountered.

Sitra Energy Audit

Energy cost is increasing at an accelerating pace of about 11% to 12% i.e., doubling every 6 years as
against about 10% for wages cost and 7% to 8% for the other input costs. The cost of energy is the
largest component of conversion cost in modern spinning mills accounting for about 35% of the total. The
annual consumption of energy for a 30,000 spindle capacity spinning mill is about 10 million units (kWh),
which works out to over Rs. 4.0 crores per year.

The TRAs have evolved energy consumption norms in terms of units per kg of yarn (UKG) for various
productive and auxiliary machines including modern textile machines based on energy audits and specific
studies conducted at mill level over a period of two decades. These norms provide valuable ‘Bench
Marks’ against which performance of different machines can be judged. The process of evolving norms is
continuous and the values are being periodically revised on the basis of progressive technological
changes in the textile industry.

Based on the production data provided by the mill under consideration and actual measurements made
during the audit, the Units per kg (UKG) of yarn production for 40s converted has been computed and
compared with SITRA Energy Norm. With the computed energy norm and UKG, in-depth analysis has
been made on energy consumption of main drives, auxiliaries, and machinery parameters, processing
parameters, electrical parameters, and electrical network system to find out and pinpoint the excess
energy consumption in a particular machine. Based on the mill level audit, a comprehensive report with
recommendations highlighting the financial implications is submitted to the mill for implementation.

Energy Saving Potential

Energy saving potential has been studied in 43 mills audited by SOTRA during the last 3 years. The
saving potential in these mills are represented in Table-1. The spindleage of the mills is on the average
about 25000 and ranges from 6000 to 60000. In the audited mills, energy cost averaged about Rs. 1800
per spindle per year and the inter-mill difference was found to be very high at about 6 times ranging from
a low of Rs. 800 to a high of Rs. 4800. The difference in the count pattern accounted for major share of
this variation. The energy cost per spindle per year being around Rs. 4000 for an average count of 25s
and slightly above Rs. 1000 for an average count of about 60s. The level of modernisation and the energy
conservation measures initiated by the mills are the other contributing factors for this wide variation. The
energy cost can be reduced on the average by about Rs. 50 lakhs per year per mill (Fig.1). Potential
savings from energy at about Rs. 200 per spindle per year is almost the same as the net profit margin a
spinning mill can earn under normal trading condition. In about one third of the mills a large saving of the
order of Rs. 200 to Rs. 350 per spindle per year is possible. Bulk of the saving accrues from productive
machines, electrical system and ancillaries accounting for one-sixth each (table 2).

Investment required to realise the projected saving Rs. 300 per spindle on the average is paid in a quick
period of just 1.7 years. In about third of the mills, the pay back is very short at a year or less. Large
investment goes to productive machines for replacement of aged spindles, conversion of energy efficient
fans in pneumafils, efficient spindle drive system for ring frames, energy efficient drive control system for
automatic cone winding machines etc., The electrical system accounts for one-sixth of investment mainly
for transformer load optimization, additional cables and capacitors, replacement of inefficient/aged
equipment etc., On an average ancillaries requires only one-fifteenth of investment. The ROI is very high
at about 150% in the case of ancillaries as against about 50% in the case of productive machines and
electrical system.

The scope for energy saving per unit spindle is found to be the same in small as well as large mill. In
modern mill, however, the expected saving was somewhat higher possibly because of high-energy
consumption and coarse count pattern. Modern mills generally consume more power but the projected
saving is not found to be governed by the level of modernisation. The excess energy consumption in
modern mills is mainly attributed to the higher consumption in ancillaries like waste evacuation system,
common pneumafil suction, compressors, fully automatic air conditioning plants etc., and high level of
automation. This has to be compensated by way of improved quality, productivity and higher earnings
through exports and labour compliments. However, the scope of energy saving is found to be the same in
modern as well as old mills.

The feed back from mills showed that 15% to 30% of the anticipated savings have been realised.
Financial constraints and lack of expertise, infrastructural facilities and awareness are the main reasons
for non-implementation of energy conservation measures in mills.

Energy Conservation Measures

SOTRA Energy Audit consists of three major sections viz., (a) Electrical Engineering, (b) Textile
Engineering and (c) Mechanical Engineering. Based on the Energy
 Table 1 Energy Saving Potential in Different Mills

Mill No. Energy Savings Saving/ Investment Investment/

Payback
Identified Spindle/year Required Spindle Period
(lakh units/yr) Rs. (lakh Rs.) Rs. (Yrs)
1 2.12 51 9.9 58 1.1
2 7.31 78 23.1 60 0.8
3 9.05 97 40.4 106 1.1
4 5.22 100 45.4 212 2.1
5 2.75 103 14.9 135 1.3
6 5.91 103 30.6 131 1.3
7. 5.2 110 42.8 222 2
8. 6.7 117 22.5 96 0.8
9 7.33 120 69.1 276 2.3
10 11.37 126 99.9 269 2.1
11 8.71 130 86 312 2.4
12 4.59 134 41.8 299 2.2
13 7.38 137 66.8 303 2.2
14 18.43 139 65.7 121 0.9
15 2.05 140 29.1 485 3.5
16 3.56 146 36 360 2.5
17 7.28 155 66.4 344 2.2
18 10.48 167 58.6 228 1.4
19 6.45 169 53.2 340 2
20 5.74 169 41.1 296 1.7
21 8.92 173 80.9 383 2.2
22 5.97 173 42.5 301 1.7
23 9.61 174 80.8 356 2.1
24 9.09 174 78.1 364 2.1
25 12.44 174 92.7 317 1.8
26 7.54 175 74 419 2.4
27 11.48 184 41.3 161 0.9
28 10.69 186 46.6 197 1.1
29 5.02 187 67.2 611 3.3
30 16.33 188 71.9 202 1.1
31 14.37 200 165.2 559 2.8
32 8.21 206 51.2 314 1.5
33 5.57 209 60.8 556 2.7
34 10.86 211 86.1 408 1.9
35 14.87 213 109.1 382 1.8
36 4.55 216 24.7 286 1.3
37 4.65 230 21.6 260 1.1
38 15.22 238 58.2 222 0.9
39 12.9 267 114.3 577 2.2
40 29.02 291 232.2 568 2
41 41.99 301 279.6 488 1.6
42 6.89 368 23.3 304 0.8
43 6.89 510 202.8 331 0.6
Total 480.0 7739 3048.4 13219 75.8
Min 2.05 51 9.9 58 0.6
Max 76.2 510 279.6 611 3.5
____________________________________________________________________________________
Avg 11.2 180.0 70.9 307.4 1.7
Table 2 Energy Saving Potential and ROI for Each Category

Category Productive Electrical Ancillary Total

Machines System
Expected 117.2 32.3 30.5 180.0
Saving/Spindle/
Year (Rs.)

Investment/ 229.3 58.0 20.1 307.4

Spindle (Rs.)

ROI 51.1 55.7 151.7 58.6

Payback 1.96 1.79 0.66 1.71

Period (Yrs)

Audit and specific scientific studies conducted in textile mills, SITRA has developed/identified various
energy efficient equipment/energy conservation measures and successfully implemented in textile mills
all over the Country after thorough evaluation.

(a) Reduction in Energy Loss in Electrical System

The electrical distribution system represents the link between the utility and the mill load namely electrical
motors connected to machines, lighting, heaters etc. In addition to increase the performance of
distribution line, improvements can be made made in the equipment used in the system, such as
transformers, cables, switchgears, and capacitor banks etc., which are considered as major source of
energy loss in a mill.

(b) Component Correction or Modifications in Productive Machines.

In the earlier periods, not much importance was given to the energy saving aspects while developing the
textile machines indigenously or elsewhere due to comparatively less power cost than the other
conversion costs. There is a lot of scope available for improvement in this area.

(c) Optimisation of Ancillary or Supporting Systems

The energy saving potential in ancillaries or supporting system is about 20%. It consists of Humidification
plants, Lighting, Compressors, Workshop, Pumping stations, water treatment plants etc.

The energy conservation measures identified in each category and the activities involved for
implementation are briefly discussed below:

1. Optimisation of load on transformers

2. Compensation of reactive power
3. De-ration of cable size on length
4. Minimising usage of voltage regulators
5. Replacement of inefficient equipment
6. Electronic end break detectors for Simplex machines
7. Lighter spindles with lower wharve diameter
8. Optimisation of ring diameter with respect to count processed
9. Use of energy efficient pneumafil suction fans – SITRA Excel Fans
10. Energy efficient spindle drive system for ring spinning and doubling frames-SITRA Enerspin
Drive System
11. Energy efficient drive control system for Automatic cone winding machine-SITRA ENERCONER
12. Modified outer pot for TFO machines
13. Optimisation of humidification system/operation
14. Efficient utilisation of compressed air system
15. Energy efficient lighting system

Implementation Strategy

Naturally, the implementation strategy should start with order of priority. While selecting the
implementation programme, the following order preference may be followed:

1. Basic cause for many other day-to-day problems

2. Measures require least investment with shorter payback period
3. Problematic measures for implementation

Basic cause for many other day-to-day problems

Sometimes, problems related to electrical system and ancillaries assume greater importance. The
following are the main reasons for higher energy consumption, higher inventory and less production in
these areas:

• Acute under voltage conditions- root cause for many motor burnouts, downtime, production loss etc.
• Adverse ambient conditions – leads to motor heating, burnouts, bearing problems, excess end
breakages etc.

Measures require least investment with shorter payback period

Some measures like optimization of process parameters in productive machines, reduction in utilisation of
ancillaries, rationalisation of load on transformers involve only good energy management practices and
require no investment. Some other measures like shifting of capacitor banks near to load end, use of
energy efficient pneumafil suction fans etc., require certain investment and at the same time provide
shorter payback period. Accordingly the implementation schedule has to be planned.

Problematic measures for implementation

Any implementation schedule invariably encounters certain practical difficulties. The major reasons for
non-implementation of energy conservation measures include: financial constraints, lack of expertise, lack
of infrastructural facilities, lack of awareness, economical viability, technical feasibility, and modernisation
plan.
The Recommendations given in the SITRA Energy Audit reports are based on scientific studies and
subsequent verification at a mill level; therefore, they are all practical in nature. But some mill have
reported problems/ difficulties during implementation or not realised the anticipated savings. The
difficulties experienced, possible cause for it and correct solution are discussed below for each
conservation measure:

Measure 1: Optimisation of load on transformers

Distribution transformers are the high current handling equipment used to transform the incoming HT
supply voltage to the required voltage level at the mill. Transformer is the heart of the electrical network
and any anomaly in its rating or functioning affects the voltage level in the system with increase in self-
energy loss. The best performance of the transformer is expected only in the load range of 50% to 60%
and near to unity pf operation. In many cases, augmentation of transformer capacity is recommended to
reduce transformer loss with improvement in voltage regulation.

Problems

1. Requirement of heavy investment.

2. Long payback period.
3. Financial constraints.

Solution:

Since it is the investment made for infrastructure, longer payback period is acceptable. Based on found
availability, the measure can be implemented as early as possible.

Measure 2: Compensation of reactive power

While using electric motors, the distribution system delivers a form of power known as “reactive power.”
Supplying large amount of reactive power through the distribution system increases current and energy
losses. To improve the efficiency of electric system, connection of capacitor at load end is recommended.
The reactive power compensation is achieved by reducing the amount of current flow in cables,
switchgears, transformers etc., thereby minimising the I2R losses in the line for energy conservation.

Problems

1. Reluctance to correct power factor (mill side), due to non-enforcement from utility side.
2. Changeover problems during power interruptions.
3. Possible power quality effects.
4. Less realisation of energy saving when compared to cost of new equipment.
5. Additional operation and maintenance cost associated with many dispersed installations.

Solutions

1. Increased incentives to mills by utilities for improvement in pf and additional penalty for low pf
maintenance.
2. Optimise VAR control function under the Distribution System Automation option so as to switch-
on the capacitors at right time.
3. Use of detuned capacitors in case of harmonic loads.
4. Use of sufficient transient and surge suppressors for all electronic loads.

Measure 3: De-ration of cable size on length

Generally, power distribution is made through cables and during power handling, transmission loss or I2R
loss in cables in imminent. This loss increases with increase in cable length. Invariably, in most of the
mills the powerhouse in situated at one end (of the mill) and end up with transporting LT power over long
distances, which involves loss of energy. To minimise the transmission loss, suitable size of cables,
rationalization of cables and additional run of cables are recommended.

Problems

1. Additional investments with longer payback period.

2. Difficulty in handling more number of runs at joints or junctions.
3. Unequal sharing of current between runs.

Solutions

1. Since the investment is for infrastructural development, longer payback period is acceptable.
2. Based on technical feasibility, the mills can opt for either additional run of same size cable or
bigger size cables wit few runs.
3. The problem of unequal sharing may be avoided by taking proper care at junctions/joints.

Measure 4: Minimising usage of voltage regulators

Many small capacity LT stabilizers are being used in some mills to overcome the voltage problems at tail
ends. This equipment itself consumes about 4% of energy and is prone to malfunction over a period of
time. Instead, it is recommended to use centralized voltage correction equipment at one place like HT
stabilizer/Buck-Boost transformer or transformers with On-load-tap-change arrangement (OLTC). In one
particular mill, saving in energy to the tune of about 4.8 lakh units per annum was identified through this
measure.

Problems

1. High investment with longer payback period.

2. Many machinery suppliers insists localized safety features.

Solutions

1. Longer payback period is justifiable because the investment is utilised for infrastructural
development.
2. The commercially available localized safety features such as under/over voltage tripping controls,
surge/spike suppressors etc., can be provided.

Measure 5: Replacement of inefficient equipment

Under continuous working condition, the machinery parts, prime movers, switchgears, protective devices
etc., are bound to undergo strain due to over loading, under voltage and adverse ambient conditions
resulting in efficiency drop over a period of time.

Problems

1. Non-replacement of inefficient equipment.

2. Non-compliance of preventive maintenance plan.

Solutions

1. No-load power measurement of motors is necessary after each and every burnout
2. If the no-load power exceeds 8% of the full load power, it is recommended to discontinue the
motor from regular service.
3. Replacement of existing motors with energy efficient motors saves about 4% of energy.
4. Provision for good ventilation to motors, positive exhaust grilles nearer to the motors for heat
dissipation and periodical cleaning of the cooling fan grilles are recommended to prevent bearing
failure especially due to over heating.

Measure 6: Electronic end-break detectors for Simplex machines.

Modern simplex machines are provided with pneumafil suction tubes in the drafting zone to collect the
broken end fibres. The installed power of pneumafil suction system is about 1.5 –2 kW. F0r energy saving
purpose, photocell based electronic end-break detectors are recommended in place of pneumafil system
especially for finer count ranges. The cost of the system is about Rs. 20,000 and the pay back period is
about 4 months. Many mills have already implemented this proposal.

Problem

The upto-electronic end break detectors are suitable for cotton and man-made fibres of medium and fine
count ranges. While producing coarser counts and dyed fibres, the stop motion system is less effective
due to accumulation of fibres over the optical path of the detector. The bottom clearer waste also causes
problems due to loose fly in the delivered material. Therefore, the pneumafil suction system cannot be
eliminated completely for coarser hank particularly at higher delivery rates.

Solutions

Though this system is slightly less effective for coarser hank, it is possible to overcome the problem by
alternative arrangements.

1. The operation of suction system can be made intermittent to collect the bottom clearer waste and
the liberated fly.
2. Whenever the end-break occurs, the suction system can be actuated by suitable electronic
circuitry/timer.

Measure 7: Lighter spindles with lower wharve diameter

In ring spinning frame, spindles consume about 30% of the energy consumption. Lighter (from 320 g to
265 g) and lower wharve diameter (from 25 mm/ 22.5mm to 18.8mm) spindles consume about 10% less
energy with lower speed operation of tin roller shaft.

Problems

1. The replacement cost of spindles is high; for a long length frame of 1008 spindles, the investment
required is about Rs. 4 lakh.
2. The pay back period is also not attractive since the average life of spindles is about 8 years.

Solution

It is recommended to implement the measure only during the normal replacement period / at the end of
their life span.

Measure 8: Optimisation of ring diameter with respect to count processed.

The ring diameter significantly influences on package power of the ring frame. Larger ring diameter
facilitates higher cop content with heavier package resulting in excess power consumption. A reduction of
about 10% in cop content lowers the ring frame UKG by about 10%. For finer counts, 38mm/ 36mm
diameter and for medium counts 40mm ring diameters are recommended. The cost of implementation is
about Rs. 70000 for a long length ring frame of 1008 spindles and the payback period is about 2 years.

Problems

1. The count range for a specific period is unpredictable.

2. The life span of existing rings is also unpredictable due to high-speed operation.
3. Overall efficiency is reduced in post spinning section due to lower cop content.

Solutions

1. Based on the count ranges, the ring frames should be segregated with suitable ring diameter. It is
recommended to select 40mm rings for 30s count and below, 38mm rings for 60s and 80s and
36mm rings for 100s and above.
2. The reduction in efficiency in post spinning section can be compensated by running the machines
at a higher speed.

Measure 9: Use of energy efficient pneumafil suction fans – SITRA excel fans.

SITRA has developed energy efficient fans for pneumafils of various textile machines viz., ring frames,
carding frames, draw frames, simplex frames, automatic cone winding machine and overhead cleaners.
The energy consumption of pneumafil system is reduced by about 30% without affecting the suction
performance. The cost of SITRA Excel Fan is about Rs. 4000 and the pay back period is only 3 months.

Problem

1. Reduction in suction pressure especially at offend of the ring frame. The reasons include wrong
selection of fans, measurement error and improper mounting.

Solutions

1. Proper care should be taken while selecting the fan for a particular machine. It should be mainly
based on outer diameter, inner diameter, width number of blades in the existing fan and its
direction of rotation. Proper selection of fans ensures recommended suction pressure for a
specific machine.
2. The measurement error on suction pressure can be eliminated by using SITRA- Pneumakit.
3. Proper care should be taken while mounting the fans. The direction of rotation and minimum gap
between fan and suction duct should be checked.

Measure 10: Energy efficient spindle drive system for ring spinning and doubling frames

SITRA has developed an energy efficient drive system for ring spinning and ring doubling frames to
reduce the energy consumption. The energy consumption of the frame is reduced by about 8% without
affecting the yarn quality. The cost of the system is about Rs. 100 per spindle and the pay back period is
only 2 years.

Problems

1. Financial constraints.
2. Reluctance in converting the frames due to lack of awareness.

Solutions

1. Based on the availability of funds, ring doubling frames and then ring spinning frames can be
converted.
2. The mills can approach SITRA for all technical assistance/successful implementation.
Measurer 11: Energy efficient drive control system for automatic cone winding machines- SITRA
enerconer

The suction fan motor consumes about 70% of the total energy in automatic cone winding machines. In
SITRA ENERCONER, the operation of suction fan motor is regulated using a variable frequency drive,
vacuum sensor and an electronic circuitry. This system saves about 20% of the total energy consumption
by optimising suction pressure requirement based on end breakage rate.

Problem

1. Financial constraint.

Suggestion

Based on the fund availability, this measure can be implemented as early as possible. The pay back
period is only 15 months.

Measure 12: Modified outer pot for TFO machines

In two for one twisting machines, the balloon tension of yarn accounts for about 50% of total power
consumption. The balloon diameter has been reduced with reduction in yarn tension by providing a
modified outer pot. This measure saves about 4% of total energy consumption in TFO.

Problem

Anticipated problem is yarn quality in terms of twist, strength and hairiness.

Remark

Study shows that there is no deterioration in yarn quality and mills can use the modified outer pot to
reduce the energy consumption in TFO.

Measure 13: Optimisation of humidification system/operation

Humidification system accounts for about 15% of the total energy consumption in a mill. The
humidification plants are to be judiciously operated based on the outside conditions in different seasons.
In multi-fan system, the non-working supply fan should be isolated to avoid recirculation of air inside the
supply plant room. The pneumafil air must be collected in a separate duct and a positive exhaust must be
provided for the same to avoid backpressure in the pneumafil system. The capacity of the exhaust and
pumping system should be 80% and 45% of the supply system respectively to avoid excess energy
consumption. Inter connection of plants is to be avoided for better performance. Provision of rotary filters
for exhaust systems, V-type filters for supply system, PVC clamp-on type water nozzles, Attic area (space
between roof and false ceiling) ventilation, proper design of ducts and grilles, separate energy meter for
plants are some of the other measures for conservation of energy.

Problems

1. Over-designed humidification plants.

2. Non-compliance of maintenance plan.
3. Lack of training for the operatives.
Solutions

1. Proper consultancy is required for optimum design of plants.

2. Routing maintenance plan should be strictly adhered.
3. To create energy saving awareness, the operatives should be trained.
Measure 14: Efficient utilisation of compressed air system

Compressed air system accounts for about 6% of total energy consumption in a mill. For compressed air
system, refrigerative air driers are preferable when compared to heatless air dryers. The pressure drop
should not be more than 0.5 kg/sq/cm in the longest line. The pipe sizes are to be designed for this
condition taking into account the airflow in each pipeline. The drop in suction air pressure due to filter
chocking will lead to reduction in compressor efficiency. Cool, clean and dry air intake gives more efficient
compression. If the atmospheric air has more than 75% RH, moisture forms during compression and as a
liquid it condenses in the after cooler and piping system. This increases the internal resistance for airflow
resulting in more pressure drop and less efficiency. For every 1o C raise in inlet air temperature, an
additional 1% energy will be needed for the equivalent output. The recommended capacity of the air
receiver is to be 0.0425 cubic metre per 6 cubic metre/hour of the compressor. If the capacity of the air
receiver is less than this size, the energy consumption of the compressor will increase. The pipeline
system handling compressed air should not have air leakages. When the compressed air pipelines were
not maintained properly, a maximum of 15% of power loss has been noticed in the mills. Pressure
reducing valves can be fitted in the pipelines so that air at reduced pressure of about 2 to 3 kg/sq. cm can
be used instead of about 7 to 8kg/sq.cm for cleaning purposes.

Problems

1. Improper selection of compressors and accessories.

2. Insignificant importance to air leakages.
3. Lack of awareness on energy saving methods.

Solutions

1. Utmost care is needed while selecting the compressor and its accessories for the intended
purpose.
2. Air leakages should be identified using ultrasonic leakage detector and arrested immediately.
3. Awareness program on energy saving methods in necessary for the operatives.

Measure 15: Energy efficient lighting system

Lighting system constitutes about 4% of the energy consumption in mill. Energy efficient fluorescent tubes
reduce the installation of number of tubes without affecting the illumination level resulting in energy
saving. The lighting system requires only around 200 V, but in a 3-phase system, 240 V is being supplied.
This higher voltage invariably increases the energy consumption and also reduces the life of fluorescent
tubes. To avoid this, LT servo stabilizer of suitable capacity is recommended in the main lighting feeder
with the set voltage of around 200V. This measure ensures a saving of about 10%. The conventional
copper ballasts can be replaced with electronic ballasts to save about 20% of energy.

Problems

1. Life of electronic ballast is less in some cases.

2. Financial constraints.

Solutions

1. Selection of good make and maintenance of correct voltage can improve the life of ballasts.
2. Based on the financial position, the implementation can be in a phased manner.

Energy Conservation Programme (ECP)

For effective control on energy in a mill, Energy Conservation Programme (ECP) must be a regular
activity and should have its own staff. The conservation routing would comprise periodical measurement
of power consumption on each individual machine, as well as comparison of the consumption levels with
that to be expected. The routine also includes diagnostic checks on checks on motors, analysis of the
extent and causes of motor burnouts, and estimating the possible savings.

The system of monitoring and reporting is essential for effective control of energy consumption in
productive machines, ancillaries and power handling system in a mill. High tension (HT) metering is
necessary to monitor the quality and quantity of utility power supply. Many mills have not given much
importance and only about less than 10% of the mills are provided with HT metering on mill side.
Similarly, a separate set of meter is required to assess the quality of power supplied by each transformer.
About 2/3 of the mills are provided with voltage, current and pf meters and only half of the mills are
equipped with frequency meters.

For effective preventive maintenance, it is necessary to keep the records like logbooks of transformers
and generators, yard maintenance schedules, data on earth resistance, motor burnout etc., Even though
most of the mills are having the records, only 50% of the mills are regularly updating it and 1/3 only
utilizing it for timely replacement and undertaking preventive measures.

ECP is not a one-time affair and it is a continuous process. The following are some of the aspects that
could be reported to the Management on a regular basis:

- A count-wise comparison of the actual UKG and mill standard UKG should be made with
the respective SITRA Norms.
- The break-up of actual and mill standard UKG for different departments including
ancillaries and the causes for the variation between the two, if any.
- The number of units per 1000 spindle shift (USS), average and variation between days
together with the standard USS. The number of days where the USS is significantly more
along with the causes.
- The units per litre of oil (ULO) for each generator as well as their utilization, loading etc.,
Causes for the variation in the consumption of lubricants between and within generators.
- The average power factor (pf) and maximum demand (MD) with level of variation from
day to day and the causes.
- Comparison of existing motor capacity (hp) and that recommended.
- Rate of motor burnouts separately for each department with capacity and type.
- List of energy conservation measures proposed, implemented, and to be undertaken
along with the reasons for delay, if any.
- Comparison of energy cost with the yarn sales revenue.

It would be useful if some of the parameters like the overall UKG, USS, energy cost, pf, and MD are
plotted in a control chart with action and warning limits so that the performance can be judged at a glance
and trends of improvement or deterioration indicated. The frequency of reporting for most aspect could be
fixed once a week.

Conclusions

Comprehensive Energy Audit undertaken in 43 mills revealed and following:

• Energy cost per spindle different widely between mills by a factor of 6, the count and type of yarn
account for about two-third of the variation.
• Energy cost can be reduced on the average by about Rs. 50 lakhs per year per mill.

• The saving potential is independent of size and level of modernisation, somewhat high in modern
mills.
• Modern mills consume more power mainly due to high consumption of ancillaries like waste
evacuation system, common pneumafil suction, compressors, fully automatic air conditioning plants
etc., and high level of automation.
• Potential saving from energy at about Rs. 200 per spindle per year is almost the same as the net
profit margin a spinning mill can earn under normal trading conditions.
• In about one third of the mills, a large saving of the order of Rs. 200 to 350 per spindle per year is
possible.
• Bulk of the saving – 65% accrues from Productive Machines, Electrical Systems and Ancillaries
accounting for about one-sixth each.
• Investment required to realise the projected saving Rs. 300 per spindle on the average is paid back in
just 1.5 years. In about a third of the mills the pay back is very short at a year or less.
• ROI is very high at over 100% in the case of investment on Ancillaries as against about 50% in the
case of Productive Machines and Electrical Systems.
• Feed back from mills showed that 15% to 30% of the anticipated savings have been realised.
• Financial constraints and lack of expertise, awareness and inadequate infrastructural facilities are the
main reasons for non-implementation of the energy conservation measures in mills.
• Effective monitoring and reporting system is not fond to be in operation in a vast majority of the mills.

The nature of problems encountered by the mills and suitable solutions are discussed individually under
15 major energy conservation measures.

Acknowledgement:

The authors would like to thank Ms. Indra Doraiswamy, Director, SITRA for the constant encouragement
in energy related studies and Shri. T. V. Ratnam, Research Advisor, SITRA for the valuable suggestions
during the preparation of this paper. The authors would also like to thank the management and staff of
member textile mills for their help and co-operation during the energy audits and specific studies related
to energy conservation. The co-operation extended by the members of SITRA Energy Audit Team for
conducting various studies at mill levels is gratefully acknowledged. The authors also acknowledge Mr. M.
Alagarsamy of Textile Instrumentation Division for compilation of mill data during the preparation of this
paper.

References

1. Energy Management by Conservation Measures in Textile Industry K.R. Chandran, R. Prakasam

and P. Muthukumarswamy International Conference on Energy –Asia Energy Vision 2020-
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Muthukukmaraswamy and R. Prakasam SITRA Publication, Vol. 45 No. 8, December 2000.
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Muthukumaraswamy, D. Shanmuganandam and T.V. Ratnam 41st Technological Conference,
BTRA, Mumbai, February 12-13, 2000, p. 189 – 195.
8. Energy Efficient Drive Control System for Automatic Cone Winding Machines- “SITRA
ENERCONER” P. Muthukumaraswamy, R. Prakasam, and H. Balasubramanian SITRA
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Reference Book:
43rd Joint Technological Conference
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