A.

Vital factors for Energy Conservation in

Spinning:
The following section has been prepared to help the industries to keep into consideration the factors highlighted while
doing in-house energy audits.
1.

Gas Generator Sets

Optimise loading

Use waste heat to generate steam/hot water /power an absorption chiller or preheat process or
utility feeds

2.

3.

Use jacket and head cooling water for process needs

Clean air filters regularly

Insulate exhaust pipes to reduce GG set room temperatures

Proper exhaust is essential to maintain the GG set room temperature

Waste heat recovery

Recover heat from flue gas, engine cooling water and engine exhaust.

Use waste heat for fuel oil heating, outside air heating, etc.

Use chiller waste heat to preheat hot water.

Use heat pumps.

Use absorption refrigeration.

Use thermal wheels, run-around systems, heat pipe systems, and air-to-air exchangers.

Electricity Distribution System

Schedule your operations to maintain a high load factor.

Shift loads to off-peak times if possible in case of ESCO services.

Minimise maximum demand by using automatic demand controller.

4.

Stagger start-up times for equipment with large starting currents to minimize load peaking.

Use standby electric generation equipment for on-peak high load periods.

Correct power factor to at least 0.95 under rated load conditions.

Relocate transformers close to main loads.

Optimize transformer working parameters.

Set transformer taps to optimum settings.

Consider proper electric load management system.

Consider on-site electric generation or cogeneration.

Export power to grid if you have any surplus in your captive generation.

Check utility electric meter with your own meter.

Shut off unnecessary equipments when not in use.

Motors

Properly size to the load for optimum efficiency.(High efficiency motors offer of 4 - 5% higher
efficiency than standard motors)

Use energy-efficient motors where economical.

Use synchronous motors to improve power factor.

Check alignment.

Provide proper ventilation (For every 10 oC increase in motor operating temperature over
recommended peak, the motor life is estimated to be halve)

Check for under-voltage and over-voltage conditions.

Use Soft-starter & Star-Delta transition as per need

Balance the three-phase power supply.

(An imbalanced voltage can reduce 3 - 5% in motor input power)

Demand efficiency restoration after motor rewinding. (If rewinding is not done properly, the
efficiency can be reduced by 5 - 8%)

5.

6.

Drives

Use variable-speed drives for large variable loads.

Use high-efficiency gear sets.

Use precision alignment.

Check belt tension regularly.

Eliminate variable-pitch pulleys.

Use flat belts as alternatives to v-belts.

Use synthetic lubricants for large gearboxes.

Eliminate eddy current couplings.

Shut them off when not needed.

Fans

Use smooth, well-rounded air inlet cones for fan air intakes.

Avoid poor flow distribution at the fan inlet.

To eliminate damper positioning use inverters to serve that purpose

Minimize fan inlet and outlet obstructions.

Clean screens, filters, and fan blades regularly.

Set schedule to clean the ducts.

Use aerofoil-shaped fan blades.

Change old Aluminium fan blades with new FRP (Fibre Reinforced Plastic) blades

Minimize fan speed.

Use low-slip or flat belts.

Check belt tension regularly.

Eliminate variable pitch pulleys.

Use energy-efficient motors for continuous or near-continuous operation.

Eliminate leaks in ductwork.

Minimise bends in ductwork.

Turn fans off when not needed.

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7.

Blowers

Use smooth, well-rounded air inlet ducts or cones for air intakes.

Minimize blower inlet and outlet obstructions.

Clean screens and filters regularly.

Minimize blower speed.

Use low-slip or no-slip belts.

Check belt tension regularly.

Eliminate variable pitch pulleys.

Use energy-efficient motors for continuous or near-continuous operation.

Eliminate ductwork leaks.

Turn blowers off when they are not needed.

o
8.

Pumps

Operate pumping near best efficiency point.

Modify pumping to minimize throttling.

Use inverters to eliminate valve control

Stop running both pumps -- add an auto-start for an on-line spare or add a booster pump in the
problem area.

Use booster pumps for small loads requiring higher pressures.

Increase fluid temperature differentials to reduce pumping rates.

Repair seals and packing to minimize water waste.

Balance the system to minimize flows and reduce pump power requirements.

o
9.

Compressed air

Install a control system to coordinate multiple air compressors.

Study part-load characteristics and cycling costs to determine the most-efficient mode for
operating multiple air compressors.

Avoid over sizing -- match the connected load.

Load up modulation-controlled air compressors. (They use almost as much power at partial load
as at full load.)

Turn off the back-up air compressor until it is needed.

Reduce air compressor discharge pressure to the lowest acceptable setting.

(Reduction of 1 kg/cm2 air pressure (8 kg/cm2 to 7 kg/cm2) would result in 9% input power
savings. This will also reduce compressed air leakage rates by 10%)

Use the highest reasonable dryer dew point settings.

Turn off refrigerated and heated air dryers when the air compressors are off.

Use a control system to minimize heatless desiccant dryer purging.

Minimize purges, leaks, excessive pressure drops, and condensation accumulation.(Compressed

air leak from 1 mm hole size at 7 kg/cm2 pressure would mean power loss equivalent to 0.5 kW)

Use drain controls instead of continuous air bleeds through the drains.

Consider engine-driven or steam-driven air compression to reduce electrical demand charges.

Replace standard v-belts with high-efficiency flat belts as the old v-belts wear out.

Use a small air compressor when major production load is off.

Take air compressor intake air from the coolest (but not air conditioned) location.

(Every 50C reduction in intake air temperature would result in 1% reduction in compressor power
consumption)

Use an air-cooled after cooler to heat building makeup air in winter.

Heat exchangers should not be stained (e.g. with oil).

Air/oil separators should not foul.

Supervise pressure drops across suction and discharge filters and clean or replace filters on time
upon alarm.

Use a right sized compressed air storage receiver.

Minimize disposal costs by using lubricant that is fully demisable and an effective oil-water
separator.

Be sure lubricating oil temperature is not too high (oil degradation and lowered viscosity) and not
too low (condensation contamination).

Consider alternatives to compressed air such as blowers for cooling, hydraulic rather than air
cylinders, electric rather than air actuators, and electronic rather than pneumatic controls.

Use nozzles or venturi-type devices rather than blowing with open compressed air lines.

Check for leaking drain valves on compressed air filter/regulator sets.

Launch a compressed air efficiency-maintenance program.

Use waste heat from a very large compressor to power an absorption chiller or preheat process or
utility feeds.

Approximately 10% of the electrical energy supplied to industry is used to compress air and
typically some 30% of this is energy is lost due to leaking systems.

Walk the system outside normal production hours - listen for leaks, valves left open and faulty
fittings.

Blocked or dirty intercoolers will increase the power used by the compressor.

Ideally you should monitor how often the compressors run on a week-by-week basis.

Blocked intake filters reduce efficiency, can increase power absorbed by 4%. Therefore saving
energy by changing an intake filter.

Poor ventilation has exactly the same effect as a blocked intake filter as this starves the
compressor. Make sure that ventilation grills are kept clear from obstruction.

Full ducted space heating. Compressor cooling air can be 20 25 oC warmer than ambient air. If
the flow is great enough, hot air can be ducted into a workshop or warehouse to provide 'free' space
heating.

Air tempering. If the hot air flow is insufficient for full space heating, it can still be

ducted into

the existing space heating system to provide pre-heating

Keeping product and packing materials dry.

Standby compressors turn on when they are not necessary.A system with insufficient storage
will also show the following symptoms:

Pressure losses increase down the distribution pipe so that the pressure at point of use is much
lower than at the compressor.

Keep air velocities in the main header system below 6 m/sec. If in doubt, ask your compressor
supplier to calculate the correct pipe size to suit your compressor.

Keep the system pressure drop below 0.2 bar. High pressure drops indicate that the air pipe is too
small, stifling the airflow.

Replace rusty pipe.

Use long radius bends instead of elbows.

Monitor the system to make sure that site pressure is acceptable for all of the production
processes. Modify the operating pressure if necessary.

Use transvector nozzles for amplifying air flow for cleaning and parts ejection.

o
10. Cooling towers

Cover hot water basins (to minimize algae growth that contributes to fouling).

Control to the optimum water temperature as determined from cooling tower and chiller
performance data.

Periodically clean plugged cooling tower water distribution nozzles.

Use two-speed or variable-speed drives for cooling tower fan control if the fans are few. Stage the
cooling tower fans with on-off control if there are many.

Turn off unnecessary cooling tower fans when loads are reduced.

Control cooling tower fans based on leaving water temperatures.

Balance flow to cooling tower hot water basins.

Optimize cooling tower fan blade angle on a seasonal and/or load basis.

Install new nozzles to obtain a more-uniform water pattern.

Replace splash bars with self-extinguishing PVC cellular-film fill.

On old counter flow cooling towers, replace old spray-type nozzles with new square-spray ABS
practically-non-clogging nozzles.

Replace slat-type drift eliminators with high-efficiency, low-pressure-drop, self-extinguishing, PVC

cellular units.

If possible, follow manufacturer's recommended clearances around cooling towers and relocate or
modify structures, signs, fences, dumpsters, etc. that interfere with air intake or exhaust.

Correct excessive and/or uneven fan blade tip clearance and poor fan balance.

Use a velocity pressure recovery fan ring.

Divert clean air-conditioned building exhaust to the cooling tower during hot weather.

Re-line leaking cooling tower cold water basins.

Check water overflow pipes for proper operating level.

Optimize chemical use.

Consider side stream water treatment.

Restrict flows through large loads to design values.

Shut off loads that are not in service.

Implement a cooling tower winterization plan to minimize ice build-up.

Install interlocks to prevent fan operation when there is no water flow.

Establish a cooling tower efficiency-maintenance program. Start with an energy audit and followup, then make a cooling tower efficiency-maintenance program a part of your continuous energy
management program.

o
11. Lighting

Reduce excessive illumination levels to standard levels using switching, delamping, etc. (Know the
electrical effects before doing delamping.)

Aggressively control lighting with clock timers, delay timers, photocells, and/or occupancy sensors.

Install efficient alternatives to incandescent lighting, mercury vapor lighting, etc. Efficiency
(lumens/watt) of various technologies range from best to worst approximately as follows: low pressure
sodium, high pressure sodium, metal halide, fluorescent, mercury vapor, incandescent.

Select ballasts and lamps carefully with high power factor and long-term efficiency in mind.

Upgrade obsolete fluorescent systems to Compact fluorescents and electronic ballasts or LED
Lights

Consider daylight, skylight savings.

Consider painting the walls in lighter colours and using less lighting fixtures or lower wattages.

Use task lighting and reduce background illumination.

Re-evaluate exterior lighting strategy, type, and control. Control it aggressively.

Change exit signs from incandescent to LED.

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12. Miscellaneous

Meter any un-metered utilities to know what normal efficient use is and to track down causes of
deviations.

Shut down spare, idling, or unneeded equipment.

Make sure that all of the utilities to redundant areas are turned off -- including utilities like
compressed air and cooling water.

Install automatic control to efficiently coordinate multiple air compressors, chillers, cooling tower
cells, boilers, etc.

Consider buying utilities from neighbours, particularly to handle peaks.

Eliminate unnecessary flow measurement orifices.

B. Vital Factors For Energy Conservation In

Processing:
Textile processing in general is considered as an art not science by the workers who have learnt this art from their seniors and
enhanced it by getting field experience. They carry out textile processing with conventional techniques and hardly adopt best
practices or any thing different from their natural working style. Due to lack of education and training, they are unable to
understand the chemistry behind each process. They cannot understand that these chemical processes are based on certain process
parameter such as temperature, concentration and PH. Slight variation in these parameters can result into either excess use of
chemicals or deterioration of fabric quality, in most of the cases. In the absence of the feeling of their importance among workers,
they consider controlling, monitoring and reading them in daily log sheets less important.
The following generic norms interpret various consumption parameters p/kg of fabric:

Water Consumption Norms (per kg)

World Consumption
50 100 litre / kg of fabric

National Consumption
Sindh 50 80 litre / kg of fabric
Punjab 200 300 litre / kg of fabric

Steam Consumption Norms (per kg)

6 8 kg of steam / 1 kg of fabric

Electricity Consumption Norms (per kg)

0.8 1.5 KWh / 1 kg of fabric

Natural Gas Consumption Norms (per kg)

0.35 m3 gas / kg of fabric

The following section has been prepared to help the processing industries to keep into consideration the factors highlighted while
doing in-house energy audits.
1.

Boilers

Preheat combustion air with waste heat

(22 0C reduction in flue gas temperature increases boiler efficiency by 1%)

Use variable speed drives on large boiler combustion air fans with variable flows.

Burn wastes if permitted.

Insulate exposed heated oil tanks.

Clean burners, nozzles, strainers, etc.

Inspect oil heaters for proper oil temperature.

Close burner air and/or stack dampers when the burner is off to minimize heat loss up
the stack.

Improve oxygen trim control (e.g. -- limit excess air to less than 10% on clean
fuels). (5% reduction in excess air increases boiler efficiency by 1% or: 1% reduction of
residual oxygen in stack gas increases boiler efficiency by 1%.)

Automate/optimize boiler blowdown. Recover boiler blowdown heat.

Use boiler blowdown to help warm the back-up boiler.

Optimize deaerator venting.

Inspect door gaskets.

Inspect for scale and sediment on the water side (A 1 mm thick scale (deposit) on the
water side could increase fuel consumption by 5 to 8%).

Inspect for soot, flyash, and slag on the fire side (A 3 mm thick soot deposition on the
heat transfer surface can cause an increase in fuel consumption to the tune of 2.5%.)

Optimize boiler water treatment.

Add an economizer to preheat boiler feed water using exhaust heat.

Recycle steam condensate.

Study part-load characteristics and cycling costs to determine the most-efficient mode
for operating multiple boilers.

Consider multiple or modular boiler units instead of one or two large boilers.

Establish a boiler efficiency-maintenance program. Start with an energy audit and

follow-up, then make a boiler efficiency-maintenance program a part of your continuous
energy management program.

2.

Steam System

Fix steam leaks and condensate leaks (A 3 mm diameter hole on a pipe line carrying 7
kg/cm2 steam would waste 33

kilo litres of fuel oil per year).

Accumulate work orders for repair of steam leaks that can't be fixed during the heating
season due to system shutdown requirements. Tag each such leak with a durable tag with
a good description.

Use back pressure steam turbines to produce lower steam pressures.

Use more-efficient steam desuperheating methods.

Ensure process temperatures are correctly controlled.

Maintain lowest acceptable process steam pressures.

Reduce hot water wastage to drain.

Remove or blank off all redundant steam piping.

Ensure condensate is returned or re-used in the process (6 0C raise in feed water

temperature by economiser/condensate recovery corresponds to a 1% saving in fuel
consumption, in boiler)

Preheat boiler feed-water.

Recover boiler blowdown.

Check operation of steam traps.

Remove air from indirect steam using equipment (0.25 mm thick air film offers the
same resistance to heat transfer as a 330 mm thick copper wall).

Inspect steam traps regularly and repair malfunctioning traps promptly.

Consider recovery of vent steam (e.g. -- on large flash tanks).

Use waste steam for water heating.

Use an absorption chiller to condense exhaust steam before returning the condensate
to the boiler.

Use electric pumps instead of steam ejectors when cost benefits permit

Water management system should be there to optimize its utilization

Establish a steam efficiency-maintenance program. Start with an energy audit and

follow-up, then make a steam efficiency-maintenance program a part of your continuous
energy management program.

3.

Insulation

Repair damaged insulation

(A bare steam pipe of 150 mm diameter and 100 m length, carrying saturated steam
at 8 kg/cm2 would waste 25,000 litres furnace oil in a year.)

Insulate any hot or cold metal or insulation.

Replace wet insulation.

Use an infrared gun to check for cold wall areas during cold weather or hot wall areas
during hot weather.

Ensure that all insulated surfaces are cladded with aluminum

Insulate all flanges, valves and couplings

Insulate open tanks

(70% heat losses can be reduced by floating a layer of 45 mm diameter polypropylene

(plastic) balls on the surface of 90 0C hot liquid/condensate).

4.

Singeing & Desizing

Adjust flame angle according to the width of the fabric. Dont fix flame length
(intensity). Best practice for gas consumption is 0.35 m3 gas / kg of fabric.

Try to dip the selvedges of fabric in water before connecting flame.

Try to switch off one burner in case of shorter width fabric

Regular monitoring needed for maintaining PH of desizing bath.

Avoid over speeding during batching of desized rollers.

Avoid excessive use of desizer in desizing bath

Avoid long batching time, otherwise fungus will attack to enzymes

5.

Bleaching

Ensure removal of solid metallic particles in water & fabric, which can result in pin
holes in fabric

Ensure the temperature of more than 80 C in pre-washer

Regular monitoring needed for chemical dozing system

Regular monitoring needed for maintaining the roof temperature otherwise,

condensate dropping on fabric will damage quality

Balance the recipe with benchmarking consumption of Caustic & Hydrogen per Oxide

Over speeding of machine to be avoided to protect from wear & tear effects

Regular monitoring needed for water lock system of bleaching machine

Regular titration needed against recipe of existing quality of fabric, even in case of
automatic dosing system

Avoid direct steaming on fabric in washing chamber, turbulence effect, condensate

dropping effect can damage fabric quality

The mechanical squeezing effect through mangles may be maximized to reduce heat /
steam load in dryers

6.

Mercerization

Proper setting required for Bome B concentration for specific qualities of fabric. This
will help in saving caustic consumption

Avoid low concentrated supply of weak alkalis to CRU, otherwise more steam will be
required for evaporating weak solution

o
7.

Ensure clean environment near alkali storage tanks

Pad Steam

Maintain roof temperature for avoiding turbulence and condensation effects of steam
on fabric

Avoid excessive drain of more water from water lock system of this machine. Try to
maintain upto 45-50 C in the tray. This will help to reduce condensation and heat losses

8.

Thermosol

Proper dissolving of dyes and auxiliaries needed in mixing dyes

Ensure low temperature for high reactive dyes and high temperature for low reactive dyes

Ensure optimized system for Infrared (IR), so that water molecules should dry rather than dye
molecules, as per the concept of low energy and high wave length

Ensure proper cleaning of radiators for getting better results of listing problems