Garment

BEST PRACTICES REPORT
(SPINNING SECTOR)
Supported by
RENEWABLE ENERGY & ENERGY EFFICIENCY
PROGRAMME (REEE)
Renewable Energy & Energy Efficiency Programme (REEE)
DISCLAIMER
The Deutsche Gesellschaft fr Technische Zusammenarbeit (GTZ) GmbH is
implementing the Renewable Energy & Energy Efficiency (REEE) Programme
on the basis of a commission from the German Federal Ministry for Economic
Cooperation and Development (BMZ). On behalf of Government of Pakistan,
Small & Medium Enterprise Development Authority (SMEDA) & National
Productivity Organization (NPO) are implementing partners in this project.
The opinions and analyses expressed in this report do not necessarily reflect
the views and official policies of the REEE Programme.
This report is based on the findings of energy efficiency audits and will be
updated on a regular basis to include more suitable measures identified in
additional energy efficiency audits.
Title
Best Practices Report (VERSION 1.0) in Spinning Sector
Date
J anuary, 2008
TABLE OF CONTENTS
INTRODUCTION................................................................................................................................... 1
BACKGROUND ...................................................................................................................................... 1
ENERGY EFFICIENCY (EE)..................................................................................................................... 1
ENERGY EFFICIENCY (EE) PROJ ECT....................................................................................................... 1
ADVANTAGES / IMPORTANCE OF ENERGY EFFICIENCY ............................................................................ 1
1 ENERGY CONSUMPTION AND DISTRIBUTION................................................................... 3
1.1 PROCESS DESCRIPTION............................................................................................................ 3
1.2 ENERGY PURCHASE................................................................................................................. 4
2 ELECTRICAL DISTRIBUTION SYSTEM................................................................................ 5
2.1 PROBLEMS.......................................................................................................................... 5
2.1.1 Explanation of Electricity Bill .......................................................................................... 7
2.1.2 Control of MDI (Maximum Demand Indicator) ............................................................. 10
2.2 PROPOSEDACTIONS........................................................................................................ 10
2.2.1 Maintenance of Transformer.......................................................................................... 10
2.2.2 Power Factor Improvement ............................................................................................ 10
2.2.3 Energy Efficient Motors ................................................................................................. 12
2.2.4 Removal of Oversized Motors ......................................................................................... 13
2.2.5 Maintenance of Motors and Equipment ......................................................................... 13
2.2.6 Placement of Inverters on Motors .................................................................................. 14
2.2.7 Electric Load Management ............................................................................................ 16
3 AIR CONDITIONING................................................................................................................ 18
3.1 PROBLEMS........................................................................................................................ 18
3.1.1 Fixed Fans...................................................................................................................... 19
3.1.2 Air Change Requirements .............................................................................................. 19
3.1.3 Water Showering ............................................................................................................ 19
3.2.1 Replacement of Fixed Fans with Variable Fans............................................................. 19
3.2.2 Volumetric Air Flow Optimization.................................................................................. 20
3.2.3 Water Spraying Nozzles .................................................................................................. 21
4 COMPRESSED AIR SYSTEM.................................................................................................. 22
4.1 PROBLEMS........................................................................................................................ 22
4.1.1 Comparison of Reciprocating and Screw Type Compressors.......................................... 22
4.1.2 Key Findings................................................................................................................... 22
4.2.1 Pressure Monitoring....................................................................................................... 23
4.2.2 Air Leakages................................................................................................................... 23
4.2.3 Cleaning Points .............................................................................................................. 23
4.2.4 Air Quality...................................................................................................................... 24
4.2.5 Alternate Compressor Option ......................................................................................... 24
5 ENERGY SAVING POTENTIAL IN THE PRODUCTION..................................................... 25
5.1 PROBLEMS........................................................................................................................ 25
5.1.1 Unnecessary Running of Auxiliary Equipment .............................................................. 25
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5.1.2 Energy Loss due to Maintenance of Machine during Off Peak Hours........................... 25
5.1.3 Running of Machines at Low Load ................................................................................ 25
5.1.4 Heating of Production Halls........................................................................................... 25
5.2.1 Process Optimization...................................................................................................... 25
5.2.2 Heating of the Production Halls..................................................................................... 26
6 LIGHTING.................................................................................................................................. 27
6.1 PROBLEMS........................................................................................................................ 27
6.1.1 Magnetic Ballasts ........................................................................................................... 27
6.2.1 Effective Lighting........................................................................................................... 27
6.2.2 Electronic Ballasts.......................................................................................................... 27
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INTRODUCTION
BACKGROUND
The Small and Medium Enterprise Development Authority (SMEDA) as well as
the National Productivity Organization (NPO) have been supported by the
Deutsche Gesellschaft fr Technische Zusammenarbeit (GTZ) GmbH to
introduce Energy Efficiency in the Textile Industry. This initiative helps the textile
sector address energy losses and related productivity, quality losses.
As a first exercise, detailed energy efficiency audits were conducted by national
consultants under supervision of international energy efficiency experts in six
textile units (two spinning units, two processing units and two integrated units).
ENERGY EFFICIENCY (EE)
Energy Efficiency (EE) by definition means using less energy to achieve same
or better output compared to pre-implementation of the energy efficiency
project.
Energy Efficiency does not mean rationing or having to do without energy.
Rather, energy efficiency means identifying wasteful energy usage, and taking
steps to reduce or eliminate that waste without adversely effecting the
production and the quality of output. Illustratively, the energy efficiency process
is depicted below as
ENERGY EFFICIENCY (EE) PROJ ECT
Energy Efficiency (EE) project refers to any process, technique or equipment
that helps to achieve reduction in energy consumption to perform a designated
operation to achieve same or better level of output while maintaining or
improving process time, quality, performance and safety with minimal
environmental impact.
ADVANTAGES / IMPORTANCE OF ENERGY EFFICIENCY
The following are some of the advantages of implementing EE projects:
Reduction in energy consumption, thereby adding directly to the profits
or bottom line of the company
Lowering the vulnerability to energy prices for unit/corporate that has
implemented EE projects
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Reducing the need for investment in newer power plants and import of
energy
Reducing the dependence on conventional resources like oil and natural
gas etc.
Reducing emissions of air pollutants in most cases

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1 ENERGY CONSUMPTION AND DISTRIBUTION
1.1 PROCESS DESCRIPTION
The general description of the processes with respect to energy consumption is
given under:
Process Description
Mixing
Bales of fibres (cotton/polyester etc) are received
from the godown are detached from the packing
materials and then opened. Raw fibres (cotton/
polyester etc.) taken out from the compressed
bales are mixed with each other manually to
make it homogenous.
Blowing
Fibres are homogenized manually as well with
machine. Foreign matters and dust particles in
the fibres are removed and clean fibres are
passed to the carding.
Carding
Carding is the first step in the spinning. Previous
processes are actually the preparatory steps for
carding. Fibres are passed through the carding
machines. Purpose of the carding is the fibre -to-
fibre opening. The tuffs of the fibres are
conveyed pneumatically into the machine and
passed over revolving belts equipped with wire
needles. A series of rotating brushes rests on the
top of the belt. The different rotation of the
needles and the brushes cause the fibres to
tease out and align into thin parallel sheets.
Shorter fibres, which would weaken the yarn, are
separated out.
Another purpose of the carding is to better align
the fibres to prepare them for spinning. The
sheets of the carded fibres are removed through
funnel and converted into loose rope like strand
called sliver.
Drawing
Several slivers are combined and fed to the
drawing machines. The drawing frame contains
several sets of rollers that rotate at successively
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Process Description
faster speeds. As the slivers pass through, they
are further drawn out and lengthened. Slivers of
different quality fibres (cotton/polyester etc.) may
be combined to form blends.
Simplex
Sliver from the finishing drawers are fed in to the
simplex machine where these are stretched
further. This process imparts a slight twist to the
stand of fibres and winds on to the rotating
spindle. The slightly twisted stand of fibres at this
stage is called Roving which is about six to eight
times the length and the diameter of the sliver.
Roving is wound on bobbins.
Ring
Roving bobbins are placed on the spinning
machines. Spinning further lengthens and
stretches roving and coverts into the yarn. Yarn is
wound on the bobbins of comparatively small
sizes.
Cone
Winding
Bobbins from the ring spinning are fed to the
cone winding machines. Yarn from the bobbins is
wound on the paper cones.
Packing
Yarn cones are inspected according to the
desired quality parameters and stored under
humid environment to provide certain moisture.
After conditioning, cones are wrapped first with
polythene sheets with plastic cone seal (stopper)
at the bottom and then packed in to
polypropylene bags/cartons.
1.2 ENERGY PURCHASE
Sources of energy in the Spinning Units are electrical energy, supplied from the
grid, natural gas, furnace oil or diesel.
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2 ELECTRICAL DISTRIBUTION SYSTEM
2.1 PROBLEMS
Proper electric distribution system is important for the reduction of energy
losses. The investigation of distribution system losses requires detailed survey
of each component of the system. For best results investigation over longer time
periods is required.
The electrical power distribution system, from the source to utilization points,
consists of electric lines of varying sizes, switches and circuit breakers,
transformers and protective equipment. The voltage in an electric circuit will
drop in proportion to the circuit resistance. Resistance varies with wire size,
temperature and metallic material. When conductor losses increase, the current
necessary to deliver a given amount of power increases at any point in the
circuit, as power derives from the product of the voltage and current. This
principle applies likewise to switches, circuit breakers and protective equipment.

Generally the electrical distribution system losses are due to voltage unbalance,
over and under voltage, low power factor, undersized conductors, leakage to
ground, and poor connections. Losses due to poor connections represent one
third of the total loses.
a) Transformer
The transformer sizing and its proper maintenance is important for the energy
conservation. Oversized and improperly maintained transformers waste energy.
When transformer oil is hydrated, its dehydration is important for its smooth
operation.
Energy losses due to transformer are added in the consumers bill as electricity
meter is installed at the up stream of the transformer. Its maintenance and
upkeep allows energy conservation.
b) Circuit Breakers
Circuit breakers selection according to the sizing is very important. Generally in
the industry, the maintenance staffs are habitual to place circuit breaker
whatever type and size is available at the time the old one is used without
considering its size. Undersize breakers result into energy losses.
c) Electrical Motors
After electrical distribution system, electrical motors play an important role in the
energy saving. The electric motors are the main consumers of the electricity.
More than 90% of the electricity is consumed by the electric motors. Major
savings of electricity can be achieved by improving the motors performance.
Following are the concerns regarding electrical motor performance:
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Old class III motors
Operation of motors at low load
Abnormal operation of motors
Power factor
Old Class III Efficiency Motors
Mostly, different types of motors are installed. Some motors are purchased from
the local market and some received as attached with the imported machines.
The local motors are of Class III efficiency whereas for the imported motors, the
efficiencies are not known. Class III efficiency motors operate at lesser
efficiencies and consume more energy.
Operation of Motor at Low Load
When a motor has a greater rating than the machine requirement, motor
operates at partial load. In this state, the efficiency of the motor is reduced.
Generally oversized motors are used in the industry due to following reasons:
Actual load of the machine is not known and electricians select oversized
motor to be on the safe side
Designers and suppliers of the machines want to ensure that their units
have ample power so they suggest a driver that is substantially larger
than the real requirement.
When replacement of motor is required and if there is no exact rating
motor available in the industry, electricians install the next larger motor
available in the store. Afterwards, when a correct sized motor is
purchased, it is not replaced and oversized motors continue to be in use.
A large motor is selected for some unexpected increase in the driven
equipment load which is not materialized.
Process requirements are reduced but oversized motors are not
replaced.
Abnormal Operation of Electrical Motors
Sometimes motors consume more energy due to their abnormal operation. It
should be in the mind of maintenance crew and the electricians that the smooth
energy transfer from one form to other like electricity to the output shaft speed,
belt transmission etc. should not produce abnormal heating, heavy noise, spark
etc. Sparks in motors are produced in case of contactor switching, loose joints
etc. Heat is produced in motors due to friction, metal to metal touch, poor
lubrication and misalignment. Sound is produced from the equipment in the form
of vibration, mounting on bed, noise from belts, bearings, metal to metal contact
etc. In case, faulty motors are kept on running, these will consume much
energy.
Motors bearings and their alignment play an important part in their abnormal
operation. In more than 50% of all cases, the failure of motor is a mechanical
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cause due to improper alignment and the failure of bearings. The failure of the
motor due to different causes is given in Table A.
Table A
Motor Faults
Motor Fault Contribution (%)
Shaft and coupling 2
Rotor bar 5
External factors (environment,
voltage etc)
16
Stator winding
(due to voltage, water, overload
etc)
16
Bearing 51
Unknown 10
Total 100
Power Factor Improvement
Mostly Power factors of the electric motors are not known. Electric motors
operating at low power factor waste energy. Not all the electrical energy
supplied to the motors is converted into the mechanical work but part of it is lost
for creating magnetic fields in the motors. About 2-3% energy is wasted when
motors operate at low power factor.
2.1.1 Explanation of Electricity Bill
It is important to understand the electricity bill, issued by Electricity Supplying
Company, as it contains numbers of variables on which electricity cost depends.
On the basis of its clear understanding, industry can take strategic decisions
regarding its use. Electricity bills depend on the following items.
Units Consumed
These are the units of electricity in kWh consumed in the month. These units
are mentioned separately as consumed during Off Peak hour (O) and Peak (P)
hour of the month. The sum of Off Peak and Peak units is the total units of the
month.
Energy Charges
These are the charges of the total units consumed in the month. These charges
are calculated on the basis of unit rate of the Off Peak and Peak hour kWh. Off
Peak hour unit rate is multiplied by the number of units consumed during Off
Peak hours of the month. Similarly Peak hour unit rate is multiplied by the
number of units consumed during Peak hours of the month. The sum of the
charges of both the units is equal to the Energy Charge. The detail of the Peak
and Off Peak hours and the unit rate is given in Table B.
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Table B
Detail of Peak and Off Peak Hours
Month Peak Hours (P) Off Peak Hours (O)
Unit Rate: Rs. 1.97/kWh Unit Rate: Rs. 1.15/kWh
December to February 5:00 PM to 9:00 PM Remaining 20 Hours
March to May 6:00 PM to 10:00 PM Remaining 20 Hours
J une to August 7:00 PM to 11:00 PM Remaining 20 Hours
September to November 6:00 PM to 10:00 PM Remaining 20 Hours
Fixed Charges
These are the charges of the Maximum Demand Indicator (MDI). Total MDI is
the sum of the MDI in Off Peak and Peak hours. MDI is written as Load Charged
in the bill. Unit charge of MDI is Rs. 290/kW. This unit rate is multiplied by the
total MDI of the month.
Low Power Factor Penalty (LPF)
When power factor of the plant is below the accepted value, penalty is paid by
the client. The minimum acceptable power factor is 0.90.
Additional Surcharge
Additional surcharge is calculated on the basis of units consumed during Off
Peak and Peak hours of the month. Its rate is equal to (Rs. 1.68 x Peak kWh +
Rs. 1.6 x Off Peak kWh).
Fuel Adjustment Surcharge (FAS)
Unit rate of FAS is Rs. 0.13/kWh. Total FAS will be obtained by multiplying 0.13
by the total units consumed in the month.
Electricity Duty (ED)
Electricity duty is the 3% of the energy charges.
Meter/Service Rent
Amount for meter rent and service charges are added in the bill.

Surcharge
Surcharge is the 10.4% of the total amount of Energy Charges, Fixed Charges,
FAS and LPF Penalty.
Income Tax
Income tax depends on the total payable amount of the bill. When bill is over
Rs. 20,000, then its value is Rs. 2,000.
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Current Bill
Total amount of the current bill is the sum of Energy Charges, Fixed Charges,
FAS, LPF Penalty, Surcharge, Additional Surcharge, Income Tax, Meter Rent
and Electricity Duty.
Example of an electricity bill for a sanctioned load of 867 kW is given in Table
C.
Table C
Example of Electricity Bill
# Bill Item Values/Calculations Total
Amount (Rs)
1 Units Consumed
Off Peak (O) 63,400 kWh
Peak (P) 16,120 kWh
Total 79,520 kWh
2 Energy Charges (63,400 x 1.15 +16,120 x 1.97) 104,666.40
3 Load Charged
(MDI)
Off Peak (O) 415 kW
Peak (P) 72 kW
Total 487 kW
4 Fixed Charges 290 x 487 141,230.00
5 LPF Penalty 0.00
6 Additional
Surcharge
(1.6 x 63,400 +1.68 x 16,120) 128,521.60
7 FAS 0.13 x 79,520 10,337.60
8 ED 0.03 x 104,666.40 3,139.99
9 Meter/Service Rent 169.50
1
0
Surcharge 10.4% of (Sr. No. 2 +4 +5+7) 26,648.34
1
1
Income Tax 2,000
1
2
Current Bill (Sr. No. 2 +4 +5 +6 +7 +8 +9 +10
+11 )
416,713
Above items can also be written as:
Bill for Off Peak (O)
Units Consumed x (1.15 x (1 +0.03 +0.104) +1.6 +0.13 x (1 +0.104)
=Units Consumed x 3.04762
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Bill for Peak (P)
Units Consumed x (1.97 x (1 +0.03 +0.104) +1.68 +0.13 x (1 +0.104)
=Units Consumed x 4.0575
Bill for MDI
(Off Peak MDI +Peak MDI) x 290 x (1 +0.104)
=(Off Peak MDI +Peak MDI) x 320.16
Non Variable Parts of the Bill
Income Tax +Meter/Service Rent =2,169.50
The average price for this consumption is Rs. 416,713/79,520 kWh = Rs.
5.24/kWh.
In this average price, an invariable sum of Rs. 2,169.50 is included which is not
influenced by the consumption or use of MDI.
The variable cost for Off Peak consumption (without MDI) is Rs. 3.04762/kWh.
For Peak consumption, it is Rs. 4.0575/kWh.
Every kW used additionally during Off Peak and Peak, costs Rs. 320.16.
2.1.2 Control of MDI (Maximum Demand Indicator)
From the above example, it is clear that increase in MDI, increases unit cost of
electricity. Electric meter records peak electric load in every 30 minutes. On the
basis of the highest peak of the month, bill is charged.
It is very important to keep MDI within minimum possible limit. Electricity bill is
increased due to increase in MDI even though electricity usage supplied by
electricity supplying company is not much.
2.2 PROPOSED ACTIONS
2.2.1 Maintenance of Transformer
It is recommended that priority should be given for the maintenance of
transformers. Generally 3% transformer losses are unavoidable whereas about
1-2% losses can be reduced by good transformer maintenance. Efficiency of
the transformer is affected when transformer oil is hydrated (absorbs moisture),
which requires dehydration for the moisture removal. Proper placement with
clean surrounding is also necessary.
2.2.2 Power Factor Improvement
It is energy efficient measure that the capacitors should be placed at the main
HT panel and in the internal LT panels. HT panels capacitors save industry from
ESCO penalty whereas capacitors in the internal distribution boxes and panels
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improve power factor of distribution and save overall energy. Power factor can
be measured by energy analyzers.
Using capacitors at motors improves their power factors and reduces overall
electrical energy consumption. These capacitors can be installed at the
individual as well as at the combined motors. Capacitors also improve motor
efficiency. The primary purpose of capacitors is to reduce the power
consumption. Additional benefits are derived by capacitor location. Maximum
benefit of capacitors is derived by locating them as close as possible to the
load. At this location, its reactive power is confined to the smallest possible
segment, decreasing the load current.
When induction motors are selected, the manufacturers motor data should be
investigated to determine the motor power factor at full load. In the past few
years, motor manufacturers have introduced premium lines of high efficiency,
high power factor motors. In some cases, the savings on power factor alone can
justify the premium price charged for some motors.
Motors should also be sized to operate as closely as possible to full load,
because the power factor of an induction motor suffers severely at light loads.
Power factor decreases because the inductive component of current that
provides the magnetizing force, necessary for motor operation, remain virtually
constant from no load to full load, but in-phase current component that actually
delivers work varies almost directly with motor loading.
It should be kept in mind that the rating of the capacitor should not be greater
than the no load magnetizing kVAr of the motor. If this condition exists,
damaging over voltage or transient torques can occur. This is why most motor
manufacturers specify maximum capacitor ratings to be applied to specific
motors. The use of capacitors is the most economical method of improving the
plant power factor when the loads consist mainly of groups of small motors. The
improvement of the plant power factor should begin at the source. The
economics of power factor correction indicate that correcting beyond 0.95 is
seldom justified. Cost of the three phase capacitors, type SH-D, operating at
415 volts and 50 Hz, is as follows:
12.5 KVAR Rs. 8,500
25 KVAR Rs. 12,500
50 KVAR Rs. 18,000
Following example is given for electrical energy saving by improving the power
factors of an electrical motor:
Power factor (PF) of the motor 0.7
kW consumed = (V x I x 1.73 x
PF)/1000
(480 x 122 x 1.73 x 0.7)/1000 =
71
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kWh consumed (720 hours) 71 x 720 =
51,120
Energy cost @ Rs. 4/kWh 204,480
Improved power factor 0.9
kW consumed (480 x 74 x 1.73 x 0.9)/1000 =
55
kWh consumed 55 x 720 =
39,600
Energy cost @ Rs. 4/kWh 158,400
Savings-Rs (204,480 158,400) =
46,080
2.2.3 Energy Efficient Motors
With more research and development, now a days more energy efficient motors
are available. These are the class I and class II motors. Comparative
efficiencies are given in Table D. Efficient motors save energy.
Presently class I motors are not available in the Pakistan. These will have to be
imported and become very expensive when taxes are added in their prices.
Class II efficiency motors are manufactured by Siemens and ABB. Replacing
old efficiency class III motors by class II will save energy. However, it is not wise
to replace all the old motors immediately, but in stages like when an old motor
breaks, it could be replaced with an efficient model.
Table D
Comparison of Motor Efficiency
Efficiency of Different Class Motors
kW EFF3 EFF2 EFF1
1.1 <76.2 >=76.2 >=83.8
1.5 <78.5 >=78.5 >=85.0
2.2 <81.0 >=81.0 >=86.4
3 <82.6 >=82.6 >=87.4
4 <84.2 >=84.2 >=88.3
5.5 <85.7 >=85.7 >=89.2
7.5 <87.0 >=87.0 >=90.1
11 <88.4 >=88.4 >=91.0
15 <89.4 >=89.4 >=91.8
18.5 <90.0 >=90.0 >=92.2
22 <90.5 >=90.5 >=92.6
30 <91.4 >=91.4 >=93.2
37 <92.0 >=92.0 >=93.6
45 <92.5 >=92.5 >=93.9
55 <93.0 >=93.0 >=94.2
75 <93.6 >=93.6 >=94.7
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90 <93.9 >=93.9 >=95.0
2.2.4 Removal of Oversized Motors
First of all, plant management should ensure that the over sized motors are not
used in the plant. For that, regular motor load monitoring will have to be carried
out for all the motors at different production loading. The recording wattmeter is
the most useful instrument for this purpose to analyze the load over a
representative period of time.
Also, management must ensure that the factors mentioned above, due to which
over sized motors are installed, are avoided.
Replacement of under loaded motors with smaller motors will allow a fully
loaded smaller motor to operate at higher efficiency. This arrangement is
generally most economical for larger motors, and only when they are operating
at less than one third to one-half capacity. Larger motors are typically installed
at the filters and air conditioning units.
For example, annual savings for replacing a 50 horsepower motor operating at
25% of rated load (83% efficiency) with a 15 horsepower motor that will operate
near full load (90% efficiency) will be obtained by using following relations:
L
FL
=0.746 (hp) (1/Eff
FL
) - 1
L
PL
=0.746 (hp) (PL) (1/Eff
PL
) - 1
Where
L =Losses in kW
E
ff
=motor efficiency
Subscripts
FL =at full load
PL =at partial load
L
FL
=0.746 (15) (1/0.90) - 1 =1.24 kW
L
PL
=0.746 (50) (0.25) (1/0.83) - 1 =1.90 kW
Reduction in losses =0.66 kW
Annual energy loss =0.66 kW x 7,920 hours =5,227 kWh
2.2.5 Maintenance of Motors and Equipment
A reduction in motor load is one of the best means of reducing electricity costs.
Proper maintenance of equipment will also reduce motor load by eliminating
friction losses from such sources as the misalignment of equipment and belt
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drag. Proper lubrication of all moving parts such as bearings and chain drives
will minimize friction losses.
Motor cooling fans should also be of proper size because these also consume
energy. Though these are fitted with the motors by the manufacturer, still their
working can be monitored and can be improved and adjusted if required. (Keep
in mind that this will void the warranty)
Motors maintenance includes:
Regular checking of motor load
Timely oiling and lubrication
Appropriate ventilation
Cleaning of motor body
Monitoring of motors with regard to noise, vibration and heating
Frequent alignment checking
It is recommended that the mechanical and electrical staff of the Spinning Unit
should have a checklist for regularly monitoring the maintenance and upkeep of
motors.
2.2.6 Placement of Inverters on Motors
For those machines operating at variable loads, it is recommended that the
inverters should be placed on them to save energy. Inverters should be
compatible with the motors. Most of the old motors can not be operated with the
inverters.
Where inverters are placed, high peak voltages can be experienced at the
motor terminals especially when the distance between the inverter (drive) and
the motor exceeds about 15 meters. Some additional heating to the motor
windings will inevitably occur because of the inverter's "synthesized" AC wave
form.
In case, motors are very old then the first choice should be to replace them, one
by one, if it is feasible. It is not advisable to invest on older motors and place
inverters. The best use of inverter is for variable flow applications. In case of air
conditioning plants, the flow is changed by changing the angles of the fans.
When the flow is reduced, motor takes less amperes but it operates at less
efficiencies. The better way to control the flow is through changing the speed of
motor by using inverters.
At the large motors with variable loads like in air conditioning and filters,
inverters can be placed. Modern inverter-duty motors are compatible with the
inverters.
The following example, in Table E, shows the comparison of manual flow control
and through the frequency controllers and gives savings.
Table E: Comparison of Manual and Frequency Control
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Control Valve Controllable Drive
Flow Hr/yr
P
as
(kW)
Consu
med
(kW) kWh
P
as
(kW)
Cons
ume
d
(kW) kWh
100% 250 10.0 0.82 12 3,049 7.3 0.80 9 2,281
85% 300 9.5 0.80 12 3,563 5.0 0.78 6 1,923
70% 450 9.0 0.80 11 5,063 3.5 0.78 4 2,019
50% 2,000 8.0 0.72 11 22,222 2.0 0.70 3 5,714
Total 33,896 11,938
Reduction in kWh/year 21,958
Unit cost of electricity (Rs./kWh) 4.72
Total reduction in cost (Rs./year) 103,643
Investment (Rs) 144,600
Pay back time in years 1.4
In some motors, there might be heating when the inverters are installed. So it
should be checked whether the motor is suitable for the inverter or not.
The estimated cost of the frequency control units are given in Table F.
Table F
Cost of Inverters
Motor kW Price (Rs)
1.10 52,425
1.50 59,775
2.20 72,450
3.00 80,775
4.00 86,550
5.50 100,275
7.50 113,025
11.00 144,600
15.00 164,775
18.50 204,600
22.00 245,850
30.00 292,500
37.00 362,700
45.00 437,100
55.00 470,175
75.00 552,675
90.00 604,875
110.00 667,125
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Date
J anuary, 2008 16
2.2.7 Electric Load Management
Spinning Units can further reduce Electricity Supply bill amount by keeping MDI
at lowest possible. For that, industry will have to manage their loads. First,
management should know the power demand of each department. Detail of
power consumption of each and every machine of the department must also be
known. On the basis of this information, management can evaluate their
maximum load. They can also plan to reduce load by distributing the load over
the entire day.
For the load management, it is essential that management must know that
which machines require to be operated at what times of the day. They can plan
to operate different machines at different timings.
Consideration of demand control often begins with automatic demand
controllers. However, several other approaches should be considered first.
If a high peak load is determined to result from the simultaneous start up of
several loads, such as might occur at the beginning of a shift, consideration can
be given to staggering start up of equipment to span two or more demand
intervals.
Another way of avoiding the use of load from electricity supplying company can
be self generation for short periods of high demand. The decision whether self
generation is favourable or not, depends on particular time period and rates of
fuel i.e. Natural Gas, diesel.
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Date
J anuary, 2008 17
Title
Date
J anuary, 2008 18
3 AIR CONDITIONING
3.1 PROBLEMS
Air conditioning units are operated for the following purposes:
Attain certain relative humidity in the production halls. Each quality of
fibre and yarn requires certain moisture otherwise there are chances of
their quality deterioration
Remove the heat produced by the machines to avoid overheating and to
keep them at lower operating temperature
Remove air contamination (fine fibres) present in the production halls
Maintain comfortable temperature inside the working areas for the
workers
Humidity is controlled by maintaining certain wet and dry bulb temperatures in
the production halls. Wet and dry bulb temperatures are selected on the basis
of required humidity.
To attain the set humidity, wet and dry bulb temperatures are maintained by
supplying humid and cool air in these departments.
Air conditioning units consume about 20% of the total power of the plant. This is
the second highest consumption area after ring frames.
Air conditioning is controlled by the following ways:
Decrease or increase flow of the air by changing the fan vanes angles
(only for the variable fans). These angles are not changed so frequently,
usually they are changed when season changes i.e. summer and winter
One or two of the supply and return fans are turned off to reduce air flow
Discharge flow rate of water pump used for water showering is increased
or decreased by throttling valve, depending on the humidity requirement
Water showering is stopped during rain or when humidity of the ambient
air is high
Supply, return and exhaust air dampers are manually controlled (opened
or closed) according to the air quality and flow requirement. Automatic
dampers control system is out of order and management is not
interested in repairing it because of its high cost. Following are the
conditions for air control:
o When high temperature is required in the production halls, return
hot air is not exhausted (or partially exhausted) to atmosphere
and again supplied in the halls
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J anuary, 2008 19
o In the hot seasons, when outside air is hot, maximum part of the
return air (which is relatively cooler) is used in the halls
o When out side air is cool, maximum part of the fresh air is used.
Dampers are controlled according to the variations in the day and
night environmental conditions.
3.1.1 Fixed Fans
Supply and return fans are used for the air conditioning. Angles of the variable
fan vanes are changed to increase or decrease the air flow according to the
requirement, mainly depending upon the seasonal variation.
During hot months, angles are set to increase the air flow. In the cold months,
these angles are set to reduce the flow. Electricity consumption of the fan
motors depends on the air flow. At higher air flows, fan motors consume more
energy and vice versa. Generally there is a difference of about 12 ampere
current between high and low air flows.
The variable fans operate only within a limited air flow range, depending on the
fan degrees to be changed.
3.1.2 Air Change Requirements
Mostly there is no control on the air supply with regard to air change
requirements for different production halls. Only humidity is the controlling
factor. Air flow is not optimized on the basis of combined factors of humidity, air
change and temperature. This practice causes significant electricity
consumption.
3.1.3 Water Showering
Mostly, two types of water showering arrangements are used. In one type, water
falls in the form of thin film. Air from the guided baffles is passed through this
water film and absorbs water. Guided baffles at the entrance provide an evenly
distributed air water contact. Eliminators in the shape of sinusoidal curve at the
exit are installed to remove entrained water droplets from the air. This humid
and cool air enters into the hall.
In other type, banks of water spraying nozzles are installed. Air is humidified by
passing through the fine water mist. Older type water showering is not
considered efficient.
3.2.1 Replacement of Fixed Fans with Variable Fans
It is recommended that the management should consider replacing all the fixed
fans with the variable fans so that the vanes angles could be changed to alter
air flow. Change in air flow will also change the electricity consumption. Air flow
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J anuary, 2008 20
control with inverters is an efficient way of changing air velocity rather changing
vanes angles.
3.2.2 Volumetric Air Flow Optimization
Mostly there is no control on the air supply with regard to air change
requirements for different production halls. Only humidity is the controlling
factor. It is recommended that the air flow should be adjusted according to the
air change requirements without compromising humidity requirement. Whatever
is the minimum air flow possible for the certain humidity, it should be adopted.
Air flow variation is only possible by placing inverters on the electric motors.
Fan power is proportional to the third power of the air volume i.e.
Fan Power (Air Flow
3
). It means that by reducing the air flow by half reduces
the fan power to approximately one eighth. When the air flow is reduced to 2%,
the fan power will be reduced to about 5% to 6%.
For the energy conservation, it is recommended that the air flow requirements
should be established by measuring air flow. It can be measured with the help
of anemometer. An anemometer measures air velocity. Air velocity should be
measured by placing this meter in the duct. Multiplying air velocity with the cross
sectional area of the duct will give volumetric air flow. While optimizing air flow,
controlling factors like temperature and the humidity of the production halls and
removal of machines heat and the contaminants.
Air flow optimization also needs to establish the percent share of the flow of the
fresh air supply, exhaust and the return air supply. Percent fresh outside air can
be calculated by simply measuring the temperature of the outside air, return air
and the mixed air by the following relation:
100
-
%
air outside air return
air mixed air return
sideair out

T T
T T
% outside air = (Return air temperature) (Mixed air temperature) X100
(Return air temperature) (Outside air
temperature)
Fresh air supply will be increased or decreased in proportion with the increase
and decrease of the temperature difference between the return and mixed air
(mixture of return and fresh air) temperature. On the other hand, fresh air supply
will be increased or decreased in inversely proportional with the increase or
decrease of the temperature difference of return and outside air temperature
while keeping the temperature of mixed air constant.
It is clear from the above relation that fresh air supply will be 100% when
outside and mixed air temperatures become nearly same.
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J anuary, 2008 21
Air flow optimization needs experimentation and frequent air velocity
measurement with the anemometer.
3.2.3 Water Spraying Nozzles
It is recommended to replace the old film type water showering with the efficient
spraying nozzles in the air conditioning units. Water nozzles are more efficient
for increasing humidity and decreasing air temperature.
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J anuary, 2008 22
4 COMPRESSED AIR SYSTEM
4.1 PROBLEMS
Most of the industries are using piston type compressors but screw type is more
efficient.
4.1.1 Comparison of Reciprocating and Screw Type Compressors
Generally piston type compressors are not considered energy efficient as
compared with rotary type compressors. Piston type compressors have 8-10
compression parts in comparison with 2-4 compression parts of the screw type
compressors.
The energy and cost savings are dependent on the size of the compressor, the
load factor, and the number of hours during which the compressor is used. The
load factor is the average fraction of the rated load at which the compressor
operates. The load factor is fairly constant for compressors that operate only
when they are actually compressing air. Most reciprocating compressors are
operated in this manner. When on, they operate with fairly constant power
consumption, usually nearly equal to their rated power consumption; when they
are cycled off, the power consumption is zero. Screw compressors have to be
operated in a different manner. When loaded (i.e. actually compressing air),
they operate near their rated power, but when compressed air requirements are
met, they are not cycled off but continue to rotate and are unloaded. Older
screw compressors may consume as much as 85% (a typical value would be
66%) of their rated power during this unload state. Therefore, if a screw
compressor is to be operated continuously, it should be matched closely to the
compressed air load that it supplies. Often, plant personnel purchase
compressors having several times the required power rating. This may be done
for variety of reasons, but often in anticipation of expansion of the facility and a
commensurate increase in the compressed air requirements.
4.1.2 Key Findings
Following are the key audit findings that could be seen about the compressed
air system:
a) Pressure Gauges
Pressure gauges are not installed on the machines or even if installed then they
might not be calibrated.
b) Auto Drains
Mostly, no auto drain is installed in any of the receiver tanks of the compressors
to control compressed air quality. Due to this, air moisture is not removed
effectively.
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J anuary, 2008 23
c) Air Leakages
Air leaks around valves and fittings in compressor air lines may represent a
significant energy cost for the mill. Sometimes up to 20% of the work done by
the compressor is to make up for air leaks. The energy loss as a function of the
hole diameter at an operating pressure of 6-7 bar is shown in Table G.
Table G
Energy Loss from air Leaks
Hole Diameter
(mm)
Free Air Wasted (m
3
/year)
By a Leak of Air at 7 bar
Energy Wasted per Leak
(kWh/h)
9.5 2,500,000 30
6.5 1,100,000 14
3.0 300,000 3.5
1.6 70,000 0.9
0.8 15,000 0.2
Mostly, for cleaning compressed air is used through large 8.5 mm diameter pipe,
resulting into energy losses.
d) Wastage of Hot Cooling Water
In water cooled compressors as water is continuously supplied in their jackets to
keep temperature of the moving parts as low as possible for their effective
performance. This water is discharged as a wastewater stream after acquiring
heat. It is a clean warm water stream at a temperature of 40
o
C approximately.
4.2.1 Pressure Monitoring
It is recommended to install pressure gauges at all the lines to monitor pressure
and assess the areas where pressure drops occur. There should be the
calibrated gauges. Delivery temperature should also be checked in accordance
with the manufacturer specifications at specified pressure to know the efficient
working of the compressor.
4.2.2 Air Leakages
Maintenance crew should survey the air distribution system and identify all the
leaking points. These points should immediately be rectified to avoid energy
losses. This measure does not require investment.
4.2.3 Cleaning Points
For reducing air consumption in the overhauling room, it is recommended that
the pipes of 8.5 mm diameter or more, used for the air cleaning, should be
Title
Date
J anuary, 2008 24
replaced with the 6 mm diameter with air guns. It will allow reduction in air use
and ultimately the energy consumption. Investment for this measure is nominal.
4.2.4 Air Quality
Use of moist air in the machines and the compressor affects their performance.
Manual bleeding off the receiver tanks is not a good practice as it wastes too
much compressed air. It is recommended to install auto bleeders on these tanks
to avoid this loss. For the better quality air, management should also use dryers
and line filters.
4.2.5 Alternate Compressor Option
It is recommended to replace piston type compressors with screw type. A screw
type compressor with a frequency inverter drive is recommended if longer
periods of unloaded operation can not be avoided.

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J anuary, 2008 25
5 ENERGY SAVING POTENTIAL IN THE PRODUCTION
5.1 PROBLEMS
5.1.1 Unnecessary Running of Auxiliary Equipment
It is general practice in the mills that when main production machines are put
off, auxiliary equipment remain in operation. Auxiliary equipments include air
conditioning units, filters and compressors. This practice causes wastage of
energy. It is seen in blow room that when there is discontinuation of feed and
main machines are stopped, still air conditioning and filters remain in operation.
Another problem, during production is that the machines remain in operation
without any feed.
In carding section sometimes, one set of carding machines is stopped for
cleaning but filter and air conditioning units remain in operation at full load.
5.1.2 Energy Loss due to Maintenance of Machine during Off Peak
Hours
Great amount of revenue could be saved if off peak hours are not utilized for
maintenance.
5.1.3 Running of Machines at Low Load
Spinning process energy efficiency is very much dependent on the production
of machines at full capacities. Machines running on partial loads will consume
more energy per unit product. It is observed that machines run at their under
capacities due to number of reasons.

5.1.4 Heating of Production Halls
Heating is required in winter in the different spinning departments like packing,
carding and simplex. This heating is achieved either by the circulation of hot air
and by installing electric heaters. Electric heating is an energy inefficient method
of heating.
5.2.1 Process Optimization
It is considered energy efficient production when machines give production for
the 75% of the total running time. Production will be energy inefficient when the
actual production time of the machines is lesser than 75%. For example, if
machine runs for the 24 hours a day, it must give production for the 18 hours.
It is recommended that the unit management should investigate in detail the
productive hours of the machines. Time for each machine running with no feed
or production should be recorded along with the reasons. This exercise should
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J anuary, 2008 26
be carried out in all the departments. In each shift, one person should be
designated for this task.
After conducting this exercise for a reasonable time period, management can
see the productivity of their machines. In case, machines production hours are
lesser than 75%, all the problems causing it must be avoided.
When machines production hours are high, then unit consumption of electricity
per output is decreased and vice versa.
5.2.2 Heating of the Production Halls
It is preferred that the localized heating should be preferred over entire heating
of the production hall. Electric rod heaters consume relatively more energy. It is
recommended that the Infra Red (IR) lamps should be used at places where
heat is required. These lamps can either be hanged on the machines or fixed at
the walls near the machine. PHILIPS infra red lamps (IR375) are available in the
market. The cost of 375 watts and 250 watts is Rs. 800 and Rs. 450
respectively.
Industry could also use hot exhaust air of compressor for the heating of
production halls. This air can be circulated in the nearby production halls
through the pipes. It will transfer its energy to the working area prior to
discharge into atmosphere.
Warm water produced in the piston compressors can be showered in the
packing section to maintain humidity and temperature.
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J anuary, 2008 27
6 LIGHTING
6.1 PROBLEMS
The quality of lighting is very important for the spinning unit. Mostly the light
intensity is low in spinning mills which affects quality and production. If an
inefficient source of illumination is used then it again wastes money and energy.
Other observations regarding lighting are given in the following section.
6.1.1 Magnetic Ballasts
In most of the spinning units 40/36 watts tube lights are used. These tube lights
consume more energy as compared with the 36/28 watts tube lights with the
same lumens. These tube lights are attached with the conventional magnetic
ballasts which are not considered energy efficient. These ballasts waste energy
in heat and noise.
6.2.1 Effective Lighting
Generally, two most common causes of lighting energy waste are excessive
illumination levels and failure to locate fixtures in relation to the activity area.
It will be helpful in improving lighting intensity if more lights are placed over the
machines instead on places like aisle and idle places. Lighting can also be
improved by reducing the height of the tube lights fixtures.
6.2.2 Electronic Ballasts
It is recommended to replace 40 watts tube lights with the 36 watts lights to
reduce electricity consumption. Tube light of 36 watts is available in two types
with different lumens. Detail of 40 and 36 watts tube lights is given in Table H.
Table H
Detail of Tube Lights
Z-Type of Tube
Light
Lumens Lamp life (Hours) Unit Price
(Rs)
TL 40 Watt 2,500 6,000 55-60
TLD 36/54 Watt 2,650 13,000 50-60
TLD 36/80 Watt 3,350 15,000 90-100
40 watt tube light with magnetic ballast consumes about 52 watts whereas 36
watts tube light with ballast consumes 44 watts i.e. 10 watts less. About Rs. 150
can be saved per year per tube light by replacing old 40 watts tube light with
new 36 watts.
It is also recommended to replace old conventional magnetic ballasts with the
recently developed efficient electronic ballasts for the tube lights. By replacing
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Date
J anuary, 2008 28
magnetic ballasts with electronic ballast, up to 14 watts can be saved per
ballast. The cost of the electronic ballast (EB-E) is Rs. 350.
For effective lighting, following are the recommendations:
Turn off the lights during break hours or when nobody is present at work
place
Use the natural light at day times wherever possible and as much as
possible
Most of the electronic ballasts available in the market are of 380 volts which can
not operate at the current voltage of 415 volts in the industry. While purchasing,
ballasts, one must consider this aspect and purchase only those ballasts which
can withstand 415 volts.

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