Before it was UKG, Now it is Kg per Unit!

Previously textile manager talked often the UKG. To

produce more Kgs, how much they max utilize the units

Now, the same manager talks how much more Kg of yarn

can be produced in the given reduced quota of electricity

A blessing in disguise in a way, this quota crisis makes us

Lesser we get, More we become wise now

Many mills responded to wakeup call. They have

maximized production and they reduced internal losses.
Energy Saving is not possible in a system running with defect.
We have to first remove the defect and then only, we can
achieve energy savings automatically.

Our World poet Tiruvalluvar says.

?
 To efficiently run Textile mill in Lean mode
Improve the individual efficiency of machine, say frame to frame.

find the optimum speed of ring frames at this half load quota.

Improve utilization of the frames & utility at lean mode working

Tune down utilities like AC plant, compressor etc & preparatory.

Mainly reduce waste evacuation system sizing

Motor takes power based on load only. So steps to reduce Load

Give more thrust to KVA instead of KW now & Compensate at load.

Make use of Maximum Demand Controller fully using Auto mode.

 Sustained & Regulated & Metered Energy intake
makes the industry profitable in the long run.
------------------------------------------------------------------

 Energy Intake by Textile Mill
Energy Losses (Between the Cup & Lip in industry)

Voltage Regulation in Stages upto Load End

Power Factor Regulation in Stages

Compressed Air Cool Dry Air in Stages

Energy Measured Digitally & Accurately

Measure Energy from Entrance to Load End .

 CONSUMER POWER BILL WHAT IS THE BREAKUP ?

EB charges the industry in terms of KWH, KVA, PF and we

in the industry maintenance must measure the same KW,

KVA, PF, KVAR and Harmonics at our load end machines.

By energy conservation in industry, we try to recover the losses

which go as waste as Excess input, and wasted output of machines.

By Energy Measurement, we draw a line between Avoidable and

Unavoidable Losses and plan to minimize same.

Meter is your tool to show motor is a efficient or not
and your Machine is healthy or not, instantaneously.

Clamp on Multi function Power meter cost Rs.9000+

Active power (KW) ,Reactive (KVAR), Apparent Power

(KVA). Power Factor (PF) & Harmonics too.

PF, other parameters for 3f 4W, 3f 3W, 1f 2W, 1f 3W.

Triple display : KW, V, A easy to read.

Reads V, A, KW, KVA, KVAR, PF, HZ, total 25 type

AC Current up to 1000A, AC Voltage up to 600V.

Dimensions of Conductor : 46.5mm

 Do we give right volts to our mill now ?
In the mill having Transformer with OLTC, we can now
reduce the voltage settings from 420 to 400 volts.

when mill having transformer without OLTC operated at

400 volt instead of 440 volt especially at night,

A standard motor operated at an average half the load

its efficiency increases around 4 %

The same standard motor at average half the load

- its power factor improves around 10%

This is applicable to standard motors and the above change

is not that much in Energy Efficient motors.
The table below Compares the behavior of 5 H.P
motor at Higher than 400 volts
courtesy Muskan Servo OEM study

Input
Current KVA PF
Voltage
400 7.5A 5.2 0.8

425 11% More 18% More 0.7

435 19% More 28% More 0.61

445 26% More 38% More 0.57

Motor de-rates at higher ambient temperature. Why at all
our Ring frame motors should lose efficiency up to 3 %
due to hotter & starved ambient harsh surroundings ?
RING FRAME MOTOR IS A BULLOCK CART UNDER HOT SUN

greasing the motor bearing is not to protect the bearing

only, it should catalyze the smooth working of motor

Existing motor is like a bullock cart climbing up the hill.

Please make motor to drive like cart smooth down the hill.

Right Quality & Quantity Lubrication at Frequent intervals

Active & Forced Ventilation surrounding the motor

Motor shaft loses 10 rpm, spindle speed loses by 100 rpm.

The more motor heat, more losses & less Spindle speed.
Motor is a Consumable = 7.5 hp replaced by 5 hp new

Motor particulars 7.5 hp std motor 5 hp E E motor

Motor rating 5.5 KW 3.7 KW
Input voltage Volts 400 400
Full load speed rpm 1430 1450
Power factor 0.84 0.89
Measured current amps 8.6 7.16
Energy consumed / hr 5.0 units 4.4 units
Units consumed MORE 0.6 unit / hr nil
Units lost per day 14 units nil
Units lost per month 430 units
 Motors with different Efficiency working in industry
now. Of the 5 Levels, Premium, Efficiency1, Efficiency2,
Standard, Rewound motor,
Where do your motor stand?
 Motors Loading Automatic
Our motors are always partly loaded say 50 %

Low end option Automatic Delta to Star converter

High end option Variable Speed Drives

The ideal thing to operate VSD in closed loop

This gives excellent saving with due protections

taken care to avoid power quality disturbances.

 Are we loading our motors efficiently ?
Please focus on your motors Part Load Efficiency to achieve
practical savings, when you BUY & OPERATE
 Running ring frame motors in star mode
Running ring frame main motors on Automatic
Star mode gives savings around 5 to 10 %.

Retrofit to utilize the star connection of the same motor

cost effective option to maximize the motor loading.

Now the conditions are that instead of 18000 rpm, only

12000 rpm run say & loading is around 30 to 40 % level

The mill sees the visible loss only in few tube lights
watts loss etc in unwanted areas at daylight times.

The mill to look into more of internal losses in machine now

by measuring the power and assess its breakdown.
Thermal Imaging Tool to Predictive
Energy Management & Maintenance
MOTOR BURNOUT & HOW TO PREVENT?
Focus on your Rewound motors now.

Motors strained due to overloaded condition,

unbalance inputs, under voltage, over voltage,
misalignment, poor ventilation, loose joints etc

Detected by, bearing tester Infrared Gun, power

clamp on meter and 3 phase 4 wire meter etc

Electronic Overload relays act better & fool-proof

compared to Thermal Overload relays to prevent
burnout at shock, quick Overloads, current unbalance,
single phasing etc hazards.
YOUR MOTOR SKIN TEMPERATURE IS SAME
at the DRIVE end & NON DRIVE end ?
Thermal Imaging is a tool to find hot spots, a symptom
of energy loss in the industry.
----------------------------------------------
Please gift a Nail cutter & a Lens to the staff.
Cleaned hands without nails & dirt And lens viewing
helps the man to avoid infections from hand to mouth.
----------------------------------------------------------------------

 Motor gets hotter without cooling fan & poor ventilation.
Raw Cogged Edged Belt reduces transmission loss from motor
to load by 3 to 5 % compared to Vee Belt.
Power Factor Correction on your 50HP Motor and this
is how your capacitor is checked not only by its input
current but by its output to increase PF & decrease
KVA at load. Check your Capacitors.

37 KW motor Now with 15 % Change in

Without Cap Kvar Capacitor parameters
37.3 KW 36.2 KW 3% Decrease
28 KVAR 15.1KVAR 46% Decrease
46.6 KVA 38.4 KVA 17% Decrease
0.8 PF 0.92 PF 15% Improved.
 Capacitor KVAR rating for Transformers
Transformers, which work on of electro-magnetic
induction, consume reactive power for their own needs
even when its secondary is not connected to any load.

To improve power factor, it is required to connect

a fixed capacitor bank at LT side of transformer

kVA of Transformer - kvar Required for compensation

Upto 315 kVA Up to 5% of kVA rating

315 1000 kVA Up to 6% of kVA rating

Above 1000 kVA Up to 8% of kVA rating

Current Based Power Quality Problems

Reactive Power Compensation

Voltage Regulation

Current Harmonics Compensation

Load Unbalancing (for 3-phase systems)

Neutral Current Compensation (for 3-ph 4-wire systems)

Inverters and what effect on Power Quality
at Incoming & at motor end ?
 How can Harmonics be Reduced?
PROPER GROUNDING -Neutral to ground conductor connect
at one location; at main panel or transformer secondary

When neutral is connected to ground at multiple locations,

interference can occur with sensitive electronic devices.

Run power and control conductors in separate raceways

Sensitive loads not to share neutral & ground conductors.

Avoid using conduit as the ground return path, run dedicated

ground wire with circuit conductors
Refer to IEEE Std 1100-1992 (Emerald Book)
EARTHING TO BE WELL MAINTAINED TO PREVENT THE
SURGES ATTACKING THE MACHINES
CONVENTIONAL
EARTHING
PAINTING LOOKS OK
BUT EARTHING IS
POORLY MAINTAINED

MAINTENANCE FREE
EARTHING : EARTHING
IS GOOD IN THE LONG
RUN and well maintained.
Please Be Aware that your
Compressor produces Milk
too!
If the Compressor is not
healthy and overloaded and
poorly maintained,

Compressed air is polluted and

Compressed air header gets
choked & pressure drops

This will affect the Machine

Health of the User machine
and machine breaks down
due to faulty pneumatics.
 CA system Air intake
Rupee wise, Paisa Foolish
Compr. Air intake Temp. 3*C raise, Power Up 1 %

100 scfm @ 7 bar Annual Comp Air use Rs. 6 Lacs

Daily clean Pre Air Filter before Air intake Filter

160 Scfm Compr. @ 7 bar at 45*C air outlet pumps

1 Litre more water in air per hour than at 35 * C
Hot air Receiver is a symptom of poor compressor health;
Let us cool the air before dryer to improve energy savings in
CA system & compressed air health
 DG Set building should be well cross ventilated
DG set surrounding temperature must not exceed 5 * C
above the ambient temperature. And this makes Engine
Healthy and Early choking of air intake filter leads to
Low power, Black smoke, Turbo-charger failure
Why Less Units per Liter in DG set now?
Ageing
Inadequate maintenance
Inadequate operation practices.
Low capacity utilisation
Fluctuating load
De-rating effect
Exhaust temperature limit the loading & KVA
Lagging of exhaust pipe is required.
Increase in air intake temperature from 25C to 40C, the air
fuel ratio decreases by about 5% resulting in increase in fuel
consumption in range of 0.5 to 2% , depends on engine design.
Automation a Tool to improve productivity with less
power consumption

Achieve more & accurate output with less input.

Reduction of Peak Loads
Environment Protection.
Improve Safety and Health.
Reduce Maintenance.
Minimize Energy consumption
Easy diagnosis of fault
Reduction in Resources
(Chemicals ,water , energy etc.)
 Energy Saving is in your Hands.
Now we are in Hare &Tortoise race.
We must not be like Hare to do ECON once and
relax for ever. We have to be like a Tortoise to do
ECON steadily at all times, and by all our people

.
 ENERGY CONSERVATION IS IN YOUR HANDS
There are two kinds of employees in your industry.

Some believe they can make things happen,

and others believe that things happen to them.

The first group believes that the outcome of Energy

conservation works is more or less in their own hands

The other group takes wait and watch approach: -

They sit around & wait for bus to take them somewhere slowly.

Now please Decide where & how fast you can save our energy
 Humidification effect on mill
Less water, more air yields more humidity to mill

Nozzles to operate at rated Pressure and Flow

Hour meter on water pump,water meter online.

High Efficiency Aerofoil designed Aluminum Pressure

die cast alloy fan Exhaust fan to suit to air changes

Nozzles not to jetting / pissing /oozing but Fogging but

spray dwell time of water in air must be more for mill.

Ring main type water distribution to the nozzles in water

circuit, instead of the present Radial system
 Pumping system savings
parameters existing new pump
Motor rating hp 7.5 5
Suction pipe mm 65 75
Delivery pipe mm 50 75
Piping material GI White PVC
Foot valve local ISI
Discharge LPS 3.68 5.03
Input power KW 6.18 4.35
Increase in discharge -- 36 %
Input power reduction 30 % --
Saving in Energy -- 48 %
 Energy Audit shows where we stand
What to do,
where to start,
at what cost and
for what benefits

First step is start with Preliminary Audit with existing Datas.

Second step is Detailed Audit & Generate more Parameters.
Indicative saving potential to achieve

Good House-keeping yields 5 - 10%

Minor Investment gives 10 - 15%
Reasonable Investment pays back 20 - 25%
 Lighting Lumens per watt
Are we sure we get max lumens at the place of work?
If not, productivity loses by 6 %
Lamp type Lumens per watt
Incandescent bulbs 15
CFL 60
Fluorescent tube 60 - 100
HPSV 100 150
Metal Halide lamps 120
LPSV 183
Light intensity from sun 1, 20,000 lumen/m2
Diffused light near window 500 600 lumens / m2
 Tube light variation in Light output & Power output

Particulars at 10% low-360 volt - at10% high 450 V

Light output Decreases by 9 % - Increases by 8 %
Power input Decreases by 15 % - Increases by 8 %

Take the case of your transformer without OLTC

Low & High voltages are 400 to 450 volts in day & night
Lighting wants safe regulated working 360 volts only
Priority is towards Energy Savings in Lighting
More priority is in Safety in lighting voltages
Tube light life increases and inventory comes down
Not only for tube lights but also for ballasts also.
In Electrical Loads, Motors are Heavy loads and Lighting is
Soft load. So Lighting needs Regulated & Reduced Steady
voltages so as to achieve savings &
we can avoid this Waste Too.
 SAFE WORKING PRACTICES LEADS TO ENERGY
SAVINGS AUTOMATICALLY.
Thinking & Acting on Conservation Measures catalyzes our
social responsibility, caring for others and sacrificing our
selfish comforts.

When we are safe and healthy, conservation prevails. If

safety fails, conservation fails and Pollution starts.

The Good Things & Bad Things happen to us because of

us Only and others can only Catalyze.

So Cultivate good House Keeping Habits to visualize &

reduce Internal Invisible Losses than showing to others that
we reduced the visible losses externally.
 Where we follow Safe & Best operating practices in the
machines and in process, along with sustainable
environment, then automatically the Energy Savings
achieved & the mill operating profit margins improves.

.
 Removal of Barriers
Technical barrier to start with:-

First stage to measure the Macro SPC of the industry

II stage to measure in the micro SPC of equipments

Measure First & then to Minimize Energy consumption.

We need both the Macro & Micro SPC as a tool to show

the mill is healthy and to catalyze the mill to go how fast &

quick in for Energy Efficient retrofits / changes in equipments

 FIVE COST REDUCTION MEASURES
OF ENERGY CONSERVATION
Identify inefficient energy use

Upgrade machinery & process in

context of energy efficiency

Improve maintenance practice

Promote employee awareness and

Conservation in domestic consumption.

 Love to Conserve Energy to become Efficient
Do not conserve out of fear, or force or for publicity. Please
Cultivate a Passion to ECON.
! -
! !

, ,

CONSERVE ENERGY & SERVE NATION
www.energymanagertraining.com
Please go through the Govt. Website
and you will find mine & more articles on Industry
Thank You S.ASHOK / COIMBATORE

PCRA FACULTY,

BEE certified Energy Auditor

cell : - 9 4 4 3 7 - 2 0 2 2 0

ID :- ashok.anbesivam@gmail.com

Pl visit my site www.energymeasuretosave.com

 SHARE KNOWLEDGE TO SAVE OUR ENERGY
Let us link to collectively Act & Consistently Educate
ourselves for the benefit of sustainable environment.