RELIANCE CHEMOTEX INDUSTRIES LTD.

, UDAIPUR
Energy Management Cell
RELIANCE CHEMOTEX INDUSTRIES LTD., UDAIPUR
Energy Management Cell
RELIANCE CHEMOTEX INDUSTRIES LTD., UDAIPUR
Energy Management Cell
RELIANCE CHEMOTEX INDUSTRIES LTD., UDAIPUR
Energy Management Cell
 PROJECT TITLE
REPLACEMENT OF CONVENTIONAL TUBE LIGHTS WITH LED TUBE LIGHTS IN UNIT 1

ACTION TAKEN
1. Replaced 740 Nos. 65W Conventional Tube Lights with 22W LED Tube Lights in
‘A’ & ‘B’ Section of Unit 1
2. Replaced 1400 Nos. 36W Conventional Tube Lights with 18W LED Tube Lights in
‘C’ , ‘D’ & ‘E’ Section of Unit 1
Energy Energy Cost savings Cost savings Investment Payback
savings / day savings / year /day / year period
1472 kWh 534336 Rs. 10,304 Rs. Rs.14,73,5 4.73
kWh 37,40,352 72 months
FURTHER ACTIONS
To replace all Conventional Tube lights in H Plant and Offices
 PROJECT TITLE
REPLACEMENT OF CONVENTIONAL TUBE LIGHTS WITH LED TUBE LIGHTS IN UNIT 2

ACTION TAKEN

Replaced about 1000 Nos. 36W Conventional Tube Lights with 18W LED Tube
Lights in Unit 2

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period
450 kWh 163350 Rs. 3,150 Rs. Rs. 3.51
kWh 11,43,450 3,34,061 months
FURTHER ACTIONS
Replacement of Unit 2A in progress. Unit 2B to be taken up
 PROJECT TITLE
OPTIMIZE SUPPLY AIR / RETURN AIR FLOW IN H-PLANTS (UNIT 2)
ACTION TAKEN
1. Adjusted blade angle of SA / RA fans of Unit 2 H Plants
2. Provided VFDs to SA fans of Link Coner H-Plant
Energy Energy Cost savings Cost savings Investment Payback
savings / day savings / year /day / year period
1284 kWh Rs. 8,988 Rs.
32,30,409
FURTHER ACTIONS
1. VFDs may be provided to SA / RA fans other H – Plants
2. Replace conventional fans with Energy Efficient fans
 PROJECT TITLE
OPTIMIZE SUPPLY AIR / RETURN AIR FLOW IN H-PLANTS (UNIT 1)
ACTION TAKEN
Adjusted blade angle of SA / RA fans of A-Extension H-Plant

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period
218 kWh 43600 kWh Rs. 1,524 3,04,752
FURTHER ACTIONS
1. Convert Belt driven fans with Direct coupled fans
 PROJECT TITLE
OPTIMIZE PUMP SPEED OF DYEING MACHINE PUMP MOTORS
ACTION TAKEN
1. Provided 37 kW VFD to M/c No. 2 and set frequency at 45 Hz.
2. Provided 55 kW VFD to M/c No. 6 and set frequency at 45 Hz.

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period
178 kWh 44500 kWh Rs. 1,245 Rs. Rs. 6.60
3,11,238 1,71,300 months
FURTHER ACTIONS
1. Indent raised for 1 No. 55 kW VFD on 13.02.2018 for M/c No. 5
2. VFDs to be provided on 2 more machines
 PROJECT TITLE
OPTIMIZE WCS PRESSURE – ‘E’ SECTION
ACTION TAKEN
1. Provided 22 kW VFD to WCS motor of ‘E’ Section and set frequency at 45 Hz. The
suction pressure available at Carding machine is around 800 – 900 Pascal

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period
69 kWh 25047 kWh Rs. 484 Rs.1,75,53 Rs. 78,000 5.33
2 months
FURTHER ACTIONS
1. To provide Closed loop with pressure transducer to maintain constant pressure at
carding
 PROJECT TITLE
COMPRESSED AIR LEAKAGE ARREST IN AUTOCONERS
ACTION TAKEN
1. Provided Kalki online compressed air monitoring system to Autoconers of Unit 1
and Unit 2 to monitor air leakages
2. Arrested air leakages in Autoconers
Energy Energy Cost savings Cost savings Investment Payback
savings / day savings / year /day / year period
392 kWh 142296 Rs. 2,744 Rs. 7,18,443 8.66
kWh 9,96,072 months
FURTHER ACTIONS
1. To monitor and arrest compressed air leakages continuously
 PROJECT TITLE
OPTIMIZE SUCTION PRESSURE OF AUTOCONERS
ACTION TAKEN
1. Optimized Suction pressure of Unit 1 & 2 POLAR and MURATA Autoconers by
setting VFD frequency to 50 - 60 Hz range

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period
269 kWh 97647 kWh Rs. 1,883 Rs.
6,83,529
FURTHER ACTIONS
1. To provide Closed loop with pressure transducer to maintain constant suction
pressure
2. To take trial on ESPERO machines by providing VFD with pressure transducer
 PROJECT TITLE
RUNNING OF OVER HEAD BLOWERS IN POWER SAVER MODE
ACTION TAKEN
1. Introduced energy saver stoppage time in Unit 2B Ring Frame, E Section Ring
Frame and Unit 2 TFOs

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period
223.39 81090 kWh Rs. 1,564 Rs.
kWh 5,67,634
FURTHER ACTIONS
1. To introduce energy saving stoppage on other Over head blowers where ever
possible.
 PROJECT TITLE
OPTIMIZE PNEUMAFIL SUCTION PRESURE IN RING FRAMES
ACTION TAKEN
1. Provided VFD with pressure transducer to R/F No. 4 (Unit 2) on trail basis.
Required pressure level set to 1000 pascal which can be achieved from a frequency
range of 45 – 48 Hz.
Energy Energy Cost savings Cost savings Investment Payback
savings / day savings / year /day / year period
26.45 kWh 9601 kWh Rs. 185 Rs. 67,209 Rs. 35,000 6.25
months
FURTHER ACTIONS
1. To provide VFDs to other Ring frames. There is potential for saving of 900 units
per day in Unit 2 alone
 PROJECT TITLE
RUN UNDER LOAD MOTORS IN ‘STAR’ MODE INSTEAD OF ‘DELTA’ MODE
ACTION TAKEN
1. Provided Automatic Delta Star converter to TFO No. 22 (Unit 1) and TFO No. 4
(Unit 2) to establish power saving potential.

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period

FURTHER ACTIONS
1. Asked the supplier to visit mills and check the installation
 PROJECT TITLE
ENERGY EFFICIENT PUMPS AND MOTORS IN H PLANT
ACTION TAKEN
1. Provided 4 Nos. Energy efficient Pumps and motors in following H-Plants of Unit 1
(a) ‘D’ Carding (b) ‘A’ Winding ( c ) ‘A’ Carding (d) ‘E’ Ring Frame

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period
72.96 kWh 18240 kWh Rs. 511 Rs. Rs. 10.9
1,27,680 1,15,960 months
FURTHER ACTIONS
1. To replace other old pumps and motors with Energy Efficient pumps and motors
(IE3 / IE4)
2. To replace conventional nozzles with High Efficiency Atomizers
 PROJECT TITLE
OPTIMIZE WCS PRESSURE – UNIT 2
ACTION PLAN
1. To provide VFD to 1 No. WCS in Unit 2

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period
 PROJECT TITLE
REPLACEMENT OF CARDING MAIN MOTOR WITH HIGHER CAPACITY
ACTION PLAN
1. To establish saving potential
2. Requested store department to get quotation of new 9.3 kW motor

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period
 PROJECT TITLE
AVODING IDLE RUNNING OF OVER HEAD BLOWERS IN POST SPINNING
ACTION PLAN
1. Impart awareness to supervisors / workers to switch off O/H Blower when
machines are not running – especially in TFO and Winding
2. To provide electrical interlocking where ever possible
Energy Energy Cost savings Cost savings Investment Payback
savings / day savings / year /day / year period
 PROJECT TITLE
REDUCE EXCESSIVE LIGHTING
ACTION PLAN
1. Impart awareness to supervisors / workers to switch off lights and fan when not
required, especially in Packing area and Offices
2. To put “Stickers” for energy conservation
3. Permanently remove / switch off lights where ever possible
Energy Energy Cost savings Cost savings Investment Payback
savings / day savings / year /day / year period
 PROJECT TITLE
EFFICIENT USE OF COMPRESSED AIR
ACTION PLAN
1. Avoid misuse of compressed air
2. Arrest leakages in machinery
3. Optimize pressure of cleaning air
4. Redesigning compressed air network
5. Timely Overhauling of compressors to increase compressor efficiency
6. Use of Air Guns for cleaning
Energy Energy Cost savings Cost savings Investment Payback
savings / day savings / year /day / year period
 PROJECT TITLE
REDUCTION OF SPEED OF RING FRAMEs / TFOs
ACTION PLAN
1. To assess energy saving potential Vs. contribution losses with the help of MIS
department.

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period
 PROJECT TITLE
USE OF LOW WEIGHT BOBBINS IN RING FRAME
ACTION PLAN
1. Requested store dept. to procure bobbins for trial

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period
 PROJECT TITLE
REPLACEMENT OF VARIATOR DRIVE WITH INVERTER DRIVE IN RING FRAME

ACTION PLAN
1. Order for 1 set of Inverter drive is placed with LMW

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period
 PROJECT TITLE
REPLACEMENT OF OLD STANDARD MOTORS WITH EE MOTORS
ACTION PLAN
1. Trial to be taken by replacing old standard motor of TFO with IE3 / IE 4 motors to
establish energy saving potentail

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period
 PROJECT TITLE
USE OF ENERGY EFFICIENT SPINDLE TAPES / OILS IN RING FRAME
ACTION PLAN
1. Maintenance department may check the feasibility of Energy efficient spindle tapes
and spindle oil

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period
 PROJECT TITLE
OPTIMAL USE OF PNEUMAFIL FAN IN SIMPLEX (UNIT 2)
ACTION PLAN
1. To explore the possibility of optimal use of Pneumafil fans of Unit 2 Simplex

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period
 PROJECT TITLE
USE OF LIGHTER SPINDLES IN RING FRAME
ACTION PLAN
1. Maintenance department may check the feasibility of use of lighter spindles in
Ring frame and optimization of Ring dia with respect to count

Energy Energy Cost savings Cost savings Investment Payback

savings / day savings / year /day / year period