SCHEDULE OF ACTIVITIES

i

SCHEDULE OF ACTIVITIES

1. Inception Visit to Different Department of Tricot industries.……………...……….19/07/2014

2. Learn basic concept of knitting and its process…………………….20/07/2014 TO 25/08/2014

3. Work on improvement of power system of Industry...……………..26/07/2014 TO 02/08/2014

4. Work on alternative source (Solar System) and comparison with diesel generator…03/08/2014

To 10/08/2014

5. Preparation of Report……….………………………………………05/08/2014 TO 09/08/2014

6. Final Report……………………….………………………………...10/08/2014 TO 11/08/2014

ii

ACKNOWLEDGEMENT This Industrial Internship was a great opportunity for us and it is done by support of many others.

We are obliged and grateful to all individuals and the Institution who contributed their ideas and

support in the completion of our internship. At first, we would like to express our sincere

gratitude to the Department of Electrical and Electronics Engineering, Kathmandu University

and CEO of Tricot industries Private Limited, Mr. Sandeep Goenka.

We are very thankful to our intern coordinator, Asst. Prof. Prabal Sapkota and Asst. Prof.

Madhav Prasad Pandey, for their continuous support. It is because of their continuous support we

are able to achieve much in the internship. We would like to express our sincere gratitude to the

Intern Supervisors Mr. Sanjeev K. Jha and Mr.Raja Dongol. Also we would like to thanks to

Mr.Umesh Shah, Ravindra Thakur and Rajkumar Shah for their valuable suggestions and

guidance for electrical power system in Tricot. We are most thankful to our operator brothers &

sisters, who helped us to understand knitting process and gave opportunity to operate hand flat &

automatic knitting machine.

Finally, we would like to thank all our friends and individuals who helped and supported us

during internship.

iii

ABSTRACT Internship in Tricot Industries was completed as a requirement of course Industrial Internship

(PCEG 436). Understanding the technology used in this industry and understanding its work-

environment was the basic aim of this internship.

The internship was divided into two major sections. In the first part we were assigned with a task

of learning by reading the manuals and understanding about the Manufacturing process and

electrical power system. The second part was to study and calculate the size of capacitor bank

required to improve power factor and design of solar photovoltaic system for the key operating

areas of industries and comparison of it with the diesel generator.

This report describes the technical and managerial aspect of Tricot industry. It also contains

details of the internship work (log-sheets of work assigned), various pictures of the work

environment and the letter of certificated from the organization.

iv

SYMBOLS AND ABBREVIATIONS

A. Symbols

Symbol Description

Ω Ohm

KΩ Kilo ohm

v Voltage

KVAR Kilo Volt-Ampere Reactive

B. Abbreviations Abbreviation Full Form

LED Light Emitting Diode

Ah Ampere hour

Wh Watt-hour

v

TABLE OF CONTENTS ACKNOWLEDGEMENT ............................................................................................................................ ii

ABSTRACT ................................................................................................................................................. iii

SYMBOLS AND ABBREVIATIONS ........................................................................................................ iv

LIST OF FIGURES .................................................................................................................................... vii

LIST OF TABLES ..................................................................................................................................... viii

CHAPTER 1 ................................................................................................................................................. 1

OVERVIEW OF ORGANIZATION ............................................................................................................ 1

1.1 Introduction ................................................................................................................................... 1

1.1.1 The history of Tricot .................................................................................................................... 1

1.1.2 Mission statement ........................................................................................................................ 1

1.1.3 Objectives .................................................................................................................................... 1

1.1.4 Organizational Structure and Hierarchy....................................................................................... 2

1.1.5 About Location (Biratnagar) ........................................................................................................ 3

1.1.6 Environment ................................................................................................................................. 4

1.1.7 Manufacturing Process Flowchart................................................................................................ 5

1.1.8 Electrical & Electronics Machinery and Equipment available .................................................... 7

1.1.9 SWOT Analysis ......................................................................................................................... 16

CHAPTER 2 ............................................................................................................................................... 17

INTERNSHIP DETAILS ............................................................................................................................ 17

2.1 Capacitor Bank Installation Analysis ................................................................................................ 17

2.2 Solar Photovoltaic System Design for Key Areas of Factory ........................................................... 19

2.2.1 Introduction ................................................................................................................................ 19

2.2.2 Objectives .................................................................................................................................. 19

2.2.3 Scope of the project.................................................................................................................... 19

2.2.4 Limitations ................................................................................................................................. 20

2.3 Financial analysis and comparison with diesel generator ................................................................. 24

2.4 Solar System Design if Tube-light is Replaced by LED Light ......................................................... 26

2.5 Financial Analysis and Comparison with Diesel Generator ............................................................. 29

2.6 Comparison of Per Unit (kWh) Cost for Diesel Generator and Utility (NEA) Power Supply ......... 32

CHAPTER 3 ............................................................................................................................................... 33

CONCLUSION & RECOMMENDATIONS ............................................................................................. 33

vi

3.1 Conclusion ........................................................................................................................................ 33

3.2 Recommendations ............................................................................................................................. 33

REFERENCES ........................................................................................................................................... 34

APPENDIX ................................................................................................................................................. 35

vii

LIST OF FIGURES Figure 1: Map of Nepal ................................................................................................................................. 3

Figure 2: Map of Rani Mills Area of Biratnagar showing tricot industries .................................................. 4

Figure 3: Top view of Tricot industries ........................................................................................................ 4

Figure 4: Production process ........................................................................................................................ 5

Figure 5: Transformer ................................................................................................................................... 7

Figure 6: UPS ................................................................................................................................................ 7

Figure 7: Battery Backup for UPS ................................................................................................................ 8

Figure 8: Control Panel ................................................................................................................................. 8

Figure 9: 200kVA Diesel Generator ............................................................................................................. 9

Figure 10: 30kVA Diesel Generator ............................................................................................................. 9

Figure 11: Steam Boiler .............................................................................................................................. 10

Figure 12: Control Panel for Steam Boiler ................................................................................................. 10

Figure 13: Pump Used in Boiler ................................................................................................................. 11

Figure 14: Boiler ......................................................................................................................................... 11

Figure 15: Automatic Computerized Knitting Machine ............................................................................. 12

Figure 16: Yarns ......................................................................................................................................... 12

Figure 17: Hand-flat Knitting Department .................................................................................................. 13

Figure 18: Linking Machine ....................................................................................................................... 14

Figure 19: Drier........................................................................................................................................... 15

Figure 20: Washing Machine ...................................................................................................................... 15

viii

LIST OF TABLES Table 1: Total Load Specification for Solar System wih Tube-light .......................................................... 22

Table 2: Investment Cost Estimation for Solar System .............................................................................. 25

Table 3: Annual Expenditure for Solar System .......................................................................................... 25

Table 4: Comparison of Expenditure of Solar System and Diesel Generator ............................................. 26

Table 5: Load Calculation Details for Solar System with Tube-light Replaced by LED Light.................. 27

Table 6: Investment Cost Estimation for LED Light .................................................................................. 29

Table 7: Annual Expenditure ...................................................................................................................... 30

Table 8: Summary of total energy, cost and size decreased by installing the LED in place of tube light .. 31

1

CHAPTER 1

OVERVIEW OF ORGANIZATION

1.1 Introduction

Tricot is an international luxury cashmere manufacturer and market leader in the Nepalese

knitwear industry. Tricot is dedicated to providing excellent customer service and delivering a

high quality product, quickly and efficiently. Tricot's long standing supplier and customer

relationships make it superior and a world class knitwear manufacturer.

1.1.1 The history of Tricot

The Golyan Group and JV Partners set up Makalu Cashmere in 1999. Makalu Cashmere grew

from strength to strength and in 2006 the group took over complete control of the company

renaming it, Tricot Industries. The Golyan Group is Nepal’s leading private sector enterprise and

has been in the textile industry for over 60 years. The Golyan Group is a family company based

around core family values, most importantly honesty, integrity, reliability and transparency. At

Tricot Industries understand the customer needs and are constantly striving to maintain excellent

customer service and high quality products.

Today, Tricot Industries has the largest knitting unit in Nepal and an extensive international

client base. Over the last decade they have adapted to change and kept up to date with the latest

technology and market trends. Recently tricot unveiled new stock service system and cutting

edge Auto-sweat production control software, which helps towards a smoother buying

experience for customers. Whether customers are international fashion brands or small retail

outlets, they can expect the same quality of service and luxury product as one another.

1.1.2 Mission statement

The company's mission is to become the global leader in high quality cashmere and strive to

maintain the core company values: Honesty, integrity, reliability and transparency. Tricot

Industries is devoted to its customers and in delivering consistently high quality products fast and

efficiently with competitive prices for luxury products. Our mission is to become the leading

supply chain partner in flat knitwear across the globe whilst continuing to uphold our core

company values.

1.1.3 Objectives

Delivery on right time with ultimate customer satisfaction in quality.

2

1.1.4 Organizational Structure and Hierarchy

Sampling

YDR Master Panel check Mending

Cutting Linking Trims open Extra Fabric Hand Hamming Stitching

Washing Pressing Measure-

ment

Checking

Buttoning Labelling Folding Taging Packing

Manager Operation

Store Incharge Cixing M/c incharge Manager-Production Knitting Incharge

Yarn store Accessory Store

Designer

Technicians

Sr. operator

Clerck(Ydr3)

Operator

Helper

MUP

Incharge

Finishing

Incharge

Utility

Incharge

Home keeping

Incharge

Managing Director

CEO

Quality Manager

Vice President

Marketing & Merchandizing

Accounts Administration

Final Checking

3

1.1.5 About Location (Biratnagar)

Biratnagar is Nepal’s second biggest city which is located near the south-eastern border to India.

It is known by agriculture, commerce and industry. Country’s most manufacturing industries are

located in this region. Tourists discover Biratnagar on their way to the Himalayan states of India,

known as Sikkim and Darjeeling. Visitors also arrives Biratnagar by air to begin their trekking to

mountains such as Kanchanjunga. In recent days, a day or two is also spent at Biratnagar city by

tourists adventuring into Nepal’s tea growing regions like Illam and Dhankuta.

Nepal's first large scale industry was setup in Biratnagar, the Biratnagar Jute Mills in 1936.

Today, the city has some of the largest industrial undertakings in the country. It is Nepal's second

biggest city which is believed to be the capital of language, culture and politics of the country.

Biratnagar Jute Mills, was set up here in 1936. Koshi Tappu Wildlife Reserve (90-minute drive)

is a bird watching spot. The Koshi Barrage on the Koshi river (two-hour drive) is an impressive

sight. Biratnagar is the hub of air routes in eastern Nepal. (Temperature 8-39 degrees Celsius.)

Figure 1: Map of Nepal

4

Figure 2: Map of Rani Mills Area of Biratnagar showing tricot industries

Figure 3: Top view of Tricot industries

1.1.6 Environment

The company respects the environment and is putting its constant effort to save it by reducing

pollution and upgrading its equipment’s.

5

1.1.7 Manufacturing Process Flowchart

Figure 4: Production process

Yarn Store & Receive

Knitting(Production)

Panel Checking

Initial Mending (If Required)

Cutting

Linking

Sewing

Hand Hemming & Light Checking

Mending (If Required)

Washing & Drying

Final Pressing

Initial Pressing

Final Mending

Quality Checking

Finishing/Packing

6

First of all yarn is received from the yarn store, (yarn are sometime send by the buyer

itself or purchased from China).

After that the knitting is done in automatic computerized flatbed knitting machine or in

hand knitting machine and the particular panel is checked in panel checking to identify

any mistake done in knitting process. If any mending (correcting the defect pieces by

hand) is required it is done.

After an initial pressing is done to unfold the folded edges of panel and cutting is done if

the shoulder slope is not proper.

When all of these processes are completed then the panel are send to the linking

department, the panel and neck are linked with the help of linking machine and the pieces

are corrected by hand sewing.

When sewing process is completed the pieces are finally checked on light table by

inserting the piece on two sleeve . After that final mending is done if required. When all

of these process is finished then the product are washed and dried in washing department

after that final pressing is done, then the product is send for quality checking in finishing

department where final mending is done if required. Finally, the products are packed.

7

1.1.8 Electrical & Electronics Machinery and Equipment available

Electrical equipment available

Transformer

Figure 5: Transformer

Uninterruptable power supply

Figure 6: UPS

Rating

KVA:50kVA

Power factor:0.8

Battery input:348V D.C

Current :122Amp

Rating

Power: 500kVA

Type: Stepdown(11kV/440V)

Phase: Three phase

8

Battery Bank for UPS

Figure 7: Battery Backup for UPS

Control Panel

Figure 8: Control Panel

9

Diesel Generators

Figure 9: 200kVA Diesel Generator

Figure 10: 30kVA Diesel Generator

Steam Boiler

Steam boiler is used to produce the steam used in steam pressing. Here the cold water is

pumped from the water source by two pump, water is pumped at the interval of 5min then

heated and converted into steam .The water is heated by burning straw motors are used

for drawing straw and the gas to the chimney. Firing cut off for Boiler is 140°C.Total

load consumed is 30-50 Amp and system voltage is 350V.The rating of the boiler is

160A, 8kv.

Rating

KVA: 200kVA

Power factor: 0.75

Rating

KVA: 30kVA

Power factor: 0.80

10

Figure 11: Steam Boiler

Figure 12: Control Panel for Steam Boiler

11

Figure 13: Pump Used in Boiler

Figure 14: Boiler

Rating

Pump efficiency: 84%

R.P.M: 2840

Power: 2.7kW

12

CIXING Chinese Automatic Computerized Knitting Machine

Figure 15: Automatic Computerized Knitting Machine

Yarns Available in Computerized Knitting Department

Figure 16: Yarns

13

Hand-flat Knitting Hall

Figure 17: Hand-flat Knitting Department

14

Linking Machine

Figure 18: Linking Machine

15

Drier

Figure 19: Drier

Washing Machine

Figure 20: Washing Machine

16

1.1.9 SWOT Analysis

Strength

Tricot industry produces fewer amounts of harmful gases and polluted water which

doesn’t harm the environment greatly.

Reduction in electricity consumption by replacement of electric iron with steam iron

which is very important to the country like Nepal which produces less electricity.

Bio briquettes for smokeless chulaha can be produced from the incompletely burned

waste from the boiler.

Automatic computerized machine which need lesser employ.

Greatest garment industry of Nepal producing high quality garment products which is

popular worldwide.

Very good quality assurance system.

Weakness

Poor electrical power system.

Low system voltage.

Voltage fluctuation.

Running with low power factor.

Inefficient electrical power supply.

Old civil structure (buildings) dangerous in country like Nepal where Earthquake occurs

frequently.

Knitting labor problem as most of the machine are closed even they have orders.

Lack of proper manpower for the maintenance of machine.

17

CHAPTER 2

INTERNSHIP DETAILS

2.1 Capacitor Bank Installation Analysis

This analysis is intended top-lift the technological standard of industrial plants. The overall

power factor of modern industries is very poor because of inductive loads absorbing reactive

power. Especially, industrial plant with variable load conditions has large inductive loads and its

power factor is very poor. These industries benefit most from automatic capacitor banks. This

bank provides improved power factor, increased voltage level on the load and reduced electric

utility bills. Besides, automatic capacitor banks may be able to eliminate kVAR energized at

light-load periods and undesirable over-voltages. In most cases, the main reason why a customer

installs a capacitor bank is to avoid penalization in the electricity bill. This inappropriate

installation without enough study gives rise to a great variety of technical problems. Therefore,

the fact that capacitor banks are designed for long-term use should be considered.

The main benefits from PF correction are:

Avoid utility penalties

Reduce transformer, cabling, and motor losses

Reduce total plant KVA for the same KW working power

Lower utility electrical billing

Improved voltage regulation

Minimize electrical distribution system investment costs

Avoid utility penalties

As PF correction reduces the magnetizing current through the power circuit, the utility company

can deliver electrical energy to other customers more efficiently.

Reduce total plant KVA for the same KW working power

Improving PF frees up actual KVA for additional loads that in turn allows system transformers

operate more efficiently.

Less investment

In new installations, the reduction in size of distribution equipment (transformers, cables,

switchgears, etc) will imply less waste of money.

Increase KW working power for the same KVA demand

Improving PF will release system capacity permitting the addition of more loads without

overloading the source transformers. By using the next formula, it is possible to verify what was

stated above.

Improved voltage Regulation

As PF correction helps to reduce line voltage drops, motors, conveyors and other equipment will

have more efficient performance.

18

Calculation:

Yearly savings from demand charge:

Apparent power rate = Rs.230/kVA

Installed transformer capacity = 500 kVA

Voltage level of system = 440, 3-phase

Existing power factor = 0.82

Corrected power factor = 0.95

Apparent power demand = 250 kVA

Active power demand = 250×0.82 kVA

= 205 kW

Corrected apparent power demand = ⁄ kVA

= 215.79 kVA

Existing monthly utility charge = Rs.230/kVA×250kVA

= Rs.57,500

Corrected monthly utility charge = Rs.230/kVA×215.79kVA

= Rs.49, 632

Monthly savings = Existing monthly utility charge – Corrected monthly utility charge

= Rs.57, 500 – Rs.49,632

= Rs.7,868

Yearly savings = 12×(Monthly savings)

= 12×Rs.7,868

= Rs.94,416

Yearly saving after eliminating low voltage problem using capacitor bank:

Price of diesel = Rs.110 per litre

Number of hours that diesel generator run due to low voltage = 10 hrs.per month

Amount of diesel consumed by generator = 20 litres per hour

Monthly diesel cost for DG = 10 hrs×20 litres×Rs.110

= Rs.22,000

Yearly diesel cost for DG = Rs.22,000×12

= Rs.2,64,000

Total yearly savings = Yearly savings from demand charge + Yearly savings from DG

= Rs.94,416 + Rs.2,64,000

= Rs.3,58,416

Capacitor size selection and total cost associated with installation:

Capacitive reactive power required,

kVAR = Active power demand×tan(cos-1

existing pf.) – tan(cos-1

corrected pf.)

kVAR = 205kW×tan(cos-1

0.82) - tan(cos-1

0.95)

= 205×tan(34.92) – tan(18.19)

= 205×(0.698 – 0.33 )

= 205×0.369

= 75.73 kVAR, use 100kVAR

Hence, selected size of capacitor bank is 100kVAR.

19

Cost of 100 kVAR capacitor bank = Rs.2,08,000

Total installation charge = Rs.25,000

Total cost = Rs.2,08,000+Rs.25,000

= Rs.2,33,000

Equipment Payback Period:

The equipment payback Period, = Total cost of capacitor bank ÷ Total yearly savings

= Rs.2,33,000 ÷ Rs.3,58,416

= 0.65 yrs.

Hence, the payback period of the equipment is 0.65 years. This indicates that installation of

capacitor bank seems to be feasible.

2.2 Solar Photovoltaic System Design for Key Areas of Factory

2.2.1 Introduction

Electrification is the prompt need of today’s world. Solar photovoltaic is one of the most cost

effective means to provide small amounts of electricity in areas without a grid. It is considered as

the only form of electricity that can be generated anytime and anywhere provided sunshine is

available. Institution like schools, VDC buildings, health post, religious building, clubs etc. at

remote places are to be electrified. Solar photovoltaic systems can serve as source of power

supply. Alternative energy promotion center (AEPC), under the Ministry of Science and

Technology and Energy Sector Assistance Program ESAP are jointly working for the promotion

of alternative energy. The program supports both Solar Home System (SHS) for domestic

purpose and Institutional Solar PV System ISPS for institutional purpose.

2.2.2 Objectives

The basic objectives of the project were to:

Identify the need and demand

Define the load for the tricot industry

Propose the optimum design of the PV panel

Propose the optimum design of the battery

Propose the size of charge controller

Propose the size of wires

Propose the size of inverter

Propose the cost of all the components required for the system

Propose the total cost of installation

Perform the financial and socioeconomic analysis of the project

Financial comparison with respect to a diesel generator for the same

2.2.3 Scope of the project

The project is intended to provide the efficient and uninterrupted power to the key area of Tricot.

The project is intended to lighten the industry and to supply power for a fan, computers and

ventilation fan. Inverters were being used previously. But the inverter was not able to supply

power for long duration and useless for powering the appliance which draws high current.

20

Photovoltaic system would be the adequate source of supply. PV modules have no moving parts

and require little maintenance compared to other electricity-generating systems. Thus there is no

Need of highly qualified manpower. If the complex is expanded the PV systems can be expanded

too and thus the power demand can be satisfied. As the PV systems generate electricity without

polluting the environment and without creating noise, it would be the best choice for the

industries.

2.2.4 Limitations

The project has the following limitations:

Temperature effect is not considered in the design.

The shading effect on the solar array is not incorporated in the design.

The design for the safety disconnect is not detailed.

2.2.5 Methodology

The design of the solar photovoltaic was started with finding the details of the site. Then

The load for the individual block of complex was defined according to the requirement.

Then the sizing of the array was done using the formula;

Iarray = Total average daily load in Ah @ system voltage/(Peak sun x derating factor x columbic

efficiency)

Then the sizing of the battery was done using the formula

Capacity of the battery = (Daily load x days of autonomy)/ (DOD x efficiency)

Then the sizing of the charge regulator was done. The maximum load current capacity

Was calculated using the formula,

Imax = Σ power consumed by appliances/ system voltage

Also the maximum charge current capacity was found. This current should be greater

then or equal to short circuit current produced by the array.

Then wire sizing for the individual section was done using the formula

S = (0.3 x length x max. current)/ Maximum allowable voltage drop in percent.

Then the inverter sizing was done. The surge power for the ac load was calculated.

Then the sizing of the dc to dc converter was performed. The maximum output current

For the dc to dc converter was calculated.

Then the safety disconnect requirements were defined. Also the grounding was designed.

Finally the financial analysis of the project was carried.

21

Computer Department

Number of room=1

Number of tube light=16 of 60W,220Vac,12 hrs per day

Total number of computer =2 of 150W,220Vac,12hrs per day

Number of fans= 2 of 75W; 220 Vac ; 12hrs per day

VHF telecommunication equipment with the following details

~ Power consumption in talk/receive mode: 50

~ Power consumption in stand-by mode: 10W

~ System voltage: -48V dc

General Manager's office




Yarn Store


Number of printer= 1 of 70W,220 Vac ; 2hrs per day



Administration


Number of computer =1 of 150W,220Vac,12hrs per day


Merchant's office


Number of computer =2 of 150W,220Vac,12hrs per day


Canteen

Ventilation fan = 1 of 80W,220 Vac ; 2hrs per day



Street


22

Finishing Block



Guard's office and Gate

Number of tube light=2 of 60W, 220Vac, 8 hrs. per day

Number of fans= 1 of 75W; 220 Vac, 12hrs. per day

Table 1: Total Load Specification for Solar System wih Tube-light

S.N Type of

load

Power(W) Numbers Total

power

Use

hours

Energy(Wh) Operating

voltage

1 Lamp 1 60 47 2820 12 33840/0.9

=37600

eqv.12

Vdc

2 Lamp 2 60 17 1020 8 8160/0.9

=9066.66

eqv.12

Vdc

3 Computers 150 9 1350 12 16200/0.9

=18000

eqv.12

Vdc

4 Fans 75 15 1125 12 13500/0.9

=15000

eqv.12

Vdc

5 Ventilator 80 1 80 8 640/0.9

=711.11

eqv.12

Vdc

6 Printer 70 1 70 2 140/0.9

=155.55

eqv.12

Vdc

7 Telephone 10 4 40 23 920 eqv.48Vdc

50 4 200 1 200

Total D.C load = 37600+9066.66+18000+15000+711.11+155.55

= 80533.32Wh for 12 vdc

And,

1120Wh for 48 vdc

Total energy required in Ampere hour =

+

= 6711.11 + 23.33

= 6734.44 Ah

Array Sizing:

Peak sun assumed: 5

Total array current required is

Iarray = 6734.44/(5 x 0.85 x 0.9)

= 1760.63 A

23

For this requirement 150W model of Astropower with Imp = 8.8 A is selected. The

Number of modules to be in parallel,

Np = 1760.63/8.8 = 200

Battery Sizing:

Autonomy day = 5 (assumed)-

The capacity of the battery bank (assumed DOD 80% and charging efficiency 0.8) is

C = (6734.44 x 5)/ (0.8 x 0.8) = 52613.593Ah, 12v

Thus, 200Ah, 12V deep cycle batteries are selected. To meet the required capacity 265 batteries

are to be connected in parallel

.

Charge regulator sizing:

Operating voltage: 12Vdc

The CR to be used must handle the full short circuit current from the array. For the

Selected model of array, the short circuit current is 9.8A. Thus the total maximum charge

Current is

Iarray = 200 x 9.8 = 1960A

Thus for CR with charge handling capacity greater or equal to 1960A is needed. A CR

With 2000A would meet the requirement.

The maximum possible load current is calculated as,

Imax = ( 2820+1020+1350+1125+80+70)/12

= 538.75 A

The load handling capacity of the CR must exceed538.75A; CR with 550 load current

Handling capacity would meet the requirement.

Wire Sizing:

We proposed load center is in the power house and array is to be mounted on the roof of the

Industry. For the purpose of wiring the following length of wires are required:

Array to load center (allowable voltage drop 3%) = 60m (cable S1)

Load center to battery bank (allowable voltage drop 1 %) = 10m (cable S2)

CR center to inverter (allowable voltage drop 3%) = 3m (cable S3)

CR to dc to dc converter (allowable voltage drop 3%) = 5m (cable S4)CR to loads

(allowable voltage drop 5%)

to Computer department = 50m (cable S5)

to Finishing block = 50m

to G.M's office=50m

to Merchant office = 50m

to Canteen = 30m (cable S5)

to Guard's room and Gate = 50m

S1 = (0.3 x 60m x Iarray)/3 = (0.3 x 60 x 1760.63)/3 = 10563.78 sq. mm.

24

S2 = (0.3 x 10m x 1760.63)/1 = 5280.9 sq. mm.

S3 = (0.3 x 3m x 1760.63)/3 = 528.09 sq mm.

S4 = (0.3 x 5m x 1760.3)/3 = 880.15 sq. mm.

S5 = (0.3m x 50m x 8.5)/5 = 42.5 sq. mm.

(Length 50m is considered for the largest distance from CR to computer department)

The same cable is to be considered for all the loads for convenience and for the cost.

If the wire of the calculated size is not found in the market, the wire size just exceeding

The calculated value is to be selected.

Inverter Sizing:

The capacity of the selected inverter is

P=(Total power x Surge power)/P.F

P = (6465 x 3)/ 0.9= 21550 VA

The input dc supply voltage of the inverter is 12V dc. Since the load is not very sensitive

To the wave shape of AC, high efficiency (0.9) square wave inverter is selected.

DC – to – DC Converter sizing:

Output voltage = 48V

Maximum output current should be greater than load current. Here

The load current = 50/48 = 1.04A

Thus, maximum output current = 2A

Efficiency, = 0.9

Grounding design:

All the ground wires from the equipment are to be connected to a ground electrode in the

earth. The entire negative is grounded.

Copper plate electrodes are to be used.

Dimensions 600mm x 600mm x 3mm

The copper plate is to be buried in a trench of minimum 2.5m depth.

The first meter of covering of the earthing plate is to be fine clay mixed with

Layers of charcoal and salt.

8SWG (4.06 mm diameter) copper wire is to be used for earth wire

2.3 Financial analysis and comparison with diesel generator

Project cost:

The project investment cost include the cost of different components, transportation,

Installation cost. The cost is as tabulated below:

25

Table 2: Investment Cost Estimation for Solar System

INVESTMENT COST ESTIMATION

S.N. Description Amount(NRs.)

1 Solar panel 2000000

2 Battery 6625000

3 Charge controller 150000

4 Inverter 5000

5 dc-to-dc converter 2,000

6 Cables 5,000

7 Safety fuses and grounding 10,000

9 Transportation 5,000

10 Installation 15,000

Total 8682000

Contingencies(5%) 434100

Grand total 9116100

The annual cost of operation is as tabulated below:

Table 3: Annual Expenditure for Solar System

Annual Expenditure


1 Annual salary 5,000

2 Repair and maintenance 1,000

Total 6,000

The estimated income from the project is as tabulated below:

Total cost of installation = Rs.9116100

Total annual expenditure = Rs.6000

Net present worth for the PV system is calculated as:

NPW(PVsystem)=-9116100-6625000(P/F,10%,5)-6625000(P/F,10%,10)-6625000(P/F,10%,15)-

6000(P/A,10%,20) [Since, batteries has to be replaced in every five years.]

=-9116100-4107500-2517500-1583375-57270

=NRs.-17381745

26

For Diesel Plant:

Size of plant required: 7kVA

From data observed, it was found that the generator at full load (6465W) requires 1.5ltr of diesel.

At 75% of load 1.5ltr is required.


The diesel-generator is required to supply 75% load for 8 hrs, 50% load for 3 hours

Therefore, total diesel required = (1.5 x 8+0.75 x 3) = 14.25 ltrs daily.

Total annual cost of operation = Rs (14.25x110x365)

=Rs 572137.5

Initial Cost of diesel-generator = NRs 300000

NPW (Diesel-generator) = -300000-572137.5(P/A,10%,20)

= NRs.-300000-5461433.863

= NRs.-5761433.863

The NPW of diesel generator is less than that of PV system. Hence, the system is financially not

feasible.

Table 4: Comparison of Expenditure of Solar System and Diesel Generator

S.N Expenditures Solar System Diesel Generator

1 Installation/Initial Cost Rs 916100 Rs 300000

2 Annual Repair and Maintenance Cost Rs 1000 Rs 3000

3 Annual Operation Cost Rs 572137.5 Rs 0

4 Net Present Worth of 20 years Rs -17381745 Rs -5786973.86

2.4 Solar System Design if Tube-light is Replaced by LED Light

Since there are many latest technologies for lighting the room with low power consumption we

can replace the tube lights where it is not necessary with LED lights which can consume less

power and illumination is also good. So, replace the traditional. According to our survey out of

64 tube lights 50 tube lights can be replaced with LED lights.

27

Table 5: Load Calculation Details for Solar System with Tube-light Replaced by LED Light

S.N Type of

load

Power(W) Numbers Total

power

Use

hours

Energy(Wh) Operating

voltage

1 Lamp 1 10 33 330 12 3960/0.9

=4400

eqv.12

Vdc

2 Lamp 2 10 17 170 8 1360/0.9

=1511.11

eqv.12

Vdc

3 Lamp 3 60 14 840 12 10080/0.9

=11200

eqv.12

Vdc

4 Computers 150 9 1350 12 16200/0.9

=18000

eqv.12

Vdc

5 Fans 75 15 1125 12 13500/0.9

=15000

eqv.12

Vdc

6 Ventilator 80 1 80 8 640/0.9

=711.11

eqv.12

Vdc

7 Printer 70 1 70 2 140/0.9

=155.55

eqv.12

Vdc

8 Telephone 10 4 40 23 920 eqv.48Vdc

50 4 200 1 200

Total D.C load = 4400+1511.11+11200+18000+15000+711.11+155.55

= 50977.77Wh for 12 vdc

And,

1120Wh for 48 vdc

Total energy required in Ampere hour =

+

= 4248 + 23.33

= 4271.33 Ah

Array Sizing:

Peak sun assumed: 5

Total array current required is

Iarray = 4271.33/(5 x 0.85 x 0.9)

= 1116.68 A

For this requirement 150W model of Astropower with Imp = 8.8 A is selected. The

number of modules to be in parallel,

Np = 1116.68/8.8 = 126.8

=127

Battery Sizing:

Autonomy day = 5 (assumed)-

The capacity of the battery bank (assumed DOD 80% and charging efficiency 0.8) is

C = (4271.33 x 5)/ (0.8 x 0.8) = 33369.765Ah, 12v

28

Thus, 200Ah, 12V deep cycle batteries are selected. To meet the required capacity 167 batteries

are to be connected in parallel.

Wire Sizing:

We proposed load center is in the power house and array is to be mounted on the roof of the

Industry. For the purpose of wiring the following length of wires are required:

Array to load center (allowable voltage drop 3%) = 60m (cable S1)

Load center to battery bank (allowable voltage drop 1 %) = 10m (cable S2)

CR center to inverter (allowable voltage drop 3%) = 3m (cable S3)

CR to dc to dc converter (allowable voltage drop 3%) = 5m (cable S4)CR to loads

(allowable voltage drop 5%)

to Computer department = 50m (cable S5)

to Finishing block = 50m

to G.M's office=50m

to Merchant office = 50m

to Canteen = 30m (cable S5)

to Guard's room and Gate = 50m

S1 = (0.3 x 60m x Iarray)/3 = (0.3 x 60 x 1116.68)/3 = 6700.08 sq. mm.

S2 = (0.3 x 10m x 1116.68)/1 = 3350.04 sq. mm.

S3 = (0.3 x 3m x 1116.68)/3 = 335.005 sq mm.

S4 = (0.3 x 5m x 1116.68)/3 = 558.34 sq. mm.

S5 = (0.3m x 50m x 8.5)/5 = 42.5 sq. mm.

(Length 50m is considered for the largest distance from CR to computer department)

The same cable is to be considered for all the loads for convenience and for the cost.

If the wire of the calculated size is not found in the market, the wire size just exceeding

The calculated value is to be selected.

Inverter Sizing:

The capacity of the selected inverter is

P=(Total power x Surge power)/P.F

P = (3965 x 3)/ 0.9= 13216.66 VA

The input dc supply voltage of the inverter is 12V dc. Since the load is not very sensitive

to the wave shape of AC, high efficiency (0.9) square wave inverter is selected.

DC – to – DC Converter sizing:

Output voltage = 48V

Maximum output current should be greater than load current. Here

The load current = 50/48 = 1.04A

Thus, maximum output current = 2A

Efficiency, = 0.9

29

Charge regulator sizing:

Operating voltage: 12Vdc

The CR to be used must handle the full short circuit current from the array. For the

Selected model of array, the short circuit current is 9.8A. Thus the total maximum charge

Current is

Iarray = 127 x 9.8 = 1244.6A

Thus for CR with charge handling capacity greater or equal to 1244.6A is needed. A CR

with 1500A would meet the requirement.

The maximum possible load current is calculated as,

Imax = ( 3965)/12

= 330.41 A

The load handling capacity of the CR must exceed 330.A41 CR with 5350 load current

Handling capacity would meet the requirement.

2.5 Financial Analysis and Comparison with Diesel Generator

Project cost:

The project investment cost include the cost of different components, transportation,

Installation cost. The cost is as tabulated below:

Table 6: Investment Cost Estimation for LED Light

INVESTMENT COST ESTIMATION


1 Solar panel 1270000

2 Battery 4175000

3 Charge controller 130000

4 Inverter 5000

5 dc-to-dc converter 2,000

6 Cables 5,000

7 Safety fuses and grounding 10,000

9 Transportation 5,000

10 Installation 10,000

Total 5612000

Contingencies(5%) 280600

Grand total 5892600

30

The annual cost of operation is as tabulated below:

Table 7: Annual Expenditure

Annual Expenditure


1 Annual salary 5,000

2 Repair and maintenance 1,000

Total 6,000

The estimated income from the project is as tabulated below:

Total cost of installation = Rs.5892600

Total annual expenditure = Rs.6000

Net present worth for the PV system is calculated as:

NPW(PVsystem)=-5892600-4175000(P/F,10%,5)-4175000(P/F,10%,10)-4175000(P/F,10%,15)-

6000(P/A,10%,20) [Since, batteries has to be replaced in every five years.]

=-5892600-2588500-1586500-997825-57270

=NRs.-11122675

For Diesel Plant:

Size of plant required: 7kVA

From data observed, it was found that the generator at 75% of full load (3965W) requires 1.5ltr

of diesel.

At 75% of load 1ltr is required.


The diesel-generator is required to supply 75% load for 8 hrs, 50% load for 3 hours

Therefore, total diesel required = (1 x 8+0.5 x 3) = 9.5 ltrs daily.

Total annual cost of operation = Rs (9.5x110x365)

=Rs 381425

Initial Cost of diesel-generator = NRs 250000

NPW (Diesel-generator) = -250000-381425(P/A,10%,20)

= NRs.-250000-3604466.25

= NRs.-3854466.25

31

The NPW of diesel generator is less than that of PV system. Hence, the system is financially

feasible.

Table 8: Summary of total energy, cost and size decreased by installing the LED in place of tube

light

Tube light LED

Energy in Wh 80533.32 50977.77

Energy in Ah 6734.44 4271.33

Total cost(NRS.) 17381745 11122675

Total number of panel used 200 127

Total number of batteries used 265 167

Rating of diesel generator 7KVA 5KVA

32

2.6 Comparison of Per Unit (kWh) Cost for Diesel Generator and Utility (NEA) Power

Supply

Per Unit (kWh) cost for Utility (NEA) Supply

Tariff 1 (6PM to 10PM) rate per unit of electricity = Rs.8.75

Tariff 2 (6AM to 6PM) rate per unit of electricity = Rs.7.10

Tariff 3 (10PM to 6AM) rate per unit of electricity = Rs.4.30

Per Unit (kWh) cost for Diesel Generator

Average load = 145A

Voltage level = 440V

Power factor = 0.74

kW = kVA × p.f.

= 440×145×0.74×√3

= 82 kW

Total number of Unit (kWh) produced in one hour is,

kWh = 82 kW×1h

= 82 Unit (kWh)

Amount of diesel consumed in 1 hour = 22 liters

Price of diesel = Rs.110 per liter

Total cost in 1 hour (82 Unit) = Rs.110×22liters

= Rs.2376

Rate per unit of electricity from Diesel Generator = Rs.2376/82

= Rs.28

Hence, we concluded that cost of electricity generated by diesel generator is four times

greater than that of Utility (NEA) cost.

33

CHAPTER 3

CONCLUSION & RECOMMENDATIONS

3.1 Conclusion

We studied about overview of Tricot Industries and gained knowledge about the Knitting

operation. We got chance to feel the professional life and introduced with staffs of the Tricot.

We gained knowledge about Capacitor Bank and solar system installation. We also gained

knowledge about the power system scenario of Industries.

Since the power bill is based on the usage of the active power – kilo-watt-hour (kWh) while the

power system equipment is built to handle the apparent power, the power company may charge a

higher rate for loads drawing below a certain power factor. By spending some money on power

factor correction equipment (Capacitor Bank) customer can save money on electricity bill due to

low power factor.

Solar system design is an ISPS for an industry place. The project would uplift the efficient power

supply. The project is technically feasible. But financially it is found to be not feasible. The use

of LED lights can save the huge amount of energy and also reduces the size of the solar system

also reduces the size of generator if generator is used instead of photovoltaic system in turns

results in consumption of diesel. The photovoltaic system reduces the harmful gas generated by

diesel generator which upgrades the concept of green industry. Another advantage of

photovoltaic system is that it does not produce sound like generator run by diesel. For this

reason the photovoltaic system can be considered.

3.2 Recommendations

Installation of Automatic Capacitor bank is needed because of the variation of load in industry.

The Solar Photovoltaic system design can be modified considering a 48V system, to reduce the

loss. Also solar tracker system can be used for maximum energy tapping from sun.

34

REFERENCES

1. S.K.Jha, “ The Design Of Solar Photovoltaic System For Muktinath Temple”

2. Alternative energy promotion center and Energy sector assistance programme,“Solar

photovoltaic system design manual for solar design Engineeers”,CRE,2003.

3. S.K.Jha, “Principle of Electrical Installations and Lighting System”, Supportive

document for PV design.

4. W.G.Sullivan, J.A.Bontadelli, E.M.Wicks, “Engineering Economy”, 11th

Edition,2000.

35

APPENDIX

36

37

38

39

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Documents

SCHEDULE OF ACTIVITIES