Evaluation Of Energy Conservation Options In Sri Lankan Apparel Industry

By

Chamalie Ahangama Withanage

B.Sc (Hons) Facilities Management

University of Moratuwa

a.w.chamalie@gmail.com

Sri lanka

Background

� Apparel industry

� Seriously affects to the country’s economy

� Energy intensive industry and energy usage is inefficient

� Energy cost is a significant component� Energy cost is a significant component

� Energy conservation

� Close link to quality and productivity improvements

� Essential for surviving and enhance this sector’s global

competitiveness

Aim

� Identify energy conservation options and the barriers of

energy conservation in practical usage that can be

applied on an apparel industryapplied on an apparel industry

Objectives

� Identify various types of energy conservation options

� Identify and analyze energy conservation options in apparel industry

� Ranking the energy conservation options according to the level of importance and comparison with current usage

� Identify the barriers of implementing energy conservation options

� Prioritizing influential (strong) energy conservation barriers

Literature Review

Energy conservation option

� Lighting - 14

� Air-conditioning with HVAC and ventilation - 19

� Boiler and Steam distribution - 19

Compressors/Pumps - 19� Compressors/Pumps - 19

� Sewing/Ironing/Cutting - 12

Barriers of energy conservation options

� Knowledge related factors - 07

� Cost related factors - 06

� Organization and employee related factors - 11

� Technological factors - 07

Research problem

Establish aim & objectives

Literature synthesis

Background study

Research Process

Further

Research

Data Collection

Guide to sampling and

identification options &

barriers

Questioner Survey

Data Analysis

Conclusion & Recommendation

Sample selection

Preliminary Survey

Data Collection

Western province BOI approved large scale garments

Distributed Questionnaires - 37

Responded Questionnaires - 30

Research Methodology

Questionnaire Survey

� Questionnaire one - Usage level of energy conservation options

� Questionnaire two - Perspective level of energy conservation

� Questionnaire three - Rank the energy conservation barriers

Statistical Tools� Mean (Wi) - Rank perspectives and current usage

� Severity Index (S.I) - Significance in affecting energy conservation

� Percentage of importance - Significance

� Coefficient of Variation (COV) - Compare relative variability

� One sample t-test - Identify significant factors

� Cronbach's Alpha - Reliability of Data

Findings

Energy conservation options

� Lighting

� Air-conditioning with HVAC and ventilation

� Boiler and Steam distribution

� Compressors/Pumps

� Sewing/Ironing/Cutting

Importance Severity index Mean rating COV

50%-90% 65%-95% Above 3 15%-40%

No Factor Mean Actual

Rank Mean

1 Energy efficiency in LED lamp 3.76 8 3.59

2Florescent light fitting with high frequency

electronic ballast3.57 1 4.16

3 Automatic Scheduling 3.54 7 3.62

Significance of factors influencing energy conservation in lighting

3 Automatic Scheduling 3.54 7 3.62

4 Task light 3.51 3 4.03

5 Natural light 3.38 11 3.19

6 Maintain correct LUX level in factory 3.35 5 3.84

7 Re design/Rearrangement 3.32 4 3.95

8 Zoning 3.30 6 3.70

9 CFL light 3.16 2 4.11

10Polished aluminium reflectors (mirror

reflector) fix to luminaries3.08 10 3.27

No Factor Mean Actual

Rank Mean

1Control the central A/C system by BMS or

CMS3. 83 11 3.59

2 Central A/C system 3.65 6 3.92

3 Centrifugal chillier 3.62 8 3.73

4 VSDs on chilled water pumps 3.59 10 3.62

5 Duty cycling 3.51 1 4.35

Significance of factors influencing energy conservation in Air conditioning

5 Duty cycling 3.51 1 4.35

6 System optimization 3.41 9 3.70

7 Optimized start /stop 3.38 2 4.19

8 Conserve energy using zoning FCU 3.35 7 3.84

9 Air curtain 3.35 4 4.11

10 Electrical demand limiting 3.32 5 3.95

11 Apply sun control films to glass 3.30 3 4.14

12 Energy conservation with VAV 3.24 15 2.84

13Energy conservation with variable speed

cooling tower 3.16 16 2.78

14 Chilled water reset 3.11 14 3.05

No Factor Mean Actual

Rank Mean

1 Install efficient burner 4.35 7 3.41

2 Duty cycling 4.14 2 4.11

3 Furnace oil boiler 4.11 16 2.57

4 Pre heat of fuel 4.03 9 3.11

Significance of factors influencing energy conservation in boiler and stream distribution

5 Air pre heater 3.95 12 3.05

6 Steam flow meters 3.92 11 3.08

7 Dampers, inlet valves, or variable speed drives 3.84 10 3.16

8 Install thermostat 3.73 14 2.70

9 Steam trap 3.70 8 3.27

10 Recycling of drain 3.59 1 4.16

11 Install them heat-insulated 3.41 3 4.03

12 Install Time switches 3.19 17 2.41

13 Utilization of heat exchanger 3.05 19 2.32

No Factor Mean Actual

Rank Mean

1 VSD (Compressor) 3.86 9 2.68

2 VSD (Pumps) 3.70 6 3.39

Significance of factors influencing energy conservation in compressor and pumps

3 Pressure optimization 3.62 1 3.84

4 Compressor selection 3.46 2 3.68

5 Minimize air leakage 3.41 3 3.66

6 Capacity bank 3.27 7 3.37

No Factor Mean Actual

Rank Mean

1 Stepper motor 4.19 3 3.95

2 Direct drive server motor 4.11 2 4.11

3Intelligent motor controllers for

3.95 12 2.38

Significance of factors influencing energyconservation in sewing

3Intelligent motor controllers for

sewing machines3.95 12 2.38

4 Full steam iron 3.92 5 3.59

5 Mini trap 3.84 4 3.76

6 Gubber cutter 3.62 9 2.76

7 Capacity bank 3.59 10 2.46

8 Control maximum demand 3.41 1 4.16

9 Maximisation of utilisation 3.19 6 3.56

Section T-Cal T(28)

Lighting 2.658 2.179

Air condition 3.453 2.110

Rank Correlation Coefficient

Boiler 0.779 2.110

Compressor -0.177 2.365

Sewing 0.847 2.228

Section FactorRank

DifferencePerspective Actual

Lighting Energy efficiency in LED lamp 1 8 -7

CFL light 9 2 7

Natural light (Solar light) 5 11 -6

Air condition Control the central A/C system by BMS or

CMS1 11 -10

Apply sun control films to glass 11 3 8

Factors having highest difference in rankings

VSDs on chilled water pumps 4 10 -6

Boiler Furnace oil boiler 3 16 -13

Low pressure and large-diameter piping 16 4 12

Radial large at bend 17 5 12

Compressor VSD (Compressor) 1 9 -8

Operate in low pressure 4 9 5

VSD (Pumps) 2 6 -4

Sewing Intelligent motor controllers for sewing

machines3 12 -9

Control maximum demand 8 1 7

Arranging continuous material flow 12 7 5

Barriers Mean Value

Cost 3.653

Knowledge 3.347

Barriers of energy conservation

Technology 3.143

Organization and employees 3.131

No Factor Mean

1High cost associated with plants and equipments

4.11

2Cost associated with energy conservation

technology is considerably high3.95

Energy conservation barrier on cost

2technology is considerably high

3.95

3Cost associated with BMS applications which

are related to energy conservation is high 3.62

4 Have a long investment payback period 3.41

No Factor Mean

1No champions who can handle energy conservation matters

4.16

2Lack of knowledge about advance management techniques

4.11

Energy conservation barrier on knowledge

management techniques

3 Low technology literacy of employees 3.95

4 Low level of adopting new technology 3.59

5Employees in organization are not monitoring

international best practices3.41

6Insufficient assessment of systems prior to

installation 3.27

No Factor Mean

1Allocating funds for energy conservation technologies are not sufficient in organization

4.03

2 Rapid change of technologies 3.84

Energy conservation barrier on technology

2 Rapid change of technologies 3.84

3Hesitating to adopt new technologies to the

organization3.70

4 Insufficient technical practice in the organization 3.41

5Have technical problems caused by the unreliability of

the technologies3.08

6Local technical training institutes provide lack of training

regarding energy conservation improvements3.05

No Factor Mean

1 Upper Management Support 4.16

2 Lack of staff support 4.11

Vision of the organization providing lack of

Energy conservation barriers on organization and employees

3Vision of the organization providing lack of support to adopt energy conservation option

3.95

4 Resistance to change by staff 3.62

5 Limited vision 3.59

6 Fear of change and uncertainty 3.41

7

Funds allocated for employees' training

programs on energy conservation are

insufficient

3.27

Conclusions

� Lighting section:

� LED lamp, Florescent light fitting with high frequency electronic ballast and

Automatic scheduling

� Air conditioning section:

� Control the central A/C system by BMS or CMS, Central A/C system and� Control the central A/C system by BMS or CMS, Central A/C system and

centrifugal chillers

� Boiler and steam distribution:

� Efficient burner, Duty cycling and Furnace oil boiler

� Compressor and piping:

� VSD (compressor), VSD (pumps) and Pressure optimization

� Sewing section:

� Stepper motor, Direct drive server motor and Intelligent motor control

Conclusions (Cont’)

� No correlation among the rankings of:

� Boiler, Compressor and Sewing sections

� Have correlation among the ranking of:

� Lighting and Air condition factors

� Cost related factors are the largest barriers for the implementation

of energy conservation strategy

Recommendation

� Eradicate the prevailing negative behavioural and

personal attitudes towards energy conservation

� Convey the message of the importance of evaluation of

energy conservation options to survive in the industryenergy conservation options to survive in the industry

� Government and external consultants: ‘energy audits’

should be conducted to identify the key areas

� Use energy conservation options after an appropriate

evaluation

Further Research

� Case study can be conducted to check the validity of the

proposed energy conservation options introduced by this

research

� Can extend this research to identify the relationship of all � Can extend this research to identify the relationship of all

the energy conservation options and organization profits

� This research outcome can be further improved and

develop as cost declining tool

� Can extend this research to other industries (ex. Hotel)

Thank You

Rank Correlation Coefficient

�Rank correlation measures the difference between Rank correlation measures the difference between Rank correlation measures the difference between Rank correlation measures the difference between

the ranks for each pairthe ranks for each pairthe ranks for each pairthe ranks for each pair

Distributed “t” with “n-2”

degree of freedom

Distributed “t” with “n-2”

degree of freedom

rrrrssss - Rank Correlation Coefficient

ddddiiii - Difference between each rankings

nnnn - Number of objectives

Difference between Ranking

The null hypothesis isaccepted. Accordingto that there is norelationship between

Compressor

relationship betweenthe rankings.Therefore there to a95% confidenceinterval it can bestated that the rankingthe factors of currentusage and experts’perspective isdifferent.

0.177 2.365

)(

n

FWIS

ii∑ ××=

%100..

Fi -Frequency of Responses

n -Total number of responses

Wi -Weight for each factor

Severity Index

Coefficient of Variation (COV)

Data Analysis

%100×=X

SCOV

COV -Coefficient of Variation

S -Standard Deviation

x -Weighted mean of sample

Coefficient of Variation (COV)

Percentage of importance

Percentage

Total no. of

respondents

No. of respondents who stated the criteria is Important

No. of respondents who stated “Significantly Important” and “Extremely Important”

+

=