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Abstract— Pakistan today is facing a serious ene the alarming depletion of energy resources demand of the industry, which has badly affecte sector in general. No doubt, this situation has em but this is also a fact that these energy crises in sector are due to orthodox processes, infrastructures/buildings, inefficient HV inadequate use of electrical and mechanical e compliance to standard inspection techniqu resulted higher energy losses. This study management of the factors, (i.e. housekeep operations and infrastructure), affecting the per plants of the spinning subsector of textile in audits were conducted to collect data. The dat and it was concluded that along with th interventions we need to introduce green infras plants of spinning mills. Index Terms—Energy Efficiency, Energy Textile Industry. I. INTRODUCTION Energy is an important factor which fulfills like lighting, heating, cooking, transportation for the achievement of socioeconomic expan [1]. Due to latest industrial growth and exp consumption in established countries is increasing. For years, the balancing of Pakistan's sup demand for electricity has remained unresolv appears as a barrier in the long-term future, implementation is assumed on priority basis. demand exceeds supply. Manuscript received May 05, 2014. F.A Aftab Khan Masood is with National Producti Ministry of Industries & Production, 2 nd floor softwar constitution avenue, F-5/1 Islamabad, Pa [email protected]) S.B. Dr. Sher Muhammad is with National Product (NPO), Ministry of Industries & Production, 2 nd floor so park constitution avenue, F-5/1 Islamabad, [email protected]) T.C. Shazia Iftikhar is with National Productivity Org of Industries & Production, 2 nd floor software technolog avenue, F-5/1 Islamabad, Pakistan (Email:shazia.shabbir0 F.D. Hammad Altaf is with National Productivity Org of Industries & Production, 2 nd floor software technolog avenue, F-5/1 Islamabad, Pakistan (Email: hammad950@ F.E. Wasi Ullah is with National Productivity Organi Industries & Production, 2 nd floor software technology avenue, F-5/1 Islamabad, Pakistan (Email: usmannpo@g S.F. Faisal Shabbir is with National Productivity Org of Industries & Production, 2 nd floor software technolog avenue, F-5/1 Islamabad, Pakistan (Email: wasi.elt92@ya Energy Efficien Analysis of Energy C First A. Engr. Aftab Khan Masood Fourth D. Engr. Hammad Altaf, Fift ergy crisis due to and increasing ed our industrial merged globally, n our industrial , conventional VAC systems, equipment, non ues which has reveal to the ping, control of rformance of AC ndustry. Energy ta was analyzed he technological structure in AC y Consumption, our basic needs n and also helps nsion objectives pansion, energy exceptionally pply against the ved. This crisis , unless proper At the present, ivity Organization, re technology park akistan (Email: tivity Organization oftware technology Pakistan (Email: ganization, Ministry gy park constitution [email protected]) ganization, Ministry gy park constitution @yahoo.com) ization, Ministry of y park constitution gmail.com) ganization, Ministry gy park constitution yahoo.com) In order to reduce the greenhouse g is of the need to: establish aw consumption, increase energy efficien fuels with renewable energy [2]. Rising energy costs and increasing efficiency an absolute priority for Paki way of bridging the energy gap. T additional supply is much higher than energy efficiency. Additional bene consumer energy bills, and a cleane GHG emissions). Energy efficiency is to the energy crisis. II. STUDY OBJECTI The sector wise energy consumption Fig. 1. Sector wise Energy Con Figure 1 shows total energy cons Pakistan, amounting to 39.4 million equivalent), 43% of which is accounte sector. [3] The industrial sector is the primary final energy consumption which opportunity for savings at 33% of ene 38% of carbon dioxide (CO 2 ) emission proven technologies it is estimated efficiency can be improved from 18- reduction of industrial CO 2 emissi Therefore, it is needed to focus on t manage energy crisis. National Productivity Organization Industries and Production, Pakistan, h for Energy & Environment Managem maximum efficiency in proper utilizat with the help of suitable energy savi contribute a major portion towards economic growth of the country. The has conducted over 200 Energy Audits Pakistan and identified up to 15 % potential. 20% 29% 2% 43% Domestic Commercial Transport Agriculture ncy in Textile Sector of Pakis Consumption of Air-Condition d, Second B. Dr. Sher Muhammad, Third C. Engr. Sh th E. Associate Engr. Wasi Ullah, and Sixth F. Engr. gas (GHG) emissions it wareness for energy ncy and replace fossil demand make energy istan. It is the least-cost The marginal cost of the cost of investing in efits include reduced er environment (lower the short-term solution IVES n of Pakistan is: nsumption. sumption by sector in n TOE (tonne of oil ed for by the industrial y contributor to global presents the biggest ergy consumption and ns in 2005 [4]. Based on that industrial energy -26% which results in ions by 19-32% [5]. this sector in order to n (NPO), Ministry of has established “Center ment (CEEM)” to attain tion of existing energy ing measures that will the productivity and e team of CEEM-NPO s in industrial sector of % of energy savings 4% 2% % Other Govt Industrial stan: ning Unit hazia Iftikhar, . Faisal Shabbir

Energy Efficiency in Textile Sector of Pakistan

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Pakistan today is facing a serious energy crisis due to the alarming depletion of energy resources and increasing demand of the industry, which has badly affected our industrial sector in general. No doubt, this situation has emerged globally, but this is also a fact that these energy crises in our industrial sector are due to orthodox processes, conventional infrastructures/buildings, inefficient HVAC systems, inadequate use of electrical and mechanical equipment, non compliance to standard inspection techniques which has resulted higher energy losses. This study reveal to the management of the factors, (i.e. housekeeping, control of operations and infrastructure), affecting the performance of AC plants of the spinning subsector of textile industry. Energy audits were conducted to collect data. The data was analyzed and it was concluded that along with the technological interventions we need to introduce green infrastructure in AC plants of spinning mills.

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  • Abstract Pakistan today is facing a serious energy crisis due to the alarming depletion of energy resources and increasing demand of the industry, which has badly affected our industrial sector in general. No doubt, this situation has emerged globally, but this is also a fact that these energy crises in our industrial sector are due to orthodox processes, conventional infrastructures/buildings, inefficient HVAC systems, inadequate use of electrical and mechanical equipment, non compliance to standard inspection techniques which has resulted higher energy losses. This study reveal to the management of the factors, (i.e. housekeeping, control of operations and infrastructure), affecting the performance of AC plants of the spinning subsector of textile industry. Energyaudits were conducted to collect data. The data was analyzed and it was concluded that along with the technological interventions we need to introduce green infrastructure in AC plants of spinning mills.

    Index TermsEnergy Efficiency, Energy ConsumptionTextile Industry.

    I. INTRODUCTION

    Energy is an important factor which fulfills our basic needs like lighting, heating, cooking, transportation and also helps for the achievement of socioeconomic expansion objectives [1]. Due to latest industrial growth and expansion, energy consumption in established countries is exceptionally increasing.

    For years, the balancing of Pakistan's supply against the demand for electricity has remained unresolved. This crisis appears as a barrier in the long-term future, unless implementation is assumed on priority basis. At the present, demand exceeds supply.

    Manuscript received May 05, 2014.F.A Aftab Khan Masood is with National Productivity Organization,

    Ministry of Industries & Production, 2nd floor software technology park constitution avenue, F-5/1 Islamabad, Pakistan (Email:[email protected])

    S.B. Dr. Sher Muhammad is with National Productivity Organization(NPO), Ministry of Industries & Production, 2nd floor software technology park constitution avenue, F-5/1 Islamabad, Pakistan (Email: [email protected])

    T.C. Shazia Iftikhar is with National Productivity Organization, Ministry of Industries & Production, 2nd floor software technology park constitutioavenue, F-5/1 Islamabad, Pakistan (Email:[email protected])

    F.D. Hammad Altaf is with National Productivity Organization, Ministry of Industries & Production, 2nd floor software technology park constitution avenue, F-5/1 Islamabad, Pakistan (Email: [email protected]

    F.E. Wasi Ullah is with National Productivity Organization, Ministry of Industries & Production, 2nd floor software technology park constitution avenue, F-5/1 Islamabad, Pakistan (Email: [email protected]

    S.F. Faisal Shabbir is with National Productivity Organization, Ministry of Industries & Production, 2nd floor software technology park constitution avenue, F-5/1 Islamabad, Pakistan (Email: [email protected]

    Energy EfficiencyAnalysis of Energy Consumption

    First A. Engr. Aftab Khan MasoodFourth D. Engr. Hammad Altaf, Fifth E.

    Pakistan today is facing a serious energy crisis due to the alarming depletion of energy resources and increasing demand of the industry, which has badly affected our industrial sector in general. No doubt, this situation has emerged globally,

    rises in our industrial due to orthodox processes, conventional

    infrastructures/buildings, inefficient HVAC systems, inadequate use of electrical and mechanical equipment, non

    hniques which has This study reveal to the

    management of the factors, (i.e. housekeeping, control of operations and infrastructure), affecting the performance of AC plants of the spinning subsector of textile industry. Energyaudits were conducted to collect data. The data was analyzed and it was concluded that along with the technological interventions we need to introduce green infrastructure in AC

    Energy Consumption,

    Energy is an important factor which fulfills our basic needs like lighting, heating, cooking, transportation and also helps for the achievement of socioeconomic expansion objectives

    expansion, energy consumption in established countries is exceptionally

    For years, the balancing of Pakistan's supply against the demand for electricity has remained unresolved. This crisis

    term future, unless proper implementation is assumed on priority basis. At the present,

    is with National Productivity Organization, floor software technology park

    5/1 Islamabad, Pakistan (Email:

    National Productivity Organizationfloor software technology

    5/1 Islamabad, Pakistan (Email:

    National Productivity Organization, Ministry floor software technology park constitution

    5/1 Islamabad, Pakistan (Email:[email protected])Hammad Altaf is with National Productivity Organization, Ministry

    floor software technology park constitution [email protected])

    is with National Productivity Organization, Ministry of floor software technology park constitution

    [email protected])ith National Productivity Organization, Ministry

    floor software technology park constitution [email protected])

    In order to reduce the greenhouse gas (GHG) emissionsis of the need to: establish awareness for energy consumption, increase energy efficiency and replace fossilfuels with renewable energy [2].

    Rising energy costs and increasing demand make energy efficiency an absolute priority for Pakistan. It is the leastway of bridging the energy gap. The marginal cost of additional supply is much higher than the cost of investing in energy efficiency. Additional benefits include reduced consumer energy bills, and a cleaner environment (lower GHG emissions). Energy efficiency is the shortto the energy crisis.

    II. STUDY OBJECTIVES

    The sector wise energy consumption of Pakistan is:

    Fig. 1. Sector wise Energy Consumption.

    Figure 1 shows total energy consumption by sector in Pakistan, amounting to 39.4 million TOEequivalent), 43% of which is accounted for by the industrial sector. [3]

    The industrial sector is the primary contrfinal energy consumption which opportunity for savings at 33% of energy consumption and 38% of carbon dioxide (CO2) emissionsproven technologies it is estimated that efficiency can be improved from 18-reduction of industrial CO2 emissions by 19Therefore, it is needed to focus on this sector in order to manage energy crisis.

    National Productivity Organization (NPO), Ministry of Industries and Production, Pakistan, has established Center for Energy & Environment Management (CEEM) to attain maximum efficiency in proper utilization of existing energy with the help of suitable energy saving measures that will contribute a major portion towards the proeconomic growth of the country. The team of CEEMhas conducted over 200 Energy Audits in industrial sector of Pakistan and identified up to 15 % of energy savings potential.

    20%

    29%

    2%

    43%

    Domestic CommercialTransport Agriculture

    Efficiency in Textile Sector of PakistanAnalysis of Energy Consumption of Air-Conditioning Unit

    Aftab Khan Masood, Second B. Dr. Sher Muhammad, Third C. Engr. Shazia Iftikhar, Fifth E. Associate Engr. Wasi Ullah, and Sixth F. Engr. Faisal Shabbir

    the greenhouse gas (GHG) emissions itto: establish awareness for energy

    consumption, increase energy efficiency and replace fossil

    Rising energy costs and increasing demand make energy efficiency an absolute priority for Pakistan. It is the least-cost way of bridging the energy gap. The marginal cost of additional supply is much higher than the cost of investing in

    Additional benefits include reduced consumer energy bills, and a cleaner environment (lower GHG emissions). Energy efficiency is the short-term solution

    BJECTIVES

    The sector wise energy consumption of Pakistan is:

    Sector wise Energy Consumption.

    shows total energy consumption by sector in Pakistan, amounting to 39.4 million TOE (tonne of oil

    , 43% of which is accounted for by the industrial

    is the primary contributor to global which presents the biggest

    33% of energy consumption and ) emissions in 2005 [4]. Based on

    proven technologies it is estimated that industrial energy -26% which results in

    emissions by 19-32% [5].Therefore, it is needed to focus on this sector in order to

    National Productivity Organization (NPO), Ministry of ction, Pakistan, has established Center

    for Energy & Environment Management (CEEM) to attain maximum efficiency in proper utilization of existing energy with the help of suitable energy saving measures that will contribute a major portion towards the productivity and economic growth of the country. The team of CEEM-NPO has conducted over 200 Energy Audits in industrial sector of Pakistan and identified up to 15 % of energy savings

    4%2%

    29%

    Other GovtIndustrial

    ector of Pakistan: onditioning Unit

    Shazia Iftikhar, Engr. Faisal Shabbir

  • This paper gives an overview of energy saving opportunities which they identified in Air conditioning unitsduring different audits. And at the end of paper future steps followed by key findings and recommendationsproposed.

    A. Industrial Sector

    The industrial sector in Pakistan accounted for 20.9% of the GDP in FY2012-13, making it the second largest contributor to the economy after agriculture [energy consumption in Pakistan is given below:

    Fig. 2. Industrial Energy Consumption.

    It can be seen from figure 2 that Textile Sector is third largest energy consumption industrial sector. major export oriented industry and it adds up to GDP, it was selected for research and development.sector contains following sub sectors: Ginning, SWeaving, Processing, Knitting, Stitching, Garments

    For further studies spinning sector was selected as major subsector of textile sector.

    III. METHODOLOGY

    In support of the above objectives, the NPO is undertaking energy audits to determine techno-economically feasible measures suitable to enhance productivity and reduce cost and consumption of energy at the designated textile units.

    In the back drop of intimidating resource constraints, rising energy crises and big gap in demand and supply, the overalobjective of the audit is to review the existing energy consumption practices in the industry, identify the key potential energy efficiency and conservation areas and provide detailed recommendations on energy optimization and cost savings. It aims to improve the competitiveness of textile sector on a sustainable basis by significantly reducing the cost of energy by developing energy management systems (EMS) & imparting practical training to the technical staff of the industries.

    A. Audit Methodology

    Informal Meeting with Management Plant Familiarization Walk Through Data Collection through interviews, observations &

    trials Calculations Data Analysis Benchmarking Discussions Suggestions

    2%

    17%6%

    5%

    25%

    10%

    28%

    Paper Sugar TextileIron and Steel fertilizer CementBrick Klin Others

    This paper gives an overview of energy saving in Air conditioning units

    during different audits. And at the end of paper future steps followed by key findings and recommendations are

    The industrial sector in Pakistan accounted for 20.9% of 13, making it the second largest

    contributor to the economy after agriculture [6]. Industrial below:

    Industrial Energy Consumption.

    Textile Sector is third largest energy consumption industrial sector. It is one of the major export oriented industry and it adds up to 57 % of the GDP, it was selected for research and development. Textile

    Ginning, Spinning, Weaving, Processing, Knitting, Stitching, Garments

    For further studies spinning sector was selected as major

    In support of the above objectives, the NPO is undertaking nomically feasible

    measures suitable to enhance productivity and reduce cost and consumption of energy at the designated textile units.

    In the back drop of intimidating resource constraints, rising energy crises and big gap in demand and supply, the overall objective of the audit is to review the existing energy consumption practices in the industry, identify the key potential energy efficiency and conservation areas and provide detailed recommendations on energy optimization

    prove the competitiveness of textile sector on a sustainable basis by significantly reducing the cost of energy by developing energy management systems (EMS) & imparting practical training to the technical

    through interviews, observations &

    B. Energy Auditing Instruments

    NPO has used following energyduring the audits as and when required

    IV. DATA COLLECTION

    Spinning sector is an export oriented as backbone in textile sector. During Energy Audits data was collected and analyzed of the entire Spinning unit including following departments:

    1. Blow Room department2. Carding department3. Drawing/Combing/Roving department4. Simplex department5. Ring department6. Auto cone department7. Packing department8. Compressor9. Air Conditioning

    A. Energy Source

    Energy in most of industries is supplied by WAPDA (The Water and Power Development Authority) and in house Power Generation.

    B. Electrical Energy

    Electricity is the major energy on which all the spinning machines are dependent.

    C. Overview of Energy Consumption

    Average electricity consumption per day in a Textile Spinning sector is as under:

    Fig. 3. Energy Consumption in spinning sector

    According to the figure 3, air conditioning system is the second largest energy consumer and an important part of the mill. As per observations ACs is being running through

    7%

    TextileCement

    Blow Room Department

    2%

    Autocone Department

    Drawing Department

    3%

    Combing Department

    4%

    Simplex Department

    4%

    Ring Department

    44%

    Power Quality Analyzer

    Power Logger Lux Meter Flue Gas Analyzer Thermal Imager Infra Red Gun Digital vane Probe

    Anemometer

    Digital Hygrometer Tachometer Ultrasonic Flow Meter for

    Liquids Belt Tension pH/Conductivity Meter

    with TDS Pitot Tube Fluke 922/Kit , Fluke 922

    Airflow Meter

    energy-auditing instruments the audits as and when required:

    DATA COLLECTION

    Spinning sector is an export oriented sub-sector. It works in textile sector. During Energy Audits data was

    the entire Spinning unit including

    Drawing/Combing/Roving department

    in most of industries is supplied by WAPDA (The Water and Power Development Authority) and in house

    Electricity is the major energy on which all the spinning

    Overview of Energy Consumption

    ge electricity consumption per day in a Textile

    in spinning sector

    , air conditioning system is the consumer and an important part of the

    . As per observations ACs is being running through

    Autocone Department

    7%Compressor

    10%

    AC26%

    Drawing Department

    3%

    Digital HygrometerTachometerUltrasonic Flow Meter for LiquidsBelt Tension MeterpH/Conductivity Meter with TDS Pitot TubeFluke 922/Kit , Fluke 922 Airflow Meter

  • conventional methods, which mostly results in low process performance. Therefore, in order to find out opportunities for improvements it was selected for further research studies

    V. DATA ANALYSIS

    Air conditioning units are operated for the following purposes: 1) Attain required relative humidity in the production halls.

    Fiber and yarn requires certain moisture otherwise there are chances of their quality deterioration

    2) Remove the heat produced by the machines to avoid overheating and to keep them at lower possible temperature

    3) Remove air contamination (fine fibers) present in the production halls

    4) Maintain comfortable temperature inside the working areas for the workers

    5) Humidity is controlled by maintaining the required wet and dry bulb temperatures in the production halls. Wet and dry bulb temperatures are selected on the basis of required humidity.

    Detailed data of electric loads, air velocity, temperature, relative humidity was collected during auditswise AC loading is given in figure 4:

    Fig. 4. Departmental AC loading

    There are three elements of Air Conditioning unitplays important role. Average running loadwater pump and supply fan is shown in figure 5.

    Fig. 5 AC-Running Load

    A. Supply Fan

    It transfers the reconditioned air to production hall as per need of the process. Its major elements are: electric fan motors, blades, ducts (through which air travels) and lowers (which equal distributes the air). Clean and humid air is

    Card/Blow Room

    AC10%

    Drawing/ Simplex

    AC16%

    Ring AC56%

    Autocone17%

    Paking AC1%

    Return Fan29%

    Water pumps16%

    supply fan

    55%

    conventional methods, which mostly results in low process Therefore, in order to find out opportunities for it was selected for further research studies.

    Air conditioning units are operated for the following

    Attain required relative humidity in the production halls. Fiber and yarn requires certain moisture otherwise there

    machines to avoid overheating and to keep them at lower possible

    Remove air contamination (fine fibers) present in the

    Maintain comfortable temperature inside the working

    ing the required wet and dry bulb temperatures in the production halls. Wet and dry bulb temperatures are selected on the basis of

    of electric loads, air velocity, temperature, s. Departmental

    lements of Air Conditioning unit which running load of return fan,

    water pump and supply fan is shown in figure 5.

    It transfers the reconditioned air to production hall as per need of the process. Its major elements are: electric fan motors, blades, ducts (through which air travels) and lowers

    Clean and humid air is

    necessary for production process, if it production losses increases, human irritation increases which may lead to high turnover and low productivity.

    Department wise data of all supply fans were collected and analyzed as in figure 6:

    Fig. 6. Supply Fan load % vs. Average Flow

    B. Return Fan

    It exhausts dirty and fluffy air from production hall which is then filtered, exhausted or reticulated after humidification. If it is not maintained properly than it does not air, due to which internal dust increases that results in low production and quality.

    Fig. 7. Return Fan load % vs. Average Flow

    High variation between power consumption and air flow can be seen in figure 6 & figure 7, which is caused by management, under skilled labour and conventional methods. This shows that we need technological interventions and technical expertise.

    C. Showering Chamber

    Showering chamber is an important part of an air

    Drawing/ Simplex

    AC16%

    Return Fan29%

    Water pumps16%

    , if it is disturbed then production losses increases, human irritation increases which

    and low productivity.supply fans were collected and

    Fig. 6. Supply Fan load % vs. Average Flow

    It exhausts dirty and fluffy air from production hall which is then filtered, exhausted or reticulated after humidification. If it is not maintained properly than it does not exhaust dust air, due to which internal dust increases that results in low

    Fig. 7. Return Fan load % vs. Average Flow

    High variation between power consumption and air flow , which is caused by lack of

    management, under skilled labour and conventional methods. This shows that we need technological interventions and

    Showering chamber is an important part of an air

  • conditioning system because it maintains the humidity of the production halls. Its main elements are water pump and nozzles. Water pumps pushes water towards nozzles and nozzles creates the fog. Proper maintenance of both elements is necessary because if the showering nozzles are blocked then it can turn into major energy loss and low productivity & quality of the system as shown in table I:

    TABLE I: CONSUMPTION PATTERNS OF SHOWERING

    Fig. 8. Percentage losses of showering pumps

    From figure 8 we can see that pump is not utilizing its capacity due to which losses are beard. Therefore, in order to minimize losses proper maintenance is required.

    D. Case Studies

    1) Supply Fans: During the case study, supply fan no. 03 was running while in first case all other fans were off. In second case 02 & 04 were off. The difference between the flow and load is given in table II:

    TABLE II: SIMPLEX SUPPLY CHAIN CASE STUDY

    Supply fan #Motor capacity (KW)

    Status

    3 7.5

    ON=ALL

    OFF=ALL

    OFF=2&4

    2) Return Fans:

    Departments Carding Drawing/SimplexPump Capacity 15 22Running kW 8.89 13.6Total Nozzles 176 176Closed Nozzles 70.4 65Opened Nozzles 105.6 111Losses% 40 37Losses kW/hr 6 9

    humidity of the Its main elements are water pump and

    nozzles. Water pumps pushes water towards nozzles and . Proper maintenance of both elements if the showering nozzles are blocked

    and low productivity &

    HOWERING CHAMBER

    Percentage losses of showering pumps

    pump is not utilizing its full Therefore, in order to

    proper maintenance is required.

    Supply Fans: During the case study, supply fan no. 03 was running while in first case all other fans were off. In second case 02 & 04 were off. The difference between

    CASE STUDY

    (m3/hr/kW)

    1806.23235.31753.6

    11161.55164.32840.85793.0

    2956.81679.6

    Fig. 9. Return Fan Case Study Vs Running Flow

    The case studies of return and supply fans (Table II & Figure 9) show that the system is not supporting the fan system to utilize it at maximum level. Proper research of infrastructure should be done to support maximum utilization of the fans.

    3) Water pumps

    TABLE III: WATER PUMP LOAD

    Fig. 10. Water pump load percentage

    We control the humidity in different times and seasons through wall throating due to which the output decreases while input energy almost remains same which leads to high specific consumption shown in (Table III & Figure 10is recommended a technological intervention mass level like mist system, inverters.

    VI. FINDINGS / OBSERVATIONS

    During audits it was observed that aare usually controlled by the following ways:1) Decrease or increase flow of the air by changing the fan

    vanes angles (only for the variable fans). These angles are not being changed.

    2) Discharge flow rate of water pump used for water showering is increased or decreased by throttling valve,

    R.F # 1 On 2 OffR.F #1 with All OnR.F # 2 On 1 Off

    95441

    34781

    86876

    159 156 157

    (m3/hr) Load%

    10% 50% 100% 10%

    16

    Card Ring 02

    52

    81 86

    18

    Drawing/Simplex Ring22

    14.517660116349

    Motor Capacity kW

    Valve Position

    1610%50%

    100%

    18.510%50%

    100%

    . Return Fan Case Study Vs Running Flow

    studies of return and supply fans (Table II & that the system is not supporting the fan

    system to utilize it at maximum level. Proper research of d be done to support maximum utilization

    OAD PERCENTAGE

    . Water pump load percentage

    We control the humidity in different times and seasons through wall throating due to which the output decreases

    ins same which leads to high shown in (Table III & Figure 10). So it

    is recommended a technological intervention may be done on

    OBSERVATIONS

    audits it was observed that air conditioning units are usually 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

    Discharge flow rate of water pump used for water showering is increased or decreased by throttling valve,

    R.F # 2 On 1 OffR.F #2 with All On

    25434

    157 171

    Load%

    50% 100%

    18.5

    Ring 02

    7791

    Total kWLoad

    %8.3 52

    12.93 8113.8 863.32 1810.86 7716.9 91

  • depending on the humidity requirement3) Supply, return and exhaust air dampers are manually

    controlled (opened or closed) according to the air quality and flow requirement.

    4) Air flow is only controlled on the basis of humidity. There is no monitoring of volumetric air flow.

    5) At some of the air conditioning units, there is water showering nozzles were blocked due to dust and scale.

    Key Points to improve Air Conditioning System in textile sector of Pakistan Lack of energy efficient infrastructure. Use of conventional infrastructure. Requirement of Research and development. Lack of innovation. Skill and capacity buildings. Proper management is required. Unrealistic supply to meet the demand which leads to

    major resource wastage. Temperature loss in ducts in summer season due to

    improper insulation. Ducts internal rough conventional infrastructure losses

    humidity and dry the air supplied so more showering is required to meet the demand which leads to energy bills.

    Any variation in the supply air property leads to production loss and quality loss and also the human resource get irritated and its productivity decreases, it increase tension between management and labour force and decreases the final profit ratio and it could be the way to lose skilled man power

    VII. RECOMMENDATIONS

    A. General recommendations:

    1) We need to work on heat generation from equipments and other resources used in the production hall.

    2) We need to have a tree plantation outside the AC unit to filter the air and protect it from sunlight, which is low cost solution rather than adding additional equipments.

    3) Proper adjustment of lowers should be done for the even distribution of air.

    4) It is recommended to optimize the air flows on the basis of humidity and air change requirements by changing air flows with the help of inverters. About 2% reduction in air flow will reduce 5% of the fans powers (1.6% of total electricity will be reduced).

    5) The system of operation to change the degree should be replaced with Variable Frequency Drive (VFD) so that air flow could be reduced by changing their frequency. Air flow control with inverters is more energy efficient way.

    6) A showering chamber contains water nozzles. Water nozzles are more efficient way of increasing humidity and decreasing air temperature. It is recommended to maintain proper housekeeping of units with water nozzles.

    B. Specific Recommendation:

    NPO recommends to build wind tower building infrastructure (Figure 11). Air changes can be managed by

    return fans supported by supply fans and the processrequirements e.g. humidity, temperature etc may also be managed by direct humidification. In this way we can reduce some percentage of supply fan load, resulting in the reduction of power consumption.

    Fig. 11. Wind Tower

    VIII. CONCLUSION

    The main objective of this study was to increase the efficient use of energy and to find opportunities for the conservation of the energy in the spinning subsector of textile industry. And also to indicate the key challenges in order to improve energy efficiency in air conditioning unit. It can be concluded here that their consumption can be minimized by improving efficiency, building infrastructure, and introducing control systems like VFD, sensors.

    During the study energy consumption of air conditioning units was observed. On the basis our analysis, a number of recommendations have been made in this paper. After applying those recommendations we can save a lot of energy from each focused areas. For air conditioning units, 20% of the energy can be saved by implementing the suggested modifications.

    Implementation of new intervention i.e. wind tower and a proper Energy Management System (EnMS) in industries and awareness on energy efficiency can add remarkablevalue in reducing the energy crises in Pakistan.

    REFERENCES

    [1] 24, May 2005. Issue Paper on Environment, Energy and Cities: Issues, Problems and Strategic Options for Urban Settlements of the Developing World. UN habitat for a better urban future. Available: http://mirror.unhabitat.org/content.asp?cid=925&catid=5&typeid=6&subMenuId=0

    [2] James J. McCarthy, Osvaldo F. Canziani, Neil A. Leary, David J. Dokken, Kasey S. White, Climate Change 2001: Impacts, Adaptation and Vulnerability Cambridge University Press, Cambridge, United Kingdom and New York, Inter-Governmental Panel Climate Change IPCC, 2001.

    [3] Pakistan Energy Year Book, FY 2011-2012[4] International Energy Agency (IEA) (2008). Worldwide Trends in

    Energy Use and Efficiency Key Insights from IEA Indicator Analysis. IEA publications. Available:

    Trench

    Production Hall

    Cool & Humid Air

    Water Spray

    Return Fan

    Fresh Air

  • http://www.iea.org/publications/freepublications/publication/name,3778,en.html

    [5] International Energy Agency (IEA) (2007). Tracking InEfficiency and CO2 Emissions. IEA publications.http://www.iea.org/publications/freepublications/publication/name,3708,en.html

    [6] Pakistan Economic Survey, FY 2012-13

    First A. Aftab Khan MasoodWaziristan Pakistan, in 1981. He has a B.Sc. in textile engineering from National Textile Faisalabad. Pakistan, .

    Currently he is working as Team Leader of CEEM department of National Productivity Organization (NPO) in Pakistan. He has 8 years of professional

    experience in Energy Efficiency, and has, over the past 8 years, focused his work to the field of Energy Efficiency & Energy conservation area. He has done more than 100 energy audits and made significant contributions.

    Mr. Khan is member of the Pakistan Engineering Council.

    Second B. Sher Muhammad was born in Sargodha Pakistan, in 1971. He has a Ph.D. in University of Kassal, Germany, 2005. He has done M.Sc. (Hons) in soil sciences from UniversityAgriculture Faisalabad, Pakistan, 1995 and B.Sc. (Hons) in soil sciences from University of Agriculture Faisalabad, Pakistan, 1993.

    Currently he is working as Chief Executive Officerat National Productivity Organization (NPO) in Pakistan. He has experience in supervising projects regarding green energy initiatives. He has more than 35 publications and presented 12 papers in conferences/seminars. His previous research disciplines of interests were related to soil and water conservations and currently his interests are related to energy efficiency in agricultural and industrial sectors.

    Dr. Muhammad is member of the Soil Sciences Society of Pakistan, Pakistan Botanical Society and Zoology Society of Pakistan

    Third C. Shazia Iftikhar was born in Sindh Pakistan, in 1987. She has a B.E. in electrical engineering from University of Engineering & Technology UET, Taxila, Pakistan, 2010 and M.Sc. in engineering management from University of Engineering & Technology UET, Taxila, Pakistan, 2012.

    Currently she is working as Management Associate in CEEM department of National Productivity Organization (NPO) in Pakistan. She has 3 years of

    professional experience in Energy Efficiency, and has worked as a team member in energy auditing projects. Mrs. Iftikhar is member of the Pakistan Engineering Council.

    Fourth D. Hammad Altaf was born in Pakistan, in 1987. He has a B.EEngineering from COMSATS Institute of Information Technology CIIT, Abbottabad, Pakistan

    Currently he is working as Management Associate in CEEM department of National Productivity Organization (NPO) in Pakistan. professional experience in Energy Efficiency, and has conducted more than 60 Energy Audits of different

    industrial sectors of Pakistan. Mr. Altaf is member of the Pakistan Engineering Council.

    Fifth E. Wasi Ullah was born in Charsadda1989. He has a B.Tech. in Electrical Engineering Federal Urdu University of Arts Sciences and Technology PIMSAT, Lahore, Pakistan

    Currently he is working as Management CEEM department of National Productivity Organization (NPO) in Pakistan. Hprofessional experience in Energy Efficiency, and has

    conducted more than 50 Energy Audits of different industrial sectors of Pakistan.

    http://www.iea.org/publications/freepublications/publication/name,37

    International Energy Agency (IEA) (2007). Tracking Industrial Energy IEA publications. Available:

    http://www.iea.org/publications/freepublications/publication/name,37

    was born in South Waziristan Pakistan, in 1981. He has a B.Sc. in

    National Textile University

    Currently he is working as Team Leader of CEEM department of National Productivity Organization

    n. He has 8 years of professional experience in Energy Efficiency, and has, over the past 8 years, focused his work to the field of Energy Efficiency & Energy conservation area. He has done more than 100 energy audits and made significant contributions.

    r. Khan is member of the Pakistan Engineering Council.

    was born in Sargodha Pakistan, in 1971. He has a Ph.D. in soil sciences from University of Kassal, Germany, 2005. He has done M.Sc. (Hons) in soil sciences from University of Agriculture Faisalabad, Pakistan, 1995 and B.Sc. (Hons) in soil sciences from University of Agriculture

    Chief Executive OfficerNational Productivity Organization (NPO) in Pakistan. He has vast

    supervising projects regarding green energy initiatives. He has more than 35 publications and presented 12 papers in conferences/seminars. His previous research disciplines of interests were related to soil and water

    ly his interests are related to energy efficiency in

    Soil Sciences Society of Pakistan, Pakistan Botanical Society and Zoology Society of Pakistan.

    was born in Sindh Pakistan, electrical engineering from

    ering & Technology UET, Taxila, engineering management

    ering & Technology UET,

    Currently she is working as Management Associate in CEEM department of National Productivity Organization (NPO) in Pakistan. She has 3 years of

    professional experience in Energy Efficiency, and has worked as a team

    rs. Iftikhar is member of the Pakistan Engineering Council.

    was born in Abbottabadhas a B.E. in Electrical

    COMSATS Institute of Information Pakistan, 2010.

    Currently he is working as Management Associate in CEEM department of National Productivity Organization (NPO) in Pakistan. He has 4 years of professional experience in Energy Efficiency, and has conducted more than 60 Energy Audits of different

    is member of the Pakistan Engineering Council.

    Charsadda Pakistan, in Tech. in Electrical Engineering from

    Federal Urdu University of Arts Sciences and , Pakistan.

    Currently he is working as Management Trainee in CEEM department of National Productivity

    He has 3 years of professional experience in Energy Efficiency, and has

    different industrial sectors of

    Sixth F. Faisal Shabbir was in 1989. He has a Diploma in Electrical Engineering from Rawalpindi Swedish Institute of Technology, Rawalpindi, Pakistan.

    Currently he is working as Management CEEM department of National Productivity Organization (NPO) in Pakistan. He has experience in Energy Efficiency, and has

    than 25 Energy Audits of different industrial sectors of Pakistan

    was born in Islamabad Pakistan, in 1989. He has a Diploma in Electrical Engineering from Rawalpindi Swedish Institute of Technology,

    Currently he is working as Management Trainee in CEEM department of National Productivity Organization

    e has 2 years of professional experience in Energy Efficiency, and has conducted more

    ectors of Pakistan.