ENERGY MANAGEMENT IN SPINNING MILLS

BYA.Kanthimathinathan CEO,WINSYS SMC

ENERGY MANAGEMENT

Energy Efficiency Energy Conservation

Energy ConservationFocus on Behaviour of PeopleA behaviour that results in less energyUse Daylighting through Roof and Windows rather than using lights in daytime

Energy EfficiencyInvolves the Energy Efficient Technology to achieve same output with less energy or more output with same energyFocus is on Machinery/EquipmentExample: Use of LED bulbs

Energy EfficencyProductive loads

Energy consumed by all machines directly used in Manufacturing of Yarn

Energy EfficencyNon Productive loads

Energy consumed by all other machienery which are not directly related to Machines used in Manufacturing(Compressor/H.Plants/AWES)

Sources of High Energy consumptionDefective parts in machinery

(Car running with Hand brake)Aged/Rewound MotorsStandard motorsUnsuitable process conditions

(High twist/Using higher lift for Fine counts)

Sources of High Energy consumptionImproper Humidity conditions

(RF Motor loses 3% energy if RH is not maintained and Hot air is not ventilated)Incoming supply Poor QualityDesign failures (Open loop line in Compressor)

Investments/PaybackInvestments on machinery maintenance instruments ?

Cost saving instruments?

Maintenance(Regular) InstrumentsSpeed test contact/non-contact typeStroboscopeDifferential pressure gauge.Anemo meter.Condition monitoring for bearings.Lux measurement instrumentSound (Decibel) meter.

Power Consumption StandardsAny Spinning mills has Spin PlanSpin Plan covers not only production expected but it clearly spells out the Machinery required and its utilisation levels

Power Consumption StandardsNecessarily mills should have conducted load study in all machines and they know the load factor for each machine collectivelyUsing the above two factors and the no of machine required , we can arrive at Standard power consumption in our units

Power Consumption StandardsBy Month End , we come to know the actual Units consumption and we need to check the Consumption departmentwiseFind out the deviation;Question yourself/team on deviation/take actions/implement CA/Review results

Power Consumption StandardsNeed for this Basic Analysis

`` SSB wise connection for each type of Machinery``

``SSB wise Meters to monitor Energy``

Power Consumption StandardsLoad Manager to measure loads in each and every MachineEach mills should have one Load Manager and Energy monitoring should be continuous one.Initial investment on Load Manager may be costly,but it pays dividendsThose who can afford , can think of online power measurement system .

Deviation in Power ConsumptionCauses for DevaitionIdle running of MachineryLower utilisation level of RFUtilisation of Part machinesPoor Lubrication***Hot environment for High capacity motors

Poor LubricationRecently one leading Energy Auditor identified & reported that Poor greasing in Tin roller Bearings resulted in 6% excess energy consumption & in other words 3% of total mills consumption

Deviation in Power ConsumptionCauses for DeviationLess Energy efficient MotorsLess production speedsHigher Utilisation of H.Plants

Possible Causes for DeviationIn RF for same count, same specification of Machinery one motor consumes 28 units and another RF consumes 32 unitsReason: Difference in Ring tube specification

Units per Kg-SITRA stdsApart from power consumption standards on our own, SITRA has benchmarked figures `Ukg`The units required to produce one kg of yarn is arrived at in any mills and compared against Benchmarked `40s converted Ukg`

Deviation From Benchmarked levelsLess Energy Efficient motorsPoor levels of Production and UtilisationefficiencyImproper maintenance of Machienry and equipmentPoor maintenance and operation of AWES/H.Plants/Compressors

Energy Efficient MotorsStandard MotorEE1EE2Super Energy Efficient Motors(EE3/EE4)

Energy Efficient MotorsMore Copper in windingReduced Fan lossMinimum 2 to 6% higher EfficiencyEven at Lower loads , high efficiency

Energy Efficient MotorsImproved Power factor

Less energy consumption

Savings are significantly higher

Economic DecisionsReplace Motors reaching fourth rewindingReplace Over loaded motorsBased on need to protect other devices in the machinery, we need to go for Super Energy efficient motors

Motor Load ManagementStar Delta Conversion

Use Of VFD

Energy Saving MeasuresTransformersDistribute loads equallyLoad only upto 65% of rated capacityWhile buying check for NL/L lossesInstall OLTC

Energy Saving MeasuresIncoming Supply

Adjust to the optimum level with OLTC

Energy Saving MeasuresLighting loads

Always use Stabilsers to bring down the Voltage to `optimised minimum`.With Electronic chokes/LED bulbs mills can set 200 V itself for lighting loads.

Harmonic ControlAs the modern Mills use more frequency drives in RF/Autoconers/H.Plants, we need to control Harmonics developed by these VFD`s.Otherwise consumption will be more

Use of Capacitor Banks in Yards

APFC can be installed in Transformer yard itself to save energy

Machines-RFProper LIFT*Ring DiaProper Speed patternOptimum twist levelLess spindle weightLess spindle wharveLesser weight Ring tubes

Carbon TubesLatest innovation in tube technology

Thickness of this Carbon tubes is 0.7 mm

Power saving in RF-8%(Proved )

Carbon TubesCost of the tube: Rs 130 per piecePayback: Yet to be concretely worked outLimitation: Only for Manual doff RFIndia is yet to develop the same

Indian Manufacturers are also working on the development of Carbon tubes equivalent in India to make it cost effective.

AutoconersArrest Air leakage

Less clearer cuts

Less repeaters/Less Cop rejection

CompressorsOut of total consumption in a Spinning mills, Compressor power should be restricted to 3%.If it is high definitely there is a scope to reduce

CompressorsAir leakages in LineAir leakages in MachinePoor layout of compressor shedPoor Loading of Compressors

CompressorsSpecific power consumption should be the lowestPoor ventilationHigher temperature of intake AirUndue High operating pressure

CompressorsOrifice vs Energy wastage

At 6 bar pressure, we loose Rs 7000 per year with 0.8 mm orifice whereas we will end up with Rs 4.2 lacs for 6.4 mm orifice

Compressor System LeakageBy switching off the total plant and keep the compressor alone running, we can take up a leakage study in Compressed Airline system.Leakage%=(Loading time*100/ (Loading time+unloading time)

Compressed Airline systemPressure drop between Compressor shed and at Machine delivery point is a cause for concern.Reason:Sharp bend /Poor dimensional specs/Poor quality pipes/Leakage

Humidification plantsAwareness of the plant operation is more importantMaintenance of the plant Automation ,if possibleEnergy efficient Fans

Humidification plantsEnergy efficient PumpsVFD for PumpsDamper MaintenanceProper Recirculation provisionsRotary filters for Exhaust Air

Energy Saving tools

Ultra sonic leak detector.

Flow meter / dew point

Thermal Imager (Non contact)

COMPRESSED AIRa)Air flow meter/counter

b)Dew Point meter pressure td dew point

c)Ultrosonic Leak Detector

Energy Online Monitoring System-RFMany vendors are available in the marketSystems provide lot of information but we should analyse and act on the same.If done, it pays back within even one year.

THANK YOU