Documente Academic
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4, DECEMBER 2001
Abstract—Conservation and efficient use of energy in industry In this paper, the energy conservation experience of the au-
has for a long time been a priority of the Government of India. thors with a textile industry is presented. The selection, in par-
In anticipation of enactment of federal legislation on energy ticular, of a textile industry has been considered because of i) the
management for industry, the State of Government of Tamilnadu,
Kerala, and other Southern States, made energy audits mandatory higher magnitude of electrical energy used in such industries,
for large-scale energy-consuming industries. So among industrial and ii) the large number of textile industries in this country.
consumers, the aspect of energy conservation is gaining due Since there is a constraint on the investment budget for energy
importance of the realization that “Energy Saved is Energy conservation measures imposed by the Management of the tex-
Produced and that too at Economical Cost.” This paper shares tile industry considered, projects conserving only electrical en-
the experiences of the authors on Energy Conservation Projects
carried out in a Textile Industry situated in Tamilnadu State. ergy have been identified and implemented since the electricity
Economic and efficient measures of Energy Conservation have cost in the total energy cost of the textile industry is found to
been followed subject to budget constraint and the effect of such be around 65%. All other energy conservation measures are re-
measures were realized through reduction in energy cost with the served for next stage of implementation at a higher budget level.
added advantage of environmental safety.
Index Terms—Energy audit, energy conservation, environ- II. STUDY OF EXISTING CONDITIONS
mental benefits, payback period, return on investment, textile
industry. A. Industry Considered
A privately owned medium size Spinning and Sewing Thread
I. INTRODUCTION industry in Tamilnadu, producing 15 Tons of yarn and 10 Tons
of sewing thread/day, is the site for which energy conservation
B. Electrical Demand
tant as never before, energy particularly its conservation in in-
dustries [3]–[7], has become the main target for all parts of the The textile industry considered is a High-Tension consumer,
World that has to be achieved as soon as possible. Textile indus- receiving electricity from the State Electricity Board (SEB)
tries are found to be energy-intensive (4% energy cost in total under Tariff I. The permitted Maximum Demand is 3250 KVA,
input cost) compared to other industries like chemical, food, and the Sanctioned Demand is 2600 KVA.
computer manufacturing, etc., and hence extensive research has
been focused [8]–[10] on such industries in the past to reduce C. Consumption
the energy cost and the total input cost. Energy Consumption: 58 250 kWh/day
In post-independence India, the industrial sector [11] has Steam Requirement: 0.6 Tons/hr
reached to a level of consuming 50% of the total commercial Furnace Oil Requirement: 1000 Liters/day.
energy available in the country. Indian manufacturing industries
like fertilizer, cement, sugar, textile, aluminum, paper, etc., are D. Electricity Tariff
found to be highly energy-intensive and their energy efficiency The textile industry is situated in a Non-Metropolitan locality
is well below that of industrialized countries. Research [12] on and HT Tariff I is applicable at the following rates:
Indian industrial sector indicates that around 25% of the total
Maximum Demand (KVA) charges: US $3.75/month.
energy consumed by the industrial sector can be saved through
Energy (kWh) charges: US $0.0875/kWh
energy conservation means.
(1 US $ IRS 40 approximately.)
E. Machineries/Equipments Inventory
Manuscript received May 8, 2000.
C. Palanichamy is with Sultan Saiful Rijal Technical College, Ministry of The Mill Engineer’s report indicates the availability of the
Education, Brunei Darussalam (e-mail: drcpc@brunet.bn). following machineries and equipments:
C. Nadarajan and P. Naveen are with Magnum Power, 21, Kumaran
Kudil, Madurai-625006, Tamilnadu, India (e-mail: ernada@pronet.net.in; Blow Rooms—2 lines
nav_p80@yahoo.com). Ring frames—96
N. S. Babu and Dhanalakshmi are with Drexel University, Philadelphia, USA
(e-mail: babu@drexel.edu; dhanam@joymail.com). Twisting frames—48
Publisher Item Identifier S 0885-8969(01)10058-6. Cone and Cheese Winding machines
0885–8969/01$10.00 © 2001 IEEE
PALANICHAMY et al.: BUDGET CONSTRAINED ENERGY CONSERVATION—AN EXPERIENCE WITH A TEXTILE INDUSTRY 341
Sewing Thread machines this project too. The details of the package were not given due
Cards, Preparatory machines, Draw frames, Combers, Lap to space constraint.
formers, etc.
Power Transformers: 2 2500 KVA D. Time Span
Power Transformers: 3 1000 KVA For This Textile Industry’s Energy Conservation project, the
Diesel Generators: 3 900 KVA EC team took 3 months for conducting the detailed Energy
Boilers: 1 2 Ton Audit; the Board took two weeks for its approval and budget
Boilers: 2 0.5 Ton. sanctioning, and again the EC team took another three months
for the implementation.
Even in case of total failure of the in-service transformers, the power losses for a total load current of 300 A was worked
capacity of the Standby transformers is good enough to service out as: 300 0.048 037 5 4.3234 KW. Assuming
the Sanctioned demand. 8000 hours of operation/year, the energy loss in the cables was
Team Recommendation: The EC team recommended, as one 8000 4.3234 34 587 kWh.
of the Energy conservation measures, to disconnect one of the For parallel cables:
1000 KVA transformers from service with the written permis- Assuming equal load sharing, the current in each cable
sion of the SEB. In case of future expansion of the industry, is 300/2 150 A. The power loss in each cable is 150
the disconnected transformer will be put back in service; until 0.048 037 5 1.0808 KW. Total power loss for both cables is
then the disconnected transformer shall be maintained without 2 1.0808 2.1616 KW and total energy loss is 17 293 kWh.
energizing. Saving in energy loss/year is (34 587 17 293) kWh
Benefits: As per the norms of the SEB, where metering of 17 294 kWh (50% saving as expected). Annual saving in energy
the High Tension service connection is on the Low Tension side, cost due to parallel cables @ $0.0875/kWh $1513.23. Cost of
i.e., on the secondary side of the transformer of capacity above 3 400 square mm cable per meter length $20. Expenditure
50 KVA, on additional 175 m cable $20 175 $3500. Labor on
i) average losses in the transformer will be calculated as running additional cable is $140, and hence total expenditure
(720 1.0 divided by 100) kWh per month where on running additional cable is $3640.
is the KVA rating of the transformer and added to the Payback period (3640/1513.23) 12 28.87 say
energy consumption indicated by the meter. The trans- 29 months.
former loss arrived shall be added to the energy consump- Return on investment 1/29 3.45% per month.
tion, even when the recorded energy consumption is nil.
ii) 1% of the transformer capacity for transformers above C. Change of Motor Connections
50 KVA will be added to the recorded maximum demand Findings: The EC team identified 21 numbers of 7.5 KW,
on the Low Tension side to arrive at the equivalent High three phase Induction Motors in the Spinning floor and 15 num-
Tension demand. The transformer loss so arrived shall be bers of 3.75 KW, three phase Induction Motors of the Polishing
added to the demand even when the recorded demand is machines, as of over capacity. These motors were connected in
nil. Delta and the torque developed by them was very high, such a
Therefore, monthly saving due to disconnected transformer high torque was not essential.
loss @ $0.0875/kWh $0.0875 (720 1.0 1000)/100 Recommendations: The EC team recommended to connect
$630. Monthly reduction in demand charges $3.75 (1000 the said Induction motors in Star. The torque developed was
1/100) $37.5. Total monthly savings due to transformer measured and found sufficient to drive the connected systems
disconnection equals $667.5 and hence an annual savings of and also the temperature rise was measured to be normal. The
$8010. change in connection resulted in a power reduction of 0.670 KW
Total expenditure (or investment) for disconnection and for a 7.5 KW motor, and 0.400 KW for a 3.75 KW motor.
off-line annual maintenance of the transformer is found to be Benefits: Assuming 8000 hours of operation/year, energy
$1325. saving by 21 7.5 KW motors is 8000 21 0.670
Therefore, Payback period (Expenditure/Total savings) 112 560 kWh, and 48 000 kWh by 15 3.75 KW motors.
12 (1325/8010) 12 1.985 say 2 months. Therefore total energy saving is 160 560 kWh and annual
Return on investment 1/Payback 1/2 50% per month. saving in cost is $0.0875 160 560 $14 049. Labor cost for
connection changes $100 (practically nil).
B. Running of Parallel Cables Payback period (100/14 049) 12 0.085 say a month.
Return on investment 1/1 100% per month.
Findings: Two Aluminum Armored, 3 core, 1.1 KV,
335 A, 400 square mm, 0.0915 resistance/core/km, PVC
Under-ground cables are running from the sub-station; one D. Power Factor Improvement
cable of length 100 meter to Air conditioning control panel Findings: The average power factor of the industry varies be-
and another of 75 meter to the Departmental over-head bus tween 0.91 and 0.93 since its commencement, which was well
bars. Considering the reliability of supply and the magnitude of above the requirement of the SEB. The average power factor of
cable power losses, it is not advisable to go for a single cable the industry was 0.92 and the Maximum demand reached has
feeding system to essential floors. been read as 2600 KVA from the Load duration curve. The load
Recommendations: The EC team recommended, as one of level reached above the sanctioned demand of 2600 KVA on cer-
the energy conservation measures, to run a similar cable in par- tain short period of time was not considered for the power factor
allel with the existing one. Since the existing cables were found improvement project. So, at the average power factor, the load
to be in sound working conditions, it was decided to retain the in KW was found to be 2600 0.92 2392 KW. 1000 KVAR
cable as it was. Instructions were given to mark the changes in Capacitors were already installed at the sub-station to improve
the Blue print for future reference. the power factor to 0.92 (average), which was not sufficient to
Benefits: Total length of both existing cables was 175 m. reduce the energy input of the industry to a great extent.
Total resistance of the cable, 3 0.0915 175/1000 Recommendations: The EC team decided to improve the
0.048 037 5 . For a load current of 300 A, the cable power factor to an average value of 0.98. The best locations
PALANICHAMY et al.: BUDGET CONSTRAINED ENERGY CONSERVATION—AN EXPERIENCE WITH A TEXTILE INDUSTRY 343
for the capacitors were identified as i) at the sub-station itself load of 2600 KVA at 0.92 power factor @ $0.0875 per kWh
to compensate the base load and ii) at the loads supply side as $150 696. Energy generated by the generator/month @
per the KW capacity, so that only when the load is on, the ca- 3 hours/day for the peaking load of 150 KVA at 0.92 power
pacitors will be on. The 1000 KVAR capacitors available at the factor lagging 150 0.92 3 30 12 420 kWh.
sub-station were just sufficient to compensate the base load to a Considering the capital investment, life time, the load factor,
power factor of 0.92. Additional capacitors of 500 KVAR were the annual operation and maintenance cost, the labor cost, the
installed to improve the power factor to 0.98. (Calculations not depreciation and the diesel fuel cost, the average energy cost
shown.) for the Diesel generator supply is worked out to be $0.19/kWhr.
Benefits: For a load of 2392 KW, the KVA demand at 0.98 Therefore, energy cost for the generator supply is $0.19
power factor is (2392/0.98) 2441. 12 420 $2359.8 and hence total charges incurred/month for
Therefore, saving in KVA is (2600 2441) 159. the peak shaving option is $162 805.8. The EC team suggested
Annual saving in cost due to KVA reduction $3.75 159 the Board that more saving in energy cost could have been
12 $7155. Cost on additional capacitors @ $12.5 per KVAR obtained through Renewable energy sources compared to the
$(12.5 500) $6250. Diesel generator supply due to reduced generation cost.
Payback period (6250/7155) 12 10.48 say 11 months. Net saving by peak shaving per month is $8021.7 and
Return on investment 1/11 9.1% per month. $96 260.4 for the whole year if peak shaving is applied for the
entire 12 months @ 3 hours/day.
E. Saving Through Peak Shaving
As per the norms of the SEB, the maximum demand charges
for any month at the point of supply shall be based on the highest F. Changing Air Conditioned Environment
KVA demand recorded during any consecutive thirty minutes
in that month or 100% of the sanctioned demand, whichever
is higher. In addition, for exceeding the sanctioned maximum Findings: The textile industry under our investigation has
demand, the charges per exceeded KVA shall be at double the 27 numbers of 1.5 Ton capacity air conditioners. Except 7, re-
normal rate (say penalty). maining 20 were used for the Computer room environment.
Findings: The Maximum Demand during the financial The general purpose air conditioned rooms and Computer room
years 1995–1996, 1996–1997, 1997–1998 and 1998–1999 has were maintained at an operating temperature of 24 C always
exceeded the Sanctioned Demand in March and April, due irrespective of the changing seasons.
to the early summer peak loads, and the production target Recommendations: Recent research [13] indicates that
initiative at the beginning of the financial year. During the Computers are working well even at 30 C. By raising the
EC project period (1998–1999), the peak demand was found computer room environment to a higher temperature of 28 C,
to be 2750 KVA. The industry did not want to apply for an energy saving of 3% has been noticed for every raise in
increased Sanctioned demand since for the rest of the period of room temperature by 1 C. Further it has been proved that,
10 months, the load was well within the Sanctioned demand. It blowing the cold air from the bottom of the air conditioner
was noticed that the available Diesel generators were used only instead from the top and sucking the warm air through the top
at the time of power-cut and at grid failure cases. instead through the bottom, can save energy to a level of 15%.
Recommendations: The EC team recommended for the use Ducts are connected to the cold air outlet and the warm air
of one 900 KVA Generator at the time of peak loads during suction inlet of the air conditioner, and the locations of the cold
1998–1999 and to transfer the excess loads to the generator air outlet and warm air inlet are switched between upper and
supply so as to avoid the excess KVA penalty charges. If critical lower portions to achieve the new method of airflow. Based on
loads also contribute to facility peaks, consider shifting these the research, the EC team decided to maintain the controlled
loads to generator power during peak periods. In case, if emer- temperature only in the computer rooms at 28 C and to modify
gency back up power is needed, the remaining two Diesel Gen- the airflow by adding ducts for 20 air conditioners as said.
erators shall be put in service even during peak periods. Note: Benefits: The energy consumption/air conditioner/hour to
For the present project, the concept of Peak shaving was applied maintain a room temperature of 24 C is found to be 3.85 kWh
only for the loads exceeding the Sanctioned demand and not for with conventional airflow. Assuming 8000 hours/year
all the loads above the base load. of working, energy consumed by 20 air conditioners is
Benefits: Considering the peak demand during March–April 616 000 kWh. The corresponding energy consumption/air
of the financial year 1998–1999, i.e., 2750 KVA exceeding the conditioner/hour to maintain a room temperature of 28 C is
Sanctioned demand by 150 KVA for duration of 3 hours/day: found to be 2.90 kWh with modified airflow. The total energy
SEB Supply: Maximum demand charges payable to consumed by 20 air conditioners 464 000 kWh. Therefore,
SEB/month $3.75 (2750 2 150) = $11 437.5. Energy energy saved per annum is 152 000 kWh. Annual saving in cost
consumption charges/month for a load of 2750 KVA at 0.92 due to change in air-conditioned environment $0.0875
power factor @ $0.0875/kWh $159 390. Total charges 152 000 $13 300. Material and Labor cost for providing the
payable/month is $170 827.5. ducts for 20 air conditioners $2700.
Generator Supply for a Load of 150 KVA: Maximum Payback period (2700/13 300) 12 2.44 months say
Demand charges $3.75 2600 $9750. Energy con- 3 month.
sumption charges/month for the energy fed by SEB for a Return on investment 1/3 33.33% per month.
344 IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 16, NO. 4, DECEMBER 2001
benefits since the direct renewable energy or renewable energy [7] S. Nadel and N. Elliott, “Overview of programmes to promote energy
through storage systems can be used for the Peak shaving option efficient motor systems in the United States,” in Energy Efficiency Im-
provements in Electric Motors and Drives: Springer, 1997, pp. 365–376.
to a great extent due to the economic cost of generation with en- [8] J. W. Tester et al., Energy and the Environment in the 21st Cen-
vironmental benefits. tury. Cambridge, England: The MIT Press, 1991.
[9] Textile Industry, “Handy manual. Output of a seminar on energy conser-
vation in textile industry UNIDO,”, 1992.
VI. CONCLUSION [10] “The textile industry and the environment technical report no. 16,”
United Nations Environmental Programme, 1993.
In this paper, the energy conservation experiences of the [11] C. Palanichamy, N. S. Babu, and C. Nadarajan et al., “Restructuring the
authors with a textile industry were presented. Since there was Indian power sector with energy conservation as the motive for economic
a constraint imposed by the Management of the Textile industry and environmental benefits,” IEEE Trans. Energy Conversion, vol. 14,
no. 4, pp. 1589–1596, Dec. 1999.
on the investment budget for energy conservation measures, [12] V. K. Garg and S. Paul. Energy conservation programme in rayon plant.
projects conserving only electrical energy have been considered [Online]. Available: http://www.exicom.org/cew/mar97/garg.htm
[13] M. Yamamoto and T. Abe, “The new energy saving way achieved by
and a saving of 18.23% on the electricity cost, i.e., 11.85% on
changing computer culture,” IEEE Trans. Power Systems, vol. 9, no. 3,
the total energy cost of the textile industry was achieved. An pp. 1563–1568, Aug. 1994.
attractive benefit/investment ratio of 61.29% during the first
year itself has been achieved along with an annual reduction
of 777.97 Tons of Carbon, 24.05 Tons of SO and 9.30 Tons
of NO through energy conservation. It has been pointed out C. Palanichamy was born in December 1953 in Tamilnadu, India. He received
the B.E., M.Sc. Engg. and the Ph.D. degrees of electrical and electronic engi-
to the Board that Peak shaving option could be applied to a neering in 1976, 1979, and 1991, respectively, all from Madurai Kamaraj Uni-
great extent even to meet the loads above the base load through versity, India. He started his academic career in 1979; he served in India, Iraq
renewable energy sources. The successful first stage energy and Malaysia and at present he is with the Ministry of Education, Brunei Darus-
salam. His areas of interest include economic operation of power systems, re-
conservation measures encouraged the industry and made them newable sources of energy, energy conservation and environmental impacts.
to grant permission to proceed with the next phase of energy
conservation at a higher budget capacity.
ACKNOWLEDGMENT C. Nadarajan was born in June 1948 in Tamilnadu, India. After his engineering
graduation in electrical engineering, he joined with the Tamilnadu Electricity
The authors sincerely thank the Management of the Textile Board, India. He served in India, Saudi Arabia and Malaysia for more than two
decades. He is the recipient of the Best Engineer Award consecutively for two
Industry and Mrs. Meena and Mrs. Loga, the Directors of years from the Hyundai Company.
Magnum Power, India for the permission given and their
uniform support.
REFERENCES P. Naveen was born in January 1980 in India. After her graduation, she is
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