Transcript Conservation of utility

Conservation of utility
• There are many type of energy
monitoring system in the industry,
which measures mainly the Electrical
Energy consumed by any machine
over period of time
Distribution of energy consumed in
a textile mill
Basics of energy
• In any industry the electrical energy is used to
achieve some mechanical work.
• It is obvious that there will be some difference
between the quantity of Input energy and out put
work, because some amount of energy will
transformed into other form during the process
like vibration heat etc. This is called
losses.Tease are of two types.
• A) Copper loss. b) Excitation loss or Iron loss.
Concept of power saving
• “Power saving” is an incomplete terms.
• It is like a vector quantity where if you don’t mention the
direction ,it will have no use.
• Likewise if we don’t mention the comparative out put of
the machine against a fixed input, it can’t be used as an
index for comparison between similar machine, so
unless and until the out put and other parameters are
mentioned, saying “savings in power” does not carry any
real sense.
• So unit consumption per unit of output (in terms of Kg,
Meter, CC etc) is the correct expression of energy
consumption pattern of any machine.
The energy concept in textile
industry
• Following methods are mostly used in Textile Industry
• Taking the reading of electricity consumed in one day.
• Number of machine working on that day
• Number of working hour on that day.
• Total production in kgs from those machines.
• Divide the Total electricity unit by the total production to find out
UKG on that particular day.
Limitation of this method
• We cant find out who is the main contributor for higher or
lower unit consumption/Kg for that day.
• There is no information available what is the unit energy
consumption for different sort/count run in that day.
• We don’t know the comparative consumption of all the
machines running with same material and with identical
parameters.
• There is huge time gap between the time when machine
actually consumes and the time when the data is analyzed.
• It is a post mortem type of procedure.
Conventional measuring
technology
• When the automation was started in the
Textile Industry, the machine speed was
also started increasing and both
manufacturer and user felt the necessity of
measuring the output , speed stoppage of
the machine in automatic manner. To fulfill
that needs of the industry, machinery
manufacturer came out with few new
features on their machines.
Phase-1
• Introduction of digital counter meter for getting the
production reading instead of mechanical counter meter.
• Introduction of digital display for eletrically measured
machine speed, Stop time
• Display of calculated efficiency based on the running
time.
• Display of the air pressure in BAR/PSI in pneumatically
controlled machines.
Phase-2
• Introduction of SSM (Ring data) to monitor
the Speed of the machine, Breaks, Rouge
Spindle, Production in Hank and finally the
efficiency.
• Introduction of Auto leveler in high speed
Drawing and Carding.
• Lastly the DSP Auto leveler for Super high
speed drawing machine.
Contd….
• In all these above steps nowhere the importance was
given on the resolution of the measurement for the
accuracy and reliability of the data except DSP
technology.
• Production ,speed and stoppage measurement is done
based on the Induction sensor or proximity sensor which
has a resolution of either 360 degree or 180 Degree.i.e 1
or 2 pulse/rotation.
• There is no such data or tool introduced by any of the
machine manufacturer by which we can asses the
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a) performance of Individual machine in terms of
Energy consumption
Contd…..
•
•
b) In terms of mechanical/electrical failure.
c) In terms of the maintenance work done
and replacement of any consumable parts in the
machine. And lastly
•
d) There is no scientific tool available for
asessing the performance of the maintenance
people and their schedule work.
Scientific tool and report
• Nowadays In every stages of
manufacturing , the necessicity of
Scientifically correct data, analytical tool is
being realised by the industry because of
High Speed of the machine, less man
power involvement, higher energy cost
involved in the process.
New concept of using Energy data
• In todays era of technology it is possible to
measure the production of any machine at very
high resolution using optical scanner and DSP
technology. This eliminates the resolution errors
of induction based production sensor.
• It is possible to measure the electrical energy
consumed by the machine at Nano seconds
intervel by using high resolution nano processor
and Sine Wave scanner (AdvancedCT).
Contd…..
• All the above measures are possible in
online also so that one can get the real
time energy data continuously.
• This online real time energy data helps us
in many ways.
Use of energy data
• It can be used as a tool to asses any
maintenance work done in the machine like,
Change of bearing, oils change, gear change etc
.
• It can be used to asses the life of any
consumable items used frequently in a machine.
• It can be used to asses the use of Compressed
Air in any area where Pneumatics are used.
• It can be utilised to know the unit consumption
per unit production of any machine with high
accuracy level(within 0.01%).
• Online energy data can be interpreted in a
continuous graphical from correlating with
UKG,KWH, SPEED,DOFFTIME etc
• This graphical form helps the people to
compare any number of machine running
with identical parameters at any instant.
This is the actual use of Technolgy for
saving the cost of production by optimising
the following
• Speed of the machine
• The life of consumable items like Ring, Ring
Traveller,
• Optimising the frequency of Maintenance
shedule work thereby reducing machine
detention Hrs, consumption of spares, improving
the machine life.
• Find out the bench mark machine of any factory
and continuous scope of improvement to reduce
the unit cost of production.
Some case study
• We will see few real time data and graphs
after installation of an online energy
monitoring system in a textile spinning
unit.
Data of KW,UKG,Speed,CFM
Doff duration loss a new way to save time loss
Actually Duration loss is very high than doffer loss
Multiple doff in single machine
Shift Consolidated 3D Report
Shift Consolidated 3D Report
Shift Consolidated 3D Report
Shift Consolidated 3D Report
Shift Consolidated 3D Report In Excel
Score board
RINGFRAME
Winding
Texray Diagram
Texray Diagram
Texray Diagram Multiple Doff Single machine
control
not existing
existing or not
working
it is noted that
onlynoted
two steps
and only two steps
control
not
or
not
working
it
is
that
occurs at very quick fashion
andItoccurs
very
is no way at
suitable
forquick
60 nec. fashion
It is no way suitable for 60 nec.
Speed control By Kalki
No speed change over , production loss 4%, time loss 3% per doff
Harmonics effect
Improper speed control functions
Harmonics effect
Improper speed control functions
Very high UKG
Have to study this in deep major problem
No speed control working
Suspects improper piecing level or
May many spindles breakages or improper ohtc running
Once again improper Speed control run
results production, and time loss
Once again improper Speed control run
results production, and time loss
Speed control is too slow loss
of 8% time and 6% production
Mechanical inspection needed
Abnormal speed down
Quicker doff higher UKG 7%
Surprise to see this , indication of very
Abnormal working conditions
Machine to machine variable speed patterns different losses
different performance less 10% doff time
Should be poor maintenance conditions
Comparison between twotypes of
machine
High end
breakes
Harmonics
effect(36%)
Power during 4pm
to 6pm when run
in generator
G5/1
LR6
Power higher by 10%
Reduced power
consumption by
improvised speed
control
MVS, Wdg, Ring Frame air report
Winding
What are the measures to be taken
• SIMPLE MEASURES ARE:
• A particularly effective and highly transferable approach to generate
savings in energy
• usagewise prioritizing the implementation of low, medium, and high
cost measures respectively.
• Several simple "good practice" measures led to multiple benefits:
• Retrofitting doors and windows at the mill’s workspaces and
• reducing excessive lighting reduced energy usage;
• Establishing an Energy Tracking System with meters and costallocation software maximized savings with minimal investment And
• Setting up a Conservation Council chaired by the Plant’s general
manager improved the capacity to make sound investment
decisions.
Different steps
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Make Energy Policy
Textile is committed to continuously improve energy conservation in all processes
and for its sustainable availability for future generations.
•
To meet the above goals, we shall strive to:
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Adopt cleaner and efficient energy sources for all our operations.
Benchmark with the best in business and install systems and practices to match
them.
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Enrich our experience on energy conservation by exchange of ideas with other
organizations.
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Enhance use of renewable energy/waste heat, wherever feasible.
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Incorporate energy efficient designs and technology in all future projects.
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To carry out regular internal and external energy audits to identify areas for
improvement.
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Promote awareness among all members of the family and train employees to make
Steps
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a. Energy Efficient new machinery with A.C. Drives
c. Energy efficient tube lights for our new plant.
d. Energy efficient tube lights for new or old plant
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e. Reduce false ceiling height
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f. Replacement of worn out motors with energy efficient motors
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g. Installed low loss (No Load & Load) Transformer.
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h. Install most advanced system of online energy monitoring system
Benefits:-1. Accurate measurement
2. Online reports resulting in speedy analysis
3. Variables (V, C, PF, KVAR, KVA and KW etc) recording round the clock
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i. Use advanced version of flow meter which works on MASS THERMAL FLOW METHOD. This
unit can be connected with energy monitoring system to convert the air consumption into KW.
Future plan
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k. Textile is an air operated industry; hence portable anemometer is a must to
measure air velocity at humidification fans, supply diffusers, return ducts, air
movement across hot spots, exhaust passages, attic ventilation.
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Or install advance version of velocity and air quantity measuring instrument so that it
can be looped with control system as well as energy monitoring system.
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Conservation Measures should be Planned For The Future
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Replacement of Energy Efficient Motors.
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Replacement of Pneumafil fans.
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Replacement of Capacitors with low loss capacitors.
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Optimization of speeds of Humidity Plants Supply & Return Air fans.
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Optimization of speeds of Draw Frame pneumafils.
• Repetition of detailed Energy Audit
• Replacement of Energy Efficient Motors.
• Replacement of Pneumafil fans.
• Replacement of Capacitors with low loss capacitors.
• Optimization of speeds of Humidity Plants Supply & Return Air fans.
• Optimization of speeds of Draw Frame pneumafils.
Our Oath
Today
• Electrical Energy is a precious
commodity “ELECTRICAL ENERGY
COST IS RISING EVERY YEAR. Don't
throw valuable money down the drain
by wasting the planet’s most valuable
commodity. Save energy and save our
•
BEAUTIFUL PLANET