International Journal of Electronics Engineering, 3 (2), 2011, pp.

165– 167  Serials Publications, ISSN : 0973-7383

Electrical Energy Audit in Textile Plant: A Study

Mandeep Singh & Jatin Gupta
Department of Electrical & Instrumentation Engineering, Thapar University, Patiala, India
E-mail: [email protected], [email protected]

Abstract: Textile plant being one of the most energy intensive processes holds a good promise of saving electrical energy.
This report through one of its preliminary study of a major textile plant identifies the key areas where electrical energy can
possibly be saved. The report opens up new vista of saving energy in a textile industry.
Keywords: Textile plant, electrical energy saving opportunity, energy audit.

1. INTRODUCTION The electrical energy saving opportunities in various

The three basic needs for human beings are food, clothing sections of this plant are identified and listed below:
and housing. Textile plants therefore fulfil the second basic
need of human beings. The process of making cloth is energy 4.1. Identifying Oversized Motors
intensive and therefore offers much scope in conservation When a motor is made to drive a load which is low as
of energy since electrical energy is the major form of input compared to the horsepower rating of the motor, efficiency
that goes in the process and energy audit of electrical energy of the motor reduces. A large number of motors are working
holds a promise. in this manner in the textile plant. There are many reasons
that lead to over-sizing of the motor in the plant. Few of
2. PROBLEM DEFINITION
them are listed below: (a) Absence of actual loading
Most of the textile plants have several common features and parameters; (b) lack of knowledge about the actual load;
therefore if the key features for conserving electrical energy (c) Incorrect future planning to handle the increase in load
are identified then it is quite possible that these can be while selecting motors; (d) To handle any motor failure in
replicated to the other plants as well. The key objective of critical process.
this work is to make a preliminary study of a major textile
plant to identify and quantify these saving opportunities. Equation that is used to estimate the proper load for a
motor is shown below:
3. METHOD
A major textile plant producing yarn fiber from caprolactam  input KW × full load efficiency 
Load (%) =   × 100
as raw material is identified in the region. After several  rated HP × 0.746 
visits, the process of yarn making is understood. Major
energy consuming devices are identified and after doing the It is observed that efficiency of a motor decreases
related literature survey the energy saving opportunities are rapidly when operated at less than 50% load [1]. It is
identified and even quantified in some cases. recommended that downsizing of the motor is economical
4. RESULTS AND DISCUSSIONS where original motor is working at less than 50% load.
Seven oversized motors in the range of 15-50 HP are
As a result of the study conducted in the textile plant, a identified.
layout of this plant so formed is shown in Figure 1.
4.2. Identifying Power Factor Improvement
Losses in the electrical system also depend on how close is
the power factor to the unity. As the power factor keeps on
going far from unity the efficiency goes on decreasing. Many
electrical systems in the plant works at very low power factor
which lead to lower efficiency. To achieve good power factor
nearing unity to gain the better power factor benefits in the
electricity bills, to reduce the Maximum Demand and
Figure 1: Textile Industry Layout applicable charges in the electricity bills, and to improve
166 International Journal of Electronics Engineering

power quality, the plant needs to employ dynamic reactive property of compressed air system gives more energy saving
power compensation equipment. opportunities [4].
timeonload
systemleakagequantity (m3 / min), q = ×compressor capacity
timeonload + timeonunload

Energy lost due to leakage = specificpower for compressed

KVAr rating = KW [ tan φ 1 – tan φ2] air generation × leakage quantity
  φ1  2  Measures that can be implemented to save energy are:
Distribution loss (%) = 1 –    × 100
  φ2  
(a) Reducing the inlet air temperature; (b) Minimising
the leakages; (c) Proper maintenance;
Figure 2: Power Factor Improvement
(d) Optimising the compressor to match its load;
(e) Proper piping size.
Figure 2 shows that by connecting capacitors we can
Implementing these measures in the plant, large energy
improve the power factor of the equipment thus reducing
can be saved.
the losses resulting in increase in energy saving [2, 3]. A
total of 187 KVAR power factor improvement capacitors 4.5. Identifying Energy Loss in the Pumping System
are recommended in the plant.
Pump systems consist of pumps, driver, pipe installation
and controls and are a part of the overall motor system. Pump
4.3. Identifying the Proper Loading of the Transformers
applications in the plant include pumps for circulating
Transformers in the plant are operated in parallel mode. This cooling fluids to various sections in the plant [5]. Measures
mode of operation is frequently required. While using that can be implemented to save energy are:
transformers, many things are there which need a lot of (a) Maintenance; (b) Proper pumping size; (c) More efficient
attention. Such as voltage-ratio, impedance matching, pumps; (d) Proper pipe sizing.
polarity matching, phase matching and proper loading. The
 m3 
break-even point for switching over form single operation hydraulic power = pump capacity  ( )
 × head (m) × fluid density kg / m ×
3

to dual operation is given by the expression in fig.  s

( )
 acceleration m / s 2
Simulating this equation, we get the graph of this break-
even point as a function of ratio of full load loss to no load
loss. This is also shown in Figure 3. The transformers under hydraulicpower
pump efficiency =
study are recommended to be operated in parallel as the electrically × motor efficiency
load goes higher than 84%.
5. CONCLUSION AND FUTURE SCOPE
Electrical energy is the most flexible type of energy since it
can be converted to any form and can be transferred with
equal ease. With every passing year the demand of electrical
energy rises much higher than its supply. And therefore the
only way to plug this gap is to identify the places where it
can be conserved.
The preliminary study of textile plant has explored the
possible energy saving areas such as in induction motors,
p.f. improvement and optimised parallel loading of
transformer. And analysis of some has been done as a way
of warm up exercise. It has been seen in this study that a
huge chunk of energy can be saved in replacing in-house
 2 × no − load losses  rewound induction motors by new motors. It is therefore
Loading (%) =   × 100 suggested that detailed study and analysis of these rewound
 full − load losses 
motors be done in the future.
Figure 3: Percentage Loading vs. Break-even Point REFERENCES
4.4. Identifying Energy Loss in the Compressed Air [1] McCoy, G. A., Douglass, J.G., “Energy Efficient Electric
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Electrical Energy Audit in Textile Plant: A Study 167

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