A Tool for PROFIT in Textile Industry

1. Role of IT in Textile Industry A Tool for PROFIT in Textile Industry

2. Beginning with IT - Website - Learning / knowledge - Fast communication - Interaction with industry members - Access of data bases - Technology - Software - Hardware - Energy conservation norms - Information about textile mills

3. Website Background Bureau of Energy Efficiency (BEE), Ministry of Power, Govt. of India, in coordination with Indo-German Energy Programme (IGEN), sponsored by German Technical Cooperation (GTZ), is institutionalizing energy efficiency services and promote energy efficiency delivery mechanisms in all sectors of the economy. This website is operated and managed by IGEN for BEE.

4. Broad Sections of the website Contd., Learning: Overview of EC Act, general information on energy management and large number of technical learning material for all sectors of industries, equipments, case studies, industries experiences, success stories. Industry overview/ process, equipment design/types, maintenance tips, case studies, best practices, books & journals on energy management. Roles & responsibilities of energy manager and energy auditors, energy audit guidelines. Specialists: Information about energy managers, energy auditors, industry specialists, consultants, temporarily accredited energy audit firms, Industry associations and state level designated agencies. Details of certified energy managers / energy auditors also provided.

5. Broad Sections of the website Equipments: Technical information on energy consuming equipments - electrical systems, boilers, steam systems, furnaces, insulation & refractors, electric motors, compressors, compressed air system, HVAC and refrigeration, cooling towers, fans & pumps, lighting systems, diesel generating systems, maintenance tips, O&M manuals, do’s & don’ts and much more. The equipment manufacturer/ suppliers contact details. Events: All important energy management events such as awarding industry for their best practices, celebrations of National Energy Conservation Day, energy management promotional activities, awareness training programmes / workshops / seminars

6. Major information on website • Contd., • Energy Conservation Act, 2001 • Energy manager/ energy auditor accreditation, • Course material, exam updates and results • Certified energy managers, energy auditors and • temporarily accredited energy audit firms. • Sector-wise specialists details • Sector-wise user group interaction • Energy audit guidelines; energy audit equipments • Sector-wise overview / process technical reading • Equipment - design, types, tips, manufacturers details. • Energy management software with suppliers

7. Major information on website • Major events, seminars, workshops on energy management, sector-wise task force meetings, and their proceedings. • Users technical papers, success stories; technical papers for issues & quizzes • Industry best practices on energy conservation • National Campaign on Energy Conservation • Books, journals on energy management. • Kaupp’s corner – a thought provocative discussion forum • Energy management related tenders • Job requirements - Energy management specialists

8. Support to Textiles sector Textile manufacturing processDescribes textile manufacturing process i.e. spinning, Weaving/ Knitting/ Stitching, Dyeing, Quality Fibre to fabric Testing Equipments for Textile Industry. Basic Principles of Rayon Fiber Production.Definitions of textiles, linen, wool, cotton, silk etc.Synthetic and cellulosic fiber formation technologyConservation of lubricants by modified dispensing equipmentsA study report on Conservation of Lubricants by Modified Dispensing Equipments and Through RecyclingImproved performance and eliminate fibre ball formationPublication on ‘Measure to Achieve Improved Performance and Eliminate Fibre Ball Formation in Weaving of Heavy Reed Sorts on Shuttleless Weaving Machines’

9. Assessment of compressed air requirement for spinningPublication on ‘Assessment of Compressed Air Requirement for Spinning and Weaving Machines.Estimation monitoring and control of energy consumptionBTRA Powerspin System, a microprocessor based instrument system to monitor and control the actual energy consumption pattern in textile mills.Compressed air system Introduction to the compressed air system and Compressed Air Consumption StudyOptimisation of compressed air costMinimising wasteful consumption of compressed and by improving the efficiency of compressors.Heat economy in textile millsSome general suggestions for heat economy in this article.

10. Effect of processing conditions at ginning on fibre propertiesThe moisture role in processing at ginning. Energy balance and accounting for boilers and process houseIt is a matter of great concern to all that boiler should run at its maximum efficiency with minimum indirect losses. Fuel saving in decentralised process house unitsThermal efficiency values for different fuels for boilers and thermic fluid heaters, areas of steam and fuel savings identified, with recommendations for the fuel savings.Preparation of fuel oils storage, handling. IT based sewing room data for improved performancemicro-controller based single system working to transmit the machine performance and production data to a computer system to store, process and generate reports, to increase productivity.

11. Cyclic activated sludge technologyA detailed technical description, salient features & advantages of the cyclic activated sludge technology.Energy saving in textile processingPractical tips and a ready reckoner for making investment decisions related to energy saving.Avenues for cost reductionsalient findings of the some mills making 100% cotton, polyester/cotton, worsted, polyester/wool blended, woven/knitted fabrics, the measures suggested/implemented/followed up for water conservation and accrued benefits.Energy savings & audit in textile industryProvides major power consuming areas in textile mill and its optimization. SITRA energy audit reports

12. Website role in Textile industry Various database accesses have been provided in this website viz. energy managers, energy specialists, energy auditors to facilitate the users to choose the desired professionals as per their requirement. We propose to make available following to the textile industry: • Brief details of the equipments used in textile industry, equipment tips, O&M information. • Supplier details of the textile machinery with their specifications. • Energy efficient equipments details along with their supplier’s details • Energy audit equipments required for energy audit.

13. Industry user group: Textiles Few technical problems posted by users 1. What are the key factors for achieving good quality of raw material in textile industry? 2. Which are responsible for dust generation in textile industry? 3. Is it advisable to run the turbine with 49Hz instead of 50Hz? Will this give any fuel saving? Any harm to the turbine? 4. How to pre-cool the Utility compressor suction air economically? The compressor in industry utility functions like a submersible pump in air. Like the submersible pump which needs water to be sucked in as well water to be surrounded by the pump to keep the pump cool and efficient; the compressor too needs clean dry cool 5. Energy conservation solutions for applications in textile industry located at Coimbatore and knit-wear industry at Tirrupur. Specific problem areas are :1. Dyeing processes and chemical effluents recovery and waste disposal 2. Electrical energy saving for textile machineries 6. COMPRESSORS--There are many cases when pressure required for say 20% equipment is 6 kg/ sq.cm and for remaining about 5 kg/sq.cm. For meeting requirement of 20% equipment, total pressure has to be kept higher. Has any body come across any manufacturer who manufactures booster compressors for such eventualities?

14. Detailed technical information on equipment design / types and Tips: •   Electrical systems • Boilers • Furnaces • Insulation & refractories • Electric motors • Compressors and compressed air system • HVAC and refrigeration • Cooling towers • Fans & pumps • Lighting system • Testing equipment

15. Typical problems that cause higher energy costs • Process operations: Incorrect set points, fouled heat exchangers, advanced control switched off, poor control timing. • Boilers: Poor air-fuel ratio, fouled exchanges, excessive blow-down, incorrect boiler selection. • Refrigeration: Fouled condenser, air in condenser, incorrect superheat settings, high head pressure settings, incorrect compressor selection. • Compressed Air: Leaks, poor compressor control, incorrect pressure • Steam:Leaks, failed traps, poor isolation, incorrect set-points, low condensate return. • Space Heating / Cooling: Excessive space temperature, excessive fan power use, overcooling, heating and cooling, high chilled water temperature • Power Generation: Poor engine performance, incorrect control settings, poor cooling tower operation, fouled heat exchangers

16. Role of IT in energy management • Track energy usage, identify wastage and generate reports. • Energy monitoring, verification on Performance Contracting. • Plan, process, monitor and compare activities. Advantages: The major advantages of the softwares for energy management is to store the data in a usable format, the calculations of effective targets for energy use, and comparison of actual consumption with the targets, early detection of poor performance, effective performance reporting.

17. Proposed software for assessment of energy consumption in Textile industry 19 – 20 March 2006

18. Software objective • Assess the energy consumption (Thermal, Electrical, Water) of textile mills. Generate identification code for proper classification of textile mills for comparative analysis.  Compare the textile mills energy consumption with the Industry average Bringing Awareness about standards of energy consumption Self assessment for improvements in the textile mill’s energy consumption. Classification of textile mills into gold/ silver/ bronze/ tin

19. Login Page Web page; http://www.energymanagertraining.com/ecsectors.php

20. Brief description of the mill Web page; http://www.energymanagertraining.com/ecsectors.php

21. Mill details and status

22. Statistics Summary

23. Electrical Rating

24. Thermal Rating

25. Water Rating

26. Extract from Dr. Kaupp’s Corner Article # 23 Become Energy Efficient. Change Colours Like a Chameleon A recommended rating for efforts under step 6 could be: 1 point for having a designated and certified energy manager appointed; 1 point for having conducted an energy audit through an accredited energy auditor and validation of self declared energy consumption data; 1 point for having submitted the energy audit report to BEE in electronic form; 1 point for having prepared a three year business plan; 1 point for submitting the business plan in electronic form to BEE or designated State Agency; The remaining 5 points could be distributed based on the degree of implementation and documentary evidence of verified energy savings and costs. Satisfying the formal requirements of the Act will already result in a 5 point effort level, while any Gold or Silver standard in efforts depends on the level of successful implementation of energy conservation measures. Web page; http://www.energymanagertraining.com/new_kaupp.php

27. Benefits to the registered members • The registration to the website is FREE. • Registered member will be entitled to the following: • Complete access to the website • Recent development in energy management. • Receive regular updates on the website • View the technical problems posted by the industry members along with the answers from the specialists. Any registered member can post any technical queries on the website • Upload profile on the website

28. Users Contribution • Submit technical papers & best practices • Submit live case studies • Useful softwares, calculating tools • Submit information on energy efficient equipment manufacturer /supplier • Become member of industry user group and submit querry • Post energy management related event details • Send feedback to improve the site • Submit your profile • SURF & PROMOTE THE SITE REGULARLY

29. Contact: ASHOK KUMAR Advisor – Information Indo-German Energy Programme (IGEN) Hall No.4, 2nd Floor, NBCC Tower 15, Bhikaji Cama Place, New Delhi – 110 066 Phone: 011-26179699 Fax :011-26178352 Email :akumar@emt.in akumar@energymanagertraining.com