The Textile Engineering & Instrumentation Division offers the following services.
1. COMPREHENSIVE ENERGY AUDIT
Conservation and management of energy have assumed tremendous significance in the last decade, particularly with the introduction of fourth generation hi-tech machines that consume more power per unit production. SITRA has been conducting different types of energy audits like Comprehensive Energy Audit and Mandatory Energy Audit in the textile mills in India and abroad for more than three decades .
SITRA Energy Cell formed in 1980s , comprising of experienced engineers in the respective fields, is under taking Energy audits and energy consumption, conservation studies in the textile mills from powerhouse to production machines. So far, it has undertaken energy audits in about 600 mills in India and abroad. SITRA has also formulated procedures and systems for the introduction of Energy Conservation Program in mills for routine control and suggested methods to audit electrical energy consumption in mills. Many textile mills have saved crores of rupees in energy cost through SITRA Energy Audits. This audit is conducted in-depth in the following three areas:
Macro energy information – energy cost – power quality – system capacity, adequacy and conservation potential – power handling losses – transformation competency and voltage profile – pf correction – capacitor aging appraisal – cable loss estimation – review of maintenance records – evaluation of mills specific energy consumption – reasoning for motor burnouts – separation of productive and auxiliary loads – machine-wise energy consumption measurement – ring frame analysis – scrutiny of conservation measures attempted – suggestions for better generation, lighting, drives and other utilities.
Humidification – system analysis for each department – supply, exhaust and pumping systems details – present condition of humidification system – air flow distribution analysis – heat load analysis – humidification power pattern – plant motor loading analysis – temperature and RH analysis – standard temperature and RH for different departments – plant operation and maintenance – compressors – power pattern – leakage analysis – boilers and thermic fluid heaters – existing system details – thermal efficiency analysis – recommendations for implementation.
Installed motor hp in mills and load distribution analysis – scope for energy conservation in preparatory, spinning and post-spinning machines – choice of energy efficient components or accessories: motors, bobbins, belts, spindles, spindle oils, spindle tapes, tin roller, pneumafil fans etc.- optimization of package size in ring frames – modification in machine design or structure to reduce load – details of SITRA studies pertaining to energy conservation – production and energy consumption analysis- economics of energy efficient equipment.
2. MANDATORY ENERGY AUDIT
The Government of Tamil Nadu has made energy audit mandatory in all High Tension Industrial and Commercial Establishment as per G.O.Ms.No.72, dated 10.5.1996. SITRA has been recognized as one of the approved and authorized energy auditors for conducting energy audit in High Tension Industries by the Government of Tamil Nadu. The Govt. of Kerala has also permitted SITRA to conduct the energy audit in the High Tension Industries. The scope of the mandatory energy audit in textile mills broadly includes the following aspects:
- Production and energy consumption of different textile machines.
- Specific energy consumption and standards for textile mills.
- Instrumentation for energy data acquisition / monitoring and recording.
- Maintenance management of electrical installation, productive and non-productive machines.
- Present status of Energy Conservation Programme.
- Short-term and long-term measures for energy conservation with/without financial commitments and pay-back period.
3. Other Studies
Power Quality Audit identifies any invisible loss present in the electrical system due to defective supply source, distribution network and special equipment: reason out the causes for frequent equipment failure, capacitor de-ration, motor over-heating etc., In this audit, power quality in terms of voltage, frequency and current and its variations/fluctuations, wave shape distortion, harmonics, unbalance, if any, will be checked in all important nodes in mill supply source, transmission and distribution net-work. It also includes suitable suggestions for subsequent rectification in the electrical network.
Humidification is an important supportive activity for the production of yarns and fabrics. With reference to energy cost, it consumes nearly 15%-20% of the total power bill of the mill. SITRA has been conducting in-depth analysis on the humidification system of textile mills in the following aspects:
- Detailed heat load analysis in different departments.
- Plant capacity requirement with respect to supply, exhaust and pumping system.
- Design of the humidification plants.
- Design of the supply air ducts and diffusers.
- Design of the exhaust air trenches and floor grills.
- Pattern of temperature and humidity inside the departments.
- Loading of the motors in the humidification plants.
- Air distribution pattern inside the departments.
- Recommended lay-out for the supply and exhaust system for uniform distribution of air.
SITRA conducts detailed study on different types of compressors existing in the textile mills with respect to the following aspects:
- Air leakage study in the existing condition.
- Existing compressed air pipe line lay-out.
- Modified pipe line lay-out for minimum air friction loss.
- Selection of energy efficient compressed air accessories like filters, dryers and moisture separators.
- Compressed air for cleaning.
- Power consumption pattern of compressors.
Noise is often a problem in the working environment, whether from production machinery in the factory or business machines in the office. Noise measurement permits precise scientific analysis of annoying sounds. Noise level measurements give a clear indication of when a sound may cause hearing damage and permit corrective measures to be taken. Hence, measurement and analysis of sound is a powerful diagnostic tool in noise reduction programme. SITRA conducts detailed sound level analysis at different sections of a textile mill with sophisticated state-of-the-art instruments.
Measurement of vibration level can be taken as a guide to the condition of a machine since increase in vibration level usually indicates wear or deformation. The level of the vibration as measured at specific positions on a machine can be used as an indication of its condition. Therefore, a fundamental requirement in all vibration work, whether it is in the design of machines, which utilize the energy, or in the creation and maintenance of smoothly running mechanical parts, is to obtain an accurate description of the vibration measurement for further analysis. SITRA regularly conducts in-depth and exhaustive vibration measurements in textile mills using sophisticated state-of-the-art instruments for the past two decades.
SITRA conducts detailed study on illumination level in different departments of a textile mill using sophisticated state-of-the-art lux level meters. Based on the existing illumination level, the following suggestions are offered to improve the same.
- Number of fittings to be added / removed for the optimum illumination level.
- Recommended lay-out of the light fittings for minimum energy consumption.
- Selection of energy efficient tube lights, ballasts and voltage stabilizers.
Assessment of existing Ukg level in the mill is vital for ascertaining energy saving potential in mills. SITRA has developed standard procedure for calculating 40s converted Ukg and 4.72 Ukg in the present standard for single yarn production. Best mills are able to achieve a 40s Ukg below 4.5. This study will help the mill to standardize their Ukg assessment procedure for comparison with industry and SITRA standards.