EnMS Program supported by GTZ-SMEDA-APTMA

IMPLEMENTATION OF ENERGY MANAGEMENT SYSTEM IN FAROOQ TEXTILE MILLS -2010

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TABLE OF CONTENTS S.# A B C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17.1 17.2 17.3 17.4 17.5 17.6 17.7 Topic Title Table of Contents Executive Summary General Information of the Textile Sector Global and Local Energy Crisis Impact on Pakistan Textile sector General Information of Company Scope of Project Scope of Report Limitation of the Report Format of the Report Our Audit Approach Data Collection Method Instruments used for Data Collection Units of Measurement Unit Cost Calculations Industry Benchmark Company Energy Consumption Performance Manufacturing Process Flow Preliminary Energy Audit Observations Detailed Energy Audit Baseline Data (As is Scenario) Energy ProducersElectrical Energy ProducersSteam Energy ProducersGas combustion at singeing Energy ConsumersElectrical Machines & Motors Energy ConsumersElectrical Lighting Energy ConsumersSteam @ machines, pipes and steam traps Management Practices Page # 1 2-3 4 5 5 5 6 6 7 7 7 8 8 9 9 10 10 17 18 21-38

39

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TABLE OF CONTENTS
S.# 18. 18.1 18.2 18.3 18.4 18.5 18.6 18.7 19 Topic Page # 42-50

Energy Management Objectives (To be Scenario) Energy ProducersElectrical Energy ProducersSteam Energy ProducersGas combustion at singeing Energy ConsumersElectrical Machines & Motors Energy ConsumersElectrical Lighting Energy ConsumersSteam @ machines, pipes and steam traps Management Practices Recommended Implementation Strategy

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Executive Summary Mohammad Farooq Textile Mills Limited (MFTML) participated in the Renewable Energy & Energy Efficiency Program of GTZ under the platform of APTMA and in coordination with SMEDA for Energy Management System Development and Implementation. Arch Associates was selected by GTZ as project consultant. This report describes the Energy Audit Findings conducted as a part of the Energy Management System Development and Implementation. Committee Draft ISO 50001 of Energy Management System (EnMS) was used as the benchmark standard for the Energy Audit and system implementation. The Energy Policy, System Procedures and related forms are compiled as a separate manual. A holistic approach for energy audit was used with focus on energy balance at the energy producer and energy consumer entities. Electricity, Steam and Heat in any form are considered as form of energy. Preliminary and detailed energy audit has identified inefficiencies mainly at the electrical power generation and consumption stage. Almost in all the energy consumption domains (electricity, steam, water, gas), the per kg fabric consumption is much higher than the international and national benchmarks. Besides cost saving opportunities related to electrical energy generation and consumption (Rs 6 million), significant cost savings can be achieved in the area of steam generation and consumption by combustion efficiency of boilers (Rs 7 million), utilizing the heat from waste gases of boiler stack, heat losses in the processing area due to steam leakages (Rs 2.6 lacs), inefficient steam traps, effective insulation of semi-insulated and bare steam pipes (Rs 52000). Also increasing the consumption efficiency of water (Rs 4.4 million) and gas in the wet processes and at singeing machine (Rs 42000) will yield high cost savings. Except for waste heat recovery from generators, rest of the identified energy conservation opportunities does not require heavy investment and merely by improving the management systems related to preventive maintenance and good housekeeping with focus on workers training and creating sense of process ownership will yield high savings. By converting from estimation based energy cost management to real time measurement of energy production and consumption efficiencies and calculating cost impact as a part of Energy Management Information System will support MFTML management in prompt identification of high cost drivers and its impact on overall cost of production
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1. General Information about Pakistan Textile Sector Pakistan Textile and Apparel industry generates about 64 % of total exports and constitutes 46 % of Manufacturing Industry. It employs 40% of Countrys working population and contributes 11% of the total GDP. Pakistani clothing export growth slowed to 8% in 2006, following three years of double digit increase. 2. Global and Local Energy Crisis Impact on Pakistan Textile Sector Pakistans textile industry has been particularly ravaged by high energy prices and shortages of supply. National exports for last year fell 25% or US$5.12 billion short of targets, and this years forecasts have been substantially scaled back as well. Despite the current global economic recession, estimates place the losses due to energy prices at around US$1 billion annually, with failure to meet orders caused by the effects of energy shortages on production times driving away future business. Given that 64% of the countrys export earnings come from textiles, the crisis is of vital importance to Pakistans economic recovery and future. 3. About Mohammad Farooq Textile Mills Limited Company Name: Mohammad Farooq Textile Mills Ltd Industrial Sector: Textile Processing Range of Products: Woven fabrics, Dyed & Printed bed sheets and curtains Address: Plot # 6& 7, Sector 21, Korangi Industrial Area. Karachi Telephone: 92-021-350515498 URL: www.mohammadfarooq.com Contact Person: Mr. M. YounusGeneral Manager Operations Energy Manager: Mr. Lucman (Utility Manager) Site Characteristics Total Space = 16 acre (65000 m2) Production Space = 44000 m2 Office Space = 603 m2 Storage Space = 498 m2 Production Capacity: 2.3 million liner meter fabric

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Mohammad Farooq Textile Mills Limited is among the oldest and largest textile units of Pakistan located in Karachi. The company is involved in the manufacturing, dyeing and printing of woven fabrics mainly related to Home Textiles. Previously the company was the complete vertical unit from spinning to garments but now due to recession and slump in textile trade, it has reduced its manufacturing operations to dyeing and printing predominantly while few weaving looms and small garment unit. Currently its products are mainly exported to USA and few lawns are for sale in the local market. Since 2001, company is maintaining ISO 9001 Quality Management System Certification and also follows buyers Code of Conduct for Corporate Social Responsibility 4. Scope of the Project German Technical Corporation (GTZ) as Project Sponsor with Small Medium Enterprise Development Authority (SMEDA) as the coordinating body and All Pakistan Textile Manufacturers Association (APTMA) as the beneficiary body initiated the Energy Management System Development and Implementation Project for the selected group of textile companies related to spinning, weaving and processing sector. The objective of the project is to not only identify the energy cost savings through energy audits but also to bring on board all the management functions of the company for sustainable energy conservation practices through documented Energy Management System development and implementation. In this regard the upcoming Energy Management Standard of ISO 50001 is selected as the benchmark model to develop the Energy Management System For Energy Management System (EnMS) development and implementation at Mohammad Farooq Textile Mills, the processing area comprising dyeing and printing is selected for EnMS development and implementation beside electrical power generation and steam production. The areas of weaving and garment are out of scope for this project. 5. Scope of the Report This report details the Energy Audit findings and the corresponding Energy Management Objectives for the processing area comprising dyeing and printing including power generation and steam production. The Energy Manual and related procedures including instructions are presented as separate document and are not part of this report.

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6. Limitation of the Report Since energy audit was performed during the period of Dec 2009Jan 2010, which is usually low production phase for the textile sector, therefore at times the data measured at the machines when it was not running at its optimum capacity. Also no measurement was collected for pad steam as it was not operational during the audit time frame. Similarly our observations and measurement were focused on energy generation, consumption and wastages as a process and does not take into account the balancing between total power generation and production capacities as currently power generation model is based on the previous manufacturing setup including spinning, weaving, processing and garments while presently the same power generation model is catering only processing and partly few looms and garment section. 7. Format of the Report The report is structured in the form of As is Scenario and To be Scenario for each component of energy producer and consumer. Each component is depicted in the form of energy input and output supported by data tables, graphs and calculations to demonstrate energy wastage and cost saving potential 8. Our Approach for Audit We take the holistic view of the total energy model employed at Mohammad Farooq Textile Mills and categorized it as Energy Producers and Energy Consumers. Under Energy Producers, gas fired Generators and Boilers (gas fired and thermo) are categorized while Electrical Panels, Machines, Motors, Pumps, Fans, Building [lighting] etc are categorized as Energy Consumers consuming energy in the form of electrical power or heat energy. To identify the energy loss at Energy Producers and Energy Consumers stage, energy balance approach is used as depicted below.
Value Added Energy Output Energy Wastage

Energy Input

Energy Conversion

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This energy process realization is used to identify the Energy Efficiency, Energy Wastages and the Cost associated with the wastages either at the input stage or output stage. For cost saving opportunities identification we initially identified the maximum possible opportunities during the preliminary energy audit and used 80/20 approach in detailed audit for data collection and cost savings potential. Only those 20% energy savings opportunities haven been taken as Energy Management Objectives (EMO) which have an impact of 80% cost savings in the total cost saving pie. 9. Data Collection Method The data collection process comprised of data provided by the organization and the measurement exercise carried out by our team during the detailed energy audit scenario. Where data reported by organization was based on estimation rather than measurement, it was measured during the detailed energy audit in order to have accuracy in energy efficiency, energy wastages and cost savings values. To the extent possible, dependability on estimated values is discouraged for calculations except in those cases where measurements for the total number of equipments (e.g. motors) was not possible and sample results are averaged and plotted for the total range of similar equipments (conditionality: similar make, rating and type of equipment) Following were the sources of data collection Data provided by organization in the form of gas bills, production figures, electricity units generated through self generation, water consumption etc Data noted from the measuring devices installed at different equipments Data collected through measurement exercise during the detailed energy audits in collaboration with Department of Energy & Environment of QUEST--Nawabshah and Environmental Research Centre of Bahria Univeristy Karachi. Data collected through visual observations

10. Instruments Used for Data Collection Flue gas analyzer Lux Meter
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PF Meter Volt Meter Electric Power Meter Analyzer Low and High Infrared Temperature Meter Tong Tester Flow Meter

11. Units of Measurement

Production = linear meter Steam = Kg/ year Electricity = Kwh/year Gas = m3 12. Unit Cost for Calculations (based on 2009 data) The unit cost calculation for gas, electricity and steam are based on the fuel consumption cost and does not take into account the overhead cost involved as in case of energy savings, the direct impact will be on the fuel cost than on the overhead cost. Also the financial savings demonstrated through energy conservation will be more accurate and verifiable in the absence of inclusion of overhead cost. The cost provided by the company and included in the tables coverts the total generation cost i.e. fuel cost plus the overhead cost. For Steam Steam Consumption= 86261760/12499886 = 6.90 kg/ meter 6.90 kg = 8.17 Rs. Cost of 1 Kg Steam = 8.17/ 6.90 = 1.18 Rs/ kg (provided by MFTML) For electricity Number of electricity units generated per month= 357131 Kwh Cost of 1 m3 Natural gas = 10.44 Rs.(derived from Gas Bill) Gas consumption for 1 Kwh = 0.346 m3 Cost for generation 1 Kwh = 3.612 Rs. /Kwh (Calculated from gas consumption and does not include overhead cost)

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13. Industry Benchmark Water Consumption Norms (per Kg) World Consumption---50-100 litres/kg of fabric National Consumption ---Sind 50-80 litres/kg of fabric Steam Consumption---6-8 kg of steam/ kg of fabric Electricity Consumption----0.81.5 KWh / kg of fabric Gas Consumption---0.35 m3 of gas/ kg of fabric

Punjab---200-300 litres/kg of fabric

14. Company Energy Consumption Performance To evaluate the company energy consumption performance against the established benchmarks / norms, data for the year 2009 was collected and analyzed. Water Consumption

Table 1Machine wise water consumption data for the year 2008-09
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Graph-1- Water Availability data per day from KDA and Well water

Graph-2-Machine wise water consumption trend during the month Analysis Average Water Consumption (2008-09) = 88897392 / 12 = 7408116 gallons per month Average Production (2008-2009) = 1047770 m per month = 209554 kg for 2009 (Assume 200 gm per linear
meter)

Average Water consumption per linear meter of fabric= 133.81 litres/kg of fabric which is much higher than the benchmark value for Sind and international norm. High consumption rate is noticeable at bleaching and washing machine. This is supported by water wastage savings identified at these machines and explained in the Detailed Audit section

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Steam Generation

Table-2- Boiler wise steam generation data

Table-3- Machine wise steam consumption data

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Graph-Steam consumption at different machines (This data is based on approximation)

Analysis Average Steam Consumption (2008-09) = 6127680 kgs per month (excluding steam consumed in stitching 1& 2, HVAC and sizing) Average Production (2008-2009) = 1047770 m per month = 209554 kg for 2009 (Assume 200 gm per linear
meter)

Average Steam consumption per linear meter of fabric= 29.24 kg of steam /kg of fabric which is much higher than the benchmark value. Since steam monthly production is not measured and recorded therefore its consumption pattern against the monthly production cant be analyzed. Electricity Consumption Table-4 Electricity Generation Data (Till Oct 2009)

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Graph

Analysis Average KWh Consumption (Jan-Nov 2009) = 7786654 KWh / 11 = 707877 KWh Average Production (Jan-Nov 2009) = 11525478 / 11 = 1047770 m per month = 209554 kg for 2009
(Assume 200 gm per linear meter)

Average Electricity consumption per kg of fabric= 3.37 KWh kg of electricity /kg of fabric which is much higher than the benchmark value. An abnormal trend is observed for the month of May 2009 when production volume increased considerably compared to April 2009 but the electricity generation in KWh is showing decreasing trend in May 2009

Gas Consumption Table

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Cumulative Gas Consumption Details Nov 2008Oct 2009

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Graphs

Analysis Average Gas Consumption (Nov 2008Oct 2009) = 638255.9167 m3. Gas consumed in production only Average Production (Nov 2008Oct 2009)= 1240565.25 m = 248113 Kg (Assume 200 gm per linear
meter)

Average Gas consumption per kg of fabric= 2.57 m3 gas /kg of fabric which is much higher than the benchmark value . Taking into consideration the gas consumed for electric power generation, the per kg fabric value comes to around 4.53 m3 . An abnormal trend is observed for the month of May 2009 when production volume increased considerably compared to April 2009 but the gas consumption is showing decreasing trend in May 2009

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15. Manufacturing Process Flow

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16.Preliminary Audit Observations

Steam Generation and Consumption 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Steam header valve is leak. Temperature, pressure and other gauges are not calibrated. Most (almost 100%) of steam traps are leakages. Steam leakage at Kuster Pre Treatment Piping insulation at Kuster PT is not proper. Condensate pipe is leak. Insulation not proper at Thermo boiler (Rotary Printing) Two Feed Water tanks are not insulated. Blow down water tank is also not properly insulated. No drainage is made for the water at the Boiler House. Condensate Water is drained. Water Flow meter not installed anywhere in the Boiler House. No any measuring device for the Steam generation, Gas Consumption, Electricity Consumption, Boiler Feed water tank is installed. Boiler Efficiency is not monitored as there is no measuring instrument installed for efficiency measurement. No any device for the measurement of NOx, SOx, and other flue gases. Energy Accounting In piping some of the line are oversized and some are undersized (No uniformity of the piping system). Steam Condensate pipes leakages are not fixed. Damaged insulation is not repaired, and where fixed the correct insulation material is not used. No pre-heating of combustion air with waste heat (22 0C reduction in flue gas temperature increases boiler efficiency by 1%). No use of variable speed drives on boiler combustion air fans with variable flows. One oil tank requires insulation. No maintenance record to conform that burners, nozzles, strainers, etc are cleaned No inspection record related to Inspection of oil heaters for proper oil temperature. Close burner air and/or stack dampers when the burner is off to minimize heat loss up the stack. Improve oxygen trim control (e.g. -- limit excess air to less than 10% on clean fuels). (5% reduction in excess air increases boiler efficiency by 1% or: 1% reduction of residual oxygen in stack gas increases boiler efficiency by 1 %.) Automate/optimize boiler blow down. Recover boiler blow down heat. Use boiler blow down to help warm the back-up boiler. Optimize deaerator venting. No Inspection of door gaskets. No Inspection for scale and sediment on the water side Page 18 of 51

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31. (A 1 mm thick scale (deposit) on the water side could increase fuel consumption by 5 to 8%). 32. No Inspection for soot, flyash, and slag on the fire side. (A 3 mm thick soot deposition on the heat transfer surface can cause an increase in fuel consumption to the tune of 2.5%.) 33. Optimize boiler water treatment. Presently continuous blow down indicates water treatment is not effective. 34. Add an economizer to preheat boiler feed water using exhaust heat. 35. Recycle steam condensate. 36. Study part-load characteristics and cycling costs to determine the most-efficient mode for operating multiple boilers. 37. Fix steam leaks and condensate leaks (A 3 mm diameter hole on a pipe line carrying 7 kg/cm2 steam would waste 33 kilo litres of fuel oil per year). 38. Accumulate work orders for repair of steam leaks that can't be fixed during the heating season due to system shutdown requirements. Tag each such leak with a durable tag with a good description. 39. Ensure process temperatures are correctly controlled. 40. Maintain lowest acceptable process steam pressures. 41. Reduce hot water wastage to drain. 42. Remove or blank off all redundant steam piping. 43. Ensure condensate is returned or re-used in the process (6 0C raise in feed water temperature by economiser/condensate recovery corresponds to a 1% saving in fuel consumption, in boiler). 44. Check operation of steam traps. 45. Inspect steam traps regularly and repair malfunctioning traps promptly. 46. Consider recovery of vent steam (e.g. -- on large flash tanks). 47. Use waste steam for water heating. 48. Repair damaged insulation (A bare steam pipe of 150 mm diameter and 100 m length, carrying saturated steam at 8 kg/cm2 would waste 25,000 litres furnace oil in a year.) 49. Insulate all flanges, valves and couplings 50. Insulate open tanks (70% heat losses can be reduced by floating a layer of 45 mm diameter polypropylene (plastic) balls on the surface of 90 0C hot liquid/condensate). Electrical Power Generation and Consumption 1. Almost all of the lights are TUBE LIGHTS and ON during the day time where sufficient daylight is available. 2. Panels in the Boiler House are very old and rust is present on them. 3. No maintenance of the electrical equipment was found. 4. There was dust on the tube lights as there is no proper cleaning system of the tube lights. 5. Power Factor on the generators is very low i.e. 0.75 6. Power Factor at the distribution side is also low Page 19 of 51

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7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Feeder # 1 :0.74 Feeder # 2 :0.83 Feeder # 3 :0.87 Feeder # 4 :0.85 Schedule your operations to maintain a high load factor Correct power factor to at least 0.90 under rated load conditions. Relocate transformers close to main loads. (Two transformers are at distance from the main load) Use energy-efficient motors where economical. Use synchronous motors to improve power factor. Use variable-speed drives for large variable loads. Check belt tension regularly. Clean screens and filters of blowers regularly. Repair seals and packing of pumps to minimize water waste. Balance the system to minimize flows and reduce pump power requirements. Consider painting the walls a lighter color and using less lighting fixtures or lower wattages. Optimize generator loading Use waste heat to generate steam through WHRB. Use jacket and head cooling water for process needs

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17.Detailed Audit--Baseline Data ( As is Scenario)

Energy Producer 17.1. Electrical Power Generation Generators Gas, Air mixture Stack Gases @ 520 C as waste Electrical Power

MFTML has three gas fired generators, out of which two are for normal operations and one used as standby arrangement. The details of engines are as below

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The operating parameters when measured on Jan 09,2010 indicated the following readings

The electrical power generated through two generators is routed to two transformers (incoming power) and four feeders (outgoing power) as per following arrangement

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The distribution of electricity in different areas is as per below table Total Electricity Generated (kWh) 213322 132132 100% 10% 20% 15% 30% 10% 10% 4% 1% 412255 455544 21415 5555 2211 2255 12221 111 Consumption (kWh) Processing Main Office Boiler RO Computer Power House unknown Etc

The low power factor at Generators and feeders indicates energy wastage which can be saved by technological intervention. The calculations for power factor improvement from existing 0.75 to 0.9 are detailed below along with cost saving potential calculations.
Generator Low Power factor Cost Impact calculation Running load of generator # 1= 650 kW Average Power Factor kVA taken at 0.75 kVA taken at 0.90 = 0.75 = 866.6 = 755 =866.6-755 Page 23 of 51

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=111*0.9 (desired power factor) = 100.04 =100.04* 8760(running hours) * 3.61(fuel cost for electricity generation) Savings on Gas fuel For two generators Total Savings on Gas bill =Rs. 3175009.44/Year =2* 3175009 =Rs. 6350018 /yr

17.2.

Steam Generation through waste gases

Similarly waste gases from the two generators are currently emitted in the atmosphere. The profile of stack gases of both the generators is tabulated below.
STACK GAS ANALYSIS FROM GENERATOR I S.No. 1 2 3 4 5 6 7 8 9 Parameters Temperature (Ambient) Temperature (Stack) Carbon Monoxide Carbon dioxide Nitrogen Oxide Nitrogen dioxide Sulphur Oxide Hydrogen Oxygen Unit o C o C ppm % ppm ppm ppm ppm % Monitoring Results 28.8 532.4 171 1.47 43 0.6 --71 18.41

STACK GAS ANALYSIS FROM GENERATOR II S.No. 1 2 3 4 5 6 7 8 9 Parameters Temperature (Ambient) Temperature (Stack) Carbon Monoxide Carbon dioxide Nitrogen Oxide Nitrogen dioxide Sulphur Oxide Hydrogen Oxygen Unit o C o C ppm % ppm ppm ppm ppm % Monitoring Results 29.6 538.6 94 0.72 17 0.3 --55 19.72 Page 24 of 51

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On the basis of oxygen and CO2 contents of the stag flue gases the combustion efficiency is in the range of 7580%. This low efficiency is due to the high oxygen content in the flue gas.

Currently the total steam requirement is around 22 TPH which is met through four gas fired boilers. Capturing of high temperature stack gases and directing them in Waste Heat Recovery Boiler (WHRB) will reduce the steam demand from conventional boilers thereby impacting on gas consumption. The calculations below demonstrate the potential for steam generation through WHRB and cost savings.
WASTE HEAT RECOVERY COST CALCULATION Power = P= 650 Exhaust temp. = 532.4 0C Pressure= 10.54 kg/cm2 Mass of stack gas = 78.6 Nm3/min=5.07 Kg/kwh Cp= 0.25 K cal/kg 0C Feed water Temp.= 70 0C H= 663.755 k cal/kg Temp of steam= 272.4 0C Hrs/year= 8760 Qty of heat available from the flue gas= 650 * 5.07 * 0.25 * (532.4- 272.4) = 214207.5 K cal/hrs Qty of Steam generated = 214207.5 / (663.755- 70) = 360.76 Kg/hrs (for one generator) = 721.52 kg /hrs (for two generators) = 721.52 * 8760 * 1.18 (steam cost) Steam Generation Cost saving = Rs. 7458207.9/ year

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17.3.

Burners Inefficiency at Singeing M/c

Burners are not adjusted with respect to the fabric width. Burner flames remains open either fabric width is 66 or 116 Usually Singeing machine consumes gas 0.0015 m3 (industry benchmark) for 1 linear meter of fabric but in MFTML singeing machine consumes 0.005 m3 for 1 linear meter of fabric. Average production = 11648599 meters for based on last 3 years (2007-2009) production data = 17472.99 If M/c consumes 0.0015 m3 gas for 1 linear meter fabric = 58242.99 m3 (machine consumes 0.005 m3 gas for 1 meter fabric) Difference Gas Cost Amount Loss = 40770 m3 = 10.44 Rs. /m3 = Rs. 425638.8

NOTE: The amount may be increased because all flames are remains open either fabric width is 66 or 116. This amount is additional to that which can be saved if flames are adjusted as per the width of the fabric. 17.4. Steam Generation

Steam Gas, Air mixture Water, chemicals Boilers Stack Gases @ 324 C as waste gas Blow Down

MFTML has four gas fired boilers generating steam primarily for the processing area while partly it is utilized in garment section and three thermo boilers in the processing area.

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Boiler#1 Make: Standard Duisburg Kessel Construction Year 1960 Chimney Height approx 28-30 ft Boiler # 2 Make: Babcock Steam Block Construction Year 1969 Chimney Height approx 50 ft Boiler # 3 Make: GWB Boilers Construction Year Chimney Height Boiler # 4 Make: GWB Boilers Construction Year Chimney Height

Type Fuel

Fire Tube Gas Fired

Type Fuel

Fire Tube Gas Fired

Not Available approx 32 ft

Type Fuel

Fire Tube Gas Fired

Not Available approx 25 ft

Type Fuel

Fire Tube Gas Fired

Thermal Rating of Oil Heater # Thermal Rating (kcal/hr) 2000 Oil circulation (m3/hr) Oil Holding Capacity (lit) 2200 Temperature (C) Machines operated Gas Electricity consumption consumption (m3/day) (kWh) 950 50

250

2 3

2200 1800

2200 2200

250 250-280

Stenter I (4chamber),Stork Steamer I. Rotary Printing, Stork Steamer II, Stenter (6 Chamber)

1250 1300

50 35

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The stack gases analysis results as follows STACK GAS ANALYSIS FROM THERMO BOILER I S.No. 1 2 3 4 5 6 7 8 9 Parameters Temperature (Ambient) Temperature (Stack) Carbon Monoxide Carbon dioxide Nitrogen Oxide Nitrogen dioxide Sulphur Oxide Hydrogen Oxygen Unit o C o C ppm % ppm ppm ppm ppm % Monitoring Results 31.4 226.9 ------0.2 --55 20.49

STACK GAS ANALYSIS FROM BOILER II S.No. 1 2 3 4 5 6 7 8 9 Parameters Temperature (Ambient) Temperature (Stack) Carbon Monoxide Carbon dioxide Nitrogen Oxide Nitrogen dioxide Sulphur Oxide Hydrogen Oxygen Unit
o o

Monitoring Results 27.8 182.6 167 Nil 1 0.1 --60 20.23

C C ppm % ppm ppm ppm ppm %

On the basis of oxygen and CO2 contents of the stag flue gases the combustion efficiency is in the range of 8085%. This low efficiency is due to the high oxygen content in the flue gas.

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STACK GAS ANALYSIS FROM THERMO BOILER II S.No. 1 2 3 4 5 6 7 8 9 Parameters Temperature (Ambient) Temperature (Stack) Carbon Monoxide Carbon dioxide Nitrogen Oxide Nitrogen dioxide Sulphur Oxide Hydrogen Oxygen Unit o C o C ppm % ppm ppm ppm ppm % Monitoring Results 31.0 324.3 5 7.02 36 0.1 --52 8.62

STACK GAS ANALYSIS FROM THERMO BOILER III S.No. 1 2 3 4 5 6 7 8 9 Parameters Temperature (Ambient) Temperature (Stack) Carbon Monoxide Carbon dioxide Nitrogen Oxide Nitrogen dioxide Sulphur Oxide Hydrogen Oxygen Unit o C o C ppm % ppm ppm ppm ppm % Monitoring Results 31.3 289.1 8 10.21 52 0.5 --29 2.99

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17.5.

Energy Consumer Cooling Mechanical Power Electrical Power Machines Motors Pumps Compressors Heat Lighting Vibration

Electrical Power Consumption

Electrical Power in MFTML is used for running the processing machines, motors, pumps, compressors, lighting, air conditioning, chillers etc. The major consumer of electric load is machines, motors and pumps. The detail of electrical load requirement for major machines is tabulated below.
MACHINE TYPE Singe-Desize Benninger Pretreatment Benninger Mercerize Cylinder Dryer Kuster Pretreatment Kuster Washing Benninger Pad Steam Monforts Thermosole I Monforts Thermosole II Jet Jigger I,II Monforts Stenter II Monforts Stenter IV Bruckener Stenter Zimmer Flat Bed Printing Zimmer Rotary Printing Kuster Calendar NOMINATIVE POWER (kW) 20 44 20 11 40 50 20 18 30 12 10 80 90 60 75 90 80

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Motors Data

COMPRESSOR DATA
There are 8 compressors in the mill. Compressor # 4,5 & 6 are not working nowdays. Description Compressor # 1 Compressor #2 Compressor #3 Compressor #7 Location Make Atlas copco Atlas copco Atlas copco Atlas copco Type Rotary screw Rotary screw Rotary screw Rotary screw type type type type Rated power 160 160 160 90 (kW) Cooling method Water Water Water Air Free Air Delivery 386 386 386 (m3/min) Set operating 6.5 6.5 6.5 6.5 pressure (bar) Receiver tank volume (m3) Drain System Manual Manual Manual Manual Dryer Install & in Install but not Install but not Install but not working working working working condition Delivery line size 3" 3" 3" 2" Suction status Normal Normal Normal Not work properly Max. Speed (rpm) 1500 1500 1500 2970 Compressor # 8 Atlas copco Rotary screw type 37 Air 98 6.2

Manual Install but not working 2" Good 3000

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On the basis of measurement exercise, the motors were found to be operated at low efficiency level i.e. 85% compared to industrial norm of atleast 90% efficiency level. MOTOR LOW EFFICIENCY COST hp= 12.7 Actual efficiency= 85 % Desired Efficiency = 90% Operating hrs/ year = 6300 Unit price = 3.61 Rs/ kwh @ 85 % efficiency = 12.7 * 0.745/ 0.85 = 11.43 kw @ 90 %efficiency = 12.7 * 0.745/ 0.90 = 10.51 kw Total loss = 11.43 10.51 = 0.917 kw Cost Saving = 0.917 * 6300 (running hours) * 3.61 (electricity generation fuel cost) = Rs. 20855.331/ year Total motors = 210 Total cost savings for all motors = Rs. 4400405 / yr (approximation used is that all motors were assumed at 12.7 HP although the Hp ranges from 0.08-60 Hp) Savings through Effective Lighting

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17.6 Steam / Heat Consumption Condensate Mechanical Power Heat (Flame, Steam, Hot Water) Fabric Machines Pipes Steam Leakage (pipes, traps) Hot water drain Loss through conduction

Measurement data demonstrated that heat energy contained in steam and hot water is wasted during steam distribution through condensate, steam leakages, steam traps, hot water drainage etc. Also gas as fuel is wasted during singeing process when flame is not adjusted as per the fabric width.

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Cost Impact Calculations for Steam Leakages.

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Cost Impact Calculations for Semi Insulated Steam pipes and bare steam pipes .

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Wastage of Water
Cooling water is drained from different areas of machines. This water can be reused. Kuster Bleaching Cost Saving from Drive motors Water of chamber # 3 & 7: From Chamber # 3 drive motor From Chamber # 7 drive motor Total 18 lit/min 24 lit/min 42 lit/min 25920 lit/day 34560 lit/day 60480 lit/day = 13321.6 gallons/day 25.92 m3/day 34.56 m3/day 60.48 m3/day

This water is used at ambient temperature. Cost of 1 gallon of water = 0.15 Rs. Drainage water cost Advice Since purpose this water is to cool the hydraulic motor drives and usually a fast flow rate is maintained , therefore this water can be reused either by transferring it to tank or use it in the washing chambers. Kuster Bleaching Post washing water will be used in the prewashing chamber; this will save the water cost i.e. Waster used in the pre washing chamber = 2 l/kg Average production = 12499886 meters for 2009 = 2499977 kg for 2009 (Assume 200 gm per linear meter) = 2499977 * 2 = 4999954 litres Water cost Total loss = 0.15 Rs. = 4999954 * 0.15 = 749993 Rs./year 2009 = 1998.23 Rs./day = 599471.36 Rs./ year (Assume 300 working days)

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DYEING From Hydraulic pump Padder motor Total 12 lit/min 12 lit/min 17280 lit/day 17280 lit/day = 3806 gallons/day 17.28 m3/day 17.28 m3/day

Cost of 1 gallon of water = 0.15 Rs. Drainage water cost SINGEING MACHINE: Cost saving at Singeing M/c. Water from Right 7.6 lit/min burner (Temp of water @ 50C) Water from Left 11.8 lit/min burner(Temp of water @ 50C) Water from Upside 33.5 lit/min Cooling(Temp of water @ 30C) Water from Downside 25.4 lit/min Cooling(Temp of water @ 30C) Total (Temp of water 78.3 lit/min @ 40C) Cost of 1 Gallon of Water= 0.15 Rs. Drain water cost 10944 lit/day 10.944 m3/day = 570 Rs./day = 171277 Rs./ year (Assume 300 working days)

16992 lit/day

16.992 m3/day

48240 lit/day

48.240 m3/day

36576 lit/day

36.576 m3/day

112752 lit/day =24835 gallons/day

112.752 m3/day

=3725.28 Rs./day = 1117585 Rs./ year (Assume 300 working days)

This water can be reused at the singeing machine.

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17.7.Management Practices
Maintenance Systems There is no formal preventive maintenance system in place for all the power producing and consuming equipments. No preventive maintenance schedules, checklists and records were shown during the audit. Machine breakdown data was not provided. The overall equipment condition, steam and water pipes condition, insulation status, apparent steam and water leakages indicated the lack of maintenance and availability of resources. Quality Control In effective process and product Quality Control is an indirect source of energy wastage. The re-work records related to stenter 2 & 4 for the year 2009 is tabulated below Month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Total = 264,010 m Stenter 2 12060 2170 3322 13836 20790 350 1550 5895 14090 15695 Stenter 4 9005 16115 16570 15760 11,157 14225 35805 2140 1665 21205 14225 16380

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Process Instrumentation Availability of gauges for monitoring of temperatures, pressures, flow rates etc during the entire course of electricity and steam generation and distribution and manufacturing processes is very scarce. Even at critical stages e.g. gas flow rate at boiler is not measured and monitored. The energy data utilized by the company is derived more from approximation rather than from measurement. No formal calibration system is in place. At places measuring devices are not in working conditions. Measurement and Monitoring of Energy Key Performance Indicators (EnKPIs) Currently company has not identified nor monitoring any EnKPIs in relation with the cost. MFTML finance department records and reports the cost of electricity generation, steam generation, electricity consumption, steam consumption on approximation basis and does not compare the consumption trends with any benchmark values. Inability to identify, measure and monitor EnKPIs deprives the organization to focus on increasing the efficiency in energy generation and consumption thereby reducing cost. Housekeeping Issues A very untidy atmosphere is prevalent in the processing area. Management and workers are not focused to capture the energy efficiency opportunities merely by practicing Good Housekeeping Practices which requires no dust and dirt in the area, no leakages of steam and spillage of water. Presently except for floor cleaning no other part of the machine, work place, including tube lights is cleaned

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Total Cost Saving Opportunities Area Power Generation Power Consumption Gas Combustion Steam Consumption Water Wastage Total Savings Domain Power Factor Improvement Using Waste Heat of Stack gases Increasing Motor Efficiency Lighting Singeing Leakages, insulation, hot water drainage etc Water for Cooling purpose Savings in Rupees/year 6350018 7458207 4400405 280479 425638 316662 1692018

20923427

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18.Energy Management Objectives (To Be Scenario)

Objective # 1
OBJECTIVE NAME DOMAIN PURPOSE OF OBJECTIVE RESULT OF OBJECTIVE TARGET START DATE APPROX INVESTMENT To improve the power factor of Generators from 0.75 to 0.90 by installing PFI panel Power Generation CATEGORY Short Term To balance the power generation and distribution efficiency in case of fluctuating load demands. Gas savings in power generation. April 2010 Rs. 1 Million TARGET COMPLETION DATE June 2010 APPROX Rs. 6 Million PAYBACK 2 months SAVINGS PERIOD

DETAILS /STEPS Seeking Managing Director approval for investment based on potential cost savings and low pack back period. Seeking quotes for PFI panel Meeting with equipment suppliers and seeking best energy efficiency arrangement and configuration. Discuss current and future power generation requirements and arrangements. Requesting potential suppliers to arrange demo of any industrial unit for application of PFI panel and its impact on cost savings. Selecting supplier Installation of PFI panel Monitoring PF improvement at power generation and consumption stages Monitor cost impact for two months. Report observations to management.

RESPONSIBILITY GM Operations Utility Manager Utility Manager

Utility Manager

Utility Manager Utility Manager Utility Manager / Energy Manager Utility Manager / Energy Manager Utility Manager / Energy Manager

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Objective # 2
OBJECTIVE NAME DOMAIN PURPOSE OF OBJECTIVE RESULT OF OBJECTIVE TARGET START DATE APPROX INVESTMENT Steam generation through Waste Heat Recovery Boiler by utilizing waste gases of generators Power & Steam Generation CATEGORY Mid Term To utilize the high temperature of stack gases from generators for steam generation Reduction in steam demand from conventional boilers thereby reducing gas consumption for steam generation Jan 2011 TARGET COMPLETION DATE Jun 2011 Rs 8 Million APPROX Rs. 7.4 PAYBACK 13 million months SAVINGS PERIOD

DETAILS /STEPS Seeking Managing Director approval for investment based on potential cost savings and low pack back period. Seeking quotes for WHRB Meeting with equipment suppliers and seeking best energy efficiency arrangement and configuration. Discuss current and future power generation requirements and arrangements and potential of steam generation. Identification of land requirements and installation area. Requesting equipment supplier to submit technical and financial data related to proposed WHRB including cost savings related to natural gas savings at conventional boilers. Evaluate simplex and duplex WHRB models and their cost impact in terms of investment. Requesting potential suppliers to arrange demo of any industrial unit for application of WHRB and its impact on cost savings. Selecting supplier Design, Fabrication and Installation of WHRB Monitoring steam generation data from WHRB at different power generation loads Monitor cost impact for two months. Report observations to management.

RESPONSIBILITY GM Operations Utility Manager Utility Manager

Utility Manager Utility Manager

Utility Manager Utility Manager

Utility Manager Supplier Utility Manager / Energy Manager Utility Manager / Energy Manager Utility Manager / Energy Manager
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Objective # 3
OBJECTIVE NAME DOMAIN PURPOSE OF OBJECTIVE RESULT OF OBJECTIVE TARGET START DATE APPROX INVESTMENT Improving the electric motors efficiency from 85% to 90% Power Consumption CATEGORY Short Term To increase motors efficiency Direct reduction in electrical load and indirect savings at power generation fuel Immediate Rs. 2 million TARGET COMPLETION DATE Dec 2010 APPROX Rs 4.4 Million PAYBACK 6 months SAVINGS PERIOD

DETAILS /STEPS This objective does not require heavy financial investment compared to commitment and determination from the Mechanical and Electrical Maintenance Team to focus on preventive maintenance of each motors and ensuring that it runs at its optimum efficiency. If the total preventive maintenance cost on all the machines is approximated at Rs.2 million per year, the payback period of this investment is 6 months. Also in case of continuing preventive maintenance , the cost on preventive maintenance will decrease appreciably while savings remains the same Randomly select motors and measure their actual efficiency and calculate the energy losses.

RESPONSIBILITY Mechanical and Electrical Managers

Energy Manager

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Objective # 4
OBJECTIVE NAME DOMAIN PURPOSE OF OBJECTIVE RESULT OF OBJECTIVE TARGET START DATE APPROX INVESTMENT Replacing existing tube lights and mercury bulbs with energy savers Power Consumption CATEGORY Short Term To achieve reduction in electric power demand Direct reduction in electrical load and indirect savings at power generation fuel April 2010 Rs 1.25 Lac TARGET COMPLETION DATE June 2010 APPROX Rs 2.3 Lacs PAYBACK 5 months SAVINGS PERIOD

DETAILS /STEPS Determine the lux value currently in each area and compare it with the required lux value.

Determine the number of energy savers required to obtained the required lux value and compare it with number of tubelights required to obtain the same lux value Based on this comparison, replace the tubelights with energy savers Monitor cost impact for two months. Report observations to management.

RESPONSIBILITY Electrical Manager for measurement Departmental Managers for identifying required lux value Electrical Manager

Electrical Manager Energy Manager Energy Manager

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Objective # 5
OBJECTIVE NAME DOMAIN PURPOSE OF OBJECTIVE RESULT OF OBJECTIVE TARGET START DATE APPROX INVESTMENT To improve burners efficiency at singeing Power Consumption CATEGORY To achieve reduction in gas consumption Gas consumption per kg of fabric will decrease. TARGET COMPLETION DATE APPROX Rs 4 lacs PAYBACK SAVINGS PERIOD Short Term

Rs. 1 Lac

3 months

DETAILS /STEPS This objective does not require heavy financial investment compared to commitment and determination from the Mechanical team and machine operator to focus on preventive maintenance of each burner and regular cleaning of the machine and ensuring that it runs at its optimum efficiency.

RESPONSIBILITY Mechanical Manager

Objective # 6
OBJECTIVE NAME DOMAIN PURPOSE OF OBJECTIVE RESULT OF OBJECTIVE TARGET START DATE APPROX INVESTMENT To eliminate steam leakages at different machines and improve efficiency of steam traps Steam Consumption CATEGORY Short Term To achieve reduction in steam consumption demand thereby reducing gas consumption

To be determined

TARGET COMPLETION DATE APPROX Rs 2.6 lacs PAYBACK SAVINGS PERIOD

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Objective # 7
OBJECTIVE NAME DOMAIN PURPOSE OF OBJECTIVE RESULT OF OBJECTIVE TARGET START DATE APPROX INVESTMENT To reduce heat losses due to semi insulated and un-insulated pipes Steam Consumption CATEGORY Short Term To achieve reduction in steam consumption demand thereby reducing gas consumption

To be determined

TARGET COMPLETION DATE APPROX Rs 52000 PAYBACK SAVINGS PERIOD

Objective # 8
OBJECTIVE NAME DOMAIN PURPOSE OF OBJECTIVE RESULT OF OBJECTIVE TARGET START DATE APPROX INVESTMENT To reduce water wastage Water CATEGORY Short Term To achieve reduction in water consumption in processing area Improved water consumption will not only reduce the water bills but also reduce the wastewater which if untreated is an environmental burden. TARGET COMPLETION DATE APPROX Rs.1.7 PAYBACK million SAVINGS PERIOD

DETAILS /STEPS Determination of areas at each machine where outflow water can either be reused in the same process/machine or used at another machine / process. Evaluate the current water inflow rate and compare it with the process requirements. Identify the impact on Quality of process and final product in case of reduction in inflow rate. Based on above, identify the viable options for each machine Determine the additional piping work and storage tanks required. In case of piping work and storage tanks, determine the cost involved at each machine and the amount of water saved and its cost. Seek management approval for piping work/storage tanks. Monitor water outflow rate and calculate cost savings.

RESPONSIBILITY Dyeing and Printing Manager Dyeing and Printing Manager Dyeing and Printing Manager Mechanical Manager Mechanical Manager

Mechanical Manager Energy Manager

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Objective # 9
OBJECTIVE NAME DOMAIN PURPOSE OF OBJECTIVE RESULT OF OBJECTIVE TARGET START DATE APPROX INVESTMENT To develop and implement effective Total Preventive Maintenance System Management Systems CATEGORY Short Term To improve machine energy consumption efficiency and reduce wastages Decreased breakdowns, improved energy consumption TARGET COMPLETION DATE APPROX PAYBACK SAVINGS PERIOD

To be determined

DETAILS /STEPS For each machine identify the electrical and mechanical parameters which needs to be regularly checked on daily, weekly and monthly basis. Focus not only machines but electrical distribution equipments including panels Train machine operators on basic machine cleaning For each breakdown maintenance , maintain the record in terms of stoppages and cost incurred on breakdown maintenance. Implement the preventive maintenance checklist and monitor the reduction in breakdown stoppages. Calculate the energy savings due to reduction in stoppages.

RESPONSIBILITY Mechanical and Electrical Managers

Mechanical and Electrical Managers Mechanical and Electrical Managers Mechanical and Electrical Managers Energy Manager

Objective # 10
OBJECTIVE NAME DOMAIN PURPOSE OF OBJECTIVE RESULT OF OBJECTIVE TARGET START DATE APPROX INVESTMENT To enhance In-process Quality Control based on Quality Plan Management Systems CATEGORY Short Term To reduce reworks at processing Indirect energy saving by improving per fabric consumption due to higher productivity. TARGET COMPLETION DATE APPROX PAYBACK SAVINGS PERIOD Page 48 of 51

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Objective # 11
OBJECTIVE NAME DOMAIN PURPOSE OF OBJECTIVE RESULT OF OBJECTIVE TARGET START DATE APPROX INVESTMENT To develop cost driven based effective Energy Management Information System based on Energy Key Performance Indicators (EnKPIs) Management Systems CATEGORY Short Term To support management in monitoring the cost of energy in relation to overall cost of production and also sponsoring areas for energy conservation. Identification of actual cost impact at each energy production and consumption point. TARGET COMPLETION DATE APPROX PAYBACK SAVINGS PERIOD

Objective # 12-a
OBJECTIVE NAME DOMAIN PURPOSE OF OBJECTIVE RESULT OF OBJECTIVE TARGET START DATE APPROX INVESTMENT To install measuring devices (temperature gauges, flow meters, pressure gauges etc) based on EnKPIs Steam Consumption CATEGORY Long term To support in the implementation of EnMIS and also in monitoring of energy production and consumption efficiency. Cost savings due to identification of areas consuming more energy or inefficient energy producers TARGET COMPLETION DATE APPROX PAYBACK SAVINGS PERIOD

DETAILS /STEPS Based on EnKPIs and EnMIS, identify the points at each machine / equipments where data related to energy production and consumption is required either by installing flow meters, pressure gauges, temperature gauges, Select measuring devices installation points based on material and energy balance approach. Determine the accuracy requirement for each measuring device Select measuring devices Seek quotations Installation of measuring devices Feeding data in EnMIS software and generating reporting containing technical data and financial calculations.

RESPONSIBILITY Energy Manager

Energy Manager Energy Manager Energy Manager Energy Manager Energy Manager Energy Manager
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Objective # 12-b
OBJECTIVE NAME DOMAIN PURPOSE OF OBJECTIVE RESULT OF OBJECTIVE TARGET START DATE APPROX INVESTMENT To engage Energy & Environmental Department Lab of QUEST for energy related testing services based on EnKPIs Steam Consumption CATEGORY Short Term

TARGET COMPLETION DATE APPROX PAYBACK SAVINGS PERIOD

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Implementation Strategy for Energy Management Objectives

Arch Associates recommends that in order to ensure complete and effective implementation of EMOs, a realistic road map based on current financial status of MFTML be developed. We propose to take on those EMO first which require an investment of upto Rs 1 million and less and after achieving savings from these actions, channelize savings in those areas which require investment of more than one million or has high payback period i.e. more than one year.

CONCLUSION: The objectives set for MFTML after being achieved the industry will be conforming to the International Industry Bench marks. The bench marks are identified for textile industry in the report as well. It means MFTML will be amongst the good practicing industries and an example for other textile units operating in the area.

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