<p>Raymond Limited's Textile Division-Chhindwara, in Madhya Pradesh, situated at Boregaon Industrial Growth Centre is a flagship company of the JK Group (Western Division). It manufactures high quality, up-market fabric in polyester-wool and polyester-viscose blends. A subsidiary unit manufactures furnishing fabric. The daily production is around 40,000 m of finished fabrics. The Finishing Department is considered as one of the largest of its kind in Asia with modern hi-tech machinery. Raymond achieved 95.5 percent capacity utilization in 1998–99, which is considered very high in the textile sector. The turnover of the company is Rs 10,000 million per annum.</p></sec><sec id="sec002"><title>Energy Consumption

With the help of benchmarking and historical analysis (called regression analysis), it was found that the unit has achieved better specific energy consumption despite increase in nonproductive connected load. The specific energy consumption for the year 2000–2001 was 4.53 kWh/m of fabric. The increase in specific consumption was due to increase of non-productive connected load by 999 HP. During the year 2002–03, with judicious and effective use of energy, the unit minimized the specific consumption to 4.00 kWh/m of fabric. See Table 1. Table 1

Specific consumption of energy

Description	Unit	2000–01	2001–02	2002–03

Electrical energy	kWh/m	4.53	4.12	4.00
Thermal energy	kCal/m	5197.29	4922.51	4915.28
Total manufacturing cost	Rs in lakh	19638.36	19646.09	18805.97
Total energy bill	Rs in lakh	2716.36	2632.63	2614.89
Energy as % of total cost of production		16.05%	15.47%	13.90%

Table 2

Energy Cell achievements over the years

Year	Energy Saving		Investment Rs. in lakh

	(lakh kWh)	Rs. in Lakh

2000–2001	2.96	54.87	12.74
2001–2002	6.17	192.78	45.49
2002–2003	35.52	179.02	53.49
TOTAL	44.65	426.67	111.72

Payback period for the Investment = 3.14 Months 10 lakh = 1 million

Table 3

M/C: TFO NO 10 P/W SPG

Spindle Speed – 9000									Count-60

Date	Status	Hour Meter Reading in Star Mode	Hour Meter Reading in Delta Mode	Running Hours in Star Mode	Running Hours in Delta Mode	kWh Meter Reading Mf-5	Unit Consumption	Unit Consumed Per Hour	Saving Per Hour

August 1, 2002	Without Del Star Converter	3191.90	487.61			23524.5
August 2, 2002	Without Del Star Converter	3191.92	510.89	0.02	23.28	23586.7	311	13.35
									2.13
August 3, 2002	Without Del Star Converter	3224.53	510.99	23.7	0.05	23644.9
August 4, 2002	Without Del Star Converter	3248.23	511.04			23698.2	266.5	11.22

Table 4

M/C: TFO NO 11 W–SPG (T1)

Spindle Speed – 7000									Count-28

Date	Status	Hour Meter Reading in Star Mode	Hour Meter Reading in Delta Mode	Running Hours in Star Mode	Running Hours in Delta Mode	kWh Meter Reading Mf-5	Unit Consumption	Unit Consumed Per Hour	Saving Per Hour

August 18, 2002	Without Del Star Converter	10781.65	20792.08			3567.05
August 20, 2002	Without Del Star Converter	10781.66	20836.48	0.01	44.4	3595.65	572	12.88
August 20, 2002	Without Del Star Converter	1078.66	20836.48			3595.65
August 20, 2002	Without Del Star Converter	1111.42	20844.55	32.76	8.07	3617.35	434	10.62

Note: On 40 HP motor of TFO M/C in the P/W SPG Department

Table 5

M/C: TFO NO 5 PW-SPG

Spindle Speed – 9000									Count-60

Date	Status	Hour Meter Reading in Star Mode	Hour Meter Reading in Delta Mode	Running Hours in Star Mode	Running Hours in Delta Mode	kWh Meter Reading Mf-5	Unit Consumption	Unit Consumed Per Hour	Saving Per Hour

September 13, 2002	Without Del Star Converter	3410.63	1000.45	4402.21
August 20, 2002	3410.65	1046.26	0.02	45.81	5113.88	711.67	15.52	NIL

Note: Due to more loading of motor, no savings were observed.

Table 6

M/C: TFO NO 10 W–SPG (T3)

Spindle Speed – 7500									Count-80

Date	Status	Hour Meter Reading in Star Mode	Hour Meter Reading in Delta Mode	Running Hours in Star Mode	Running Hours in Delta Mode	kWh Meter Reading Mf-5	Unit Consumption	Unit Consumed Per Hour	Saving Per Hour

August 18, 2002	Without Del Star Converter	1475.65	1629.5			3726.02
August 20, 2002	Without Del Star Converter	1475.69	1728.7	0.04	99.2	3786.68	1213.2	12.22
									1.45
August 20, 2002	Without Del Star Converter	1373.30	1629.4			3670.84
August 20, 2002	Without Del Star Converter	1475.65	1629.5	102.35	0.1	3726.02	1103.6	10.77

Table 7

Summary of study on four machines

Machine No.	Saving/Hr	Running Hours in Saving Mode/Day	Total Annual Saving (for 357 Days @ Rs 4.40/unit) in Rs/Annum	Investment (in Rs)	Payback Period

PW-TFO-5	Nil	Nil	Nil	10,818	–
PW-TFO-10	2.13 KW/HR	23	76,953	10,818	2 Months
T1-TFO-11	2.26 KW/HR	16	56,800	10,818	3 Months
T3-TFO-10	1.45 KW/HR	23	52,386	10,818	3 Months
Average Saving Per Machine	46,534	10,818	Approx. 3 Months

Saving per machine – Rs 46,534 per Annum @ RS 4.40/unit

Table 8

Installation of Delta Star Converter on 40 HP/50 HP motor on TFO m/c at PW-Spg PV-Spg W-Spg Department

Department	TFO No. * (PV Spg - 50 HP Motor) * (PW/W. Spg -40 HP Motor)	Saving in kWh/Annum	Saving in Rs/Annum	Investment

PW Spg	1 to 16 no m/c	391,308 kWh	1,721,758	Rate of Delta star converter Rs 10, 818 per piece Total Rs 400,266
PV Spg	1,2,4,7,5
W-Spg-T1 Shed	11
W-Spg-T1 Shed	1,2,3,4,7,8,9,10
W-Spg-T3 Shed	1,2,3,7,8,10,11
Total 37 Nos.

Figure 3Specific energy consumption in kWh/mtr

Figure 4Energy cost as a percent of total manufacturing cost

Energy Conservation Commitments, Policy and Set-up

The unit is committed to monitor continuously the savings achieved and reduce specific energy consumption by 1 percent every year up to 2010. A clear-cut strategy has been formulated for energy conservation, which includes:

Formation of an Energy Conservation Cell (ECC)

Day-to day monitoring of energy consumption pattern and give it to user departments

Calculation of specific energy consumption on monthly basis and comparing it with own benchmarking

Adoption of newest/latest technologies with automation feasibility

Implementation of energy conservation projects

Conducting of Energy Audit (by internal team as well as through external agencies)

Formation of Small Group Activities for energy conservation. Creating awareness among the employees through various programs, competition and suggestion schemes

ROI analysis

Raymond has an ECC at the corporate level as well as at individual unit levels headed by the general manager–engineering, who reports to the works director and vice president (Textiles).

An energy manager coordinates the activities among the ECC members, constituting staff from all streams of engineering. The present team consists of six dedicated engineers. All members in the ECC are constantly conscious about energy saving wherever feasible. The ECC is equipped with advanced instruments such as Energy and Hour Meters, Load Managers, Pyrometers, Lux Meters, Anemometers, Tachometers, Stroboscopes, Flue gas analyzers and See-Tech software packages.

Once the ECC members identify an energy saving potential, they collect and analyze the data for calculating the benefits. This is followed by trials conducted on machines and close monitoring of energy being saved for some time. A detailed report of savings, investment and ROI and other achievements is prepared. Subsequently, the project is implemented.

The implementation of the energy conservation project through the ECC is given the highest priority. Implementation of the project is followed by close monitoring on saving patterns through one year. Best practices at all units are shared. Internal audits are also conducted between the units.

In addition, small teams are formed in various departments to work on the shop floor for energy conservation. Suggestions by this team are implemented with the help of the ECC. Till date the results from this team initiative have been encouraging.

Initiative 1: Modification of Compressed Air PipelineProject background

The basic aim of the project was to find ways in which the right kind of power can be supplied to user point with the minimum leakage, loss in pressure, and at the lowest operating cost. Compressed air is one of the most expensive sources of power since compressors are only 5–20 percent efficient. Hence, leakage should not exceed 5 percent of the total capacity. Besides, pressure drop at end point should not exceed 10 percent of discharge pressure.

System description

The system consists of seven lubricated screw compressors (Atlas Copco make), with a capacity of 478 CFM each, of associated 1050 HP.

Observation made

The existing pipeline proved undersized as the number of machines utilizing high-pressure air increased to meet the demand for enhanced quality and production. This increased the demand for compressed air.

The increased air demand created high-pressure drop at the user end. This compelled the Unit to run compressors at high pressure, which increased power consumption in the compressor, air leakage in pipelines, and maintenance costs due to high wear and tear of compressor and accessories. The peak demand for air was 3,092 CFM. Modified compressed air line

Technical and financial analysis

A new network of piping was installed. Air receivers were provided for intermediate and intermittent demands (possible at the end of long lines), which otherwise can cause serious pressure lost at such points. By installing air receivers as close as possible to the demand point, power storage could be increased, and thus reduce pressure drop. The compressor–dryer–receiver layout was changed to compressor–receiver– dryer, which considerably reduced the load on the dryer.

After implementing the above pipeline modifications, we have reduced the cut of pressure from 133 PSI to 110 PSI by which we could save considerable amount of power.

Initiative 2: Reduction in Power Consumption by Vfds in Humidification Plant during the Winter SeasonProject background

Humidification plants provide the required condition to user departments. Temperatures in Chhindwara can dip to 10°C during winters. Inverters are installed for providing the required airflow to the user department.

Power consumption before modification

May 31 to July 14, 2002
Total consumption	: 481,637 units
Number of days	: 45
Average consumption/day	: 10,703 units
Power consumption after modification
August 16–28, 2002	: 124,161 units
Average unit consumption/day	: 8,868 units
Savings in unit consumption/day	: 1,835 units
Savings in Rs per annum @ Rs 4.25 for 357 days	: Rs 2,784,153
Investment	: Rs 25 lakh
Payback	: Less than one year.
Implementation	: Since August 2002

Observations made

In winters, ambient temperatures become less. By regulating airflow, the required condition could be maintained. Inverter settings were managed as per the ambient condition. Settings were closely monitored and altered as required.

Initiative 3: Energy Saving by Installing Auto Del Star Converter on 40 HP Motor of TFO M/C at PW Spinning DepartmentProject background

In any industries electrical motors accounts for 55 percent to 60 percent of the electrical energy consumption. Induction motors operate efficiently as long as they loaded up to 60 percent to 85 percent loading. When these motors are operated below 50 percent loading, the efficiency and power factor is very low.

Observation

In TFO machines installed in the Spinning Department, several motors are run at less than 50 percent loading. During less than 50 percent loading, it is preferable to run the motor in star instead of delta mode.

Technical and financial analysis

Power consumption April-September 2002 (Summer)	: 2,636,601 units
Power consumption October 2002–March 2003 (Winter)	: 2,280,598 units
Net power saving	: 356,003 units
Net saving in Rs	: 3.56 lakh units @ Rs 4.30 per unit = Rs 15.13 lakh
Implemented for the period October 2002–March 2003

Technical and financial analysis

Advantages of running the motor in star mode when loading is less than 50 percent. The voltage across the winding reduces to 58 percent of rated voltage and line current reduces to onethird. Reduction in iron and copper losses reduces power consumption.

Improvement in power factor and efficiency

Energy saving from 5 to 35 percent, depending on percent loading of motors (No load to 50% loading. At 50% load, minimum saving and at no load maximum saving).

Decrease in line current gives additional saving and reduces losses in cable and switch gears.

Energy efficiency initiatives in Raymond's Textile Division in Chhindwara