2016, IEEE International Conference on Control Computing Communication and Material (ICCCCM-2016),
United College of engineering & research, Allahabad (21-22 October-2016)
Energy Audit in Textile Industry-A Study with
Ring Frame Motor
Saurabh Kumar Rajput
Engineering Division, Northern India Textile
Research Association, Ghaziabad, India
Email: saurabh9march@gmail.com
Abstract - Textile industries use energy both in the
utilities and process. Electrical energy is also used in these
areas. Energy audit provides the scope of energy savings in
different utilities and process of textile industries. Electric
motors contribute to more than 70% of the total electrical
load. Three phase induction motor is prominently used in
the textile industry because of its ruggedness and
versatility. Loss of motor efficiency with operation and
time is a very common problem in textile industry. This
paper deals with scope of energy savings by energy audit
analysis in textile industries. A case study is also included
for comparison of efficiency of old motor with energy
efficient motor. This study would be useful in finding the
areas where the energy can be saved in textile industries,
scope for saving of energy, cost, CO2 emission by replacing
the old rewound/ faulty motors with energy efficient
motors.
Keywords: Textile Industry, Energy audit, three phase
motor, Efficiency
I. INTRODUCTION
The textile sector plays a very important role in
public life because textile industries fulfill the basic
need of human beings that is cloth. Different forms of
energy are used in the process of making cloth and
therefore there is much scope of energy conservation
in textile mills. Since electrical energy also
contributes in the process of making the cloth in
textile industries, there is also large scope of
electrical energy saving in textile process [1].
In the textile industry, there is shortage of
man power because the textile mill machineries
produce dust and noise. These are the reasons;
workers are never interested in working at textile
mills, which compel the management of textile mill
to deploy automated machines. Hence, the textile
machines are becoming automated day by day and
the electrical energy requirement of these automated
machines are also very high [2].
Apart from machinery, electrical energy in
the textile industry is also used as a power source for
lighting, office equipment, cooling and temperature
control systems etc. A composite textile plant covers
spinning process, weaving process and wet
processing in the same site; Figure 1, shows the use
of electricity in different processes of a composite
Omveer Singh
Electrical Engineering Department, Gautam Buddha
University, Greater Noida, India
textile plant. As shown in the figure, spinning
consume 41% of total electricity used by a composite
plant followed by the humidification 19% and
weaving 18%. Rest of the electrical energy is used by
wet processing, lighting and other activities [3].
Others
Lighting
8%
4%
Spinning
Wet- 41%
processing
10%
Humidificatio
n…
Weaving
18%
Figure1 Power map of a composite mill
The major part of electrical energy (41%) is
used in spinning process and also textile industry
uses large number of three phase electric motors in
spinning only. So the major part of electrical energy
is provided to three phase induction motors. In some
cases, motors with a control board controlling are
also used. In textile industries, nearly 70-80% of the
load is carried by three phase induction motors [4].
II. PROBLEM DEFINITION
During the energy audit visit investigators find that
the consumption of electricity in textile sector is
increasing. It is due to the use of large number of
electrical equipments in textile sector. The energy
cost and production cost is around 15% to 20 % and
this comes second to raw material. So investigators
prime focus area now is energy consumption at load
end and by optimizing the energy usage of textile
2016, IEEE International Conference on Control Computing Communication and Material (ICCCCM-2016),
United College of engineering & research, Allahabad (21-22 October-2016)

machines, investigators can have multiple benefits of leakages, install VFD on supply air fan of
fewer units per kilogram of production and health of humidification towers, replace the existing aluminum
machines also enhance. impeller with FRP of pneumatic fans, replace
existing pumps with energy efficient pumps
III. METHODOLOGY
In this section, Figure 2 shows the methodology, Table1 Power distribution in textile mill (Section
which is adopted for achieving the desired energy wise)
savings by energy audit process.
Description Installed, kW Total load ,
%
Blow room 57.78 2.39
Carding 328.60 13.32
Draw frame 609.00 2.48
Comber 60.23 2.41
Speed frame 67.32 2.78
Ring frame 1,159.88 47.12
Autoconer 195.35 7.98
Winder 27.40 1.07
Humidification 285.30 11.56
Plant
Waste collection 46.48 1.85
Figure 2 Energy audit process Buffing 7.50 0.28
Compressor 92.50 3.78
Methodology includes the discussions with Lighting 34.15 1.43
the plant officials to identify the areas for energy Sewage Plant 8.25 0.29
conservations. Energy audit team visits the site, and
Water Pump 19.70 0.76
collects data of operations and distribution of load
within the plant. This collected data is then analyzed Admin Office 10.84 0.48
and a base line is identified to get best possible Total power 1,459.28 100
energy conservation opportunity.
To identify the pattern of energy use and Case Study: Replacement of old motor with new
losses in the system, continuous or time lapse energy efficient motor:
recording is done by appropriate and calibrated During the energy audit visit, it has been found that
energy audit instruments. Actual methodology of the plant is using 30kW, 92% efficiency IE2 motors
energy auditing is presented in Figure 2. in ring frame machines [5]. Plant management is
planning to replace the existing motors with energy
IV. OBSERVATIONS efficient Opti-Power motors (30 kW, 94%
Energy audit was done in one of the leading textile efficiency).
mill. The mill is located in Himachal Pradesh. Energy Flow chart for comparing two motors is as follows
audit team collected data of installed power of the
mill; which is plotted in Table 1 (department wise).
By the help of Table 1, figure 2 is drawn and that
area has recognized where major part of power is
being used and energy can be conserved. From the
collected data it was found that the major powers
saving regions are replacing old ring frame motors
with newer energy efficient motors, optimize the size
of ring frame suction tubes, improve the power factor
from 0.98 to 0.995 and above, replace the broken
suction tube cap of autoconer and using smaller
diameter caps, replace the existing fluorescent tube
lights with LED lights, install a separate lighting
feeder and install voltage stabilizer, prevent the
power loss occurring due to heavy compressed air
2016, IEEE International Conference on Control Computing Communication and Material (ICCCCM-2016),
United College of engineering & research, Allahabad (21-22 October-2016)

the purpose of comparison, name plate efficiencies of

Selection of rewound motor
Measurement of motor parameter
Calculation of motor losses &
efficiency
both motors have considered as their running
efficiencies and calculation has been made.
Following are the detailed calculations:
(Calculations are made by using SIEMENS software)
Table 2 shows the profile of motors which
are under consideration. The motors are four pole,
three phase, 400 volt, 50 Hz, 30 kW induction motor
which are applied in ring frame machine without
ignition protection and the energy price is Rs.
5.80/kWh.

Selection of energy efficient motor

Analyzing the motor for energy

saving

Calculation of parameters:
The parameters of three phase induction motor are
calculated by using the formulas as listed below.
These parameters are used to calculate the power
losses of motor at different stages of power flow from
input to output and motor efficiency is then
calculated by motor input and output powers

120 ×f
Figure 3 Name plate rating of old motor and energy
(a) Synchronous speed, Ns = RPM efficient motor
P
(b) Stator resistance of No-load motor,
T2+235 Table 2 Motor profile
R2 = R1 × Ω
T1+235
(c) Stator copper loss at full load, Motor Profile
Pst = √3 × (Ifull-load)2 × RWatt
Power: Ignition protection:
Stator copper loss at no load,
30kW without
Pst = √3 × (Ino-load)2 × R Watt
Iron and Friction & Windage losses, Pole No: Application :
(d)
Pi + Pf&w = Pno-load - Pst KW 4 Ring Frame
(e) No load slip, Net: Energy Price:
𝑁𝑠−𝑁 3AC/ 400V/ 50Hz ₹ 5.80/kWh
Sno-load (%) = × 100
𝑁𝑠
(f) Full load rotor losses, Table 3 Operation profile of motor
Protor = (Slip × Air-gap power) Watt
(g) Stray loss, Operation Profile
Pstray = 0.015 × Pfull-load Watt
(h) Full load output power, Operation- Motor 2/ 3/ 4/
Pout-put = Pfull-load - Pstray - Protor - Pst KW days / year load 4 4 4
(i) Efficiency at full load, (360)
𝑃
ηfull-load = 𝑜𝑢𝑡𝑝𝑢𝑡 × 100
𝑃𝑓𝑢𝑙𝑙−𝑙𝑜𝑎𝑑
Operation- Power 15 22 30 kW
Theoretical Calculation (IE2 vs IE3): hours / day Output .5
It is not possible to measure the exact motor (23)
efficiency on the shop floor. Hence, it is advised to
test the old motor efficiency on the motor test bed. Operation- Operat 8 14 1 hour/
This will provide the exact power saving by replacing hours / year ing
the existing motor with energy efficient motor. For
2016, IEEE International Conference on Control Computing Communication and Material (ICCCCM-2016),
United College of engineering & research, Allahabad (21-22 October-2016)

(8395) hours day

Table3 presents that the operation profile of

motors under consideration. The motors are running
for 360 days in a year and 23 hours per day so the
total operating hours for motors are 8395 per year.
Also the motors are running at half load
condition for 8 hours, at three-fourth load for 14
hours and at full load condition for one hour (in a
day) so the power output of motors are 15 kW for
half load condition (8 hours), 22.5 kW for three-forth
load condition (14 hours) and 30 kW for full load
condition (1 hour).

Table 3 Load and percentage efficiency of old motor

Reference motor: Existing 30kW
Efficiency class Motor load 2/4 3/4 4/4
IE2 Efficiency 92.6 92.8 92.3
Figure 4 Energy saving graph for old motor and
energy efficient motor
Table 4 Load and % efficiency of energy efficient
motor V. RESULTS AND DISCUSSION
Table 5 and Table 6 show the technical and
Alternative motor: Optipower 30kW commercial results of reference existing motor and
alternative energy efficient optipower motor. The
Efficiency class Motor load 2/4 3/4 4/4 results are compared and energy saving as well as
IE3 cost saving is calculated. The existing motor is
energy efficiency class 2 motor (IE2) and optipower
Motor Price: Efficiency 94.4 94.4 93.6 motor is energy efficiency class 3 motor (IE3), hence
there would not be a substantial power saving by
83,480 replacing IE2 motor with IE3 motor as shown in the
table. Also the CO2 emission saving is 1649 kilogram
annually with payback period of 4.5 years.
Table 3 and Table 4 present the efficiency of
old motor and new energy efficient motor at different Table 5 Technical Results
loading conditions. By the calculation, it is clear that
the efficiency of energy efficient optipower motor is Technical Results Energy Energy
always more than old motor at any load condition. Demand Saving
Figure 4 shows the graphical representation potential
of kilo Watt power requirement of optipower motor Reference motor: 194923
and existing motor and it very clear that power Existing 30 kW kWh/year
required by optipower motor is less than old existing motor
motor at any loading condition throughout the
operating hours of the day Alternative motor: 191720 3202
Optipower motor 30 kWh/year
kWh/year
kW

Table 6 Commercial Results

Commerci Energy Cost Inves Pay
al Results Cost saving tment
back
2016, IEEE International Conference on Control Computing Communication and Material (ICCCCM-2016),
United College of engineering & research, Allahabad (21-22 October-2016)

Reference Rs.
motor: 1130553
Existing 30 /year
kW motor

Alternative Rs. Rs. Rs. 4.49

motor: 1111976 18572 83480 years
Optipower /year /year
motor
30kW

VI. CONCLUSION
In this article, case study depicts that there is a large
scope of energy savings in textile mills and by energy
audit in regular intervals; users can find the areas
where the energy can be saved. Also by replacing the
old rewound/ faulty motors by energy efficient
motors, there is scope for saving of energy, cost, CO2
emission with less payback time.

REFERENCES
[1] M. Singh and J. Gupta, “Efficiency of Rewound
Induction Motors in a Textile Plant: An Analysis,”
International Journal of Electronics Engineering, vol.
3, no. 2, pp. 185– 187, 2011.
[2] Y. Dhayaneswaran and L. A. Kumar, “A Study on
Energy Conservation in Textile Industry,” Journal
Institution of Engineers India Ser. B, vol. 94, no. 1,
pp. 53–60, March–May 2013.
[3] S. K. Rajput and P. Godhar, “AC Motors Burn
out in Textile Industry - Causes and Impact on Motor
Performance,” 56th Joint Technological Conference,
SITRA, Coimbatore, 2015.
[4] H. W. Penrose, Financial Impact of Electrical
Motor System Reliability Programs, All-Test
Division, BJM Corporation, 2003.
[5] S. H. John and D. K. John, “Comparison of
Induction Motor Field Efficiency Evaluation
Method,” IEEE Transactions on Industrial
Applications, vol. 34, no. 1, January/February 1998.