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					Resource Conservation
         at
  TTBG (Utilities)


                        1
       RESOURCES OF UTILITIES


                    Water




Resource

                                Fuel

                  Energy

                                Power

                                        2
                  Summary of improvements in Utility


S.         Area              Saving/Year        Saving/Year
No.                          ( 2007~08 )        ( 2008~09 )

1     Power (Lac kWh)             18.0                 16.77


2     Fuel (KL)                   825                  368.65


3     Water (m3)                 74825              159870
                              (205 m3/day)       (438 m3/day)




                                                                3
Power Conservation
        at
 TTBG (Utilities)


                     4
                      Yearly KWH / MT Trend and 08-09 projection

                                                                                       Projected
                                                                                       KWH/M
     4200                                                                              T is based
                                                                                        on Apr -
     4100                                                                                 08 to
                                                                                         Feb-09
     4000                                                                                Actual
                                                                                          data
     3900
     3800
     3700
     3600
     3500
     3400
     3300
     3200                                                                                    2008-09
              2000-01   2001-02 2002-03*   2003-04   2004-05   2005-06   2006-07   2007-08
                                                                                              PROJ
   KWH / MT    3982      4168     3885     3831.9     3778      4025      3778      3663       3567


There is continuous reduction in KWH/ MT except
                                                                                                       5
in 05-06 as there was expansion of the plant
              23000.0
                        24000.0
                                  25000.0
                                            26000.0
                                                      27000.0
                                                                                  28000.0
                                                                                                                                29000.0
          1
          2


                                                                                                                                                                                                                                                                                                        SN
          3
          4
          5
          6
          7




                                                                                                                                                                                           2
                                                                                                                                                                                                                                       1


                                                                                                                                                          3
          8
          9
         10
         11
         12
         13
         14
         15
         16
         17
         18
         19
         20




May-07
         21
         22
         23




                                                                                                                     Stopped
         24
         25
         26




                                                                                                                   3 PSA Plant
         27
         28
         29
         30
         31
          1
          2
          3
          4
          5
          6
          7
          8
          9
         10
         11
         12
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         16
         17
         18




Jun-07
         19
         20
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         22
         23
         24
         25
         26
         27
         28
         29
         30
          1
          2
          3
          4
          5
          6
          7
          8
          9
         10
         11
         12
         13
         14
         15
         16
         17
         18




Jul-07
         19
         20




                                                                                                                     kg/cm2
         21
         22
         23
                                                                                                                                                                                                                                                                                                        Improvement




         24
         25




                                                                    kg/cm2
                                                                                                                 Pr. 10.2 to 9.6
         26
         27
         28
         29
         30




                                                                Pr. 10.2 to 9.4
         31
          1
          2
          3
          4
          5
          6
          7
          8
          9
         10
         11
         12
         13
         14
         15
         16
                                                                                                                                                                                                                                                                               (through Silver PSP-1)




         17
         18
         19
         20




Aug-07
         21
         22
         23
         24
         25
         26
         27
         28
         29
         30
         31
          1
          2
          3
                                                                                                                   kg/cm2



          4
          5
          6
          7
                                                                                                                Pr. 9.8 to 9.2




          8
          9
         10
         11
         12
         13
         14
         15
         16
                                                                                                                                          Actual power
                                                                                                                                                          Stoppage of 3rd nitrogen plant




         17
         18
         19




Sep-07
         20
         21
         22
         23
         24
         25
         26
         27
         28
         29
         30
          1
          2
          3
          4
          5
          6
          7
          8
          9
         10
         11
         12
         13
         14
         15
         16
         17
         18
         19




Oct-07
         20
         21
                                                                                                                                                                                                                                       Reduction in Compressed Air Pressure




         22
         23
         24
         25
         26
         27
         28
         29
         30
         31
          1
          2
                                                                                                                                                                                           Reduction in air pressure modulation band




          3
          4
          5
          6
          7
          8
          9
         10
         11
         12
         13
         14
         15
         16
         17
         18
         19




Nov-07
         20
         21
         22
         23
         24
         25
         26
         27
         28
         29
         30
          1
          2
          3
          4
          5
          6
          7
          8
          9
         10
         11
         12
         13
         14
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         16
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         19



Dec-07
         20
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         29
         30
         31
          1
          2
          3
          4
          5
          6
          7
          8
          9
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         16
         17
         18
         19
Jan-08



         20
         21
         22
         23
         24
         25
         26
         27
                                                                                                                                          Monthly Power




         28
         29
                                                                                                                                                                                                                                                                                                                      Power conservation in Air compressors




         30
         31
          1
          2
          3
          4
          5
          6
          7
          8
          9
         10
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         12
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         14
                                                                                                                                                                                                                                       2496


                                                                                                                                                          1368




         15
         16
         17
         18
Feb-08




         19
         20
                                                                                            venting from Dryer




         21
         22
         23
         24
         25
                                                                                                                                                                                                                                                                               KWh/day




         26
         27
         28
         29
          1
          2
          3
                                                                                                                                                                                                                                                                              Power saving




          4
          5
          6
          7
          8
          9
         10
         11
         12
         13
         14
                                                                                            07 is high due to continuous air




         15
         16
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         18
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         20
Mar-08




         21
         22
         23
         24
         25
                                                                                            Average Power Consumption in Aug-




         26
          6




         27
         28
         29
         30
         31
              Power conservation in Refrigeration
SN   Improvement                                           Power saving
     (through Silver PSP-2)                                  kWh/Day
                                                          ( Year Average)
1    Power consumption reduced in refrigeration      7427 ( Low power consumption
     plant by increasing efficiency of Electrical     equal to 1171 kwh due to low
     chiller and increasing utilization of VAM      production in Dec’08 & Jan’09 is
     machines .                                              not considered )




                                                                                       7
                           Power reduction in refrigeration system                           2008-09



                         Power conservation in Refrigeration system




Increasing refrigeration efficiency                   Reducing refrigeration requirement




Maximum TR generation      Increasing Efficiency of    Optimize department   Identify and stop conditioning of
through VAM                electrical chiller          condition             non critical area




                                                                                                         8
                                             Journey of continual power reduction in refrigeration system


Better
                                                 Operation of Electrical chiller machine at fresh air
                                                               enthalpy-17 Kcal/kg
                                                                                                                          Budgeted for May
                                                                                                                          2008~09- 2.4 nos
                                                                                                                          elect chiller
 Nos. of electrical chilling machine




                                         5             4.7
                                       4.5
                                         4                                       3.5
                                       3.5
                                         3                                                               2.6
                                       2.5
                                         2                                                                                            1.7
                                       1.5
                                         1
                                       0.5
                                         0
                                               Before Installation of   With one VAM(2007~08) Operation of three VAM        After modiification in
                                                 VAM 2006~07)                                (after installation of CHW    cooling water system (
                                                                                             Boosting system for poly            May 2008)
                                                                                                                                  June end
                                                                                                   )-April 2008~09
                                                                             Improvement activities




                                                                                                                                                     9
  Refrigeration Power consumption & Fresh air Enthalpy (Budget Vs Actual)


                             Actual power
                            consumption is
                              less due to
                            lower enthalpy




                                                                                                                                   •Maximum
                                                                                                                                   benefit in power
                                                                                   E
                                                                                                                                   saving will be
                                                                                         s                                         during monsoon
                                                                                         t                                         period.
                                                                                         .
                                                                                                                                   •Expected Saving
                                                                                  A
                                                             Average         Enthalpy
                                                                                  c                                                for the year of
                                                                                  t                                                2008-09 is 20 Lac
                            21                                                    u
                            20                                                    a
                                                                                                                                   KWh
                            19
                            18                                                    l
   Enthalpy (KCAL/Kg)




                            17
                            16
                            15
                            14
                            13
                            12
                            11
                            10
                             9
                             8
                             7
                                  Apr        May     Jun      Jul    Aug     Sep       Oct     Nov    Dec    Jan    Feb    Mar

                        2008-09   12.30      14.80   19.03   19.93   19.81   18.51     14.4    10.5   9.8    8.7    9.5
                        2007-08   12.90      15.30   18.50   19.80   19.50   17.80     11.60   9.90   7.90   7.40   8.00   11.50




Inspite of higher enthalpy ,the power cons is lesser .                                                                                          10
             Power conservation in other utility Areas
SN   Improvement                                             Power saving
                                                               kWh/day
1    Optimization of cooling water consumption in process.       396
2    Resizing of DG cooling tower pump with smaller              312
     capacity.
3    Replacement of dynodrives with invertors                    360


4    Optimization of air flow in new yarn plant (inverter        168
     room)
5    Modification in condensate transfer system for MCPL         120


6    Installation of diffused Aeration System in Aeration        550
     tanks of Effluent treatment plant.


Total Power saving achieved from above is at 1906 kwh/day.
                                                                            11
Fuel Conservation
       at
TTBG (Utilities)


                    12
                              Reduction in Fuel consumption
SN Improvement                                                    Fuel Saving KL/day
1     1)Improved fuel generation ratio in steam boiler (from                   2.95
      budgeted value13.0 to 14.8)
      2)Reduction in steam peak load duration by rescheduling
      the distillation cycle in Poly
      3) Reduction in steam consumption
      4)Reduction in transportation losses
2     Increased the efficiency of Thermic fluid heater                         1.01
                                 Total saving (KL/day)                         3.96
                                  F.O. Fuel Consumption
                                                                              BETTER
               10

               8              8.82
    KL / Day




               6                                                   2.5 KL/day saved due to
                                                                   TFH stoppage is included
               4

               2
                                                                 2.36
               0
                            2007~08                      2008~09(upto Feb'09)
                                                                                              13
Water Conservation
        at
 TTBG (Utilities)


                     14
                                                                      Water conservation
SNo          Improvements                                                                                                                    water saving
                                                                                                                                               m3/day
  1          a) Reduction in effluent water quantity                                                                                                     205
             b) Recycling of low COD water (AW condensate water,
             Blow down water)
  2          Utilization of waste water (including treated effluent)for                                                                                  438
             reproducing de-mineralized water .
                                                                                  Total Saving (M³/day)                                                  643

                                                                                                                                                Recycling of vacuum
                                                                                                                                                pump’s cooling water
           1500
                              Previous
           1400                 Year                                                          Production                                                                      Current
                                                                                               capacity
                                                                                              expanded                                                                         Year
           1300
                                                Water consumption reduced
                                                      by various water
m3 / Day




           1200
                                                conservation activities like
                                                     installation of drip
           1100                                   irrigation, recycling of
                                                 process cooling water etc
           1000

           900                                                                                                                      PTRO
                                                                                                                                 commissioned in
           800                                                                                                                      Nov’09


           700




                                                                                                                                                               Apr ~ Sep-08

                                                                                                                                                                               Oct'08 to
                  1996-97


                            1997-98


                                      1998-99


                                                  1999-00


                                                            2000-01


                                                                        2001-02


                                                                                    2002-03


                                                                                                   2003-04


                                                                                                             2004-05


                                                                                                                       2005-06


                                                                                                                                   2006-07


                                                                                                                                               2007-08




                                                                                                                                                                                Feb'09
                                                                                                                                                                                      15
                  Way forward

• Possibility of further reduction in power consumption in
compressed air system
•Optimization of use of air conditioning equipments
•Possibility to stop cooling water return pumps in
spinning




                                                             16
THANKS

         17
                        Diffused aeration system                                2008-09
Membrane
                                             •     In fine bubble diffused aeration,
                                                   compressed air is released through 0.6
Patented                                           mm holes in diffuser lines placed just
 clip-in
  Joint                                            above the bottom of aeration tank. The
            Collar to
                                                   rising bubbles transfer oxygen to the
           avoid fold                              water, as well as transport bottom
               of                                  water to the surface.
           membrane
                                             •     While in surface aeration, water is
                                                   rotating with the help of mechanical
                                                   agitators, during this operation, only
                                                   the surface water comes in contact
                                                   with atmospheric air and absorbs
                                                   oxygen.
                                             •     The efficiency of diffused aeration
                                                   system is high ( 17 % at 3.5 height )
                                                   whereas efficiency of surface aerator
                                                   is ( 5% at same height)
                                             •     This will replace 22 kw x 2 nos.
                                                   surface aerator with only one 22 kw
                                                   blower .
                                             Expected saving in kwh/day :550




                                                                                      18
Air Compressor – G Trend With and Without inverter

        Air Compressor for Loom ( With & without Inverter)                                                     KWH             NM3( 7.5 PA+ IA)            KWH/NM3

35000                                                                                                                                                 32185                 0.180
                                             30137                    29708     30206                   29858       29989       29665
                     29006                                                                  29388                                          33301                 29490      0.160
30000    28149                    27751                   28265
                                              0.154                   0.155     0.153
                     0.159                                0.157                                                                                                             0.140
          0.169                   0.159
25000                                                                                                                           0.138
                                                                                                                    0.131                                         0.128     0.120
                                                                                                        0.126
                                                                                                                                           0.118       0.121
20000                                     Without Inverter                                                                                                                  0.100
                                                                                            0.106

15000                                                                                                                                                                       0.080
                                                                                                             With Inverter
                                                                                                                                                                            0.060
10000
                                                                                                                                                                            0.040
          4747        4598        4424        4635        4430        4608       4623
                                                                                                        3760        3919        4101        3931       3889       3777
5000                                                                                        3114
                                                                                                                                                                            0.020

   0                                                                                                                                                                        0.000
         2/18/2009   2/19/2009   2/20/2009   2/21/2009   2/22/2009   2/23/2009 2/24/2009   2/25/2009   2/26/2009   2/27/2009   2/28/2009   3/1/2009   3/2/2009   3/3/2009




                      SAVINGS OF 23 KW/HOUR WITH INVERTER

                                                                                                                                                                            19
                    Water Conservation
Plate and tube type reverse osmosis plant installed for treatment of waste and
reutilized in process (Saving is approx 240 m3/day)




                                                                                 20
                       Problem faced during 2007~08



Low VAM output :-
•   Low Hot water temperature
•   Low chilled water pressure in poly while VAM is operated (without electrical
    chillers)
•   Low chilled water return temperature as load shared by electrical chiller
    machine .




                                                                                   21
  Tree diagram for increasing Refrigeration generation through VAM
                                         Insulation on Hot
                                         water line -MCPL
                   Increase Hot
                   water
                   temperature            Utilize additional heat
                                          of steam condensate


                                          Utilize additional heat
                                          of flue gas of MCPL
                                          Engines

                                           Increase chilled water
                                           return temperature

Increase
Refrigeration      Increase
Generation TR      Chilled water
through VAM        load on VAM



                                           Optimising CHWS
                                           temp. from Elect M/c

                                          Install boosting pump
                                          in poly-I
                    Increase
                    Chilled water
                    Pressure at
                    Poly I & II          Increase boosting pump
                                         capacity in poly-II

                                       Optimise cooling water
                                       temperature
                    Increase the
                    efficiency of
                    cooling water

                                       Optimise cooling water
                                       flow

                                                                     22
                                              Summary of actions to increase TR of VAM
S                Possible solution                 Area                                        Status                                                Results
N
1   Insulation on hot water line                  MCPL      Area wise joint inspection by SRF and MCPL was carried out and                 Hot water temperature
                                                            identified un-insulated lines were insulated .                                 increased by 3 deg cent.

2   Utilize the heat of steam condensate          Near      Heat of condensate water was transfer to increase the temperature of hot       Increased hot water
                                                  VAM       water by taking PHE in line                                                    temperature by 1.0 oC

3   Utilize additional heat of flue gases .       MCPL      •DOB approval to be taken for commissioning of PHE (Drawing has been
                                                            submitted ,
                                                            •PHE capacity to be increased (Po is released, Expected delivery is first
                                                            week Oct-08 )
                                                            •Steam generation to be increased by utilizing the heat of flue gases and to
                                                            be further utilized for generating hot water through PHE



4    Increase return chilled water temperature    VAM       •Chilled water return temperature was checked at individual source             Delta ‘T’ of the VAM
    to VAM                                                  •CHW return temp at air washers outlet was high (~14 deg cent)                 Increased by 1.0 oC which
                                                            •Return line of new textile Air washers was connected with VAM return          resulted in increased TR
                                                            line .                                                                         generation through VAM




5   Install chilled water boosting pump –Poly     Poly II   Chilled water boosting pump was installed                                      Pressure at Poly Plant II
    II                                                                                                                                     increased from 4.5 to 6.5
                                                                                                                                           kg/cm2
6   Increase capacity chilled water boosting      Poly I    Higher capacity pump was placed from 20 Mtr head to 50 mtr head                Pressure at Poly I increased
    pump –Poly I                                                                                                                           from 4.8 to 5.5 kg/cm2
7   Optimize cooling water temperature                      Not considered                                                                               -
                                                  VAM
8   Optimize cooling water flow                   VAM       Not considered                                                                               -
                                                                                                                                                                23
Chilled water boosting pump Poly II      Chilled water boosting pump Poly I




 PHE of steam condensate at VAM        Return Chilled water line of Twisting air
                                      washer Plant-2 connected with VAM chilled
                                                     water header




                                                                                   24
Schematic diagram of chilled water after implementation of improvement activity
                                                              AIR WASHER




                                                                                                            PHE


                            Chilled water circuit
                                                                               Plant-1


                                                                                                                          condensate
  C                               Close
  H
                                                                    A      B       C
  IL
  L                                   open                                                                  Proposed PRV
  E                                                                                      Close                  station
  R                                                                        VAM
                                                                                                                  Steam
                                                                                                                  to SRF
                                                                                         Hot water
                                                                                                            @ 12 kg/cm²
                 Plant-II             Twisting Air washer 4,5,6,7
                                                                                                     MCPL




           Modification carried out
            Proposed Modification




                                                                                                                               25
 Journey of continual power reduction in refrigeration system
                     Improvement in VAM




TR generation increased after implementation of improvement activities
                                                                         26
                              Improvement in Electrical chillers




                     Month wise Chiller power consumption & Ave Enthalpy

         0.8                                                                  25
         0.7




                                                                                   Ave Enthalpy (K- Kal/kg)
                                                                              20
         0.6
         0.5
KWH/TR




                                                                              15
                                                                                                              KWh/TR
         0.4
                                                                                                              Avg Enth
         0.3                                                                  10
                           Avg power cons per TR
         0.2                         0.73
                           (Area for improvement )                            5
         0.1
          0                                                                   0
                Apr May Jun    Jul   Aug Sep Oct      Nov Dec Jan   Feb Mar
                                              Month




               KWh/TR is high during Monsoon season due to high fresh air enthalpy

                                                                                                                         27
   Tree diagram for reducing power consumption of electrical chillers

                                           Increasing cooling
                                           tower approach
                      Increase
                      condensers
                      efficiency
                                           Increase size of
                                           condensers/Modify condenser
Reducing power
consumption of       Max. utilisation of
electrical Chiller   VAM
during peak season




                      Using Pinch
                      Technology




                                                                         28
              Action to reduce power consumption of Electrical Chillers


SN       Possible solution       Area                             Status                                     Results
1.   Increasing cooling tower   Utility   •Process cooling water system was optimized               Utility Cooling tower
     approach                   Cooling   ( Cooling water supply started to Poly I & II from        approach (utilized for
                                tower     cooling tower no. II in place of cooling tower I & II )   chillers) improve from 5 to
                                          •Interconnection of utility cooling tower and process     3 deg, which increased the
                                          cooling tower was carried out .                           efficiency of the Electrical
                                          •Separation of cooling water system for compressed air    chiller
                                          and chillers was done
                                          ( with above modifications Process cooling tower I
                                          used for Air compressor ,Nitrogen plant )
2.   Maximum utilization of     Utility   Explained in previous slides
     VAM

2    Clean condensor            Utility   Cleaned the condenser                                     No change in efficiency of
                                                                                                    chiller was noted .

3    Pinch Technology           Utility   Not considered .                                          -




                                                                                                                           29
          Chiller - A
          Chiller - B                                 Air Comp. A

          Chiller - C                                 Air Comp. B

          Chiller - D                                 Air Comp. C

          Chiller - E                                 Air Comp. D




Poly-I
          Chiller - F                                 Air Comp. E
                                                      Air Comp. F
          Dryer - A
                                                      Air Comp. G
          Dryer - B

          Dryer - C

          Dryer - D
                                                                    Nitrogen
          Dryer - E                                                  Plant
                                                                                                             UTILITY COOLING TOWER




Poly-II
                                                                                                                                     Cooling water distribution system




                        PROCESS COOLING TOWER – 2ND




    30
                                                                               PROCESS COOLING TOWER – 1ST
                                                                                                                                Cooling water distribution system after first modification
                                                                                                                                                                                     UTILITY COOLING TOWER                                  Stand-by
                                                                                                                                                                                                                                        PROCESS COOLING TOWER – 1ST




                                                                                                                                                                  Nitrogen
                                                                                                                                                                   Plant
                                                                                                                                                                                                                                Close




                                                                                                                                                                                                                                        Close      Close      Close
              Air Comp. A




                                                                                                                            Air Comp. G
                                                                   Air Comp. D
                                Air Comp. B
                                                 Air Comp. C


                                                                                    Air Comp. E
                                                                                                      Air Comp. F




                                                                                                                                                                                                                                        Close



                                                                                                                                                                                               Modification was carried out       PROCESS COOLING TOWER – 2ND
                                                                                                                                                                                               for utilizing only one process
                                                                                                                                                                                                cooling tower for both poly
                                                                                                                                                                                                           process
                                                                                                                                                                                                        Modification
                                   Chiller - C
                                                     Chiller - D
Chiller - A
                  Chiller - B




                                                                      Chiller - E
                                                                                        Chiller - F




                                                                                                                                                 Dryer - C

                                                                                                                                                             Dryer - D
                                                                                                                Dryer - A

                                                                                                                                     Dryer - B




                                                                                                                                                                         Dryer - E




                                                                                                                                                                                                              Open



                                                                                                                                                                                                                  Open

                                                                                                                                                                                                                                                              31
                                  Poly-I                                                                                                                                                                 Poly-II
                                                                                                                            Cooling water distribution system after second modification
                                                                                                                                                                                                             UTILITY COOLING TOWER

                                                                                                                                                                                                                                                           PROCESS COOLING TOWER – 1ST




                                                                                                                                                                          Nitrogen
                                                                                                                                                                           Plant
                                                                                                                                                                                                                                                        Open




                                                                                                                                                                                              Close
Close
                      Air Comp. A




                                                                                                                                    Air Comp. G
                                                                           Air Comp. D
                                        Air Comp. B
                                                         Air Comp. C


                                                                                            Air Comp. E
                                                                                                              Air Comp. F




                                                                                                                                                                                                                                                               Open
                                                                                                                                                                                                      Open


                                                                                                                                                                                                         Open
                                                                                                                                                                                 Close                                   Modification carried out in     PROCESS COOLING TOWER – 2ND
                                                                                                                                                                                                                         Feb’08 for utilising process
                                                                                                                                                                                                                             cooling tower I for
                                                                                                                                                                                                             Close       compressed air system and
                                                                                                                                                                                                                                 N2 system
                                           Chiller - C
                                                             Chiller - D
        Chiller - A
                          Chiller - B




                                                                              Chiller - E
                                                                                                Chiller - F




                                                                                                                                                         Dryer - C

                                                                                                                                                                     Dryer - D
                                                                                                                        Dryer - A

                                                                                                                                             Dryer - B




                                                                                                                                                                                  Dryer - E




                                                                                                                                                                                                       Closed
                                                                                                                                                                                                                                Modification
                                                                                                                                                                                                                                Open




                                                                                                                                                                                                                                        Open

                                                                                                                                                                                                                                                                                  32
                                          Poly-I                                                                                                                                                                                 Poly-II
                                                                                                                                    Cooling water distribution system after third modification
                                                                                                                                                                                                UTILITY COOLING TOWER

                                                                                                                                                                                                                                                 PROCESS COOLING TOWER – 1ST


                                                                                                                                                                                                                                          Open




                                                                                                                                                                          Nitrogen
                                                                                                                                                                           Plant




Close
                      Air Comp. A




                                                                                                                                    Air Comp. G
                                                                           Air Comp. D
                                        Air Comp. B
                                                         Air Comp. C


                                                                                            Air Comp. E
                                                                                                              Air Comp. F




                                                                                                                                                                                                            Modification carried out In      PROCESS COOLING TOWER – 2ND
                                                                                                                                                                                                            May’08 for Water and heat
                                                                                                                                                                                                            balance during operation of
                                                                                                                                                                                                             separate cooling tower for
                                                                                                                                                                                                           Close
                                                                                                                                                                                                               compressor & chiller
                                           Chiller - C
                                                             Chiller - D
        Chiller - A
                          Chiller - B




                                                                              Chiller - E
                                                                                                Chiller - F




                                                                                                                                                         Dryer - C

                                                                                                                                                                     Dryer - D
                                                                                                                        Dryer - A

                                                                                                                                             Dryer - B




                                                                                                                                                                                 Dryer - E




                                                                                                                                                                                             Close                 Modification
                                                                                                                                                                                                                   Open




                                                                                                                                                                                                                          Open

                                                                                                                                                                                                                                                                       33
                                          Poly-I                                                                                                                                                                    Poly-II
                                      tower approach
               Improvement in coolingUTILITY COOLING TOWER after modifications
                        in cooling water distribution system


                                     Cooling Tower Approach
           6
                             5
           5


           4
Approach




                                                              3
           3

           2


           1

           0
                           Before                           After


           With above improvement cooling tower approach reduced from 5 to 3

                                                                                 34
                      Optimization of Utilities parameters


  SN          Area         Specifications   Process value in   Current Process Value
                                 oc          2007~08 (oc)          2008~09 (oc)
   1.     Twisting hall       28(+/-)3           26-27                28-29

   2.      Take up hall       25(+/-)3           24-26                26-28

   3       Chilled water     7 (+/-)0.5         6.0-6.5              6.8-7.0*
          temperature to
               poly

* Microprocessor based control system installed at 2 chillers in place of
electromechanical system


Remarks:
1) Process conditions are established through planned experimentation at
processes.
                                                                                       35
                   Identify and stop conditioning of non critical area
SN                 Area                       Proposed Action                          Targets date


1.   Yarn waiting hall              To stop circulation of conditioned air in   1.   Completed (approx saving
                                    yarn waiting area through Take-up AW.            is ~200 TR)



2    Air Washers                    1.Air leakage through air tight doors to    1.   Aug-08
                                    be attended                                 2.   Work is under progress.
                                    2.Heat transfer efficiency through               Chilled water coils are being
                                    chilled water coils to be increased              replaced by copper fins coil.
                                                                                     Target is dec-09


3    Across TTB-G (Specially        1.Awareness to be increased for follow      1.   Meeting with individual at
     Twisting and spinning areas)   up door opening discipline in                    shop floor is going on
                                    conditioning area




                                                                                                                     36
                              Improvement in Electrical chiller




                     Month wise Chiller power consumption & Ave Enthalpy

         0.8                                                                  25
         0.7




                                                                                   Ave Enthalpy (K- Kal/kg)
                                                                              20
         0.6
         0.5
KWH/TR




                                                                              15
                                                                                                              KWh/TR
         0.4
                                                                                                              Avg Enth
         0.3                                                                  10
                           Avg power cons per TR
         0.2                         0.73
                           (Area for improvement )                            5
         0.1
          0                                                                   0
                Apr May Jun    Jul   Aug Sep Oct      Nov Dec Jan   Feb Mar
                                              Month




               KWh/TR is high during Monsoon season due to high fresh air enthalpy

                                                                                                                         37
                          Power conservation in Air conditioning                                                     2008-09
                        Modification in conditioned air distribution system of inverter room AHUs

S   Improvement                 Power                    Activities Carried out                            Remarks
N                               saving
                                kWh/day
1   Stoppage of one                  168                 •Conditioning requirement was reduced by
    inverter room AHU                                    optimizing inverter room size .
                                                         • conditioning air distribution system was
                                                         modified .


              Before                                                                 After
                                                                            Close
       6 mtr inverter                                                           6 mtr inverter
                                                                                                   Close
        room AHU                        0 mtr inverter                           room AHU                     0 mtr inverter
          7.5 kw                         room AHU                                  7.5 kw                      room AHU
                                           11 kw                                                                 11 kw




                                                   Ducts                                                                 Ducts



          6 mtr inverter room                                                       6 mtr inverter room




          0 mtr inverter room                                                       0 mtr inverter room
                                                                                                                                 38
          Both AHU in operation                                                 Only one AHU in operation
                                 Power conservation in Boiler Area                                                         2008-09
                                                   Modification in condensate transfer system

S        Improvement                   Power               Activities Carried out                                Remarks
N                                      saving
                                       kWh/day
1        Stoppage of MCPL                        120       •Piping route for condensate transfer to
         condensate transfer                               SRF and MCPL boilers were modified for
         pump ( by utilising                               reducing total head .
         the SRF condensate                                •Piping modified for avoiding overflow of
         transfer pump for                                 SRF de-aerator .
         both purpose )
                        Condensate transfer system                                            Condensate transfer system

Before                  CV in line
                                                                        After                 close

    condensate tank                  Deaerator                            condensate tank                Deaerator

                                                                 MCPL                                                           MCPL



       Condensate                                                            Condensate
                                Condensate                                                           Condensate
    Transfer pumps to                                                     Transfer pumps to
                             Transfer pumps to                                                    Transfer pumps to
     Deaerator (SRF)                                                       Deaerator (SRF)
                             Deaerator (MCPL )                                                    Deaerator (MCPL )


                                                                                                                                39
                 Both pumping station in line                                       Only one pumping station in line
                                      Schematic diagram of chilled water                                                                          2008-09
                                                                   AIR WASHERS                                                 PHE installed during VAM
                                                                                                                               project but could not
                                                                                                                               commissioned as per
                                        T/W-I   T/W-II   T/W-III   T/up-I   T/up-I   Quench-I   Quench-II                      direction of DOB




                                                                                                                                     PHE


                               Chilled water circuit
                                                                                         Plant-1


  C
  H
                                                                             A       B          C
  IL
                                                                                                                                     condensate
  L
                                                                                                                                     at 98
  E
                                                                                     VAM                                             deg.cent
  R
                                                                                                                                             Steam
                                                                                                                                             to SRF
                                                                                                            Hot water
                    Plant II                                                                                                          @ 12 kg/cm²

                                         Twisting Air washer 4,5,6,7
                                                                                                                        MCPL




•Before expansion refrigeration load ~1600 TR (max. month avg.)
•After expansion refrigeration load ~2800 TR ( max. month avg.)
•VAM was installed and commissioned in 2006~07
                                                                                                                                                          40
  Month-wise refrigeration requirement before & After of plant expansion
                                                                      2008-09
                                           Refrigeration Load (Ave TR)

      3000
                                With plant-1                                               With plants 1 and 2
      2500                   (Before expansion)                                             (After expansion)

      2000
 TR




      1500

      1000

       500

         0
             ay




                                      ay
                     e




                                     ne
                               Au ly




                               Au ly
                              ce er




                              ce er
                                     ch




                                     ch
                            F e ar y




                            F e ar y
                                em t




                                em t
              il




                                      ril
                             Ja er




                             Ja er
                             O er




                             O er
                              ve r




                              ve r
                                      ry




                                      ry
                                       s




                                       s
                           No obe




                           No obe
           r


                      n
                                   Ju




                                   Ju
                          Se gu




                          Se gu
        Ap




                                   Ap
                          De mb




                          De mb
                                  ua




                                  ua
                                    b




                                    b
                                   ar




                                   ar
                                    b




                                    b
               M




                                   M
                   Ju




                                  Ju
                                 nu




                                 nu
                                 m




                                 m
                                M




                                M
                                ct




                                ct
                               br




                               br
                             pt




                             pt
                   2003~04                                Months               2006~07


Data of 2003~04 & 2006~07 is taken for comparison as during above years refrigeration system
(consumption) was stable :-

• Year 2004~05 and 2005~06: Plant was under commissioning
•Year 2007~08 : Refrigeration load was manually reduced due to water crisis and problem in chillers

                                                                                                                 41
Miscellaneous energy conservation projects carried out in
Utilities :
 S.N.   Area       Project Description                  Saving
 1      Utility    3 no. Return air fans of Take up air 3 x 5 KW = 15 KW /hr.
                   washers ( I & II )were running with
                   dyno drive consuming 10.5 KW/hr
                   power . So dyno drives were replaced
                   with inverters to reduce the Power
                   consumption to 5.5 KW/hr .
 2.     Utility    One 30 KW pump was continuously 13 KW / hr.
                   running to maintain the header pressure
                   of DG cooling tower consuming 15.5
                   KW/ hr. which was replaced with 3.7
                   KW pump after line modification due to
                   which consumption came down to 2.5
                   KW/hr.


 Saving :
 Power saving              ~ 28 KW / Hr
 Power saving / annum      ~ 2.5 lac Kwh


                                                                                42
                                                            Verifying the results

				
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