Conservation and management of energy have assumed tremendous significance in the last decade, particularly with the introduction of fourth generation hi-tech machines that consume more power per unit production. SITRA has been conducting different types of energy audits like Comprehensive Energy Audit and Mandatory Energy Audit in the textile mills in India and abroad for more than three decades .
SITRA Energy Cell formed in 1980s , comprising of experienced engineers in the respective fields, is under taking Energy audits and energy consumption, conservation studies in the textile mills from powerhouse to production machines. So far, it has undertaken energy audits in about 600 mills in India and abroad. SITRA has also formulated procedures and systems for the introduction of Energy Conservation Program in mills for routine control and suggested methods to audit electrical energy consumption in mills. Many textile mills have saved crores of rupees in energy cost through SITRA Energy Audits. This audit is conducted in-depth in the following three areas:
a. Electrical Engineering
Macro energy information - energy cost - power quality - system capacity, adequacy and conservation potential - power handling losses - transformation competency and voltage profile - pf correction - capacitor aging appraisal - cable loss estimation - review of maintenance records - evaluation of mills specific energy consumption - reasoning for motor burnouts - separation of productive and auxiliary loads - machine-wise energy consumption measurement - ring frame analysis - scrutiny of conservation measures attempted - suggestions for better generation, lighting, drives and other utilities.
b. Mechanical Engineering
Humidification - system analysis for each department - supply, exhaust and pumping systems details - present condition of humidification system - air flow distribution analysis - heat load analysis - humidification power pattern - plant motor loading analysis - temperature and RH analysis - standard temperature and RH for different departments - plant operation and maintenance - compressors - power pattern - leakage analysis - boilers and thermic fluid heaters - existing system details - thermal efficiency analysis - recommendations for implementation.
c. Textile Engineering
Installed motor hp in mills and load distribution analysis - scope for energy conservation in preparatory, spinning and post-spinning machines - choice of energy efficient components or accessories: motors, bobbins, belts, spindles, spindle oils, spindle tapes, tin roller, pneumafil fans etc.- optimization of package size in ring frames - modification in machine design or structure to reduce load - details of SITRA studies pertaining to energy conservation - production and energy consumption analysis- economics of energy efficient equipment.