1. DS TEXTILE
AUDIT
By
PITCO (Pvt.) Ltd.

2. Name Plate Data
Three phase Induction Motor
Main Motor Data
Power 22 KW
Voltage 400 V
Current 39.2 A
Frequency 60 Hz
Connection ∆ (Delta)
Insulation Class B
Weight 215 KG

3. Motor Measured Data
Motor Voltage Current PF KW KVAR KVA
No. (Volt) (Amp)
1 405.4 16 0.774 8.7 7.7 11.67
2 419 14.1 0.76 7.9 7.6 10.1
7 415.8 20.2 0.831 12.58 8.45 14.85
8 399.9 25.5 0.774 11.38 9.7 14.99
9 394.6 16.8 0.857 9.654 5.88 11.55
10 394.4 15.5 0.87 9.2 5.3 10.7
11 394.8 17.3 0.816 9.63 6.76 11.9
25 423 16.3 0.75 9 7.6 11.9
41 417.6 20.3 0.65 10.98 12.85 17.3
56 413.4 25.1 0.44 7.8 15.66 17.9
Note: Motor No. 41 & 56 are DOL (Direct On Line)

4. Percent Load = (Running KW/ Rated KW) ×
100
Motor Number Running KW Rated KW % Load
1 8.7 22 39.54
2 7.9 22 35.91
7 12.58 22 57.18
8 11.38 22 51.72
9 9.654 22 43.88
10 9.2 22 41.81
11 9.63 22 43.77
25 9 22 40.91
41 10.98 22 49.91
56 7.8 22 35.45

5. Graph between Load (%) and Efficiency (%)
Eff1= High Efficiency Motor Curve
Eff2= Standard Efficiency Motor Curve
Source: CEMEP (Committee of European Manufacturers of Electrical Machines and Power Electronics )

6. Graph
Eff1= High Efficiency Motor Curve
Eff2= Standard Efficiency Motor Curve
Source: CEMEP (Committee of European Manufacturers of Electrical Machines and Power
Electronics )

7. Rewinding
 All motors in the industry were rewound.
Most of them were rewound twice and
some even thrice.
 Rewinding once reduces the efficiency
from 2 to 3 percent.
 The cost of rewinding is 65% of the initial
motor cost.
 All the motors were more than 20 years old
which is more than their normal life span.

8. Calculations
KWsaved = L × KWRated × [( / Effold motor) – ( /Effnew motor)] × 00
KWhsavings = KWsaved × Annual Operating Hours
Operating Hours = (365× 24) – [10% of (365 × 24)] = 7884 hrs
Total Savings (Rupees) = KWhsavings × Unit Charges (Rupees/KWh)
L = Load Factor
Effold motor = Standard Motor Efficiency(Eff2)
Effnew motor= High Efficiency Motor Efficiency(Eff1)
 The extra cost of an energy efficient motor is often quickly repaid in energy
savings.

9. Payback
 Time required for the savings to equal the initial cost.
Simple Payback = Motor price
Annual Savings
 Operational cost is about six times its initial purchase.
 Purchase price of Energy Efficient motor is 15% to 30%
more than standard motor that can be recovered within 2
years.

10. Results

11. Conclusion
Total KW in operation 96.824
No. of Motors 10
Total KW saved 12.643
Total Saving (Rupees) 996812
Total Investment (Rupees) 2870350
50% off Price 1435175
Payback Time 1year 6 months
Hence from these facts and figures,
replacement of all the motors is recommended