The textile mills are aware now that in their total Electricity units consumed per day towards compressed air, they are losing more than 30 % units in compressed air. But, in the total Electricity units per day consumption, the mill can achieve only around 5 to 10 % reduction in that Units Per Day after the energy audit & implementation.
But here in compressed air, they find the Low Hanging Fruit with zero & low cost payback. Compressed air leakage is a hidden losses daily happening in the mill and if not identified and corrected today, this aggravates the losses, which are accelerating now.
When the mill goes for modernization, the automated production demands more compressed air usage. So instead of arresting the existing air leakages, now the mill buys more compressors so satisfy the production demands, but leakage increases more.
Mechanical finishing of cotton. Stiff, soft, wrinkle resistant, water repellent, flame retardant and enzyme (bio-polishing) finishing of cotton; Milling, decatizing and shrink resistant finishing of wool; Antistatic and soil release finishing; Heat setting of synthetic fabrics; Minimum application techniques; Pollution control and treatment of effluents.
TOPICS COVERED: ASOLUTE AND RELATIVE HUMIDITY MOISTURE REGAIN AND CONTENT Regain-Humidity Relations of Textiles Regain VS Relative Humidity Curve Factors Affecting the Regain of Textile Materials Effect of moisture on properties
Mechanical finishing of cotton. Stiff, soft, wrinkle resistant, water repellent, flame retardant and enzyme (bio-polishing) finishing of cotton; Milling, decatizing and shrink resistant finishing of wool; Antistatic and soil release finishing; Heat setting of synthetic fabrics; Minimum application techniques; Pollution control and treatment of effluents.
TOPICS COVERED: ASOLUTE AND RELATIVE HUMIDITY MOISTURE REGAIN AND CONTENT Regain-Humidity Relations of Textiles Regain VS Relative Humidity Curve Factors Affecting the Regain of Textile Materials Effect of moisture on properties
A machine or apparatus for stretching or stentering fabrics. The purpose of the Stenter machine is to bringing the length and width to pre determine dimensions and also for heat setting and it is used for applying finishing chemicals and also shade variation is adjusted. The main function of the Stenter is to stretch the fabric widthwise and to recover the uniform width.
VDQ pulley (Variable Dia for Quality Pulley): It is a very important part of the machine. It controls the quality of the product. Altering the position of the tension pulley changes the G.S.M. of the fabric.
As the dryer pressure rating increases, the increase in steam temperature may not be sufficient to offset the increase in conductive resistance of the shell. In fact, it is possible for a dryer with a higher steam pressure rating that is operating at its rated pressure to have less drying capacity than a dryer with a lower steam pressure rating that is operating at its rated pressure.
A machine or apparatus for stretching or stentering fabrics. The purpose of the Stenter machine is to bringing the length and width to pre determine dimensions and also for heat setting and it is used for applying finishing chemicals and also shade variation is adjusted. The main function of the Stenter is to stretch the fabric widthwise and to recover the uniform width.
VDQ pulley (Variable Dia for Quality Pulley): It is a very important part of the machine. It controls the quality of the product. Altering the position of the tension pulley changes the G.S.M. of the fabric.
As the dryer pressure rating increases, the increase in steam temperature may not be sufficient to offset the increase in conductive resistance of the shell. In fact, it is possible for a dryer with a higher steam pressure rating that is operating at its rated pressure to have less drying capacity than a dryer with a lower steam pressure rating that is operating at its rated pressure.
Energy saving in compressors and compressor performance assessment, process excellence involved in running compressor section. Energy optimization potential in compressors, leakage test of compressed air.
General Air Products, Inc. - Air Compressor Selection and Design for Dry Pipe Fire Sprinkler Systems. This presentation is designed to educate fire sprinkler professionals, especially designers, engineers and technicians on the fundamentals of air compressor design, function and proper sizing and selection. For questions on this presentation please contact us at 800-345-8207 or visit our web site www.generalairproducts.com
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
COMPRESSED AIR SYSTEM . ENERGY CONSERVATION OPPORTUNITIESManohar Tatwawadi
The presentation gives an idea as to how the compressed air system is designed and the performance of the compressed air system. The losses, conservation of energy, the cost of leakages etc are discussed in the presentation
How to maximize air compressor efficiency and reduce the total maintenance co...cemenntcompressor
Compressor design, speed, suction and outlet pressure and temperature, gas composition, suction and outlet pipe design, and valve design impact the amount of losses. Losses that are significant in specific applications may be minor in others. Therefore, while constructing a performance prediction model, you must study the wide range of compressor designs, valve designs, gas molecular weight, and operating circumstances.
ABSTRACT
Air compressor operation and care. Compressed air is one of the most used service fluids in industry. The article introduces the basic design concepts of an air compressor and discusses some of the common problems and solutions found in both reciprocating (piston goes up and down) and rotary screw (twin, meshed, rotating, helix) air compressors.
Air compressor overview and basic selection guideAnilkumar B Nair
Provide an overview of Air compressors
Provide a generic guideline for Air compressor selection process
This presentation is prepared for target audience:Facility Managers, Utility Engineers. Technicians and Process associates
RMSC is your one-stop-shop for air compressor repairs, with a 24/7 full-service facility and experienced team. Air compressor repair is the process of diagnosing, troubleshooting, and fixing issues that may arise with air compressors. Air compressors are machines that convert power into compressed air, which can be used to power tools and equipment in various industries, such as manufacturing, construction, and automotive repair. Air compressor repair services may include preventative maintenance, routine inspections, and repairs of various components such as compressors, motors, belts, and hoses. Common issues that may require repair include air leaks, pressure problems, oil contamination, and motor failure.
Website: https://rmsccolorado.com/air-compressor/
Similar to Compressed air Energy saving possibilities in textile mills (20)
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
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Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
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Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
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Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
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A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
Compressed air Energy saving possibilities in textile mills
1. WHY TEXTILE MILLS GIVE PRIORITY TO THEIR COMPRESSED AIR SAVINGS NOW?
The textile mills are aware now that in their total Electricity units consumed per day towards compressed air,
they are losing more than 30 % units in compressed air. But, in the total Electricity units per day consumption, the mill can
achieve only around 5 to 10 % reduction in that UPD after the energy audit & implementation.
But here in compressed air, they find the Low Hanging Fruit with zero & low cost payback. Compressed air leakage is
a hidden losses daily happening in the mill and if not identified and corrected today, this aggravates the losses, which are
accelerating now.
When the mill goes for modernization, the automated production demands more compressed air usage. So instead of arresting
the existing air leakages, now the mill buys more compressors so satisfy the production demands, but leakage increases more.
WHY LOSSES ARE MORE IN THE COMPRESSED AIR SYSTEM NOW?
The root cause of the problem is that the water & dirt getting accumulated in the compressed air pipe lines are not
removed automatically from the pipe lines. The water & dirt in the compressed air pipe lines make the pneumatic fittings weak
and leaky over a period of time. Any pneumatic fitting and components has a life and beyond its life, this starts leaking micro
way and shortly, these leak heavily.
The compressor post air cooler, refrigerated dryer, and the Zero air loss drain valves fixed in the Air Receivers at the
compressor house, Tail end and Feed end Receiver Fig 1 (shown in last page) the above three sub systems have to work
perfectly so that water is not at all trapped into the distribution and load ends. More important, the water ingress in the air
actuation elements, solenoid valves etc in the machine will spoil their health.
WHERE IS THE LOSS HAPPENING IN COMPRESSED AIR GENERATION ?
Compressed air generation is Less due to :-
Now compressor takes 5to 10 *C above the surrounding Ambient thro choked air intake filters. This is 2 % KWH loss. Cool
dry Compressor delivers more air output. So try to give cool dry air to the compressor air inlet Fig 5. Keep the Load / Unload
settings to the minimum Bar Pressure just 0.7 Bar i.e.10 % above the minimum required pressure demand from equipments.
Fix pressure gauge one at just after the compressor and other gauge at the compressor house air delivery line / receiver. Fix a
temperature gauge on air receiver and its temperature 5 * C above the ambient is a sign of unhealthiness of compressor package.
Fig 2. Pressure sensor located inside now. Fig 3. kw Fluctuations in Minute trend graph.
We understand many mills have more pressure drop around 1 to 2 Bar in the compressor house itself. First
bring down the pressure drop to less than 0.7 Bar now. We are providing air receiver in the compressor house to arrest the
compressed air pulsation and fluctuation due to frequent loading and unloading of compressor.
The above images show that the location of pressure sensor Fig 2. matters to us since this aggravates the cyclic fluctuation of
load & unload Fig 3. This can be solved by shifting the compressed air pressure sensor from the hood to the receiver. Many
industries achieved savings and safety after shifting this Pressure Detection & Control Sensor to air receiver. Other comforting
option is to expand the compressor hot air exhaust so that the air & oil sub systems within the hood work comfortably.
2. HOW DO YOU ACCOUNT TH ECOMPRESSED AIR LOSSES IN DISTRIBUTION?
Analogous to the other T & D (Transmission & Distribution) losses, the compressed air lost in the transmission is less
up to the sub header, compared to the Air Distribution Loss that is more in the machine. The Flanges, O rings gaskets, fixed in
the main header pipe lines are prone to leak more shortly. To study this and correct the same.
Provide Intermediate or Feed Air receiver to each of the air consuming department. This will help the mill to measure
separately, the air losses in the transmission (compressor & header) And the losses in the distribution (sub header & equipments
at the dept.)
The air receiver to have pressure gauge, isolation ball valve, preferably solenoid operated & receiver water drain valve system.
Mill Project team always reduces its budget to invest in these sub systems, but the mill compressed air running cost goes up
because of the absence of these field sub systems; which are useful to condition monitor the mill, air daily demand and supply
air flow at rated pressure with minimum allowable pressure drops.
ARE WE SEEING COMPRESSED AIR LOSSES IN MACHINE USAGE?
Still I find many mills are operating at 7 to 8 Bar band as load & unload. What is wanted is only 6 to 6.5 Bar as the load &
unload pressure settings. Invest in air bottles to each of the compressed air consuming machine. Many mills are fixing digital air
pressure gauge (it is the machine OEM initiative) and give only the minimum pressure which is required for the machine.
Say the autoconers can be retrofitted with 3 inch PPR pipe under the total machine length and this will give 200 liter buffer
tank. All the control and working pressure tapping can be taken from this retrofit pipe. Mills think of Pressure Booster to satisfy
machine OEM’s higher pressure demands. Discuss with OEM first, how to reduce the machine operating pressure with spare
air bottle as buffer.
HOW TO PRIORITISE THE COMPRESSED AIR LOSSES IN LEAKAGE?
The losses are happening in the compressed air generation, distribution in the usage. In the usage part, the leakage in
the machine is more than the machine usage now. Hence the question of arresting the leakage is becoming a priority now.
What is the leakage in the machine during OFF time? Measure this first to arrest next.
This is similar to our domestic 1000 liter overhead tank where, 100 liter /hr or ( %) water enters the from the top of
the tank. 50 liter /hr or (%) is drained silently thro the bottom drain plug. And the balance 50 liter /hr (%) only is used for the
house. Like that, some mills record more than 50 % compressed air leakage.
By arresting the leakage losses to the minimum, the mills stand to gain now and ROI, the Return on Investment is
around 6 months only. But keep in mind, any mill cant’ achieve Zero % leakage practically speaking. So arrest the air leakage
to the minimum possible %.
HOW THE AIR CONSUMING MACHINE OEM & COMPRESSOR OEMS CAN HELP NOW?
The machine OEMS in the other segments have realized the preciousness of compressed air. Please try to keep OUT,
the air sub header, FRL, etc input components visible to the user daily. Dont' keep the inlet air header under closed door but it
must stand out of the machine for easy and timely attendance of air input problems.
Provide a buffer bottle or pipe line so that air supply to the machine individual pneumatic actuation mechanism is not
restricted or starved of air. Always give open access to the worker so that he will daily remove the water collected at the
machine end water drain valve at the bottom most point. If possible, provide digital air pressure gauge to the machine inlet.
Some mills are already planning to put Rotameter type or Digital type air flow instant metering.
Provide Air intake Delta Pressure gauge outside the compressor hood so that each mill can around 2 % KWH on
condition monitoring the same. Kindly educate the air consumer on how to keep compressed air useful to the pneumatic
machine health.
When installing the machine, give the consumer The BEST Installation Possible. The compressor & compressed air
Inefficiency starts from compressor house only to start with. Allow no Tee but Y only, pipe connections in the house.
3. WHY THE COMPRESSED AIR SYSTEM INSTALLATION IS NOT PROFESSIONAL?
Fig 4. I Image wrongly done and II image rightly done. - Do’s & Dont’s of compressor hot air Exhaust ducting
On a scale of 10, during my energy audit of more few hundred industries, 8 out of 10 mills have fixed same size duct to
match mouth size, but longer lengths Fig 4. But they must provide the duct double the mouth size as expanded duct; to exhaust
hot air from the compressor hood. That was only cost saving in duct achieved that day, but compressor struggles to breathe
forever, the damage done to machine right from the installation!
Mills buy the latest and efficient compressor or machines, they dont' plan to mark a tiny fraction of budget cost towards
installation and also; never give time to commission the same professionally.
I request the compressed air users to revisit their compressor installation manuals and commissioning reports and
check for Non-conformance. First of all, the mill must have commissioning report of what kw / cfm achieved as told by the
OEM? Then, the mill must do FAD test twice a year by pump up capacity method.
I found many mills are forced to change their compressor Air End elements within its life period (its cost is half the
compressor cost) prematurely because of this poor installation and the post air cooler is getting choked ( this is bound to
happen in each textile mill, due to textile micro fluff floating in ambient.) This situation can only improve if the machine HX
suction is oriented towards to the outer ambient. If the HX sucks only the machine hot air, then it functions poorly.
COMPRESSED AIR HEADER FLOW DECIDES
DYNAMIC PRESSURE DROP IN COMP AIR SYSTEM
Fig 5. Pre-filter to existing Air intake Filter, pipe Extension to Air Entry. Fig 1. Invest in Air Receiver - / Tail End model
DOES COMPRESSED AIR METERING HELP?
As Energy Professional, we are aware that the efficiency of compressed air generation is very poor. So today, first
install a Multi function meter to know what is daily kWH of compressor during loading, unloading and total Units. The relative
condition monitoring of the machine input KWH will show the relative compressor consumption deviations.
4. More accurate will be to provide compressed air flow meter in the compressed air main header. This will prompt the
user to know what each compressor gives per KWH input power, say 3 to 6 CFM? When the OEM says it is 6 cfm / kw, the
mill user finds it around 3 to 5 cfm only per kw.
This input kw / output cfm ratio will indicate the mill user to find out the healthy parameters in each compressor. The
user can also close & open the intermediate air receiver valves in each department air to know the individual dept consumption.
So header flow metering will give macro view to the management about the efficacy and % compressor costing in the
mill power break up in units / day. And the portable digital flow meter can be used in each machine, to routinely measure the
machine air consumption at the ON & OFF time.
WHAT ARE ZERO AND LOW COST WAYS TO REDUCE COMPRESSED AIR CONSUMPTION?
First give priority to leakage arresting first. Outsourcing Today, the Leakage Detection & Correction Exercise will
immediately give result in three months. It is a wise decision taken quickly and instantly implementable.
Many mills have stopped one of out of their three daily running compressors after arresting their leakages. Any
compressed air pipe line or machine, when you are able to hear the compressed air leak, then it means one third, say 33 % of air
flow in that airline is Leaking. First arrest the Audible leaks. Then make use of the ULD - Ultrasonic Leakage Detector to arrest
the minute leaks, further.
BEE says, any machine above 10 HP operated for more than 6000 hours an year i.e. two shifts a day, please fix a
KWH meter to assess the machine productive health. Here we can measure both compressor's air power and tare power now.
Kindly invest in Air receiver, Other retrofits like comforting the compressor and Zero Air loss compressed air drain
valves with a pre-fixed Y type strainer that is daily cleanable on-line to save the main drain valve, Daily cleanable Pre-filter to
the existing air intake filter, Positive Cross Ventilation inside the compressor hood, Load & unload Pressure sensor shifting to
air receiver etc many finer points of daily condition monitoring will bring down the mill compressed air energy
consumption by ONE THIRD.
Ashok.S / BEE Accredited Energy Auditor, Coimbatore, India. Mail to :-ashok@energymeasuretosave.com
For more details, Pls visit the website www: energymeasuretosave.com