Pump

1. 9/3/20XX Presentation Title 1
TALK ON
ENERGY
EFFICIENCY
By – Ajai Arora

2. Agenda
1. Steam Efficiency
2. Compressor Efficiency
3. Motor Efficiency
4. Pumps Efficiency
5. Textile Efficiency
6. Final Thoughts

3. STEAM
How to make
Steam usage
more energy
efficient?

4. STEAM
Steam is the most popular mode
of energy in industrial processes.
High latent heat
High heat transfer rate
Easy to distribute & control
Cheap & inert

5. STEAM LOSSES
GENERATION
Hot air exhaust
Excess Air
Unburnt Coal
DISTRIBUTION
Insulation
Steam Traps
Leakages
UTILIZATION
Insulation
Steam Traps
Equipment Cleaning
Condensate recovery

6. PIPING
LAYOUT

7. PIPE LINE
TAPPING

8. COLD
LIQUID
CONDENSATE
STEAM
Steam Vapors
DIRTY FOULED
TUBES
IN
HOT
LIQUID
OU
T
HEAT EXCHANGER

9. STEAM TRAPS

10. STEAM
DISTRIBUTION
LOSSES
Improper sizing and lengthy
steam pipes
Improper or lack of insulation
Excessive pressure drop in the
system
Improper selection, incorrect
location and malfunction of steam
traps
Condensate recovery
Steam leakages from valves,
joints, etc

11. STEAM LEAKS
2 mm Size Hole in LP Steam Line
Steam Loss will be = 500 kgs / day
= 2.4 Lac Rs / year

12. STEAM Loss from
UNINSULATED
PIPES
4 inch Size of 1 meter
uninsulated LP Steam
Line
Steam Loss will be
= 300 kgs / day
= 2.0 Lac Rs / annum

13. LOSSES IN
STEAM
DISTRIBUTIO
N
CONDENSATE RECOVERY
FOR EVERY 6 DEGREE C RISE IN
BOILER FEED WATER
TEMPERATURE
THERE WILL BE
REDUCTION IN
FUEL CONSUMPTION BY 1 %

14. STEAM UTILIZATION
USE STEAM AT LOW PRESSURE.
REDUCTION IN PROCESSING
TEMPERATURE.
PREHEATING USING WASTE HEAT
RECOVERY OF HEAT FROM
VAPOURS

15. ROUTINE
PREVENTI
VE
MEASURE
S
Schedule Cleaning of
Equipments.
Attending leakages.
Schedule checkup of
Steam Traps.
Schedule Insulation –
repair.
Proper monitoring of
Temp , Pressure of Steam

16. STEAM DATA SHEET
Sr.
No.
Location Type of Trap Status (OK / Not OK
Steam Traps
Sr.
No.
Location Line Pressure Status
(Leaking or Not
Leaking)
Steam Lines, Flanges, Valves
Sr.
No.
Location Insulation Type Status
(Insulation/ No
Insulation)
Steam Lines Insulation

17. Insulation is defined as a strategy for slowing the transfer of heat
Insulation (1/3)
Reduces overall
energy consumption
Offers better process control by
maintaining process temperature
Prevents corrosion by keeping the exposed surface
of a refrigerated system above dew point
Provides fire protection to
equipment
Absorbs Vibration
Benefits of
insulation
Types of insulation based on temperature
Low temperature
insulation (up to 90°C)
Medium temperature
insulation (90 – 325°C)
High temperature insulation
( Above 325°C)

18. Insulation (2/3)
Emerging trends :
Modes of heat
transfer
Electromagnetic radiation :
Controlled by absorbing or
reflecting surfaces
Conduction : Controlled by
less conductive element
Convection : Controlled by
creation of small cells within
which temperature gradient
are small
Elastomeric foam Acoustic insulation
Environment
friendly insulation
Spray form insulation

19. Steam System
Monitoring
• First step in cutting steam cost
• Install steam flow meters
• Account for temperature & pressure
effects
• Steam trap – The quiet thief in plants
• Steam trap selection
• Steam trap monitoring, standardisation
• Insulation
• Recruiting steam trap engineer
• Boiler water control, Blowdown

20. COMPRESSO
R
How to make
Compressor
more energy
efficient?

21. 1. Reduce unloaded
running hours
2. Eliminate air leaks
3. Reduce the
pressure band

22. 4. Turn compression heat into
useful energy with heat
recovery
5. Ensure the correct size
of compressor is
installed
6. Consider a Variable
Speed Drive
compressor

23. 7. Get an air audit
8. Reap the benefits of
modern compressed air
equipment
9. Don’t forget the impact
of regular maintenance

24. 10. Reduce inlet air
temperature
11. Optimize air pressure

25. Load/Unload of Compressor
9/3/20XX Presentation Title

26. Load/Unload of Compressor

27. Load/Unload of Compressor

28. Load/Unload of Compressor

29. Load/Unload of Compressor

30. Load/Unload of Compressor

31. MOTORS
How to make
Motors more
energy
efficient?
9/3/20XX 31

32. MOTOR
• It is a Device –
• ELECTRICAL ENERGY
• MECHANICAL ENERGY
• TYPES OF MOTORS
• * DC Motors
• * AC Commutator Motors
• * AC Motors

33. AC Motor`
• AC Motors are rotating electrical machines
running on AC Electrical supply.
• Available in – Single Phase
• – Three Phase
• Basic formula for Motor Power:
• Single phase = Volt x Amp x PF
• Three phase = 1.732 x Volt x Amp x PF
•

34. Causes of
Energy
Wastage
in Motors:
Oversized / Under loaded Motors
Idle Running.
Unbalanced Input Supply Voltage.
Overheating of Motors.
Frequent switching ON & OFF.
Poor power factor.
Use of less efficient motors.
Mechanical overloading OR Misalignment.
Repeated Rewinding of motors.

35. Sizing of the motor is
critical and important
* Over sizing will result in
- More losses
- Lower Running Efficiency
* Under sizing will result in
- Overloading
- Overheating & failures
* Optimal sizing will result in
- Minimum losses
- Maximum Running efficiency

36. General Practices To Increase Motor
Efficiency
Eliminate the voltage
unbalance
Maintain motor shaft
alignment
Minimise idle running
Minimise rewinding
Selection of motor
properly matched
with load
Star delta
changeover
Use of variable
speed drives
Preventive
maintenance,
Thermal imaging
Vibration analysis

37. Load (%)
Efficiency
and
Power
factor
Effect of Load on Motor Efficiency

38. Tips on
Energy
Conservati
on in
Motors:
Use proper size
of motor for the
equipment to
be driven.
Use Energy
Efficient motors
wherever
economical.
Check for
proper
alignment.
Lubricate
bearing
periodically.
Ensure
balanced
supply voltage.
Checking &
Cleaning of
motor
cooling fins and
fan cover
periodically.

39. Tips on
Energy
Conservati
on in
Motors:
Avoid water spray
on motors.
For every 10 deg C
increase in motor
body temperature,
motor life becomes
half.
Use VFD for speed
reduction
•wherever required.
Replacement of
repeated
rewound motors by
new motor.
Because every
rewinding
reduces motor
efficiency by
1-2 %.

40. Motor
efficiency and
losses

41. EE Motors

42. Agenda
PUMPS
Ways to make
PUMPS
installation
more energy
efficient

43. •What is the pump?
Pump is a mechanical device which
transfers the liquid from one place to
another place

44.  Positive
displacement pump
 Centrifugal pump
Types of pump

45. PUMPING
SYSTEM

46. LIFE CYCLE COST FOR A PUMP
2% 8%
90%
INITIAL COST
MAINT. COST
ENERGY COST

47. Efficiency of a pumping system =
Pump
+
Motor
+
Coupling
+
Piping system

48. Care should be taken during :
Installation Maintenance Operation

49. Pump should be located as near as possible
to the source.
 
INSTALLATION

50. Pump should be properly aligned.
 

51. Pump suction pipe should be at least 1.5
times of pump inlet nozzle size.
D1 = 1.5 x D2
L = 7 x (D1 – D2)
D1
D2
L

52. Suction reducer must be eccentric.
All piping must be as straight as possible.
Pump
Pump

53. OPERATION
Centrifugal pump
should always be
started with
discharge valve in
closed position.
Pump should not be
run with its discharge
valve throttled.
Instead VFD’s should
be installed in order
to reduce the flow if
there is requirement
of variable flow.

54. MAINTENANCE
Optimum tightening
of gland.
As far as possible
pump should have
mechanical sealing.
Check and ensure
wear ring clearances
during overhauling.

55. Type of pumps
Based on Principle
1. Reciprocating Pumps
2. Centrifugal Pumps
3. Other Commercial Types
• Open Well Submersible
• Bore Well Submersible
• Horizontal Spilt Casing
Based On Number of Stages
• Single Stage Pump
• Multi Stage Pump

56. Pump efficiency
• Pump Efficiency = Hydraulic
Power / Shaft Power
• Overall Efficiency = Pump
Efficiency x Motor Efficiency

57. Effect of
speed
variation

58. Series and parallel
operation
Series Operation
• Same flow, Head more
Parallel Operation
• Same Head, flow more

59. Flow
control
strategies
• Pump control by varying speed
• Parallel operation of pumps
• Stop/start control
• Throttling
• By-pass control
• Impeller trimming

60. Textile
Advanced
Technologies to
make Textile
Industries more
energy efficient

61. Introduction
The textile industry retains a record of the lowest efficiency in energy utilization and is one of the major
energy consuming industries.
About 34% of energy is consumed in spinning, 23% in weaving, 38% in chemical processing and another
5% for miscellaneous purposes.
Power dominates consumption pattern in spinning/weaving, while thermal energy is major for chemical
processing.
It is known that thermal energy in textile mill is largely consumed in two operations, in heating of water and
drying of water.
Fuel consumption in textile mills is almost directly proportional to amount of water consumed.
Hence if consumption of water can be reduced, it will also save energy.
Conservation of energy can be affected through process and machine modification, proper chemical
recipes, and new technologies.

62. Focus Areas for Energy
Conservation
Thermal Energy:
As already indicated, wet processing of textiles consume a very high proportion of thermal
energy mainly for the evaporation of moisture from textiles. at various stages of wet processing
and also for heating of process chemicals. Table 1 indicated the department wise percent
steam consumption in a composite textile mill.
Steam is generated employing boilers by using either coal or furnace oil and lately low sulphur
heavy stock oil available from the refineries as fuel having average calorific values of 4200
6200, 10280 and10700 Kcal respectively.

63. Focus Areas for Energy Conservation
Electrical Energy:
The wet processing of textiles consumes only a small portion of electrical energy, say around 15% of total electrical
energy, mainly for running the various processing machinery's.
By and large, most of the textile mills draw their power requirements and from respective state electricity boards.
However, the supply is adversely affected sometime resulting in severe power cuts for the industry
, in order to supplement this; several mills have gone in for their own captive generation in spite of the higher cost.
Some mills have tried for steam turbines by taking the advantage of tail race low pressure steam,
however non-availability of low to medium turbines, and their maintenance as compared to diesel engines limits
their use.

64. Energy Conservation:
1. Electrical Energy
The major consumption of electrical energy in the textile industry is in the manufacture of yam and
cloth, amounting to nearly 3/4th or 4/5th of the total power requirement in a textile mill, where as
hardly 15 to 20% of electrical power is consumed for running various machines in textile wet
processing.
As far as the electrical power saving is concerned the following measures can be affected:
Reduce The Processing Steps By Combining Some Of The Constituent Wet Processing
Operations In A Given Processing Sequences. This May Help in Reducing Number of
Washings and Dryings e.g.
One bath bleaching may enable to save around 70% electrical inputs.
Reduced number of ends / turns jiggers may help in saving around 20% electrical input.
Elimination of curing in printing saves 100% electrical input for curing step.
Combined drying - cum - curing in resin finishing saves around 35% electrical input.

65. Energy Conservation:
1. Electrical Energy
Explore The Scope For An Increased Output Per Unit Duration Of Various Electrically Driven Machines.
Use of high efficiency motors in place of standard motors with proper application will save 2 to 4 %.
Replacement of under size and over size motors - saving depending upon the percentage of loading on the
motors.
Use of high temperature grease according to insulation class of motors.
No load power study of motor, replacement of motors consuming high no load power
Investigation of exact burning reason, rewinding as per original technical data.
Motors convert electrical energy into mechanical energy to drive machinery. During this conversion, some
energy is lost.
Current motors feature improved designs and incorporate the latest developments in materials technology. The
most efficient of these motors are termed High Efficiency Motors (HEMs)
Other advantages of HEMs besides energy savings are:
Higher power factor,
Longer lifespan and fewer breakdowns,
Run cooler and less susceptible to voltage and load fluctuations, and
Produce less waste heat and noise

66. Energy Conservation:
2. Thermal Energy:
Apart from electrical energy, the wet processing department of a textile mill requires substantial
quantities of thermal energy in the form of steam as a source of heating . The various ways and means
by which a substantial portion of huge quantities of thermal energy consumed during the course of
textile wet processing can be saved include the following.
Since Most Of The Thermal Energy Is Wasted In Removal Of Water, Different Attempts Have Been
Made To Reduce The Energy As Follows.
Efficient removal of water using heavy squeezing enables 15-20% reduction in energy requirement for
drying .
Vacuum impregnation squeezes out the air from the cloth 'and provides better dye or chemical
impregnation and more uniform application and this process enables 60-65% fuel saving compared to
conventional system.
Vacuum roll extractor enables 70-75% saving in energy.

67. Some Developments Relating To Increased In Efficiency of
Drying and Setting Units
The heating up time on conventional stenters and hot flue
driers are 10-20 sec. and 40-60 sees. resp. But by employing
sieve drum drier which reduces the time of heat up to 1.3
sees. and gives almost 60-70% energy saving.
Radio frequency is used for uniform heating through out the
mass of the material which gives 60% saving in energy.
Use of heat transfer fluids (thermo pack) like hydro-carbon of
enabling temperatures up to 300oC . This process gives 80%
savings in energy.
Some Developments Relating To Techniques Based On
Reduced Liquor- To- Material Ratio In The Operations.
Foam application technique gives almost. 50- 60% savings in
energy for low wet pick-up applications. Use of low M. L. R. jet
dyeing machines saves 40-60%fuel. Azeotropic / emulsion based
system of processing saves 60-70% fuel considerably because of
significantly low water content of the system.

68. •Reduction in pressure kier time by kier modification from 6-8 hrs. enables 60-65% energy
saving.
•By using reducing agents like Anthraquinne the scouring time can be reduced to 3-4 hrs
ITom 6-8 hrs. This process enables 40- 50% savings in energy.
•By solvent scouring process 60-80% energy can be saved.
•Cold bleaching by activating sodium chloride by hypochlorite use no thermal energy and
hence 80-90% energy saving is possible. e: Hot mercerisation enables the combining of
scouring and mercerisations and saves energy around 30-40% .
•Mather and Platts vaporIac bleaching process is a continuous so curing and bleaching
under pressure which can be completed in 3-7 minutes and this process saves around 40-
50% energy.
•Du -Ponts two minutes bleaching uses hydrogen peroxide at very high pH value with a
special formulation to prevent undue decomposition of peroxide and damage to the fadrid.
An energy saving around 80-85% is possible with this process.
Some Developments Relating To Process Developments and Process
Modifications.

69. •Combined one step hypochlorite bleaching and scouring at R. T. enables almost 100%
energy saving.
•Combined one step desizing, scouring and bleaching by redox system reduces almost 60%
energy requirement.
•Use of solar energy for de-sizing and scouring enables almost 40-50% energy saving.
•Cold pad batch method for reactive dyeing by sodium silicate for fixation of kthe dyestuff
gives 100% energy saving.
•Rapidogen development by dry heat fixation with compounds like urea uses no acid ager
and hence saves 40% energy.
•Low temperature curing of pigment prints by using highly active catalysts
•Like ammonium chloride, ammonium suplhate etc. saves 30-40% energy.
•Use of flash agers for reactive color printed and dried goods the printed and dried cloth is
padded with alkaline solution of high electrolyte content and steamed for about 30-60
minutes. This method saves almost 50% steam
•Dyeing cum sizing of denim warps enables almost 40% saving in energy.
Some Developments Relating To Process Developments and Process
Modifications.

70. Novel Concepts of Energy Conservation
Higher energy consumptions involved in textile operations make pathway to
innovations in various operations involved in the chemical processing of textile
materials.
Supercritical Dyeing Technique
Supercritical dyeing technique is an innovation to conserve the thermal energy as the
fabric is in the dried state because at the end of process CO2 is released in gaseous
state. This is a new technique of using supercritical carbon dioxide as a dyeing
medium. Dyeings are performed in a high pressure vessel called an autoclave.
Carbon dioxide exists as a supercritical fluid at temperature at about 31C and
pressures above 72 bar. The anhydrous process offers number of ecological and
economical advantages such as, no preparation of processing water and low energy
consumption for heating up liquor.
Ultrasonic Assisted Wet Processing
Ultrasonic assisted process is an alternative to conventional high temperature
processing of the textile materials. Ultrasound equipment installed in the existing
machines offer improved performance in fabric preparation and dyeing without
impairing the properties of the processed materials. The influence of ultrasound
intensifies the mass transfer in the wet processing of textile materials. The
advantages of ultrasonic in textile wet processing include energy saving by reduced
processing temperature, time and lower consumptions of auxiliary chemicals and
further processing enhancement by control of overall costs. Therefore, the areas that
demand higher energy consumption can be benefited using ultrasound techniques.

71. Foam Technology
The application of foam processing leads to considerable savings in
the energy required for heating, drying, thermo-fixing, and
steaming and so on because the water content is very low. The
foam processes bring down the liquor ratios required for
pretreatment, dyeing and finishing by producing uniform foam with
the required characteristics in terms of viscosity, stability, and blow
ratio. De-sizing, bleaching and finishing as well as fluorescent
brightening of goods can be done using a foam technique. It offers
potential savings in materials and energy.
Conclusion
Modernization through plant and machinery could be effective in reducing energy
consumption. Some of the important factors for energy conservation are energy
audit, maintenance, instrumental control, waste heat recovery, etc. Much research
has been carried out for the use of solar energy. However, due to high capital cost,
these have not been found wide application in textile industry.

72. Final Thoughts

73. Why Energy
Conservatio
n?
National Interest & today’s need.
- Depleting National Resources
Business Interest
- Reduced Manufacturing Cost
- Improved Cost Competitiveness

74. What is
energy
efficiency
• In very simple terms, energy efficiency means using
less energy to get the same job done. Using less will
energy will result in lower energy bills and less pollution.
Many products, homes, and buildings use
more energy than they actually need, through
inefficiencies and energy waste.
• While gas and electricity may not be your biggest bills,
price volatility means that it’s well worth taking a closer
look at your energy expenditure. The Government’s
projections suggest energy prices will continue to
increase. By implementing energy efficiency measures,
your business can take control of its energy use, limit
avoidable losses and reduce bills.
• Based on experience, the average SME could reduce its
energy bill by up to 30% by implementing energy
efficiency measures. Typically, 10% saving can be
achieved with little or no capital cost.

75. Why invest
in energy
efficiency?
Increase competitiveness
Being more energy efficient will help your business to:
• lower your running costs and increase profit margins
• protect your business from current and future risks, such as increasing energy costs and carbon tax
• win new business, as large businesses and public sector organisations tighten their supplier requirements
Boost reputation
Committing to reduce your climate impact will help your business to:
• improve staff morale, as employees across all sectors increasingly want to work for employers who are climate-aware
• retain employees, as improved staff morale also increases staff retention
• meet customer expectations around sustainability
Elevate branding
Making a commitment to save energy and reduce emissions will help your business attract and grow your base
of customers whose interest in climate change and sustainability has grown hugely in recent years
Protect the environment
Businesses for around 13% of the country's greenhouse gas emissions. Reducing the energy that your
business uses will reduce your carbon emissions and help minimise your environmental impact.

76. What is the role of Bureau of Energy
Efficiency?
• The Bureau of Energy Efficiency is an
agency of the Government of India, under
the Ministry of Power created in March
2002 under the provisions of the nation's
2001 Energy Conservation Act. The
agency's function is to develop programs
which will increase the conservation and
efficient use of energy in India.
What is BEE pat scheme?
• Perform, Achieve and Trade (PAT) is a
regulatory instrument to reduce Specific
Energy Consumption (SEC) in energy
intensive industries, with an associated
market based mechanism to enhance the
cost effectiveness through certification of
excess energy saving which can be traded

77. For any further questions
related to Energy Efficiency
Contact:
Name: Ajai Arora
Phone No: +91-9324784232
Email: ajaibharat@yahoo.com