1. UKG Calculation
STEP 01: UnbalancedLoad Calculationsystemfor 3Φ
VLN =
VLL
√3
PA = VLN * IA * Pf
PB = VLN * IB * Pf
PC = VLN * IC * Pf
Pload = PA +PB + Pc
Here,
VLN = Line to Neutral voltage
VLL = Line to Line voltage
IA = 1st
phasecurrent
IB = 2nd
phasecurrent
IC = 3rd
phasecurrent
PA = 1st
phaseLoad

2. PB = 2nd
phase Load
PC = 3rd
phaseLoad
Pf = Power Factor
Example: Given that,
I1 I2 I3 VLL P1 P2 P3 Load
Amp. Amp. Amp. Voltage Watt Watt Watt Watt
20.9 21.1 20.6 400 ? ? ? ?
Sol
n
: VLN =
VLL
√3
=
400
√3
= 230.94
PA = VLN * IA * Pf = 230.94*20.9*0.9018 = 4352.671
PB = VLN * IB * Pf = 230.94*21.1*0.9018 = 4394.324
PC = VLN * IC * Pf = 230.94*20.6*0.9018 = 4290.193

3. Then, We get
I1 I2 I3 VLL P1 P2 P3 Load
Amp. Amp. Amp. Voltage Watt Watt Watt Watt
20.9 21.1 20.6 400 4352.671 4394.324 4290.193 13037.19
STEP 02: Power Consumption Details
Power Consumption Details
M/C
M/C
No. I1 I2 I3 VLL P1 P2 P3 Load
M/C
Qnty. kW
Total Load in
KW
Amp. Amp. Amp. Voltage Watt Watt Watt Watt
Ring 1 20.9 21.1 20.6 400 4352.6714 4394.3238 4290.1929 13037.188 72 1071.3819 1577.199157
" 30K/W 2 19.5 19 20 400 4061.1049 3956.974 4165.2358 12183.315
" 3 27.6 24.9 24 400 5748.0254 5185.7185 4998.2829 15932.027
" 4 26 25 24 400 5414.8065 5206.5447 4998.2829 15619.634
" 5 12.2 13 12.5 400 2540.7938 2707.4033 2603.2724 7851.4694
" 7 22.5 25 27 400 4685.8903 5206.5447 5623.0683 15515.503
" 8 19 18.5 21.3 400 3956.974 3852.8431 4435.9761 12245.793
" 104 33 33.5 32.3 400 6872.639 6976.7699 6726.8558 20576.265
" 103 18.5 19.1 18.1 400 3852.8431 3977.8002 3769.5384 11600.182

4. " 101 28.6 30 29 400 5956.2872 6247.8537 6039.5919 18243.733
" 100 29 29.1 27 400 6039.5919 6060.4181 5623.0683 17723.078
" 99 31 33.5 22.1 400 6456.1155 6976.7699 4602.5855 18035.471
" 30 K/W 96 24 25 25 400 4998.2829 5206.5447 5206.5447 15411.372 2 30.822745
" 30 K/W 94 20 20.4 19.7 400 4165.2358 4248.5405 4102.7572 12516.534 1 12.516534
" 30 C/W 78 23.5 22.3 23 400 4894.152 4644.2379 4790.0211 14328.411 14 195.15518
" 79 18.5 23.2 19.4 400 3852.8431 4831.6735 4040.2787 12724.795
" 81 23.5 31 23.3 400 4894.152 6456.1155 4852.4997 16202.767
" 82 19.1 24.3 24.8 400 3977.8002 5060.7615 5164.8924 14203.454
" 83 20.8 22.5 22.6 400 4331.8452 4685.8903 4706.7164 13724.452
" 84 23.1 23.6 23.9 400 4810.8473 4914.9782 4977.4568 14703.282
" 85 23.1 23.4 23.5 400 4810.8473 4873.3259 4894.152 14578.325
" 86 16.4 18.1 17.6 400 3415.4933 3769.5384 3665.4075 10850.439
" 87 22.9 22.8 22.2 400 4769.195 4748.3688 4623.4117 14140.975
" 32 K/W 57 18 16.7 17.8 400 3748.7122 3477.9719 3707.0598 10933.744 6 78.12941
" 59 13.1 13.2 12.5 400 2728.2294 2749.0556 2603.2724 8080.5574
" 60 23.5 25.2 23.9 400 4894.152 5248.1971 4977.4568 15119.806
" 62 29 29.2 28 400 6039.5919 6081.2442 5831.3301 17952.166
" 24 C/W 74 28.8 30 29 400 5997.9395 6247.8537 6039.5919 18285.385 8 132.08796
" 75 26.8 26.7 30 400 5581.4159 5560.5898 6247.8537 17389.859
" 77 30.2 30.6 31.7 400 6289.506 6372.8107 6601.8987 19264.215
" 107 26.1 26.5 27 400 5435.6327 5518.9374 5623.0683 16577.638
" 108 18.5 18 16.5 400 3852.8431 3748.7122 3436.3195 11037.875
" 30 SLUB 37 18 17.9 17.4 400 3748.7122 3727.886 3623.7551 11100.353 4 46.067508
" 40 19.5 18.8 19 400 4061.1049 3915.3216 3956.974 11933.401
" 14 SLUB 41 18 18 17 400 3748.7122 3748.7122 3540.4504 11037.875 1 11.037875
Simplex 415 1 11.5 11.6 11.4 400 2395.0106 2415.8368 2374.1844 7185.0317 10 79.035349 123.3118053

5. " 11 13.5 13.8 14.1 400 2811.5342 2874.0127 2936.4912 8622.0381
" 1415 12 12.9 13.5 13.3 400 2686.5771 2811.5342 2769.8818 8267.993 2 16.535986
" FL 100 8 10.7 11.6 11.2 400 2228.4011 2415.8368 2332.532 6976.7699 3 18.80604
" 9 8.8 9 7.4 400 1832.7037 1874.3561 1541.1372 5248.1971
" 10 10.4 10.5 10.7 400 2165.9226 2186.7488 2228.4011 6581.0725
" HY492C 14 14.1 15 13.8 400 2936.4912 3123.9268 2874.0127 8934.4308 1 8.9344308
Drawing(F) SBD-35 1 7.4 7 6.5 400 1541.1372 1457.8325 1353.7016 4352.6714 3 13.151732 38.26810375
" 2 7.2 7.1 6.9 400 1499.4849 1478.6587 1437.0063 4415.1499
" DX7A 1 8 7.8 7.9 400 1666.0943 1624.442 1645.2681 4935.8044 2 9.8716088
" 2 7.9 8 7.8 400 1645.2681 1666.0943 1624.442 4935.8044
" DX8 8 7.9 8.3 8.2 400 1645.2681 1728.5728 1707.7467 5081.5877 3 15.244763
Drawing(B) SBD-15 1 6.5 6.3 6.6 400 1353.7016 1312.0493 1374.5278 4040.2787 3 12.027118 37.78910163
" 2 6.2 6.7 6.2 400 1291.2231 1395.354 1291.2231 3977.8002
" DX7A 1 8.1 8.4 8.2 400 1686.9205 1749.399 1707.7467 5144.0662 4 20.534612
" 2 7.9 8.3 8.4 400 1645.2681 1728.5728 1749.399 5123.24
" DX8 8 8 8.9 8.2 400 1666.0943 1853.5299 1707.7467 5227.3709 1 5.2273709
Lap Former 1 8.5 8.6 8.7 400 1770.2252 1791.0514 1811.8776 5373.1542 1 5.3731542 5.373154159
Comber VC5A 1 7.4 7.5 7.5 400 1541.1372 1561.9634 1561.9634 4665.0641 6 27.90708 27.90707974
" 2 7.4 7.2 7.5 400 1541.1372 1499.4849 1561.9634 4602.5855
" 3 7.2 7.6 7.7 400 1499.4849 1582.7896 1603.6158 4685.8903
Carding TC 03 19 24.1 24.5 24 400 5019.1091 5102.4138 4998.2829 15119.806 13 168.76147 336.2872529
" 20 19.5 19.6 18.9 400 4061.1049 4081.9311 3936.1478 12079.184
" 21 20 18.7 17.7 400 4165.2358 3894.4955 3686.2337 11745.965
" DK 780 9 17.9 17.3 17.1 400 3727.886 3602.929 3561.2766 10892.092 4 44.401413
" 10 18.1 17.9 18.3 400 3769.5384 3727.886 3811.1907 11308.615
" DK 903 26 19.5 20.2 20 400 4061.1049 4206.8881 4165.2358 12433.229 8 100.54879
" 27 20.5 21 19.5 400 4269.3667 4373.4976 4061.1049 12703.969

6. " DK 800 14 19.5 15.2 19.5 400 4061.1049 3165.5792 4061.1049 11287.789 2 22.575578
Blow Room 160 163 148 400 33321.886 33946.672 30822.745 98091.303 1 98.091303 98.09130267
Autocone Savio 7 23.2 25 25 400 4831.6735 5206.5447 5206.5447 15244.763 12 188.01874 227.1719596
" 8 24.4 25.7 25.5 400 5081.5877 5352.328 5310.6756 15744.591
12 25.6 25.5 25.8 400 5331.5018 5310.6756 5373.1542 16015.332
" Schlafrost 1 17 16 14 400 3540.4504 3332.1886 2915.665 9788.3041 4 39.153216
Quality
Room 1 4.6 4.3 1.8 400 958.00423 895.52569 374.87122 2228.4011 2.2284011 2.228401143
Filter 1 82 78 79 400 17077.467 16244.42 16452.681 49774.568 3 171.08706 171.0870597
" 2 39 39.5 38 400 8122.2098 8226.3407 7913.948 24262.498
" 3 162 150 154 400 33738.41 31239.268 32072.316 97049.994
Compressure 1 71.5 74.6 72 400 14890.718 15536.329 14994.849 45421.896 4 182.06246 182.062456
" 2 74 74 71 400 15411.372 15411.372 14786.587 45609.332
AC Plant 1 101 104 107.5 400 21034.441 21659.226 22388.142 65081.809 6 566.74281 566.7428067
" 2 117.6 120 118.5 400 24491.586 24991.415 24679.022 74162.023
" 3 348 321 388 400 72475.103 66852.034 80805.574 220132.71
" 4 173.9 176.5 178.8 400 36216.725 36758.206 37237.208 110212.14
" 5 66 55.5 66 400 13745.278 11558.529 13745.278 39049.085
" 6 97 91 91 400 20201.394 18951.823 18951.823 58105.039
Mechanical C.G.M. 1 6.7 6.8 6.8 400 1395.354 1416.1802 1416.1802 4227.7143 4.2277143 262.8458859
Lighting Ring 22 23 22 220 2519.9676 2634.5116 2519.9676 7674.4469 18 46.046682
"
Blow &
Car. 44.5 73.5 21.9 220 5097.2073 8418.9828 2508.5132 16024.703 16.024703
" Others 94 15.1 0.4 220 10767.134 1729.6142 45.817594 12542.566 12.542566
Dust Collec. Ring 1 4.7 4.9 4.7 400 978.83041 1020.4828 978.83041 2978.1436 3 2.9781436
" Back Side 2 11.2 11.3 11.4 400 2332.532 2353.3582 2374.1844 7060.0747 2 14.120149
Blow
Room 0 0 0 7500 2 15
Bell Press 15.2 15.1 15.3 400 3165.5792 3144.753 3186.4054 9496.7376 9.4967376
Boiler 34 34.5 38.5 400 7080.9008 7185.0317 8018.0789 22284.011 22.284011

7. pump 0 0 0 60000 60
Air
Conditioning 93.7 94 101 400 19514.13 19576.608 21034.441 60125.179 60.125179
Grand
Total 3656.3655 4250
STEP 03: Energy Consumption Summary of different Machines
Type of Machine
Power
Consumption per
Hour(KW)
Utilization Factor Power Consumption per 8
Hours (kWh)
Power
Consumption per
24 Hours (kWh)
Blow Room + Carding 434.379 0.9
3397.45 10192.346
Drawing(Breaker) 37.7891016 0.9
272.0815315 816.2446
Drawing(Finisher) 38.2681037 0.9
275.5303466 826.591
Lap Former + Comber 33.28 0.95
252.928 758.784
Simplex(Fly frame) 123.311805 0.92
907.5748848 2722.725
Ring Frame 1577.1992 0.96
12249.53 36748.518
AutoCone 227.17196 0.95
1726.506896 5179.521
Others 1134.153 1
9073.2 27219.67
Total 3656.36917
28154.80031 84464.4

8. Type of Machine KWh for 8 Machine running
hour
Productionrate per 8 hours Productionrequirement for
100 kg of yarn (kg)
Chute feed Blow room
+Carding
3397.45/27 = 125.83 336 118
Drawing Breaker 272.08/8 = 34.01 982 105
Finisher 275.53/8 = 34.44 916 105
Simplex(Fly frame) 907.58/16 = 56.7 4 103
Ring Frame 12249.53/108 = 113.4 130 100
AutoCone 1726.51/16 = 108 8.06 100

9. STEP 04: Calculation of UKG for 30 S/1 KW
Chute feed Blow room +Carding =
125.83×118
336
= 44.25
Breaker Drawing =
34×105
982×2
= 1.82
Finisher Drawing =
34.44×105
916×2
= 1.97
Simplex Frame =
56.7×103
4×120
= 12.2
Ring Frame =
113.4×100
516×0.130
= 169
AutoCone =
108×100
60×8.06
= 22.33
Others =
9073.2 ×100
7244.64
= 125
Total units for 100 kg of yarn = (44.25 +1.82 +1.97+12.2+169+22.33+125) =376.5
UKG for 30 count =
376.5
100
= 3.77
UKG for 40 Ne Conversion = 3.77÷.67 = 5.62