Implementation of EnMS at MFT

8/3/2019 Implementation of EnMS at MFT

http://slidepdf.com/reader/full/implementation-of-enms-at-mft 1/51

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EnMS Program supported by

GTZ-SMEDA-APTMA

IMPLEMENTATION OF ENERGY MANAGEMENT SYSTEM

IN

FAROOQ TEXTILE MILLS -2010



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TABLE OF CONTENTS

S.# Topic Page #

A Title 1

B Table of Contents 2-3

C Executive Summary 4

1 General Information of the Textile Sector 5

2 Global and Local Energy Crisis Impact on Pakistan Textile sector 5

3 General Information of Company 5

4 Scope of Project 6

5 Scope of Report 6

6 Limitation of the Report 7

7 Format of the Report 7

8 Our Audit Approach 7

9 Data Collection Method 8

10 Instruments used for Data Collection 8

11 Units of Measurement 9

12 Unit Cost Calculations 9

13 Industry Benchmark 10

14 Company Energy Consumption Performance 10

15 Manufacturing Process Flow 17

16 Preliminary Energy Audit Observations 18

17 Detailed Energy Audit –Baseline Data (As is Scenario) 21-38

17.1 Energy Producers—Electrical

17.2 Energy Producers—Steam

17.3 Energy Producers—Gas combustion at singeing

17.4 Energy Consumers—Electrical Machines & Motors

17.5 Energy Consumers—Electrical Lighting

17.6 Energy Consumers—Steam @ machines, pipes and steam traps

17.7 Management Practices 39



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TABLE OF CONTENTS

S.# Topic Page #

18. Energy Management Objectives –(To be Scenario) 42-5018.1 Energy Producers—Electrical

18.2 Energy Producers—Steam

18.3 Energy Producers—Gas combustion at singeing

18.4 Energy Consumers—Electrical Machines & Motors

18.5 Energy Consumers—Electrical Lighting

18.6 Energy Consumers—Steam @ machines, pipes and steam traps

18.7 Management Practices

19 Recommended Implementation Strategy 51



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Executive Summary

Mohammad Farooq Textile Mills Limited (MFTML) participated in the Renewable Energy & Energy

Efficiency Program of GTZ under the platform of APTMA and in coordination with SMEDA for EnergyManagement System Development and Implementation. Arch Associates was selected by GTZ as

project consultant.

This report describes the Energy Audit Findings conducted as a part of the Energy Management System

Development and Implementation. Committee Draft ISO 50001 of Energy Management System (EnMS)

was used as the benchmark standard for the Energy Audit and system implementation. The Energy

Policy, System Procedures and related forms are compiled as a separate manual.

A holistic approach for energy audit was used with focus on energy balance at the energy producer and

energy consumer entities. Electricity, Steam and Heat in any form are considered as form of energy.

Preliminary and detailed energy audit has identified inefficiencies mainly at the electrical power

generation and consumption stage. Almost in all the energy consumption domains (electricity, steam,

water, gas), the per kg fabric consumption is much higher than the international and national

benchmarks.

Besides cost saving opportunities related to electrical energy generation and consumption (Rs 6

million), significant cost savings can be achieved in the area of steam generation and consumption by

combustion efficiency of boilers (Rs 7 million), utilizing the heat from waste gases of boiler stack, heat

losses in the processing area due to steam leakages (Rs 2.6 lacs), inefficient steam traps, effective

insulation of semi-insulated and bare steam pipes (Rs 52000).

Also increasing the consumption efficiency of water (Rs 4.4 million) and gas in the wet processes and at

singeing machine (Rs 42000) will yield high cost savings.

Except for waste heat recovery from generators, rest of the identified energy conservation

opportunities does not require heavy investment and merely by improving the management systems

related to preventive maintenance and good housekeeping with focus on workers training and creating

sense of process ownership will yield high savings.

By converting from estimation based energy cost management to real time measurement of energy

production and consumption efficiencies and calculating cost impact as a part of Energy Management

Information System will support MFTML management in prompt identification of high cost drivers and

its impact on overall cost of production



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1. General Information about Pakistan Textile Sector

Pakistan Textile and Apparel industry generates about 64 % of total exports and constitutes 46 % of

Manufacturing Industry. It employs 40% of Country’s working population and contributes 11% of thetotal GDP. Pakistani clothing export growth slowed to 8% in 2006, following three years of double digit

increase.

2. Global and Local Energy Crisis Impact on Pakistan Textile Sector

Pakistan’s textile industry has been particularly ravaged by high energy prices and shortages of supply.

National exports for last year fell 25% or US$5.12 billion short of targets, and this year’s forecasts have

been substantially scaled back as well. Despite the current global economic recession, estimates place

the losses due to energy prices at around US$1 billion annually, with failure to meet orders caused by

the effects of energy shortages on production times driving away future business. Given that 64% of the country’s export earnings come from textiles, the crisis is of vital importance to Pakistan’s

economic recovery and future.

3. About Mohammad Farooq Textile Mills Limited

Company Name: Mohammad Farooq Textile Mills Ltd

Industrial Sector: Textile Processing

Range of Products: Woven fabrics, Dyed & Printed bed sheets and curtains

Address: Plot # 6& 7, Sector 21, Korangi Industrial Area. Karachi

Telephone: 92-021-350515498URL: www.mohammadfarooq.com

Contact Person: Mr. M. Younus—General Manager Operations

Energy Manager: Mr. Lucman (Utility Manager)

Site Characteristics

Total Space = 16 acre (65000 m2)

Production Space = 44000 m2

Office Space = 603 m2

Storage Space = 498 m2

Production Capacity: 2.3 million liner meter fabric

http://www.mohammadfarooq.com/






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Mohammad Farooq Textile Mills Limited is among the oldest and largest textile units of Pakistan

located in Karachi. The company is involved in the manufacturing, dyeing and printing of woven fabrics

mainly related to Home Textiles. Previously the company was the complete vertical unit from spinning

to garments but now due to recession and slump in textile trade, it has reduced its manufacturing

operations to dyeing and printing predominantly while few weaving looms and small garment unit.

Currently its products are mainly exported to USA and few lawns are for sale in the local market.

Since 2001, company is maintaining ISO 9001 Quality Management System Certification and also

follows buyers Code of Conduct for Corporate Social Responsibility

4. Scope of the Project

German Technical Corporation (GTZ) as Project Sponsor with Small Medium Enterprise DevelopmentAuthority (SMEDA) as the coordinating body and All Pakistan Textile Manufacturers Association

(APTMA) as the beneficiary body initiated the Energy Management System Development and

Implementation Project for the selected group of textile companies related to spinning, weaving and

processing sector. The objective of the project is to not only identify the energy cost savings through

energy audits but also to bring on board all the management functions of the company for sustainable

energy conservation practices through documented Energy Management System development and

implementation.

In this regard the upcoming Energy Management Standard of ISO 50001 is selected as the benchmark

model to develop the Energy Management System

For Energy Management System (EnMS) development and implementation at Mohammad Farooq

Textile Mills, the processing area comprising dyeing and printing is selected for EnMS development and

implementation beside electrical power generation and steam production.

The areas of weaving and garment are out of scope for this project.

5. Scope of the Report

This report details the Energy Audit findings and the corresponding Energy Management Objectives for

the processing area comprising dyeing and printing including power generation and steam production.

The Energy Manual and related procedures including instructions are presented as separate document

and are not part of this report.



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6. Limitation of the Report

Since energy audit was performed during the period of Dec 2009—Jan 2010, which is usually low

production phase for the textile sector, therefore at times the data measured at the machines when itwas not running at its optimum capacity. Also no measurement was collected for pad steam as it was

not operational during the audit time frame. Similarly our observations and measurement were

focused on energy generation, consumption and wastages as a process and does not take into account

the balancing between total power generation and production capacities as currently power

generation model is based on the previous manufacturing setup including spinning, weaving,

processing and garments while presently the same power generation model is catering only processing

and partly few looms and garment section.

7. Format of the Report

The report is structured in the form of “As is Scenario” and “To be Scenario” for each component of

energy producer and consumer. Each component is depicted in the form of energy input and output

supported by data tables, graphs and calculations to demonstrate energy wastage and cost saving

potential

8. Our Approach for Audit

We take the holistic view of the total energy model employed at Mohammad Farooq Textile Mills and

categorized it as Energy Producers and Energy Consumers.

Under Energy Producers, gas fired Generators and Boilers (gas fired and thermo) are categorized while

Electrical Panels, Machines, Motors, Pumps, Fans, Building [lighting] etc are categorized as Energy

Consumers consuming energy in the form of electrical power or heat energy.

To identify the energy loss at Energy Producers and Energy Consumers stage, energy balance approach

is used as depicted below.

Energy InputEnergy Conversion

Value Added Energy

Output

Energy Wastage



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This energy process realization is used to identify the Energy Efficiency, Energy Wastages and the Cost

associated with the wastages either at the input stage or output stage.

For cost saving opportunities identification we initially identified the maximum possibleopportunities during the preliminary energy audit and used 80/20 approach in detailed audit for

data collection and cost savings potential. Only those 20% energy savings opportunities haven been

taken as Energy Management Objectives (EMO) which have an impact of 80% cost savings in the

total cost saving pie.

9. Data Collection

Method

The data collection process comprised of data provided by the organization and the measurementexercise carried out by our team during the detailed energy audit scenario.

Where data reported by organization was based on estimation rather than measurement, it was

measured during the detailed energy audit in order to have accuracy in energy efficiency, energy

wastages and cost savings values.

To the extent possible, dependability on estimated values is discouraged for calculations except in

those cases where measurements for the total number of equipments (e.g. motors) was not possible

and sample results are averaged and plotted for the total range of similar equipments (conditionality:

similar make, rating and type of equipment)

Following were the sources of data collection

Data provided by organization in the form of gas bills, production figures, electricity units

generated through self generation, water consumption etc

Data noted from the measuring devices installed at different equipments

Data collected through measurement exercise during the detailed energy audits in

collaboration with Department of Energy & Environment of QUEST--Nawabshah and

Environmental Research Centre of Bahria Univeristy –Karachi.

Data collected through visual observations

10. Instruments Used for Data Collection

Flue gas analyzer

Lux Meter



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PF Meter

Volt Meter

Electric Power Meter Analyzer

Low and High Infrared Temperature Meter

Tong Tester

Flow Meter

11. Units of Measurement

Production = linear meter

Steam = Kg/ year

Electricity = Kwh/year

Gas = m3

12. Unit Cost for Calculations (based on 2009 data)

The unit cost calculation for gas, electricity and steam are based on the fuel consumption cost and does

not take into account the overhead cost involved as in case of energy savings, the direct impact will be

on the fuel cost than on the overhead cost. Also the financial savings demonstrated through energy

conservation will be more accurate and verifiable in the absence of inclusion of overhead cost. The cost

provided by the company and included in the tables coverts the total generation cost i.e. fuel cost plus

the overhead cost.

For Steam

Steam Consumption= 86261760/12499886 = 6.90 kg/ meter

6.90 kg = 8.17 Rs.

Cost of 1 Kg Steam = 8.17/ 6.90 = 1.18 Rs/ kg (provided by MFTML)

For electricity

Number of electricity units generated per month= 357131 Kwh

Cost of 1 m3 Natural gas = 10.44 Rs.(derived from Gas Bill)

Gas consumption for 1 Kwh = 0.346 m3

Cost for generation 1 Kwh = 3.612 Rs. /Kwh (Calculated from gas consumptionand does not include overhead cost)



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13. Industry Benchmark

Water Consumption Norms (per Kg)

World Consumption---50-100 litres/kg of fabricNational Consumption ---Sind –50-80 litres/kg of fabric Punjab---200-300 litres/kg of fabric

Steam Consumption---6-8 kg of steam/ kg of fabric

Electricity Consumption----0.8—1.5 KWh / kg of fabric

Gas Consumption---0.35 m3

of gas/ kg of fabric

14. Company Energy Consumption Performance

To evaluate the company energy consumption performance against the established benchmarks /

norms, data for the year 2009 was collected and analyzed.

Water Consumption

Table 1—Machine wise water consumption data for the year 2008-09



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Graph-1- Water Availability data per day from KDA and Well water

Graph-2-Machine wise water consumption trend during the month

Analysis

Average Water Consumption (2008-09) = 88897392 / 12 = 7408116 gallons per month

Average Production (2008-2009) = 1047770 m per month = 209554 kg for 2009 (Assume 200 gm per linear

meter)

Average Water consumption per linear meter of fabric= 133.81 litres/kg of fabric which is much higher

than the benchmark value for Sind and international norm.

High consumption rate is noticeable at bleaching and washing machine. This is supported by water

wastage savings identified at these machines and explained in the Detailed Audit section



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Steam Generation

Table-2- Boiler wise steam generation data

Table-3- Machine wise steam consumption data



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Graph-Steam consumption at different machines (This data is based on approximation)

Analysis

Average Steam Consumption (2008-09) = 6127680 kgs per month (excluding steam consumed in

stitching 1& 2, HVAC and sizing)

Average Production (2008-2009) = 1047770 m per month = 209554 kg for 2009 (Assume 200 gm per linear

meter)

Average Steam consumption per linear meter of fabric= 29.24 kg of steam /kg of fabric which is much

higher than the benchmark value.

Since steam monthly production is not measured and recorded therefore its consumption pattern

against the monthly production can’t be analyzed.

Electricity Consumption

Table-4 –Electricity Generation Data (Till Oct 2009)



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Graph

Analysis

Average KWh Consumption (Jan-Nov 2009) = 7786654 KWh / 11 = 707877 KWh

Average Production (Jan-Nov 2009) = 11525478 / 11 = 1047770 m per month = 209554 kg for 2009

(Assume 200 gm per linear meter)

Average Electricity consumption per kg of fabric= 3.37 KWh kg of electricity /kg of fabric which is much

higher than the benchmark value.

An abnormal trend is observed for the month of May 2009 when production volume increased

considerably compared to April 2009 but the electricity generation in KWh is showing decreasing trend

in May 2009

Gas Consumption

Table



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Cumulative Gas Consumption Details Nov 2008—Oct 2009



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Graphs

Analysis

Average Gas Consumption (Nov 2008—Oct 2009) = 638255.9167 m3. Gas consumed in production onlyAverage Production (Nov 2008—Oct 2009)= 1240565.25 m = 248113 Kg (Assume 200 gm per linear

meter)

Average Gas consumption per kg of fabric= 2.57 m3

gas /kg of fabric which is much higher than the

benchmark value . Taking into consideration the gas consumed for electric power generation, the per

kg fabric value comes to around 4.53 m3

.

An abnormal trend is observed for the month of May 2009 when production volume increased

considerably compared to April 2009 but the gas consumption is showing decreasing trend in May

2009



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15. Manufacturing Process Flow



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16. Preliminary Audit Observations

Steam Generation and Consumption

1. Steam header valve is leak.

2. Temperature, pressure and other gauges are not calibrated.

3. Most (almost 100%) of steam traps are leakages.

4. Steam leakage at Kuster Pre Treatment

5. Piping insulation at Kuster PT is not proper.

6. Condensate pipe is leak.

7. Insulation not proper at Thermo boiler (Rotary Printing)

8. Two Feed Water tanks are not insulated.

9. Blow down water tank is also not properly insulated.

10. No drainage is made for the water at the Boiler House. 11. Condensate Water is drained.

12. Water Flow meter not installed anywhere in the Boiler House.

13. No any measuring device for the Steam generation, Gas Consumption, Electricity Consumption, Boiler

Feed water tank is installed.

14. Boiler Efficiency is not monitored as there is no measuring instrument installed for efficiency

measurement.

15. No any device for the measurement of NOx, SOx, and other flue gases. Energy Accounting

16. In piping some of the line are oversized and some are undersized (No uniformity of the piping system).

17. Steam Condensate pipes leakages are not fixed.

18. Damaged insulation is not repaired, and where fixed the correct insulation material is not used.19. No pre-heating of combustion air with waste heat (22 0C reduction in flue gas temperature increases

boiler efficiency by 1%).

20. No use of variable speed drives on boiler combustion air fans with variable flows.

21. One oil tank requires insulation.

22. No maintenance record to conform that burners, nozzles, strainers, etc are cleaned

23. No inspection record related to Inspection of oil heaters for proper oil temperature.

24. Close burner air and/or stack dampers when the burner is off to minimize heat loss up the stack.

25. Improve oxygen trim control (e.g. -- limit excess air to less than 10% on clean fuels). (5% reduction in

excess air increases boiler efficiency by 1% or: 1% reduction of residual oxygen in stack gas increases

boiler efficiency by 1 %.)26. Automate/optimize boiler blow down. Recover boiler blow down heat.

27. Use boiler blow down to help warm the back-up boiler.

28. Optimize deaerator venting.

29. No Inspection of door gaskets.

30. No Inspection for scale and sediment on the water side



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31. (A 1 mm thick scale (deposit) on the water side could increase fuel consumption by 5 to 8%).

32. No Inspection for soot, flyash, and slag on the fire side. (A 3 mm thick soot deposition on the heat

transfer surface can cause an increase in fuel consumption to the tune of 2.5%.)

33. Optimize boiler water treatment. Presently continuous blow down indicates water treatment is not

effective.

34. Add an economizer to preheat boiler feed water using exhaust heat.

35. Recycle steam condensate.

36. Study part-load characteristics and cycling costs to determine the most-efficient mode for operating

multiple boilers.

37. Fix steam leaks and condensate leaks (A 3 mm diameter hole on a pipe line carrying 7 kg/cm2 steam

would waste 33 kilo litres of fuel oil per year).

38. Accumulate work orders for repair of steam leaks that can't be fixed during the heating season due to

system shutdown requirements. Tag each such leak with a durable tag with a good description.

39. Ensure process temperatures are correctly controlled.

40. Maintain lowest acceptable process steam pressures.

41. Reduce hot water wastage to drain.

42. Remove or blank off all redundant steam piping.

43. Ensure condensate is returned or re-used in the process (6 0C raise in feed water temperature by

economiser/condensate recovery corresponds to a 1% saving in fuel consumption, in boiler).

44. Check operation of steam traps.

45. Inspect steam traps regularly and repair malfunctioning traps promptly.

46. Consider recovery of vent steam (e.g. -- on large flash tanks).

47. Use waste steam for water heating.

48. Repair damaged insulation (A bare steam pipe of 150 mm diameter and 100 m length, carrying

saturated steam at 8 kg/cm2 would waste 25,000 litres furnace oil in a year.)

49. Insulate all flanges, valves and couplings

50. Insulate open tanks (70% heat losses can be reduced by floating a layer of 45 mm diameter

polypropylene (plastic) balls on the surface of 90 0C hot liquid/condensate).

Electrical Power Generation and Consumption

1. Almost all of the lights are TUBE LIGHTS and ON during the day time where sufficient daylight is

available.

2. Panels in the Boiler House are very old and rust is present on them.

3. No maintenance of the electrical equipment was found.

4. There was dust on the tube lights as there is no proper cleaning system of the tube lights.

5. Power Factor on the generators is very low i.e. 0.75

6. Power Factor at the distribution side is also low



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Feeder # 1 :0.74

Feeder # 2 :0.83

Feeder # 3 :0.87

Feeder # 4 :0.85

7. Schedule your operations to maintain a high load factor

8. Correct power factor to at least 0.90 under rated load conditions.

9. Relocate transformers close to main loads. (Two transformers are at distance from the main load)

10. Use energy-efficient motors where economical.

11. Use synchronous motors to improve power factor.

12. Use variable-speed drives for large variable loads.

13. Check belt tension regularly.

14. Clean screens and filters of blowers regularly.

15. Repair seals and packing of pumps to minimize water waste.

16. Balance the system to minimize flows and reduce pump power requirements.

17. Consider painting the walls a lighter color and using less lighting fixtures or lower wattages.

18. Optimize generator loading

19. Use waste heat to generate steam through WHRB.

20. Use jacket and head cooling water for process needs



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17. Detailed Audit--Baseline Data ( As is Scenario)

Energy Producer

17.1. Electrical Power Generation

MFTML has three gas fired generators, out of which two are for normal operations and one used as

standby arrangement. The details of engines are as below

Gas, Air mixture

Generators Electrical Power

Stack Gases @ 520 C as

waste



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The operating parameters when measured on Jan 09,2010 indicated the following readings

The electrical power generated through two generators is routed to two transformers (incoming power) and

four feeders (outgoing power) as per following arrangement



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The distribution of electricity in different areas is as per below table

Total

Electricity

Generated

(kWh)

Consumption (kWh)

Processing Main

Office

Boiler RO Computer Power

House

unknown Etc

213322 412255 455544 21415 5555 2211 2255 12221 111

132132

100% 10% 20% 15% 30% 10% 10% 4% 1%

The low power factor at Generators and feeders indicates energy wastage which can be saved by

technological intervention. The calculations for power factor improvement from existing 0.75 to 0.9

are detailed below along with cost saving potential calculations.

Generator Low Power factor Cost Impact calculation

Running load of generator # 1= 650 kW

Average Power Factor = 0.75

kVA taken at 0.75 = 866.6

kVA taken at 0.90 = 755

=866.6-755



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=111*0.9 (desired power factor) = 100.04

=100.04* 8760(running hours) * 3.61(fuel cost for electricity generation)

Savings on Gas fuel =Rs. 3175009.44/Year

For two generators =2* 3175009

Total Savings on Gas bill =Rs. 6350018 /yr

17.2. Steam Generation through waste gases

Similarly waste gases from the two generators are currently emitted in the atmosphere. The profile of

stack gases of both the generators is tabulated below.

STACK GAS ANALYSIS FROM GENERATOR I

S.No. Parameters Unit Monitoring Results

1 Temperature (Ambient) oC 28.8

2 Temperature (Stack) oC 532.4

3 Carbon Monoxide ppm 171

4 Carbon dioxide % 1.47

5 Nitrogen Oxide ppm 43

6 Nitrogen dioxide ppm 0.6

7 Sulphur Oxide ppm ---8 Hydrogen ppm 71

9 Oxygen % 18.41

STACK GAS ANALYSIS FROM GENERATOR II








7 Sulphur Oxide ppm ---

8 Hydrogen ppm 55

9 Oxygen % 19.72



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On the basis of oxygen and CO2 contents of the stag flue gases the combustion efficiency is in the range of 75-

80%. This low efficiency is due to the high oxygen content in the flue gas.

Currently the total steam requirement is around 22 TPH which is met through four gas fired boilers.Capturing of high temperature stack gases and directing them in Waste Heat Recovery Boiler (WHRB)

will reduce the steam demand from conventional boilers thereby impacting on gas consumption.

The calculations below demonstrate the potential for steam generation through WHRB and cost

savings.

WASTE HEAT RECOVERY COST CALCULATION

Power = P= 650

Exhaust temp. = 532.4 0C

Pressure= 10.54 kg/cm2

Mass of stack gas = 78.6 Nm3/min=5.07 Kg/kwh

Cp= 0.25 K cal/kg 0C

Feed water Temp.= 70 0C

H= 663.755 k cal/kg

Temp of steam= 272.4 0C

Hrs/year= 8760

Qty of heat available from the flue gas= 650 * 5.07 * 0.25 * (532.4- 272.4)

= 214207.5 K cal/hrs

Qty of Steam generated = 214207.5 / (663.755- 70)

= 360.76 Kg/hrs (for one generator)

= 721.52 kg /hrs (for two generators)

= 721.52 * 8760 * 1.18 (steam cost)

Steam Generation Cost saving = Rs. 7458207.9/ year



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17.3. Burners Inefficiency at Singeing M/c

Burners are not adjusted with respect to the fabric width. Burner flames remains open either fabric width is 66”

or 116”

Usually Singeing machine consumes gas 0.0015 m3 (industry benchmark) for 1 linear meter of fabric but in

MFTML singeing machine consumes 0.005 m3 for 1 linear meter of fabric.

Average production = 11648599 meters for based on last 3 years (2007-2009) production data

= 17472.99 If M/c consumes 0.0015 m3 gas for 1 linear meter fabric

= 58242.99 m3 (machine consumes 0.005 m3 gas for 1 meter fabric)

Difference = 40770 m3

Gas Cost = 10.44 Rs. /m3

Amount Loss = Rs. 425638.8

NOTE: The amount may be increased because all flames are remains open either fabric width is 66” or 116”.

This amount is additional to that which can be saved if flames are adjusted as per the width of the fabric.

17.4. Steam Generation

MFTML has four gas fired boilers generating steam primarily for the processing area while partly it is

utilized in garment section and three thermo boilers in the processing area.

Gas, Air mixture

Water, chemicals

Boilers

Steam

Stack Gases @ 324 C as

waste gas

Blow Down



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Boiler#1

Make: Standard Duisburg Kessel

Construction Year 1960 Type Fire TubeChimney Height approx 28-30 ft Fuel Gas Fired

Boiler # 2

Make: Babcock Steam Block

Construction Year 1969 Type Fire Tube

Chimney Height approx 50 ft Fuel Gas Fired

Boiler # 3

Make: GWB Boilers

Construction Year Not Available Type Fire Tube


Boiler # 4

Make: GWB Boilers

Construction Year Not Available Type Fire Tube


Thermal Rating of Oil Heater

# Thermal

Rating

(kcal/hr)

Oil

circulation

(m3/hr)

Oil

Holding

Capacity

(lit)

Temperature

(˚C)

Machines

operated

Gas

consumption

(m3/day)

Electricity

consumption

(kWh)

1 2000 2200 250 Stenter I

(4chamber),Stork

Steamer I.

950 50

2 2200 2200 250 Rotary Printing,

Stork Steamer II,

1250 50

3 1800 2200 250-280 Stenter (6

Chamber)

1300 35



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The stack gases analysis results as follows

STACK GAS ANALYSIS FROM THERMO BOILER I




3 Carbon Monoxide ppm ---

4 Carbon dioxide % ---

5 Nitrogen Oxide ppm ---



8 Hydrogen ppm 55

9 Oxygen % 20.49

STACK GAS ANALYSIS FROM BOILER II





4 Carbon dioxide % Nil




8 Hydrogen ppm 60

9 Oxygen % 20.23

On the basis of oxygen and CO2 contents of the stag flue gases the combustion efficiency is in the range of 80-

85%. This low efficiency is due to the high oxygen content in the flue gas.



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STACK GAS ANALYSIS FROM THERMO BOILER II


1 Temperature (Ambient)o

C 31.02 Temperature (Stack) oC 324.3






8 Hydrogen ppm 52

9 Oxygen % 8.62

STACK GAS ANALYSIS FROM THERMO BOILER III









8 Hydrogen ppm 29

9 Oxygen % 2.99



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17.5. Energy Consumer

Electrical Power Consumption

Electrical Power in MFTML is used for running the processing machines, motors, pumps, compressors,

lighting, air conditioning, chillers etc. The major consumer of electric load is machines, motors and

pumps. The detail of electrical load requirement for major machines is tabulated below.

MACHINE TYPE NOMINATIVE POWER (kW)

Singe-Desize 20

Benninger Pretreatment 44

Benninger Mercerize 20

Cylinder Dryer 11

Kuster Pretreatment 40

Kuster Washing 50

Benninger Pad Steam 20

Monforts Thermosole I 18

Monforts Thermosole II 30

Jet 12

Jigger I,II 10

Monforts Stenter II 80

Monforts Stenter IV 90

Bruckener Stenter 60

Zimmer Flat Bed Printing 75

Zimmer Rotary Printing 90Kuster Calendar 80

Electrical Power

Machines

Motors

Pumps

Compressors

Mechanical Power

Heat

Vibration

Lighting

Cooling



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Motors Data

COMPRESSOR DATA

There are 8 compressors in the mill. Compressor # 4,5 & 6 are not working nowdays.

Description Compressor # 1 Compressor #2 Compressor #3 Compressor #7 Compressor #

Location

Make Atlas copco Atlas copco Atlas copco Atlas copco Atlas copco

Type Rotary screw

type

Rotary screw

type

Rotary screw

type

Rotary screw

type

Rotary screw

type

Rated power

(kW)

160 160 160 90 37

Cooling method Water Water Water Air Air

Free Air Delivery

(m3/min)

386 386 386 98

Set operating

pressure (bar)

6.5 6.5 6.5 6.5 6.2

Receiver tank

volume (m3)

Drain System Manual Manual Manual Manual Manual

Dryer Install & in

working

condition

Install but not

working

Install but not

working

Install but not

working

Install but not

working

Delivery line size 3" 3" 3" 2" 2"

Suction status Normal Normal Normal Not workproperly

Good

Max. Speed (rpm) 1500 1500 1500 2970 3000



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On the basis of measurement exercise, the motors were found to be operated at low efficiency level i.e. 85%

compared to industrial norm of atleast 90% efficiency level.

MOTOR LOW EFFICIENCY COST

hp= 12.7

Actual efficiency= 85 %

Desired Efficiency = 90%

Operating hrs/ year = 6300

Unit price = 3.61 Rs/ kwh

@ 85 % efficiency = 12.7 * 0.745/ 0.85 = 11.43 kw

@ 90 %efficiency = 12.7 * 0.745/ 0.90 = 10.51 kw

Total loss = 11.43 – 10.51 = 0.917 kw

Cost Saving = 0.917 * 6300 (running hours) * 3.61 (electricity generation fuel cost) = Rs. 20855.331/ year

Total motors = 210

Total cost savings for all motors = Rs. 4400405 / yr (approximation used is that all motors were

assumed at 12.7 HP although the Hp ranges from 0.08-60 Hp)

Savings through Effective Lighting



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17.6 Steam / Heat Consumption

Measurement data demonstrated that heat energy contained in steam and hot water is wasted during

steam distribution through condensate, steam leakages, steam traps, hot water drainage etc. Also gas

as fuel is wasted during singeing process when flame is not adjusted as per the fabric width.

Heat (Flame, Steam,

Hot Water)

Fabric

Machines

Pipes

Mechanical Power

Steam Leakage (pipes,

tra s

Loss through conduction

Hot water drain

Condensate



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Cost Impact Calculations for Steam Leakages.



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Cost Impact Calculations for Semi Insulated Steam pipes and bare steam pipes

.



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Wastage of Water

Cooling water is drained from different areas of machines. This water can be reused.

Kuster Bleaching

Cost Saving from Drive motors Water of chamber # 3 & 7:

From Chamber # 3

drive motor

18 lit/min 25920 lit/day 25.92 m3/day

From Chamber # 7

drive motor


Total 42 lit/min 60480 lit/day =

13321.6 gallons/day

60.48 m3/day

This water is used at ambient temperature.

Cost of 1 gallon of water = 0.15 Rs.

Drainage water cost = 1998.23 Rs./day = 599471.36 Rs./ year (Assume 300 working days)

Advice

Since purpose this water is to cool the hydraulic motor drives and usually a fast flow rate is maintained ,

therefore this water can be reused either by transferring it to tank or use it in the washing chambers.

Kuster Bleaching

Post washing water will be used in the prewashing chamber; this will save the water cost i.e.

Waster used in the pre washing chamber = 2 l/kg

Average production = 12499886 meters for 2009

= 2499977 kg for 2009 (Assume 200 gm per linear meter)

= 2499977 * 2 = 4999954 litres

Water cost = 0.15 Rs.

Total loss = 4999954 * 0.15 = 749993 Rs./year 2009



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DYEING

From Hydraulic pump

Padder motor


Total 12 lit/min 17280 lit/day =

3806 gallons/day

17.28 m3/day

Cost of 1 gallon of water = 0.15 Rs.

Drainage water cost = 570 Rs./day = 171277 Rs./ year (Assume 300 working days)

SINGEING MACHINE:

Cost saving at Singeing M/c.

Water from Right

burner (Temp of

water @ 50C)

7.6 lit/min 10944 lit/day 10.944 m3/day

Water from Left

burner(Temp of water

@ 50C)


Water from Upside

Cooling(Temp of

water @ 30C)


Water from Downside

Cooling(Temp of

water @ 30C)


Total (Temp of water

@ 40C)

78.3 lit/min 112752 lit/day

=24835 gallons/day

112.752 m3/day

Cost of 1 Gallon of Water= 0.15 Rs.

Drain water cost =3725.28 Rs./day = 1117585 Rs./ year (Assume 300 working days)

This water can be reused at the singeing machine.



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17.7.Management Practices

Maintenance Systems

There is no formal preventive maintenance system in place for all the power producing and consuming

equipments. No preventive maintenance schedules, checklists and records were shown during the

audit.

Machine breakdown data was not provided. The overall equipment condition, steam and water pipes

condition, insulation status, apparent steam and water leakages indicated the lack of maintenance and

availability of resources.

Quality Control

In effective process and product Quality Control is an indirect source of energy wastage. The re-work

records related to stenter 2 & 4 for the year 2009 is tabulated below

Month Stenter 2 Stenter 4

Jan 12060 9005

Feb - 16115

Mar - 16570

Apr 2170 15760

May 3322 11,157

Jun 13836 14225Jul 20790 35805

Aug 350 2140

Sep 1550 1665

Oct 5895 21205

Nov 14090 14225

Dec 15695 16380

Total = 264,010 m



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Process Instrumentation

Availability of gauges for monitoring of temperatures, pressures, flow rates etc during the entire

course of electricity and steam generation and distribution and manufacturing processes is very scarce.

Even at critical stages e.g. gas flow rate at boiler is not measured and monitored.

The energy data utilized by the company is derived more from approximation rather than from

measurement.

No formal calibration system is in place. At places measuring devices are not in working conditions.

Measurement and Monitoring of Energy Key Performance Indicators (EnKPI’s)

Currently company has not identified nor monitoring any EnKPI’s in relation with the cost. MFTML

finance department records and reports the cost of electricity generation, steam generation, electricity

consumption, steam consumption on approximation basis and does not compare the consumption

trends with any benchmark values. Inability to identify, measure and monitor EnKPI’s deprives the

organization to focus on increasing the efficiency in energy generation and consumption thereby

reducing cost.

Housekeeping Issues

A very untidy atmosphere is prevalent in the processing area. Management and workers are not

focused to capture the energy efficiency opportunities merely by practicing Good Housekeeping

Practices which requires no dust and dirt in the area, no leakages of steam and spillage of water.

Presently except for floor cleaning no other part of the machine, work place, including tube lights is

cleaned



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Total Cost Saving Opportunities

Area Domain Savings in Rupees/year

Power Generation Power Factor Improvement 6350018

Using Waste Heat of Stack gases 7458207

Power Consumption Increasing Motor Efficiency 4400405

Lighting 280479

Gas Combustion Singeing 425638

Steam Consumption Leakages, insulation, hot water

drainage etc

316662

Water Wastage Water for Cooling purpose 1692018

Total Savings

20923427



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18. Energy Management Objectives (To Be Scenario)

Objective # 1

OBJECTIVE NAME To improve the power factor of Generators from 0.75 to 0.90 byinstalling PFI panel

DOMAIN Power Generation CATEGORY Short Term

PURPOSE OF

OBJECTIVE

To balance the power generation and distribution efficiency in case of

fluctuating load demands.

RESULT OF

OBJECTIVE

Gas savings in power generation.

TARGET START DATE April 2010 TARGET COMPLETION DATE June 2010

APPROX INVESTMENT Rs. 1 Million APPROX

SAVINGS

Rs. 6 Million PAYBACK

PERIOD

2 month

DETAILS /STEPS RESPONSIBILITY

Seeking Managing Director approval for investment based on

potential cost savings and low pack back period.

GM Operations

Seeking quotes for PFI panel Utility Manager

Meeting with equipment suppliers and seeking best energy

efficiency arrangement and configuration. Discuss current and

future power generation requirements and arrangements.

Utility Manager

Requesting potential suppliers to arrange demo of anyindustrial unit for application of PFI panel and its impact on

cost savings.

Utility Manager

Selecting supplier Utility Manager

Installation of PFI panel Utility Manager

Monitoring PF improvement at power generation and

consumption stages

Utility Manager / Energ

Manager

Monitor cost impact for two months. Utility Manager / Energ

Manager

Report observations to management. Utility Manager / EnergManager



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Objective # 2

OBJECTIVE NAME Steam generation through Waste Heat Recovery Boiler by utilizing

waste gases of generatorsDOMAIN Power & Steam Generation CATEGORY Mid Term

PURPOSE OF

OBJECTIVE

To utilize the high temperature of stack gases from generators for steam

generation

RESULT OF

OBJECTIVE

Reduction in steam demand from conventional boilers thereby reducing gas

consumption for steam generation

TARGET START DATE Jan 2011 TARGET COMPLETION DATE Jun 2011

APPROX INVESTMENT Rs 8 Million APPROX

SAVINGS

Rs. 7.4million

PAYBACK

PERIOD

13months


Seeking Managing Director approval for investment based onpotential cost savings and low pack back period.

GM Operations

Seeking quotes for WHRB Utility Manager

Meeting with equipment suppliers and seeking best energy

efficiency arrangement and configuration. Discuss current and

future power generation requirements and arrangements and

potential of steam generation.

Utility Manager

Identification of land requirements and installation area. Utility Manager

Requesting equipment supplier to submit technical and

financial data related to proposed WHRB including costsavings related to natural gas savings at conventional boilers.

Utility Manager

Evaluate simplex and duplex WHRB models and their cost

impact in terms of investment.

Utility Manager

Requesting potential suppliers to arrange demo of any

industrial unit for application of WHRB and its impact on cost

savings.

Utility Manager

Selecting supplier Utility Manager

Design, Fabrication and Installation of WHRB Supplier

Monitoring steam generation data from WHRB at different

power generation loads

Utility Manager / Energ

Manager

Monitor cost impact for two months. Utility Manager / Energ

Manager

Report observations to management. Utility Manager / Energ

Manager



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Objective # 3

OBJECTIVE NAME Improving the electric motors efficiency from 85% to 90%

DOMAIN Power Consumption CATEGORY Short TermPURPOSE OF

OBJECTIVE

To increase motors efficiency

RESULT OF

OBJECTIVE

Direct reduction in electrical load and indirect savings at power generation fue

TARGET START DATE Immediate TARGET COMPLETION DATE Dec 2010

APPROX INVESTMENT Rs. 2 million APPROX

SAVINGS

Rs 4.4 Million PAYBACK

PERIOD

6 month


This objective does not require heavy financial investment compared

to commitment and determination from the Mechanical and Electrical

Maintenance Team to focus on preventive maintenance of each

motors and ensuring that it runs at its optimum efficiency.

If the total preventive maintenance cost on all the machines is

approximated at Rs.2 million per year, the payback period of this

investment is 6 months.

Also in case of continuing preventive maintenance , the cost on

preventive maintenance will decrease appreciably while savings

remains the same

Mechanical and

Electrical Managers

Randomly select motors and measure their actual efficiency andcalculate the energy losses. Energy Manager



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Objective # 4

OBJECTIVE NAME Replacing existing tube lights and mercury bulbs with energy savers


OBJECTIVE

To achieve reduction in electric power demand

RESULT OF

OBJECTIVE

Direct reduction in electrical load and indirect savings at power generation fue

TARGET START DATE April 2010 TARGET COMPLETION DATE June 2010

APPROX INVESTMENT Rs 1.25 Lac APPROX

SAVINGS

Rs 2.3 Lacs PAYBACK

PERIOD

5 month


Determine the lux value currently in each area and compare it

with the required lux value.

Electrical Manager for

measurement

Departmental

Managers for identifying

required lux value

Determine the number of energy savers required to obtained

the required lux value and compare it with number of

tubelights required to obtain the same lux value

Electrical Manager

Based on this comparison, replace the tubelights with energy

savers

Electrical Manager

Monitor cost impact for two months. Energy Manager Report observations to management. Energy Manager



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Objective # 5

OBJECTIVE NAME To improve burners efficiency at singeing


OBJECTIVE

To achieve reduction in gas consumption

RESULT OF

OBJECTIVE

Gas consumption per kg of fabric will decrease.

TARGET START DATE TARGET COMPLETION DATE

APPROX INVESTMENT Rs. 1 Lac APPROX

SAVINGS

Rs 4 lacs PAYBACK

PERIOD

3 month


This objective does not require heavy financial investment compared

to commitment and determination from the Mechanical team and

machine operator to focus on preventive maintenance of each burner

and regular cleaning of the machine and ensuring that it runs at its

optimum efficiency.

Mechanical Manager

Objective # 6

OBJECTIVE NAME To eliminate steam leakages at different machines and improveefficiency of steam traps

DOMAIN Steam Consumption CATEGORY Short TermPURPOSE OF

OBJECTIVE

To achieve reduction in steam consumption demand thereby reducing gas

consumption

RESULT OF

OBJECTIVE


APPROX INVESTMENT To be determined APPROX

SAVINGS

Rs 2.6 lacs PAYBACK

PERIOD



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Objective # 7

OBJECTIVE NAME To reduce heat losses due to semi insulated and un-insulated pipes

DOMAIN Steam Consumption CATEGORY Short Term

PURPOSE OF

OBJECTIVE

To achieve reduction in steam consumption demand thereby reducing gas

consumption

RESULT OF

OBJECTIVE



SAVINGS

Rs 52000 PAYBACK

PERIOD

Objective # 8

OBJECTIVE NAME To reduce water wastageDOMAIN Water CATEGORY Short Term

PURPOSE OF

OBJECTIVE

To achieve reduction in water consumption in processing area

RESULT OF

OBJECTIVE

Improved water consumption will not only reduce the water bills but also

reduce the wastewater which if untreated is an environmental burden.


APPROX INVESTMENT APPROX

SAVINGS

Rs.1.7million

PAYBACK

PERIOD


Determination of areas at each machine where outflow watercan either be reused in the same process/machine or used at

another machine / process.

Dyeing and PrintingManager

Evaluate the current water inflow rate and compare it with the

process requirements. Identify the impact on Quality of

process and final product in case of reduction in inflow rate.

Dyeing and Printing

Manager

Based on above, identify the viable options for each machine Dyeing and Printing

Manager

Determine the additional piping work and storage tanks

required.

Mechanical Manager

In case of piping work and storage tanks, determine the cost

involved at each machine and the amount of water saved and

its cost.

Mechanical Manager

Seek management approval for piping work/storage tanks. Mechanical Manager

Monitor water outflow rate and calculate cost savings. Energy Manager



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Objective # 9

OBJECTIVE NAME To develop and implement effective Total Preventive Maintenance

SystemDOMAIN Management Systems CATEGORY Short Term

PURPOSE OF

OBJECTIVE

To improve machine energy consumption efficiency and reduce wastages

RESULT OF

OBJECTIVE

Decreased breakdowns, improved energy consumption



SAVINGS

PAYBACK

PERIOD


For each machine identify the electrical and mechanicalparameters which needs to be regularly checked on daily,

weekly and monthly basis. Focus not only machines but

electrical distribution equipments including panels

Mechanical andElectrical Managers

Train machine operators on basic machine cleaning Mechanical and

Electrical Managers

For each breakdown maintenance , maintain the record in

terms of stoppages and cost incurred on breakdown

maintenance.

Mechanical and

Electrical Managers

Implement the preventive maintenance checklist and monitor

the reduction in breakdown stoppages.

Mechanical and

Electrical Managers

Calculate the energy savings due to reduction in stoppages. Energy Manager

Objective # 10

OBJECTIVE NAME To enhance In-process Quality Control based on Quality Plan

DOMAIN Management Systems CATEGORY Short Term

PURPOSE OF

OBJECTIVE

To reduce reworks at processing

RESULT OF

OBJECTIVE

Indirect energy saving by improving per fabric consumption due to higher

productivity.



SAVINGS

PAYBACK

PERIOD



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Objective # 11

OBJECTIVE NAME To develop cost driven based effective Energy ManagementInformation System based on Energy Key Performance Indicators

(EnKPI’s) DOMAIN Management Systems CATEGORY Short Term

PURPOSE OF

OBJECTIVE

To support management in monitoring the cost of energy in relation to overall

cost of production and also sponsoring areas for energy conservation.

RESULT OF

OBJECTIVE

Identification of actual cost impact at each energy production and consumptio

point.



SAVINGS

PAYBACK

PERIOD

Objective # 12-a

OBJECTIVE NAME To install measuring devices (temperature gauges, flow meters,pressure gauges etc) based on EnKPI’s

DOMAIN Steam Consumption CATEGORY Long term

PURPOSE OF

OBJECTIVE

To support in the implementation of EnMIS and also in monitoring of energy

production and consumption efficiency.

RESULT OF

OBJECTIVE

Cost savings due to identification of areas consuming more energy or

inefficient energy producers



SAVINGS

PAYBACK

PERIOD


Based on EnKPI’s and EnMIS, identify the points at each

machine / equipments where data related to energy

production and consumption is required either by installing

flow meters, pressure gauges, temperature gauges,

Energy Manager

Select measuring devices installation points based on material

and energy balance approach.

Energy Manager

Determine the accuracy requirement for each measuring

device

Energy Manager

Select measuring devices Energy Manager

Seek quotations Energy Manager

Installation of measuring devices Energy Manager

Feeding data in EnMIS software and generating reporting

containing technical data and financial calculations.

Energy Manager



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Objective # 12-b

OBJECTIVE NAME To engage Energy & Environmental Department Lab of QUEST for

energy related testing services based on EnKPI’sDOMAIN Steam Consumption CATEGORY Short Term

PURPOSE OF

OBJECTIVE

RESULT OF

OBJECTIVE



SAVINGS

PAYBACK

PERIOD




GTZ-SMEDA-APTMA

Implementation Strategy for Energy Management Objectives

Arch Associates recommends that in order to ensure complete and effective implementation of EMO’s, a

realistic road map based on current financial status of MFTML be developed.

We propose to take on those EMO first which require an investment of upto Rs 1 million and less and after

achieving savings from these actions, channelize savings in those areas which require investment of more than

one million or has high payback period i.e. more than one year.

CONCLUSION:

The objectives set for MFTML after being achieved the industry will be conforming to the International

Industry Bench marks. The bench marks are identified for textile industry in the report as well. It meansMFTML will be amongst the good practicing industries and an example for other textile units operating

in the area.

Implementation of EnMS at MFT

Documents

Transcript of Implementation of EnMS at MFT