Energy Auditing and Assessment of Power Quality Problem in Industries: (A Case Study of Almeda Textile Factory)

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Addis Ababa University


Nowadays energy is one of the major areas which need greater attention throughout the world. The textile industry is one of the major energy consuming industries and retains a record of the lowest efficiency in energy utilization. Energy in the textile industry is mostly used in the form of electricity as a common power source for machinery, heating and ventilating air conditioner, lighting system and other equipment etc. In Alameda textile factory about 20.35% energy is consumed in weaving, 42.4% in spinning, 22.39 % in processing, 7.22% new garment and 7.64% in lighting and others. This is a total of 44.31MWh per year. From the information it is difficult to consider the energy loss. Had it been administered an energy audit, the amount of energy mismanaged and lost would be easily estimated. An energy audit is an inspection, survey and analysis of energy flows of energy conservation in a factory, process system to reduce the amount of energy input into the system without negatively affecting the output. The main objective of this thesis is to identify the energy wastage areas and to asses power quality related problem (harmonics) to take possible measures for improving the energy performance of the manufacturing process of the selected plant. Motor Master +International Software was used to evaluate the performance of the existing motors with the energy efficient motors and Digital Simulation of Electrical Network software (DIgSILENT) was used to assess harmonics. It was found that the specific energy consumption difference between the Almeda Textile and the benchmark is 9.07kWh/Kg. As a result, the company spends an extra 286,703.7$ annually as compared to the benchmark. From the assessment, since the PF for the four transformers in the garment departments was found to be 0.969, most of the energy loss was found in the weaving and spinning departments. After designing multi single tuned passive filters for the two transformers T1 and T2 of the two departments, the THDI for T1 and T2 was reduced to 0.867% and 0.824% from 25.5% and 21.4% respectively. And the THDV for T1 and T2 was reduced to 2.91% from 8.8% for both. In addition, the THDI of substation transformer was reduced to 0.3% from 21.6%.



Energy Auditing, Energy Intensity, Power Quality