VLT DRIVES - CASE STORY

Drives and Controls

Humidification the Cost-Saving Way

Indian textile manufacturers Sri Ramco Spinners and Rajapalayam Spintext are cutting down energy expenses by utilising Danfoss VLT frequency converters for humidifier control

Danfoss was well known from the outset at the Sri Ramco Spinners. The picture shows a VLT frequency converter controlling a Ring Frame.

Substantial energy savings and increased product quality at a short payback time. Those were the three main reasons for cotton spinning mill Sri Ramco Spinners and Rajapalayam Spintext domiciled in the South Indian town Rajapalayam, to install Danfoss VLT frequency converters at a humidification plant in their factories.The starting point was a plant with maximum capacity based on peak summer requirements. This capacity was employed throughout the year, irrespective of the requirement for humidification. Correspondingly, the energy consumption was constant, whether on a hot and dry summer day or
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a cold and rainy winter day. This wintertime over-capacity was until recently throttled by dampers - a simple and efficient technology, yet expensive in operation: dampers and valves do not change the speed of fans and pumps, but merely make up a cork in the bottle,so to speak.

VLT is a registered Danfoss trademark

Consequently, fans and pumps are running much too fast during the winter using costly energy of no use.

Convincing results

of approximately 2.5 years. So Mr. Madhavan gave the go-ahead to the installation in other plants also after getting green signal from Top Management.

In order to streamline this process Mr. R. Madhavan, Factory Manager at Sri Ramco Spinners & Rajapalayam Spintext, asked his regular supplier of control solutions, Coimbatore-based TexServices, to work out a control system for the humidifier. Being an authorized selling agent of Danfoss VLT frequency converters as well, Mr. N. Kanakarajan, Chief Executive of TexServices, decided to develop a humidity control system including three VLT converters (see fig. 1). The system was handed over to Rajapalayam Spintext for test purposes on a free trial basis.The new control system was applied to an existing Luwa Humidification plant, and the results of the preliminary test were convincing: in projection a conservative estimate promised minimum energy savings at 20 percent, bringing about a payback time

Mr. R. Madhavan with VLT frequency converters controlling supply air fan and return air fan of the humidification plant.

Fig. 1 Lay-out of humidity control system. The three VLT frequency converters communicate with the HUMICON controller which calculates the speed of the fans and the pump based on actual temperature and humidity measurements. The controller communicates with the frequency converters using the RS 485 interface. DKDD.PN.51.T1.02 VLT is a registered Danfoss trademark 2

Improved air quality and more than 25% energy savings

After being put into operation the new humidifier control system has turned out even more promising, more than 25% energy savings has lowered the payback time to 2 years - a critical issue when you are subject to high rates of interest and operating in a volatile market. On top of the energy savings Rajapalayam Spintext has also noticed an improvement of the air quality in the spinning mill. Its temperature and humidity are more stable than can be obtained with dampers (see fig. 2), an important issue for Rajapalayam Spintext who export all their products to the highly quality conscious Japanese market. Mr. Murugan .S, Assistant factory Manager is very much satisfied with the performance of the renewed humidifier, even though the good results have not taken him by surprise: We have known the VLT frequency converters 4-5 years from the spinning process where they control our carding machines, speed frames and ring frames. In fact we have more than 100 installed. That is another reason we felt confident when choosing Danfoss for the humidifier.

They are all praise to the service provided by TexServices and Danfoss, not least the constant readiness to assist during the commissioning period. And not only has it been decided to install similar control systems in Sri Ramco Spinners remaining humidification plants. Mr. Madhavans colleague, Factory In-charge of the nearby Rajapalaiyam Textiles unit, Mr. S. Saravanan, has already performed a test in a different humidification plant of the LTG brand - with similar favourable results. In consequence, a permanent installation is on its way.

Easy installation

Mr. Murugan . S mentions easy installation on existing plants as a strong point of the new control system: We did not have to change the humidifier in any way. All we needed was to connect the temperature and humidity sensors and the RS 485 serial communication cable, the Assistant factory Manager explains.
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Fan and pump speed depending on required air and water flow.

VLT is a registered Danfoss trademark

Temperature
40

Power failure
35

C
30

Without frequency converter

25
40

Power failure
35

o
30

With frequency converter

25
00 06 12 18 00 06 12 18 00 06 12 18 00 06 12 18 00 06 12 18 00 06 12 18 00 06 12 18 00

Da y1

Day 2

Day 3

Day 4

Day 5

Day 6

Day 7

Hours/Days

Humidity
70 66 62 58 54

%Rh

50 46 42 38 34 30

Power failure

Without frequency converter

70 66 62 58 54 50 46

%Rh

42 38 34 30

Power failure

With frequency converter

Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7

Hours/Days

Temperature and humidity measurements with damper control and after installation of the frequency converters. Both humidity accuracy and temperature accuracy have improved after the system was upgraded.

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VLT is a registered Danfoss trademark

Mr. R. Madhavan and two plant engineers inside an air duct. No. 2 from the right Mr. N. Kanakarajan of Texservices supplier of the control system.

11 kW water pump for an air washer in the humidification plant. The pump motor is controlled by a VLT frequency converter.

Tangible Benefits

Installing humidification plant controls featuring VLT frequency converters from Danfoss has brought about the following benefits for Sri Ramco Spinners and Rajapalyam Spintext: More than 25% energy savings A more accurate humidity level Increased system reliability Better air flow control Pay back in less than two years The Ramco Group of Industries Ltd at a Glance The Ramco Group started out in 1938 as a cotton spinning mill in Rajapalayam, India. Today the company makes up an industrial group of 20 units mills, supplemented with a number of plants primarily within the building material industry in India and abroad. The Ramco Group of Industries is a market leader when it comes to quality and price. The annual turnover amounts to approximately 230 million US$, brought about by some 19,000 employees. They benefit from a modern manpower policy, ensuring them wages above average, housing, pension, supplementary education etc.

DKDD.PN.51.T1.02

VLT is a registered Danfoss trademark