Effects of Power Quality On Manufacturing Costs in Textile Industry

Scientific Research and Essay Vol.4 (10), pp.
1085-1099, October 2009

Available online at http://www.academicjournals.org/SRE
ISSN 1992-2248 2009 Academic Journals

Full Length Research Paper

Effects of power quality on manufacturing costs in
textile industry

F. Koyiit
1
, E. Yankolu
1
, A. S. Yilmaz
2*
and M. Bayrak
1

1
Sakarya University, Electrical-Electronics Engineering Department, Sakarya, Turkey.
2
Sutcu Imam University, Electrical-Electronics Engineering Department, Kahramanmaras, Turkey.

Accepted 15 July, 2009

This paper reports the effect of electrical power quality on textile industry. For this purpose, power
quality measurements have been done for six months in two different sectors of textile industry. All
parameters affecting power quality have been measured by using ION 7650 Power Analyzer according
to the EN 50160 standard. Because textile industries have high technology machines including
electronic control cards and driver controlled motors, poor power quality may damage the system and
cause production failure. Measurements showed that the losses caused by electrical power quality were
significantly high, being around 15% of the annual net profit of the textile industry.

Key words: Power quality, power quality metering, textile industry.

INTRODUCTION

In the worlds new economic system, in other words, the
global economy, the conditions for existence have
become quite difficult for establishments. The fast-
growing Far East, becoming a manufacturing center, has
significantly pulled down the profit rates of industrial
establishments. The profit percentages which were
represented by two-digit and even three-digit figures have
decreased to single-digit figures due to excess supply
and intense competition. Both the shrinkage in the market
and the decreases in profitability have forced industrial
establishments to manage their costs effectively (Sullivan
et al., 1996).
In order to manage their costs, the companies have not
only oriented towards qualified human resources but also
have started to pay attention to quality energy supply,
which is another fundamental factor in the sector.
Manufacturing loss due to poor power quality is reflected
on the income statements and balance sheets of these
companies, as an increased cost due to inefficiency.
Along with this, in a world of such intense global
competition, the penal outcomes as well as the
adversities which can lead to losing the customer or

*Corresponding author. E-mail: a.s.yilmaz@gmail.com.
customers as a result of the non-delivery of products,
which cannot be manufactured because of a machine
break-down due to energy failure or poor power quality,
are the results which cannot be endured by todays
establishments. Due to such reasons, the customer-
focused establishments pay attention to quality power
sources including electrical power and increasing their
quality (Szen et al., 2007; Grupta et al., 2004; Davis et
al., 2000; Nooij et al., 2007).
Besides other sectors, the influence of electrical power
quality on the textile sector and textile establishments
have not been sufficiently analyzed with studies until
now, being quite superficial. There has not been any
study requiring on-site measurements for more concrete
data until now. This study presents data from measure-
ments and monitoring of over 6 months at an integrated
textile establishment in Bursa and Kahramanmara,
Turkey.
For this, the energy quality measurements at a textile
establishment were made by ION 7650 power monitoring
and analysis device and the poor power quality was
assessed in accordance with EN 50160 standard; the
damage from such poor quality of energy suffered by the
establishment was also calculated. The findings and the
impacts on weaving, yarn, etc. departments have been
analyzed in detail (Koyiit et al., 2008).
1086 Sci. Res. Essays

Table 1. Categories and typical characteristics of power system electromagnetic phenomena.

Categories Spectral content Duration Voltage magnitude
1. Transients
a. Impulsive
Nanosecond 5 ns rise < 50 ns
Microsecond 1 s rise 50 ns 1 ms
Milisecond 0.1 ms rise > 1 ms
b. Oscillatory
Low frequency < 5 kHz 0.3-50 ms 0 - 4 pu
Medium frequency 5-500 kHz 20 s 0 - 8 pu
High frequency 0.5-5 MHz 5 s 0 - 4 pu

2. Short duration variations
a. Instantaneous
Sag 0.5 - 30 cycles 0.1 - 0.9 pu
Swell 0.5 - 30 cycles 1.1 - 1.8 pu
b. Momentary
Interruptions 0.5 - 30 cycles < 0.1 pu
Sag 30 cycles 3 s 0.1 - 0.9 pu
Swell 30 cycles 3 s 1.1 - 1.4 pu
c. Temporary
Interruptions 3 s - 1 min < 0.1 pu
Sag 3 s - 1 min 0.1 - 0.9 pu
Swell 3 s - 1 min 1.1 - 1.2 pu
3. Long duration variations
Interruptions sustained > 1 min 0.0 pu
Undervoltages > 1 min 0.8 pu
Overvoltages > 1 min 1.1-1.2 pu

4. Voltage imbalance SS 0.5 - 2%

5. Waveform distortions
DC offset SS 0 - 0.1%
Harmonics 0-100 th H SS 0 - 20%
Interharmonics 0-6 kHz 0 - 2%
Notching SS
Noise Broadband SS 0 1%

6. Voltage fluctuations > 25 Hz Intermittent 0.1 - 7%
7. Power frequency variations < 10 s

SS : Steady state

DEFINITION OF POWER QUALITY

Power quality (PQ) is defined by (IEEE Std 1159.3 2003)
as set of parameters defining the properties of the power
supply as delivered to the user in normal operating condi-
tions in terms of continuity of supply and characteristics
of voltage (symmetry, frequency, magnitude and
waveform). Also, PQ deals with not only voltage quality
but also current quality. It is the combination of voltage
and current quality. In practice, there are several types of
PQ disturbances such as voltage sag/swell/interruptions,
switching transients, flickers, harmonics, notches, etc.
caused by faults, nonlinear loads and dynamic operating
conditions (IEEE Std 1159, 1995; Alkan and Yilmaz,
2006). Table 1 illustrates categories and typical charac-
teristics of power system electromagnetic phenomena
Kocyigit et al. 1087

Figure 1. Weaving machines (Dobby machines).

(EN Std 50160, 1999).

EFFECTS OF PQ ON WEAVING-KNITTING

Textile weaving covers a very wide range of products.
Most of the garments, surface coverings of the sitting
sets in our rooms, tulle and curtains, carpets, towels in
the bathrooms, and even the airbags in our cars are of
fabrics manufactured through textile weaving or knitting.
Todays weaving and knitting machines are high
technology machines. They include tens of sensors,
driver controlled ac and dc electrical machines, communi-
cations cards, cpu units, touchscreens, ethernet cards
and encoders. These equipments operate at different
voltage values. If any interruption, in the machines at the
weaving room occurs for any reason, it can take up to 4 h
for the machinery park to return to the acceptable
performance values. Thus, any short-term or long-term
interruption means a direct manufacturing loss. These
machines which are sensitive to sinusoidal form of
electrical power can shut down if a voltage drop, voltage
sag and voltage fluctuations occur. These machines
include special encoders used for position determination
and interruptions without any reason can lead to the
break down of this device (values approximately $500)
and its replacement means at least 2 h of interruption.
Voltage sags can result in excess current drawings,
which cause the engines operating at approximately 6
kW to draw higher currents, leading to the break-down of
electronic cards driving such engines. Such cards cost
approximately $2500 and their replacement may take
minimum 2 h.
At a typical weaving establishment shown in Figure 1
(sample establishments), the average daily turnover of a
weaving loom can be considered to be $2,400. Such
turnover indicates that the value added to the economy in
1 h by one machine is $100. In our country, the average
number of the weaving machines for each establishment
in corporate companies is between 100 and 1000. In
such establishments, it can be simply calculated that
even a 1 h interruption means a weaving manufacturing
loss between $10,000 and $100,000. When such
interruption occurs at an organized industrial zone with
several textile plants, the loss will reach to more dramatic
values.
High current and voltage harmonics and the other
distortions can cause such machines to stop. Harmonics
shorten the life of all electrical and electronic equipments
in the machines. They cause break-downs, resulting in
repair costs and manufacturing losses. They also shorten
the depreciation periods of the machines, leading to
increasing costs and thus losses (De Abreu and Emanuel,
2002).

EFFECTS OF PQ ON DYEING PROCESSES

Dyeing processes in the textile sector can be classified
under main categories of fiber, yarn and fabric dyeing.
Despite the differences in physical structures of such
machines, they operate under similar principles as the
materials they dye are the same. All fiber, yarn and
fabrics are made of raw materials such as acrylic, polyes-
ter, cotton or viscose. These machines include driver-
controlled pumps, level gauges, calorimeters, liquid
meters, PLC devices or cpu including control cards,
touchscreen panels, actuator valves, proportional valves
and several other electrical, electromechanical and
electronic sensors and equipments.
Dyeing machinery equipments can be interrupted in
most of the poor quality electrical energy situations. The
amount of losses suffered depends on the duration of
such interruptions. In situations of voltage drop and volt-
age fluctuations, the machinery may activate the
automatic protection and shut itself down. If the poor

quality situation lasts for short periods (before the water
inside the kier cools), the repair process called
"reinforcement" is performed. This results in extension of
the process time as well as water, energy, chemical and
depreciation losses. It usually costs the half of the dyeing
expenditures. If we assume that polyester is dyed in a
dyeing kier of 1000 kg, it means that the loss per
kilogram will be $0.5, making a total loss of $500. In
cotton or viscose dyeing processes, the loss is doubled. If
the process involves fabric dyeing for automotive sector,
the process may have to be repeated all over again. This
results in the loss being doubled. A worse situation is the
loss of the yarn or fabric in the dyeing kier. In some of the
interruptions, the material dyed may have to be scrapped
due to the nature of the raw material or product.
If there is yarn in a kier of one ton, and for example if it
is polyester, the loss will be between $2,000 and $4,000.
And if it is fabric, the loss will reach to $4,000 - $20,000.
There are minimum 10 dyeing kiers in corporate dyeing
houses. If these are assumed to dye polyester, we can
say that they can perform the dyeing process 60 times a
day. If we assume that the average kier capacity is 500
kg, the daily dyeing capacity would be 30 tons. Given that
there are hundreds of dyeing houses in our country, the
loss can be estimated from the above figures. Our coun-
trys textile sector has witnessed a significant downfall in
the recent years. With each year, several dyeing houses
are closed. The turnover of a dyeing house performing
yarn-dyeing in a one-ton kier would be $1500, its best
profit being $300. As explained above, a single energy
problem can lead to a loss amounting to 500 or 1000 or
even $2,000. Therefore, the significance of electrical quality
is obviously seen. High quality electrical energy has an
important role in the sustainability of such companies in
todays commercial environment of low profitability.

EFFECTS OF PQ ON FINISHING PROCESSES

Finishing process means the last processes performed
on the textile products and involves a wide range of
machines. The mid-part of the stenter machines is the
heated drying section which is also known as the oven.
This section varies between 15 and 35 m depending on
the establishment. The fabric is stabilized through heating
by hot oil or natural gas. Two different processes can be
carried out before the drying process. The first process is
putting the fabric into a chemical-filled basin at the inlet of
the machine. Here the fabric is processed with chemicals,
as a result of which the fabric attains features such as
delayed ignition, anti-germ and in the case of jeans
fabric, prevention of leg turn-ups. In the second process,
the said chemicals are only applied to one surface of the
fabric in the covering unit, again at the inlet of the
machine.
The total length of the stenter machine is between 30
and 60 m. We can take the average length as 50 m.
From inlet to the outlet of the machine, there are about

fifty driver-controlled motors. Within the panel of the
machine, which is more than 10 m long, there are PLC,
drivers, hundreds of control elements, sensors most of
which have modbus communication, touchscreen control
panels, computer-controlled weft straignteners operating
synchronously with the machine, automatic fabric
accumulator, J-Box machine and several other equip-
ments. The electrical control panel of such machines is
longer than 10 m.
A problem at any component of this complicated line
ends up with the shut down of the line. The fabric passes
through the machine at a certain speed. The speed range
is between 10 and 100 m/d. At this stage, the tem-
perature at the oven is between 100 - 180C. The speed
and the temperature vary depending on the process and
fabric types. With each halt of the line which is sensitive
to poor quality energy, the fabric left inside the machine is
deformed from the heat and is scrapped. The value of
any fabric with an average length of 50 m is between
$100 and $1,000. Re-manufacturing of such fabric would
be even more costly. If special chemicals are used, their
cost will also be added as a loss.
The shortening of the depreciation period due to poor
power quality is even more significant in this machine.
Any such line costs between 750.000 and $1.250.000,
depending on the accessories. There are hundreds of
finishing establishments operating with such machines in
our country. In the meantime, the equipments breaking
down due to harmonics and other poor power quality
problems are counted as direct loss. When the
equipments break down, the machine stops and the time
required for detection of the break-down and repair is a
significant amount of time. In such situations, the
manufacturing losses will reach to higher values. Let us
give the most optimistic scenario. Let us assume that the
cost of a one-meter process in a finishing process is $1.
The processing speed of the machine is 30 m/d. Under
this scenario, the manufacturing loss will be 1800 m per
h, with a cost of $1800. If the machine remains out of
operation for 10 h, the loss will be $18000. In the real
establishments, there have been some break-downs with
10 days of repair period (waiting for replacements, etc.).
Such break-downs were witnessed in the establishments
where the measurements took place for this study.

MEASUREMENT METHODS AND STANDARDS

In our country, energy quality is monitored in accordance
with the Regulation on supply sustainability, commercial
and technical quality of electrical energy provided through
the distribution system in the electricity market which is a
translation of EN 50160 standard.
Measurements regarding power quality should be
carried out in accordance with this regulation. To achieve
this, the required devices should both momentarily monitor
energy flow and all the parameters related to quality, as well
as record the problems (quality deviations). It is essential

Figure 2. ION Enterprise software interface.

that such devices are internationally accredited, in other
words, the measurements performed should be legally
recognized and acceptable. The measurements have
been carried out with ION 7650 device, performing three-
phase and neutral measurement which is compliant to
the requirements above. The six months measurements
performed at two different establishments within this
study, were fully conducted and planned in accordance
with EN 50160 standard.
The measurements were recorded real-time on the
computer using the ION enterprise software. The inter-
face of the software is given below (Figure 2). The power
quality and continuous event records can be reached
from an effective menu.
With the privatization of energy production, transmis-
sion and distribution, energy has begun to be considered
as a meta that should be produced and distributed in
accordance with certain standards and rules among the
companies supplying the energy and the industrial
organizations utilizing the energy. Companies or organi-
zations producing and/or selling energy have become
liable to supply the electrical power they have to generate
within certain boundaries called electrical quality, in an
uninterrupted and trouble-free manner. In the industry,
the energy quality (or poor quality) is monitored and
reported in accordance with certain power quality stan-
dards and regulations.

MEASUREMENT RESULTS

All parameters affecting the power quality were measured
momentarily (by taking 1024 samples from one period)
and the related parameters were recorded on the main
computer through ethernet connection. Besides recording
of all parameters, the deviations from power quality
(according to EN 50160) were kept in a separate file.
Since the poor power quality was recorded in transient
measurements, irrelevant data did not occupy space on
the computer. As time was also recorded for energy
quality deviations, the manufacturing losses and the
reasons for the damage could be approximately
estimated.
In selection of the establishments, attention was paid to
choose them from different parts of the country. Com-
bined with the features of the industrial zones they were
located, it was demonstrated that those two plants were
operating on electrical energy of very different quality

Figure 3. Successive voltage sag occurrences recorded.

values. One of our establishments was located in an
organized industrial zone in the Marmara Region. In this
organized industrial zone, electricity is fed through double
lines and in addition to this the same main busbar is fed
by three high power natural gas plants. As a result of the
measurements performed, it was demonstrated that of
the two establishments this one was operating on higher
electrical quality. Naturally, the effects of and material
loss from poor quality were insignificant in this
establishment. On the other hand, in the establishment
located in the Eastern Region, there was another
autoproducer in the main busbar of the distribution line
from which the establishment was supplied electrical
energy. As it will be explained in the following sections,
there were several poor power quality incidents in this
establishment. This resulted in excessive material burden
for the establishment. As a result of the measurements
performed, it was seen that the poor quality of electrical
energy incidents explained in the second section were
seen in the first establishment for several times. In the
other establishment, the incidents mentioned occurred
fewer times than the first establishment. When the in-
cidents occurred, the corresponding problems in the plant
were also recorded. On the basis of such records, the
costs were calculated in cooperation with the planning
and production departments of the establishments. The
calculations were related to the direct costs and the
indirect costs such as loss of reputation and customers
were not included.

Voltage sag measurements and their cost

During the six-month-measurements in the first
establishment, there were 155 voltage sag occurrences
recorded. In the second establishment, on the other
hand, the number of voltage sag occurrences was six.
The depth and duration of such occurrences determined
the effects on the establishment. The six occurrences in
the second establishment did not have any effects on the
establishment. The Figure 3 shows an example of the
measurements and the voltage sag records. The current
variations at the time the voltage sag occurred are shown
in Figure 4. The occurrences resulted in manufacturing
losses and breakdowns in the first establishment. Voltage
sags with greater depth and duration caused some
machines to shut down as well as some breakdowns.
Voltage sags were in succession at times and they
sometimes resulted in power failures. Successive voltage
sags could be readily monitored. The records could be
transformed into a graphic with a simple option in the
software. In the first establishment, some of the voltage
sags resulted in general interruption, some caused partial
interruption and some others led to breakdowns and
combinations. The records and calculations revealed that
the six-month-occurrences resulted in a cost of $110,000.

Figure 4. Current variations in the successive voltage sag occurrences recorded.

The details are shown in Table 2.

Transient measurements and their costs

As a result of the measurement process, 44 transient
occurrences were recorded in the first establishment
while there were no transient records in the second
establishment. In measurement of the transient
occurrences the device was set to the highest sensitivity
and the occurrences were momentarily recorded during
two periods. The calculated number of the points during
the two periods was 2048. Thus, the time between two
points reached to a very sensitive value, nearly 20 s.
Figure 5 shows the graphic of the transient moments.
Figure 6 shows the three phase current wave forms at
the moment of the transient occurrence and Figure 7
demonstrates the voltage harmonics at the moment of
the occurrence.
When the figures are analyzed, it is seen from the cur-
rent reaching to a five-fold higher value and the releases
occurring on voltage curves that a high-power condenser
group was activated. The fact that the current
harmonicsreach to high frequency values and their
amplitude exceeds 100%, shows the occurrence of a
resonance. This led to problems such as the explosion or
breakdown of the condensers in the compensation panel,
the burning and melting of the contactor contacts, as well
as the mel-ting of the connected cables. Here, the
greatest hazard is the continuous fire risk.
The cost of the problems such as material and labor
loss as a result of such occurrences in the first establish-
ment was calculated to be around $1000. No such
occurrence or related cost was seen in the second
establishment.

Harmonic measurements and their costs

The current and voltage harmonics were continuously
measured until the 63th harmonic. As shown in Figures 8
and 9 both current and voltage harmonics measured in
the both establishments were over the limit values. The
values in the graphic represent the average values, so
the harmonics occurring in the establishment are above
such values. It is seen that the voltage harmonics exceed
6% and the current harmonics exceed 20%. The current
harmonics frequently reach to 30 - 35%. In addition to the
problems created at the compensation panel of the esta-
blishment, these harmonic components can obviously
damage the other machines and fixings operated in the
establish-ment. The current and voltage magnitudes
including such high-value harmonics can damage the
electronic cards and create negative results on the lives
of the other electrical machinery. Replacing the compen-
sation panel of the establishment with a harmonic-filtered
compensa-tion panel is compulsory, given the resonance
occur-rences.

Voltage interruptions

One of the most significant causes of the losses in the
establishments is the power failures. When the machines

Table 2. Costs of voltage sag in establishment 1.

Duration Phase A Phase B Phase C Problems encountered Cost ($)
0,4190 51,382 52,054 51,171 Partial Interruption, breakdown 14,500
0,0690 89,742 89,961 89,546
0,1600 88,386 89,149 80,255
0,1400 75,291 88,744 74,863 Partial Interruption 2,000
0,3210 93,074 88,362 90,621
0,3190 85,790 86,499 94,818
0,6000 81,873 81,814 81,660
0,1690 5,921 3,927 6,336 Interruption, breakdown 18,500
0,1190 91,258 88,700 92,205
0,1810 87,257 88,277 79,876
0,9100 76,054 77,386 75,856 Breakdown 3,000
0,9610 88,260 89,317 92,986
0,8790 88,495 89,276 93,221
0,26 80,831 80,257 80,373
0,3190 84,683 88,350 89,196
0,9910 80,595 81,383 81,185
0,1790 92,087 89,654 92,771
0,3090 80,662 81,456 80,934
0.4410 82,763 85,879 87,233
1,01 76,666 77,671 77,203 Breakdown 2,500
0,2290 80,475 81,388 80,791
0,7910 80,301 79,627 80,725
0,7900 77,507 78,690 78,503 Breakdown 2,500
0,9200 76,215 77,481 76,436 Breakdown 2,000
0,9800 86,202 86,877 86,708
0,1390 91,471 82,469 74,690
0,1300 92,969 77,311 48,946 Breakdown 2,000
0,1590 84,499 85,148 84,973
0,2100 87,402 87,646 78,818
0,3390 86,149 86,881 86,436
0,3180 88,878 92,976 88,897
0,3900 84,774 85,409 85,834
0,7210 89,309 86,212 87,191
0,0500 87,875 88,261 87,811
0,24 81,387 81,394 81,809

Figure 5. Three phase voltage wave form at the moment of the transient occurrence.

Figure 6. Three phase current wave form (at the moment of the transient occurrence in Figure 6).

Figure 7.Voltage harmonics (at the moment of the occurrence in Figure 6).

Figure 8. Variations in the 6-month voltage and current harmonics of the first establishment.

Figure 9. Variations in the 6 -month voltage and current harmonics of the second establishment.

Table 3. Electrical failures in establishment 1.

Time label V1-Irpt durtn V2-Irpt durtn V3-Irpt durtn
02/05/2008@ 12:07:33.267 PM 5098.174 5098.174 5098.174
03/05/2008@ 04:47:16.841 AM 869.347 869.347 869.357
03/05/2008@ 06:25:49.112 AM 4222.712 4222.712 4222.722
23/05/2008@ 08:12:59.655 AM 7374.369 7374.369 7374.369
24/05/2008@ 05:06:33.902 AM 3519.939 3519.939 3519.939
26/06/2008@ 10:14:03.382 AM 426.742 426.742 426.742
14/08/2008@ 06:29:08.813 AM 1217.348 1217.348 1217.348
15/08/2008@ 08:49:43.032 AM 835.605 835.605 835.605
19/09/2008@ 04:25:07.430 AM 2602.133 2602.133 2602.133

Table 4. Electrical failures in establishment 2.

Time label V1-Irpt durtn V2-Irpt durtn V3-Irpt durtn
24032008@102634.764 PM 2035.566 2035.496 2035.496
13042008@090101.233 AM 12548.032 12548.032 12548.032
19042008@062338.632 AM 146.782 146.793 146.772
16062008@052757.349 AM 398.137 398.137 398.147
23062008@020350.010 AM 497.88 497.88 497.9
12072008@022100.444 AM 2297.264 2297.274 2297.264
01082008@022159.570 AM 419.267 419.267 419.267
01082008@025708.098 AM 2107.798 2107.798 2107.798
05082008@022729.161 AM 1241.322 1241.301 1241.311
27092008@055541.534 PM 18.47 18.47 18.47

stop due to failures, their re-activation takes some time
which results in reduced efficiency and manufacturing
losses. Secondly, when the power failures last for long
periods, the machines cool down and after their re-
activation, there is loss in efficiency until they reach to the
previous high efficiency rates. When the failures are
uncontrolled interruptions, the mechanical and the driving
electrical and electronic equipments in high speed and
high moment machines may break down, resulting in an
additional cost. The interruptions in establishment 1 and
2 are shown in Tables 3 and 4. The first column shows
the time label of the occurrence. In the following three
columns, the interruption periods for each phase are
given in seconds.
In the first establishment, there were 9 different
interruptions with a total power failure time of 26,166 s.
This makes approximately 436 min, in other words 7 h
and 16 min. When the direct manufacturing loss is
calculated on $4,000/h, the total is $29,000. (for 6
months). The efficiency loss in complete re-activation of
the establishment after the interruptions should also be
calculated. When we consider an approximate manufac-
turing loss of half an hour for each interruption, it will
make $2000/ interruption. However, in calculation of the
number of the interuptions, it will be appropriate that we
count the interruptions occurring on the same day as a
single one. Thus, if we consider that there are 7
interruptions, the material loss for 6 months will be
$14000. The uncontrolled interruption can also lead to
breakdowns. The material loss from such breakdowns is
calculated to be $3000 for 6 months.
The number of the interruptions in the second
establishment was slightly higher than that of the first
one. The number of the interruptions in this establishment
after the measurement for 6 months was 10. The total
duration of such interruptions was 21710 s. In other
words, it was around 360 min, corresponding to 6 h. In
this establishment, the manufacturing loss per hour was
$5000. Given the situation, the material loss due to the
duration of the interruption for 6 months was calculated to
be $30000. The material loss stemming from the reduced
efficiency in re-activation of the establishment can be
calculated from manufacturing loss per hour for each
interruption in a similar way as the first establishment.
This value will be $2500/interruption for this
establishment. If we take 9 interruptions in total since the
interruptions were successive on 1
st
August, the
calculated loss will be $22500. In this establishment, the
uncontrolled interruptions due to the failures cost $2500
for six months. The loss was calculated to be $55000 in
total for six months. This means an annual loss of $110,000.
The calculations show that it is compulsory that the mea-
sures are taken against the failures in both establishments.

Voltage flicker

Voltage flicker measurements were performed at both

establishments. The results revealed that there were
intense poor power quality occurrences in the first esta-
blishment. Despite there were voltage flicker recordings
in the second establishment, there were no voltage flicker
and thus periods exceeding the limits values during the 2
h periods (according to EN50160). The material loss from
the voltage flicker suffered by the establishments could
not been clearly determined. Since there were several
poor voltage quality occurrences in the establishments, it
was difficult to make a classification to determine such
damage.
Identification would be easier in an establishment
where the only poor electrical quality occurrence relates
to voltage flicker. In some establishments voltage flicker
may directly result in defective products. The voltage
flicker values in the first establishment did not cause any
directly defected products. Figures 11 and 12 show the
graphics of voltage flicker indices from both
establishments. As seen from the figures, there were
moments when the limits were exceeded.
While the limit value for the voltage flicker parameter
Plt was 0.8, the limit value for Pst was 1. In Figures 10
and 11 the values of 0.8 and 1 can be followed by the
dashed lines. In the second establishment, both the
number of the exceeded limits and the amount of the
limits exceeded was lower. It is seen that in the first
establishment the values were exceeded much more
both in quantity and rate.

Total costs

The 6-month costs for poor electrical quality in the first
establishment were calculated as being $149000 due to
voltage sag, $46000 due to failures and $3000 due to
transient occurrences, harmonics and voltage flickers.
Thus, the total cost for 6 months was $198000, corres-
ponding to an annual cost of $396000. In the second
establishment, the annual costs were calculated as being
$110000 from voltage sags and $5000 from harmonics,
making a total of $115000. The losses of the first
establishment were higher due to the poor quality of the
network and the shortcomings in their own infrastructure.
In the second establishment, except for the voltage
interruptions, the costs were relatively lower due to the
quality of the network and their own infrastructure.

Conclusions

As demonstrated by the measurements, although the
harmonic currents are above the standards in the textile
industry, nearly all of the material loss suffered due to
poor energy quality is from sudden voltage variations
(particularly short-term voltage variations) and power
failures. The loss incurred by the first establishment is
significantly high, being around 15% of the annual net profit
of the facility where measurements were performed. On the

Figure 10. Monthly voltage flicker graphic of the first establishment.

Figure 11. Monthly voltage flicker graphic of the second establishment.

Figure 12. Monthly voltage flicker graphic of the second establishment

other hand, there was no significant cost in the second
establishment, except for the power failures. Despite this,
it appears that measures should be taken against the
loss from failures. Textile industry is a comprehensive
sector with various processes carried out in different
machinery parks. Therefore, the losses from poor power
quality will vary depending on the establishment. While
founding a new establishment the investment feasibility
parameters should include the high quality electrical
power costs along with land costs, qualified staff costs,
etc. The fact that the loss incurred by the first
establishment is nearly four times greater than that of the
second one which utilizes higher quality energy.
The textile sector inour country is troubled with serious
global competition and sustaining its existence. There-
fore, the government produces incentives and support
packages to reinforce this sector which provides
employment for around 3 million people, and the main
condition for benefiting from such packages is to transfer
the establishments to the Eastern or Southeastern
Region. The industrialists to transfer their establishments
to those regions should take the power quality into
consideration, if it is to have a serious effect on the
processes and the losses.
The next study will focus on the efficiency losses due to
the poor electrical energy quality and proposed solutions
to reduce or eliminate the osts. Depending on the costs
incurred, the feasibility of the system investments will be
considered within the scope of the proposed solutions.

ACKNOWLEDGEMENTS

The authors would like to extend their thanks to
Schneider Electric Turkey and Mr. Grkan Erdeniz and
also thank Mr. Mustafa Beker for his contributions.

REFERENCES

Alkan A, Yilmaz AS (2006). Frequency Domain Analysis of Power
Systems Transients using Welch and Yule Walker Ar Methods,
Energy Conversion Manage. , 7: 2129-2135.
Davis EJ, Emanuel AE, Pileggi DJ (2000). Evaluation of Single Point
Measurement Method for Harmonic Pollution Cost Allocation, IEEE
Trans. Power Delivery, 15 (1): 14-18.
De Abreu JPG, Emanuel AE (2002). Induction Motor Thermal Aging
Caused by Voltage Distortion and Imbalance: Loss of Useful Life and
Its Estimated Cost, IEEE Trans Indus. Appl., 38 (1): 12-20.
De Nooij M, Koopmans C, Bijvoet C (2007). The Value of Supply Se-
curity The Costs of Power Interruptions: Economic Input for Damage
Reduction and Investment in Networks, Energy Econs., 29: 277-295.
EN Std 50160 (1999). Voltage Characteristics of Electricity Supplied by
Public Distribution Systems EN Standards.
Grupta CP, Milanovic JV, Aung MT (2004). The Influence of Process
Equipment Composition on Financial Losses due to Voltage Sags,
11
th
International Conference on Harmonics and Quality of Power.
IEEE Std 1159 (1995). Recommended Practice for Monitoring Electric
Power Quality, IEEE Standards, IEEE Press.
IEEE Std 1159.3 (2003). Recommended Practice for the Transfer of
Power Quality Data, IEEE Standards, IEEE Press.

Koyiit F, Yankolu E, Yilmaz AS, Bayrak M (2008). Energy Quality
Measurements in a Textile Industry and the Cost of Poor Energy
Quality for he Facility (in Turkish), Eleco Congress, Bursa, Turkey.
Szen A, Bayrak, M, Yein EM (2007). Cost of Poor Energy Quality in a
Paper Industry, (in Turkish), Energy Efficiency and Quality
Symposium, Kocaeli, Turkey.


Sullivan MJ, Vardell T, Suddeth BN, Vojdani A (1996). Interruption
Costs, Customer Satisfaction and Expectations for Service
Reliability, IEEE Transactions on Power Systems, 11 (2): 989-995.

Effects of Power Quality On Manufacturing Costs in Textile Industry

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Effects of Power Quality On Manufacturing Costs in Textile Industry

Uploaded by

Copyright:

Available Formats

Scientific Research and Essay Vol.4 (10), pp.

1085-1099, October 2009

You might also like