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Scientific Research and Essay Vol.4 (10), pp. 1085-1099, October 2009Available online at http://www.academicjournals.org/SREISSN 1992-2248 © 2009 Academic Journals

Full Length Research Paper

Effects of power quality on manufacturing costs intextile industry

F. Koçyiit1, E. Yanıkolu1, A. S. Yilmaz2* and M. Bayrak1

1Sakarya University, Electrical-Electronics Engineering Department, Sakarya, Turkey.

2Sutcu 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. Allparameters affecting power quality have been measured by using ION 7650 Power Analyzer accordingto the EN 50160 standard. Because textile industries have high technology machines includingelectronic control cards and driver controlled motors, poor power quality may damage the system andcause production failure. Measurements showed that the losses caused by electrical power quality weresignificantly 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 world’s new economic system, in other words, the

global economy, the conditions for existence havebecome quite difficult for establishments. The fast-growing Far East, becoming a manufacturing center, hassignificantly pulled down the profit rates of industrialestablishments. The profit percentages which wererepresented by two-digit and even three-digit figures havedecreased to single-digit figures due to excess supplyand intense competition. Both the shrinkage in the marketand the decreases in profitability have forced industrialestablishments to manage their costs effectively (Sullivanet al., 1996).

In order to manage their costs, the companies have notonly 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 reflectedon the income statements and balance sheets of thesecompanies, as an increased cost due to inefficiency.Along with this, in a world of such intense globalcompetition, the penal outcomes as well as theadversities which can lead to losing the customer or

*Corresponding author. E-mail: [email protected].

customers as a result of the non-delivery of products

which cannot be manufactured because of a machinebreak-down due to energy failure or poor power qualityare the results which cannot be endured by today’sestablishments. Due to such reasons, the customer-focused establishments pay attention to quality powesources including electrical power and increasing theiquality (Sözen et al., 2007; Grupta et al., 2004; Davis eal., 2000; Nooij et al., 2007).

Besides other sectors, the influence of electrical powequality on the textile sector and textile establishmentshave not been sufficiently analyzed with studies untinow, being quite superficial. There has not been anystudy 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 integratedtextile establishment in Bursa and KahramanmaraTurkey.

For this, the energy quality measurements at a textileestablishment were made by ION 7650 power monitoringand analysis device and the poor power quality wasassessed in accordance with EN 50160 standard; thedamage from such poor quality of energy suffered by theestablishment was also calculated. The findings and theimpacts on weaving, yarn, etc. departments have beenanalyzed in detail (Koçyiit 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 µs 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 µs 0 - 8 pu

High frequency 0.5-5 MHz 5µs 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 powersupply as delivered to the user in normal operating condi-tions in terms of continuity of supply and characteristicsof voltage (symmetry, frequency, magnitude andwaveform)”. Also, PQ deals with not only voltage quality

but also current quality. It is the combination of voltageand current quality. In practice, there are several types oPQ disturbances such as voltage sag/swell/interruptionsswitching transients, flickers, harmonics, notches, etccaused by faults, nonlinear loads and dynamic operatingconditions (IEEE Std 1159, 1995; Alkan and Yilmaz2006). 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 sittingsets in our rooms, tulle and curtains, carpets, towels inthe bathrooms, and even the airbags in our cars are offabrics manufactured through textile weaving or knitting.Today’s weaving and knitting machines are hightechnology machines. They include tens of sensors,driver controlled ac and dc electrical machines, communi-cations cards, cpu units, touchscreens, ethernet cardsand encoders. These equipments operate at differentvoltage values. If any interruption, in the machines at theweaving room occurs for any reason, it can take up to 4 hfor the machinery park to return to the acceptableperformance values. Thus, any short-term or long-terminterruption means a direct manufacturing loss. Thesemachines which are sensitive to sinusoidal form ofelectrical power can shut down if a voltage drop, voltagesag and voltage fluctuations occur. These machinesinclude special encoders used for position determinationand interruptions without any reason can lead to thebreak 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 6kW to draw higher currents, leading to the break-down ofelectronic cards driving such engines. Such cards costapproximately $2500 and their replacement may takeminimum 2 h.

At a typical weaving establishment shown in Figure 1(sample establishments), the average daily turnover of aweaving loom can be considered to be $2,400. Suchturnover indicates that the value added to the economy in1 h by one machine is $100. In our country, the average

number of the weaving machines for each establishmenin corporate companies is between 100 and 1000. Insuch establishments, it can be simply calculated thaeven a 1 h interruption means a weaving manufacturingloss between $10,000 and $100,000. When suchinterruption occurs at an organized industrial zone withseveral textile plants, the loss will reach to more dramaticvalues.

High current and voltage harmonics and the otherdistortions can cause such machines to stop. Harmonicsshorten the life of all electrical and electronic equipmentsin the machines. They cause break-downs, resulting inrepair costs and manufacturing losses. They also shortenthe depreciation periods of the machines, leading toincreasing costs and thus losses (De Abreu and Emanuel2002).

EFFECTS OF PQ ON DYEING PROCESSES

Dyeing processes in the textile sector can be classifiedunder main categories of fiber, yarn and fabric dyeingDespite the differences in physical structures of suchmachines, they operate under similar principles as thematerials they dye are the same. All fiber, yarn andfabrics are made of raw materials such as acrylic, polyes-ter, cotton or viscose. These machines include driver-

controlled pumps, level gauges, calorimeters, liquidmeters, PLC devices or cpu including control cardstouchscreen panels, actuator valves, proportional valvesand several other electrical, electromechanical andelectronic sensors and equipments.

Dyeing machinery equipments can be interrupted inmost of the poor quality electrical energy situations. Theamount of losses suffered depends on the duration osuch interruptions. In situations of voltage drop and volt-age fluctuations, the machinery may activate theautomatic protection and shut itself down. If the poor




quality situation lasts for short periods (before the waterinside the kier cools), the repair process called"reinforcement" is performed. This results in extension ofthe process time as well as water, energy, chemical anddepreciation losses. It usually costs the half of the dyeingexpenditures. If we assume that polyester is dyed in a

dyeing kier of 1000 kg, it means that the loss perkilogram will be $0.5, making a total loss of $500. Incotton or viscose dyeing processes, the loss is doubled. Ifthe process involves fabric dyeing for automotive sector,the process may have to be repeated all over again. Thisresults in the loss being doubled. A worse situation is theloss of the yarn or fabric in the dyeing kier. In some of theinterruptions, the material dyed may have to be scrappeddue to the nature of the raw material or product.

If there is yarn in a kier of one ton, and for example if itis 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 dyeinghouses. If these are assumed to dye polyester, we cansay that they can perform the dyeing process 60 times aday. If we assume that the average kier capacity is 500kg, the daily dyeing capacity would be 30 tons. Given thatthere are hundreds of dyeing houses in our country, theloss can be estimated from the above figures. Our coun-try’s textile sector has witnessed a significant downfall inthe recent years. With each year, several dyeing housesare closed. The turnover of a dyeing house performingyarn-dyeing in a one-ton kier would be $1500, its bestprofit being $300. As explained above, a single energyproblem can lead to a loss amounting to 500 or 1000 oreven $2,000. Therefore, the significance of electrical qualityis obviously seen. High quality electrical energy has an

important role in the sustainability of such companies intoday’s commercial environment of low profitability.

EFFECTS OF PQ ON FINISHING PROCESSES

Finishing process means the last processes performedon the textile products and involves a wide range ofmachines. The mid-part of the stenter machines is theheated drying section which is also known as the oven.This section varies between 15 and 35 m depending onthe establishment. The fabric is stabilized through heatingby hot oil or natural gas. Two different processes can be

carried out before the drying process. The first process isputting the fabric into a chemical-filled basin at the inlet ofthe machine. Here the fabric is processed with chemicals,as a result of which the fabric attains features such asdelayed ignition, anti-germ and in the case of jeansfabric, prevention of leg turn-ups. In the second process,the said chemicals are only applied to one surface of thefabric in the covering unit, again at the inlet of themachine.

The total length of the stenter machine is between 30and 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 themachine, which is more than 10 m long, there are PLCdrivers, hundreds of control elements, sensors most owhich have modbus communication, touchscreen contropanels, computer-controlled weft straignteners operatingsynchronously with the machine, automatic fabric

accumulator, J-Box machine and several other equip-ments. The electrical control panel of such machines islonger than 10 m.

A problem at any component of this complicated lineends up with the shut down of the line. The fabric passesthrough the machine at a certain speed. The speed rangeis between 10 and 100 m/d. At this stage, the temperature at the oven is between 100 - 180°C. The speedand the temperature vary depending on the process andfabric types. With each halt of the line which is sensitiveto poor quality energy, the fabric left inside the machine isdeformed from the heat and is scrapped. The value oany fabric with an average length of 50 m is between$100 and $1,000. Re-manufacturing of such fabric wouldbe even more costly. If special chemicals are used, theircost will also be added as a loss.

The shortening of the depreciation period due to poopower quality is even more significant in this machineAny such line costs between 750.000 and $1.250.000depending on the accessories. There are hundreds ofinishing establishments operating with such machines inour country. In the meantime, the equipments breakingdown due to harmonics and other poor power qualityproblems are counted as direct loss. When theequipments break down, the machine stops and the timerequired for detection of the break-down and repair is asignificant amount of time. In such situations, the

manufacturing losses will reach to higher values. Let usgive the most optimistic scenario. Let us assume that thecost of a one-meter process in a finishing process is $1The processing speed of the machine is 30 m/d. Undethis scenario, the manufacturing loss will be 1800 m perh, with a cost of $1800. If the machine remains out ooperation for 10 h, the loss will be $18000. In the reaestablishments, there have been some break-downs with10 days of repair period (waiting for replacements, etc.)Such break-downs were witnessed in the establishmentswhere the measurements took place for this study.

MEASUREMENT METHODS AND STANDARDS

In our country, energy quality is monitored in accordancewith the “Regulation on supply sustainability, commerciaand technical quality of electrical energy provided throughthe distribution system in the electricity market” which is atranslation of EN 50160 standard.

Measurements regarding power quality should becarried out in accordance with this regulation. To achievethis, the required devices should both momentarily monitoenergy flow and all the parameters related to quality, as welas record the problems (quality deviations). It is essentia




Figure 2. ION Enterprise software interface.

that such devices are internationally accredited, in otherwords, the measurements performed should be legallyrecognized and acceptable. The measurements havebeen carried out with ION 7650 device, performing three-phase and neutral measurement which is compliant tothe requirements above. The six months measurementsperformed at two different establishments within thisstudy, were fully conducted and planned in accordancewith EN 50160 standard.

The measurements were recorded real-time on thecomputer 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 reachedfrom an effective menu.With the privatization of energy production, transmis-

sion and distribution, energy has begun to be consideredas a meta that should be produced and distributed inaccordance with certain standards and rules among thecompanies supplying the energy and the industrialorganizations utilizing the energy. Companies or organi-zations producing and/or selling energy have becomeliable to supply the electrical power they have to generatewithin certain boundaries called electrical quality, in anuninterrupted and trouble-free manner. In the industry,

the energy quality (or poor quality) is monitored andreported in accordance with certain power quality stan-dards and regulations.

MEASUREMENT RESULTS

All parameters affecting the power quality were measuredmomentarily (by taking 1024 samples from one period)and the related parameters were recorded on the maincomputer through ethernet connection. Besides recordingof all parameters, the deviations from power quality

(according to EN 50160) were kept in a separate fileSince the poor power quality was recorded in transienmeasurements, irrelevant data did not occupy space onthe computer. As time was also recorded for energyquality deviations, the manufacturing losses and thereasons for the damage could be approximatelyestimated.

In selection of the establishments, attention was paid tochoose them from different parts of the country. Com-bined with the features of the industrial zones they werelocated, it was demonstrated that those two plants wereoperating on electrical energy of very different quality




Figure 3. Successive voltage sag occurrences recorded.

values. One of our establishments was located in anorganized industrial zone in the Marmara Region. In thisorganized industrial zone, electricity is fed through double

lines and in addition to this the same main busbar is fedby three high power natural gas plants. As a result of themeasurements performed, it was demonstrated that ofthe two establishments this one was operating on higherelectrical quality. Naturally, the effects of and materialloss from poor quality were insignificant in thisestablishment. On the other hand, in the establishmentlocated in the Eastern Region, there was anotherautoproducer in the main busbar of the distribution linefrom which the establishment was supplied electricalenergy. As it will be explained in the following sections,there were several poor power quality incidents in thisestablishment. This resulted in excessive material burdenfor the establishment. As a result of the measurementsperformed, it was seen that the poor quality of electricalenergy incidents explained in the second section wereseen in the first establishment for several times. In theother establishment, the incidents mentioned occurredfewer times than the first establishment. When the in-cidents occurred, the corresponding problems in the plantwere also recorded. On the basis of such records, thecosts were calculated in cooperation with the planningand production departments of the establishments. Thecalculations were related to the direct costs and theindirect costs such as loss of reputation and customers

were not included.

Voltage sag measurements and their cost

During the six-month-measurements in the firsestablishment, there were 155 voltage sag occurrencesrecorded. In the second establishment, on the othehand, the number of voltage sag occurrences was sixThe depth and duration of such occurrences determinedthe effects on the establishment. The six occurrences inthe second establishment did not have any effects on theestablishment. The Figure 3 shows an example of themeasurements and the voltage sag records. The currenvariations at the time the voltage sag occurred are shownin Figure 4. The occurrences resulted in manufacturinglosses and breakdowns in the first establishment. Voltagesags with greater depth and duration caused somemachines to shut down as well as some breakdownsVoltage sags were in succession at times and theysometimes resulted in power failures. Successive voltagesags could be readily monitored. The records could betransformed into a graphic with a simple option in thesoftware. In the first establishment, some of the voltagesags resulted in general interruption, some caused partiainterruption and some others led to breakdowns andcombinations. The records and calculations revealed thathe 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 transientoccurrences were recorded in the first establishment

while there were no transient records in the secondestablishment. In measurement of the transientoccurrences the device was set to the highest sensitivityand the occurrences were momentarily recorded duringtwo periods. The calculated number of the points duringthe two periods was 2048. Thus, the time between twopoints reached to a very sensitive value, nearly 20 µs.Figure 5 shows the graphic of the transient moments.Figure 6 shows the three phase current wave forms atthe moment of the transient occurrence and Figure 7demonstrates the voltage harmonics at the moment ofthe occurrence.

When the figures are analyzed, it is seen from the cur-rent reaching to a five-fold higher value and the releasesoccurring on voltage curves that a high-power condensergroup was activated. The fact that the currentharmonicsreach to high frequency values and theiramplitude exceeds 100%, shows the occurrence of aresonance. This led to problems such as the explosion orbreakdown of the condensers in the compensation panel,the burning and melting of the contactor contacts, as wellas the mel-ting of the connected cables. Here, thegreatest hazard is the continuous fire risk.

The cost of the problems such as material and laborloss as a result of such occurrences in the first establish-

ment was calculated to be around $1000. No suchoccurrence or related cost was seen in the secondestablishment.

Harmonic measurements and their costs

The current and voltage harmonics were continuouslymeasured until the 63th harmonic. As shown in Figures 8and 9 both current and voltage harmonics measured inthe both establishments were over the limit values. Thevalues in the graphic represent the average values, sothe harmonics occurring in the establishment are abovesuch values. It is seen that the voltage harmonics exceed6% and the current harmonics exceed 20%. The currenharmonics frequently reach to 30 - 35%. In addition to theproblems created at the compensation panel of the esta-blishment, these harmonic components can obviouslydamage the other machines and fixings operated in theestablish-ment. The current and voltage magnitudesincluding such high-value harmonics can damage theelectronic cards and create negative results on the livesof the other electrical machinery. Replacing the compen-sation panel of the establishment with a harmonic-filteredcompensa-tion panel is compulsory, given the resonanceoccur-rences.

Voltage interruptions

One of the most significant causes of the losses in theestablishments 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

0,3090 36,312 37,923 37,388 Interruption, breakdown 18,000

0,9330 15,534 14,714 28,568 Interruption, breakdown 17,5000,1810 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 2,5000,2290 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).


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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

[email protected] PM 2035.566 2035.496 2035.496

[email protected] AM 12548.032 12548.032 12548.032








[email protected] PM 18.47 18.47 18.47




stop due to failures, their re-activation takes some timewhich results in reduced efficiency and manufacturinglosses. Secondly, when the power failures last for longperiods, the machines cool down and after their re-activation, there is loss in efficiency until they reach to theprevious high efficiency rates. When the failures are

uncontrolled interruptions, the mechanical and the drivingelectrical and electronic equipments in high speed andhigh moment machines may break down, resulting in anadditional cost. The interruptions in establishment 1 and2 are shown in Tables 3 and 4. The first column showsthe time label of the occurrence. In the following threecolumns, the interruption periods for each phase aregiven in seconds.

In the first establishment, there were 9 differentinterruptions with a total power failure time of 26,166 s.This makes approximately 436 min, in other words 7 hand 16 min. When the direct manufacturing loss iscalculated on $4,000/h, the total is $29,000. (for 6months). The efficiency loss in complete re-activation ofthe establishment after the interruptions should also becalculated. When we consider an approximate manufac-turing loss of half an hour for each interruption, it willmake $2000/ interruption. However, in calculation of thenumber of the interuptions, it will be appropriate that wecount the interruptions occurring on the same day as asingle one. Thus, if we consider that there are 7interruptions, the material loss for 6 months will be$14000. The uncontrolled interruption can also lead tobreakdowns. The material loss from such breakdowns iscalculated to be $3000 for 6 months.

The number of the interruptions in the secondestablishment was slightly higher than that of the first

one. The number of the interruptions in this establishmentafter the measurement for 6 months was 10. The totalduration of such interruptions was 21710 s. In otherwords, it was around 360 min, corresponding to 6 h. Inthis establishment, the manufacturing loss per hour was$5000. Given the situation, the material loss due to theduration of the interruption for 6 months was calculated tobe $30000. The material loss stemming from the reducedefficiency in re-activation of the establishment can becalculated from manufacturing loss per hour for eachinterruption in a similar way as the first establishment.This value will be $2500/interruption for thisestablishment. If we take 9 interruptions in total since the

interruptions were successive on 1st

August, thecalculated loss will be $22500. In this establishment, theuncontrolled interruptions due to the failures cost $2500for six months. The loss was calculated to be $55000 intotal 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 wereintense poor power quality occurrences in the first establishment. Despite there were voltage flicker recordingsin the second establishment, there were no voltage flickerand thus periods exceeding the limits values during the 2h periods (according to EN50160). The material loss from

the voltage flicker suffered by the establishments couldnot been clearly determined. Since there were severapoor voltage quality occurrences in the establishments, iwas difficult to make a classification to determine suchdamage.

Identification would be easier in an establishmenwhere the only poor electrical quality occurrence relatesto voltage flicker. In some establishments voltage flickemay directly result in defective products. The voltageflicker values in the first establishment did not cause anydirectly defected products. Figures 11 and 12 show thegraphics of voltage flicker indices from bothestablishments. As seen from the figures, there weremoments when the limits were exceeded.

While the limit value for the voltage flicker parameterPlt was 0.8, the limit value for Pst was 1. In Figures 10and 11 the values of 0.8 and 1 can be followed by thedashed lines. In the second establishment, both thenumber of the exceeded limits and the amount of thelimits exceeded was lower. It is seen that in the firstestablishment the values were exceeded much moreboth in quantity and rate.

Total costs

The 6-month costs for poor electrical quality in the firs

establishment were calculated as being $149000 due tovoltage sag, $46000 due to failures and $3000 due totransient occurrences, harmonics and voltage flickersThus, the total cost for 6 months was $198000, corres-ponding to an annual cost of $396000. In the secondestablishment, the annual costs were calculated as being$110000 from voltage sags and $5000 from harmonicsmaking a total of $115000. The losses of the firstestablishment were higher due to the poor quality of thenetwork and the shortcomings in their own infrastructureIn the second establishment, except for the voltageinterruptions, the costs were relatively lower due to thequality of the network and their own infrastructure.

Conclusions

As demonstrated by the measurements, although theharmonic currents are above the standards in the textileindustry, nearly all of the material loss suffered due topoor energy quality is from sudden voltage variations(particularly short-term voltage variations) and powefailures. The loss incurred by the first establishment issignificantly high, being around 15% of the annual net profiof 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 secondestablishment, except for the power failures. Despite this,it appears that measures should be taken against theloss from failures. Textile industry is a comprehensivesector with various processes carried out in differentmachinery parks. Therefore, the losses from poor powerquality will vary depending on the establishment. Whilefounding a new establishment the investment feasibilityparameters should include the high quality electricalpower costs along with land costs, qualified staff costs,etc. The fact that the loss incurred by the firstestablishment is nearly four times greater than that of thesecond one which utilizes higher quality energy.

The textile sector inour country is troubled with seriousglobal competition and sustaining its existence. There-fore, the government produces incentives and supportpackages to reinforce this sector which provides

employment for around 3 million people, and the maincondition for benefiting from such packages is to transferthe establishments to the Eastern or SoutheasternRegion. The industrialists to transfer their establishmentsto those regions should take the power quality intoconsideration, if it is to have a serious effect on theprocesses and the losses.

The next study will focus on the efficiency losses due tothe poor electrical energy quality and proposed solutionsto reduce or eliminate the osts. Depending on the costsincurred, 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 toSchneider Electric Turkey and Mr. Gürkan Erdeniz andalso thank Mr. Mustafa Beker for his contributions.

REFERENCES

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