Analysis of Power Supply System for Pakokku

Spinning and Weaving Factory

Ma Thaw Tar Tun, Thet Tin

Abstract—Electrical power supply and distribution features will provide all the necessary power during the system debugging
be planned/delineated concurrently with planning stages of new stage.

installations and/or new facilities on existing installations. At present,

electrical energy is one of the most important forms of energy in the
world. Transformer is one piece of equipment in the electrical
distribution network of electrical utilities, power stations of industry,
which is the most difficult to replace. The transmission lines 66kV of
the Kyun Chaung Gas Turbine generating station is going on
II. SPINNING AND WEAVING FACTORY
A complete textile factory consists of two main sections:
Spinning and weaving section and finishing section. There are
some textile factories which produce only yarn and there are

the Pakokku spinning and weaving factory. The choice of power
voltage and distribution voltage in the factory area is 66kV of the total
inlet power voltage of the factory. This factory is continued with
10000kVA (66/11) kV and 1250kVA (11/0.4) kV transformers. In
this paper, analysis of power supply system of Pakokku spinning and
weaving factory is described. In the power supply system, three- phase,
11000/400V, 50Hz, 1250kVA transformer and so many factory
loadings are included.
Keywords—Spinning and Weaving Factory, Cotton Yarn
Manufacturing Process, Carding System, Load Distribution
others which operate up to finishing stage. The work of
producing yarn from cotton and then from yarn to textile is
very interesting works which benefit the people. There are
several processes involved by the time the finished cloth comes
out of a mail from its basic raw material, cotton picked up from
the fields.

I. INTRODUCTION

he most feasible method of supplying and distributing

T electrical power will be determined by first quantifying
the electrical power requ rements (or maximum demand
load) for the installation. In the early design stages, this
demand should be based on area or population; in later design
stages, summation of individual building connected loads
modified by suitable demand and diversity factors will be
used. For early stages, use of kW, kVA, and hp
interchangeably on a one to one basis is sufficiently precise.
During final design, hp will be converted to kVA; and kVA may
be multiplied by the estimated power factor to obtain kW if
required. The calculation of full load amperes will utilize kVA.
The power supply assumes a very unique role within a
Fig. 1. Process Flow of Cotton Yarn Manufacturing

typical system. In many respects, it is the mother of the

system. It gives the system life by providing consistent and A. Cotton Yarn Manufacturing Process
repeatable power to its circuits. It defends the system against When a spinning factory is to be set up, the following
the harsh world outside the confines of the enclosure and machines are needed.
protects its wards by not letting them do harm to themselves. If  Blowing Machine
the supply experiences a failure within itself, it must fail  Carding Machine
gracefully and not allow the failure to reach the system.  Drawing Machine
Alas, mothers are taken for granted, and their important  Roving Machine
functions are not appreciated. The power system is routinely  Spinning Machine, etc

left until late in the design program for two main reasons. First, more exciting circuits and rarely do engineers have a
nobody wants to touch it because everybody wants to design
 The process of cotton yarns manufacturing is the
conversion of cotton fiber into yarn. In relation to spinning,
background in power systems. Secondly, bench supplies
Ma Thaw Tar Tun is a master candidate student of the Mandalay
Technological University; e-mail: thawtartun@ gmail.com
technology is concerned with the study of the production of a
yarn. Spinning
refers to the conversion of a large quantity of individual
unordered fibers of relatively short length into a linear,
ordered product of very great length by using suitable
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machines and devices. In processing natural fibers, the same
basic operations are always involved. This included the
general operations of opening, picking, carding, drawing,
roving, and ring spinning in the production of the so called
carded yarn.
B. Blowing system
With dealing with raw cotton, this set of machines blends
and opens the raw cotton, and clean its trash contents, thereby
producing even and clean laps for further processing on
carding machines. The Blowing Room machinery is
respectively composed of the following individual machines.
 Automatic bale plucker
 Heavy separator
 Double roll cleaner
 Multi-mixer
 Porcupine opener
 Step opener
 Saw-blade beater opener
 Scutcher
C. Carding System
The card machine is the most important machine in the yarn
manufacturing process. It performs second and final-level
cleaning functions in an overwhelming majority of cotton
textile mills. It spins them into standard silvers and stored in a
silver can for next process.
Fig. 2. Carding Machine
D. Drawing System
Drawing is the first process in yarn manufacturing that
employs roller drafting. In drawing, practically all draft results
from the action of rollers. Containers of silver from the
carding process are staked in the creel of the drawing frame.
Drafting occurs when silver is fed into a system of paired rollers
moving at different speeds.
Drawing straightens the fibers in the silver by drafting to
make more of the fibers parallel to the axis of the silver.
Parallelization is necessary to obtain the properties desired
when the fibers are subsequently twisted into yarn. Drawing
also produces silver that is more uniform in weight per unit of
length and helps to achieve greater blending capabilities. The
fibers that are produced by the final drawing process, called
finisher drawing, are nearly straight and parallel to the axis of
the silver. Weight per unit length of finisher-drawing silver is
too high to permit drafting into yarn on conventional ring-
spinning systems.
E. Roving System
Roving is a process in yarn manufacture, in which the silver
is being drawn twisted and wound onto the bobbin for next
process. The roving process reduces the weight of the silver to
a suitable size for spinning into yarn and inserting twist, which
maintains the integrity of the draft strands.
Fig. 4. Processing of Cotton Roving Machine
F. Spinning System
Spinning is the single most costly step in converting cotton
fibers to yarn. Currently, over 85% of the world’s yarn is
produced on ring-spinning frames, which are designed to draft
the roving into the desired yarn size, or count, and to impart
the desired amount of twist. The amount of twist is
proportional to the strength of the yarn. Bobbins of roving are
placed onto holders that allow the roving to feed freely into the
drafting roller of the ring-spinning frame. The lengths of
yarn on the bobbins are too short for use in subsequent
processes and are doffed into “spinning boxes” and delivered to
the next process. In the modern production of heavier or coarse
yarns, open-end spinning is replacing ring spinning. A
silver of fibers is fed into a high speed rotor. Here the
centrifugal force converts the fibers into yarns. There is no
need for the bobbin, and the yarn is taken up on the package
required by the next step in the process.
G. Weaving System
The weaving process interfaces the warp, which are the
length-wise indigo dyed yarn and the filling, which are the
natural colored cross-wise yarn. The warp thread is in the form
of sheet. The weft thread is inserted between two layers of warp
sheets by means of a suitable carrier, such as Shuttle,
Projectile, Rapier, Air Current, Water current, etc. The
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selection of carrier depends upon the type of weaving

machinery used. The two different technologies available for

Fig. 3. Drawing Machine
weaving machines are Conventional Shuttle Weaving System
which is done by Ordinary looms or Automatic looms; and the
Shuttle less Weaving System which is done by Air jet, Water
jet Rapier or a projectile weaving machine. The Conventional
Shuttle loom results in lesser production due to slow speed
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and excessive wear and tear of machinery. As such, now denim
is generally woven through Shuttle less Weaving System
namely, Air jet looms, rapier looms or projectile looms.
III. ELECTRICAL COMPONENTS AND SUPPLY SYSTEM USED IN
SPINNING AND WEAVING FACTORY
In the operation of carding machine, four motors are used to
operate the machine. The cleaning roller motor is 0.55kW, 2890
rpm, is used to clean the dust in the machine. FAN motor, 2.2
kW, 2890 rpm is used to suck the dust and dirt. The cylinder
motor is 3.8kW, 960 rpm is used to draw the picker laps by the
two rollers. Doffer motor, 1.5 kW, 960 rpm is used to draft the
cleaning cotton. In the carding system, PLC, 220 V is used to
control the operating of the machine. The control system
consists of the two step-down transformers.
normal speed. The motor FAN, 0.75 kW, 2840 rpm is to clean
the dusts in the machine.
Roving system is to reduce a half of yarn size of draw silvers
from the drawing machine. In the roving machine, three-phase
asynchronous motor is used. The main motor, 10 kW, 20.6A,
960 rpm, is used to build cone shape by winding the yarn on the
bobbin. The Pneumatic motor is 0.25kW, 1500 rpm, 1.55 A, is
used to clean the dirt and each fiber upon the machine.
In the spinning system, three-phase asynchronous motors are
mainly used. The ring rail lifting motor, 0.18 kW, 1400 rpm, is
used to lift the ring rail from doffing position to a suitable
position. After that, the ring rail motor stops and the suction
motor starts. The suction motor, 2.2 kW is used to suck the dirt
and each fibers. The clear motor, 0.25kW is used to suck the
dirt of the upper machine. The clearer removing motor, 1.5 kW
moves the suction pipe from head end to off- end of the upper
machine. The main shaft motor is a double speed motor. The
motor speed is 1450/960 rpm.

IV. LOAD DISTRIBUTION AND CALCULATION RESULTS The

main distribution system of Pakokku spinning and
weaving factory consists of sixteen groups. They are described
in Table I. Table I is also mentioned the calculation results of
real, reactive power for each section. The results are based on
following equations:
Real power P= VIcosØ =VIxpf (1)
Power factor angle Ø = cos-1pf (2)
Reactive power Q = VIsin Ø (3)
Table I. Load Distribution And Calculated Results
N Descript- Equip. Req’ p.f P Q
o ions Capac. Fact- (kW) (kvar)
(kW) or kc
1 Air-con.1 101.9 0.9 0.8 91.71 68.85
2 Repairin
g Room 3.05 0.3 0.8 0.91 0.68
3 Air-con.2 101.9 0.9 0.8 91.71 68.85
4 Spinning 182.96 0.75 0.8 137.22 103.02
5 Drawing 27 0.66 0.64 17.32 21.38
6 Roving 68 0.7 0.75 47.6 41.96
7 Spinning 182.96 0.75 0.8 137.22 103.02
8 Carding
Dust. 77.4 0.5 0.8 38.7 29.05
9 Core
Winding 42 0.75 0.75 31.5 27.77
10 Drawing 27 0.66 0.64 17.82 21.38
Roving 68 0.7 0.75 47.6 41.96
11 Spinning 160.09 0.75 0.8 120.06 90.14
12 Spinning 182.96 0.75 0.8 137.22 103.02
Fig. 5. Overall Supply System of Spinning and Weaving Factory 13 Leather
Roller 11.7 0.5 0.7 5.85 5.96
In the drawing machine, main motor and FAN motor are 14 Needle
used. These motors are three-phase induction motors. Main Grinding 9.42 0.3 0.7 2.82 2.87
motor is a double speed motor. The speed of the main motor is 15 LabII 1.25 0.8 0.8 1 0.75
1475/355 rpm. The power consumption of this motor is 16 Lighting 75.1 0.95 0.95 71.34 23.45
3.5kW/0.8kW. The duration time of low speed to high speed is 40.5 0.95 0.95 38.47 12.64
1~9.9 sec. After that, the machine runs at high speed. The high Total 1036 766.75
speed is used for normal running of the machine. Therefore, at Capacitor -270
the shift moment from low speed to high speed, the motor gets Compensation
combined speed, so that the speed increase is smooth at the
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accomplish useful work is the key to the industrial progress

which is essential to the continual improvement in the standard
of living of people everywhere. To discover new sources of
energy for the future, to make energy available wherever
needed, and to convert energy from one form to another and use
it without creating the pollution. The industry is faced with
problems created by every rapid growth. Electrical engineers
are needed to develop and implement the advances of science
to solve these problems and to assure a very high degree of
system reliability along with the almost regard for the problems
of our ecology.

Fig 6. Real and Reactive Power Load Distribution of Factory
Consider as the simultaneous factory factor = 0.95
ACKNOWLEDGMENT
The author would like to express her gratitude and
appreciation to the teachers who taught her everything from
childhood till now and all the persons who assisted directly or
indirectly in her research. Thanks are also extended to her dear
parents and friends for their support.

So, the total real power loadings PT = 984.2 kW

REFERENCES
Total reactive power loadings, QT = 728.4 kvar
[1] William D. Stevenson, JR. 1975. Elements of Power System
Factory Compensated Capacitor QC = 270 kvar Analysis.4th Edition. MC Graw-Hill, Inc.
Therefore, Resultant reactive power QR = 458.4kvar [2] Hadi Saadat. 1999. Power System Analysis. Singapore: MC Graw-

Total apparent power loadings S = JP 2 + Q 2 Hill Companies.Inc.

T T T [3] J. Arrillage, C. P. Arnold and B.J. Harker.1983. Computer

Modelling of Electrical Power Systems. John Wiley & Sons Ltd.
without Capacitor = 1224.4kVA [4] Ramasamy Natarajam. 2002. Computer-Aided Power System
Overall power factor of Factory without Capacitor = PT/ST Analysis. The United States of America. Marcel Dekker, Inc.
= 0.80 lagging [5] I J Nagrrath and D P Kothari. 1994. Power System engineering.
Tata Mc Graw-Hill Company Limited.
And Total apparent power loadings ST = JPT 2 + QR 2 [6] J. B. Gupta, 1998. "Transmission and Distribution" .
[7] Bernard P.C.Textilies fibes to Fabric 6th .ed. New York, 1983.
with Capacitor =1085.7kVA
Overall power factor of Factory without Capacitor = PT/ST
= 0.90 lagging
P
Maximum possible continuous current, I= (4)
3 V cos 

= 984.2
3  400 0.9
= 1578.4 A
Table II. Load Distribution Board
No Description Equip. ACB Load Cable
Capac. (A) (A) (A)
(kW)
1 Air-con 101.9 315 196.2 2x190
2 Spinning 182.96 500 323.6 2x261
3 Drawing 61.8 160 146.0 190
4 Roving 68 225 149.5 260
5 Carding 77.4 315 165.1 283
6 Dust 54.4 200 116.4 205

V. CONCLUSION
The cotton yarn manufacturing process which produces Yarn
mainly used in weaving system has been considered. Spinning
is operated by manual in those past days. Nowadays, it is
operated by modernize industries. A distribution system
connects all the individual loads in a given locality to the
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transmission lines. Development of sources of energy to