Textile Mill Supplements Sporadic Grid Power with Cat® Generator Sets

POWER NEED

Founded in 1987 and now an icon of the Pakistani spinning industry, Din Textile Mills, Ltd. produces premium yarn for both domestic and international markets. With three state-of-the-art spinning units and one dyeing unit, Din is a pioneer of mélange and core-spun yarn manufacturing in Pakistan. Their diverse product portfolio includes a range of high-quality textiles for knitting and weaving, which they manufacture and supply to well-known global sports apparel brands.

In 2015, an influx of yarn imported from India flooded the Pakistani market, resulting in reduced demand and declining prices throughout the region. A shortage of gas and electricity worsened the situation for local textile manufacturers including Din. Today, power from the Water and Power Development Authority (WAPDA), the Pakistani public utility, continues to be intermittent. Din requires a reliable prime power source for their spinning mills, or the company risks losing business to low-priced imports in this highly competitive industry.

“In order to continuously supply quality products to both regional and global customers, we have to maintain a safe, uninterrupted source to supply power to the mills from our power house,” said Tariq Shahab Ansari, technical director at Din Textile Mills. “Our existing solution includes a 21-year old generator set that has been providing reliable prime power for nearly 100,000 hours – a testament to the durability of Cat® products, the expertise of our maintenance staff, and the reliability of our local Cat dealer, Allied Engineering & Services, Ltd., who delivered genuine Cat parts when we needed them.”

SOLUTION

To supplement sporadic grid power, Din relies on two Cat 3612 furnace oil generator sets originally installed by Allied in 1997. As the only authorized Cat dealer in Pakistan, this was Allied’s second installation of a heavy fuel oil (HFO) generator set in the country and the turn-key project has been delivering high power output, reliability and fuel efficiency for more than two decades.

Allied trained Din staff on the performance of regularly scheduled maintenance and equipped them with skills and knowledge to carry out day-to-day operations independently, with ongoing guidance and specialized services provided by the Cat dealer as needed. These two Cat 3612 furnace oil generator sets have undergone three overhauls throughout the years – all performed by skilled members of the Din operations team. In August 2017 at 99,301 hours, it was time for a fourth overhaul.

“Our technical staff employed knowledge and proficiency gained over 21 years of working with these generator sets to perform this overhaul independently, and it was a complete success,” added Ansari. “Contributing to this remarkable achievement, Allied supplied all of the parts and materials required to help us get the job done. These two Cat 3612 furnace oil generator sets have many operating hours ahead of them.”

Din has several other Cat generator sets onsite powering this facility, including one Cat C32 diesel generator set producing power from 910 kVA to 1500 kVA at 50 Hz, and three Cat G3520C natural gas generator sets each rated for 2500 to 3750 kVa at 50 Hz.

RESULTS

Since the overhaul was completed in March 2018, Din has carried out scheduled maintenance at recommended intervals to ensure the generator sets continue to operate at optimal performance levels.

“Uptime, continuity of operations and peace of mind are extremely important in the textile industry,” said Ansari. “Allied Engineering & Services has always been very cooperative, providing dependable support and professional service. With years of experience working together, we also trust in the reliability of Cat generator sets to deliver continuous power – helping us maintain our reputation for delivering high-quality yarn for customers around the world.”

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