air & water distribution

8/14/2019 Air & Water Distribution

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Why Should We Go For Air?

Air is available in plenty. Air is compressible.

Air in compressed form is easily storable.

Air is transportable over long distances.

No need of return lines.

Compressed air to a large extend insensible totemperature.

Relatively clean and non pollutant. High speed operations are possible.Speed andforces can be varied.


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Disadvantages of Compressed Air.

Compressed air needs good preparation.Dirt,

humidity may not present.

It is not possible to achieve constant piston

speed.Application of Compressed Air:

Component clamping in milling machine.

Control circuits of Vertical broaching machines.

Nut runner.

Conveyor chain tensioning.

Welding machines.


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Basic Compressed Air System

Compressor


5/49

Air Compressor

Air Compressor is a machine, which

takes in air at certain pressure

compresses the same and delivers

the air at higher pressure.


6/49

Types of Compressor

Types of

compressors

Reciprocating

compressors

Rotary piston

compressors

Flow

compressors

Piston Diaphragm Radial Flow Axial Flow

Two axial

Screw

Sliding

Vane rotary

Roots

Blowers


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Reciprocating Piston Compressor

Electric

Motor

Power

Transmission

Piston

Compressor

AirReceiver

For

Distribution
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Line Diagram of Piston Operation


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Reciprocating Compressor Side View

Air Filter

Water Inlet

Water Outlet

Inter Cooler

AfterCooler

HP Cylinder

LP Cylinder

Piston rod

Piston Piston

Connecting Rod

Piston rod

Compressed

Air outlet

Air inlet

Water Inlet

Two stage Reciprocating Air Compressor


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Reciprocating Compressor Front View

LP Cylinder Piston

HP Cylinder PistonLubrication Pump

V

Belts

Drive Motor

Two stage Reciprocating Air Compressor

Driven Pulley

Drive Pulley


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Reciprocating air compressors are positive displacement machines That they increase the pressure of the air by reducing its volume.

The reciprocating air compressor accomplishes this by a piston within

a cylinder as the compressing and displacing element.

Single-stage and two-stage reciprocating compressors arecommercially available.

Single-stage compressors are generally used for pressures in the

range of 70 psig to 100 psig.

Two-stage compressors are generally used for pressures in the

range of 100 PSI. to 250 PSI

Thee/multi stage compressors are generally used for pressures above

250 PSI.

Reciprocating Piston Compressors


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S

M

P

F

A

S

C

A

P

C

A

W

C

P

SV

T

S

K

D

C

CAS

SY

ETP

STP

WO

A

A

S

T C

D

CS

CANT. LC

Ashok Leyland, Unit-2 layout

Compressor

House


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Compressor House Layout

500CFMC3500CFMC4

1250

CFM C2

1250

CFM C1 1250CFM C5 1250CFM C6

D: C3 &

C4

R

4

R

3

D2:

C2R

2

D2:

C1R

1

D2:

C5R

5

D2:

C6R

6

Demand

Controller

1

4 3 2

1: CAS,CAW,VTS&KDC

2:CAP,Eng.Dressing.

3&4: FAP,FAS,SMP&AAS


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Compressed Air Receiver

The Compressed air receiver serves to

stabilize the compressed air supply.

It smoothens pressure fluctuations in the

network where air is consumed.

Heat exchange to assist air cooling and thus

produce condensate drop out before the air

enters distribution line.

Pressure

Relief

Valve

Air In

Air Out

Manho

le


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Dryers

There are three drying methods used for industrialsystems:

2. Refrigeration drying.

3. Adsorption drying.4. Absorption drying.


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S

M

P

F

A

S

C

A

P

C

A

W

C

P

SV

T

S

K

D

C

CAS

SY

ETP

STP

WO

A

A

S

T C

D

CS

CANT. LC

Ashok Leyland, Unit-2 layout

CompressorHouse


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Air Distribution

1. Pressure drop

2. Flow rate

3. System pressure

4. Air leakage

5. Regulation

6. Receiver

7. Air accumulators

8. Air mains

9. Installation


19/49

1.Pressure Drop

In a compressed air system pressure drop is

unavoidable.

It is the result of turbulence(fast flow) and

friction in the compressed air whilst it flows

through pipes,fittings and valves.

The pressure drop should preferably not

exceed 0.1 bar.


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2.Flow Rate

The flow rate calculation of compressed air for

a system with many actuators and process

consuming compressed air may seems to be

straight forward if one simply adds together the

free air consumption of all compressed air

actuators.

But to calculate actual/real required flow rate,

we have to consider duty cycles of actuators.


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3.System Pressure

The total system pressure is made up from the

minimum operating pressure plus the system

pressure drop the cut in / cut out pressure

difference plus a safety margin pressure.

The system pressure drop is assumed thepressure drop caused by turbulence and

friction.

Cut-in / Cut-out pressure differential is

governed by compressor demand controller.


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4. Air Leakage

33446.310

8.311.21.65

3.14.20.63

0.30.40.061

kWhp.mm3/min.mm

Power required forcompression

Airleakage at

6bars

Holediameter


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How to calculate System Leakage?

Calculate the air leakage:

QL=System Leakage rate, m3/min.

Qc = Compressor free air delivery, m3/min.

T : time taken between cut-out and cut-in. inmin.

T = time taken between cut-in and cut-out. Inmin.

QL= Qc x t(T+t)


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5.Regulation

In order to maintain the required delivery

volume of the compressor to the fluctuating

consumption, it is necessary to regulate

compressor.

Types of regulation:

3. No load regulation: a)Exhaust, b)Shut-off,

C)Grip arm

4. Low speed regulation

5. On-off regulation


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7.Accumulators

Air accumulators are secondary receivers

installed at intermediate locations to equalize

pressure variations within the system to ensure

that operating pressures as constant as

possible for all consumers.


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8.Air Mains

The air mains is the piping system into which

the compressed air is fed from the receiver.It is

a permanently installed system of

interconnected pipes carrying the air to the

connections for various consumers.


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9.Installations

Branch Lines

Ring Circuit

Interconnected system.

Ring Circuit

Using this type

of compressed

air lines,

uniform supply

can be obtained

where there is

heavy

consumptions

of air.


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Schematic Diagram of Ring Circuit


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Sources of water for AL-H2

Sipcot Bore well

Sipcot Dam

Private/Tanker

Month Dam Borwell Private

Total

WaterRecived

(KL)

Apr-08 7580 904 11980 20464

May-08 6530 1117 16275 23922

Jun-08 4309 833 12700.6 17842.6Jul-08 7114 893 15091 23098

Aug-08 7659 972 13540.4 22171.4

Sep-08 2637 738 12113.4 15488.4

Oct-08 5325 836 10919.6 17080.6


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Water consumption Vs. Production.

Daily Water consumption Vs monthly production

( April ' 08-Sep ' 08 )

494.6 561.0 493.2 543.2 544.6 510.0

1807

21551947 1888

2017

1262

Apr-08 May ' 08 June '08 July ' 08 Aug ' 08 Sep '08

Month

Values

Month Water Consumption per day

Vehicle Produced Linear (Vehicle Produced)


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Water Consumption

Month

Industrial

(KL) (ETP

total -

Cooling

water)

Cooling(

KL)

(DG,Com

p & Cool

Tow)

Domestic

(KL)(Cant

een+

Toilet

Tank)

Garden(

KL)Apr-08 1563 468 1935 16498.0

May-08 1215.40 469.4 1933.5 20303.7

Jun-08 1450.8 468.1 1848 14075.7

Jul-08 1550.3 646 2020.0 18881.7

Aug-08 2190.5 511.5 1995.0 17474.4Sep-08 1940.5 796.2 1911 10840.7

Oct-08 1912.46 218.98 1943 13006.6

Average 1689 511 1941 15869


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Water Distribution Lay Out

Photo copy showing overall plant


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Rinsing dilute waste waterCapacity-250 KLD

Consented for 225 KLD

Concentrated waste waterDesigned 10 KLD

Consented for 6 KLD

Canteen waste water

Designed 150 KLD

Consented for- 75 KLD

Multi grade filter and

Activated carbon filter

To improve outlet

quality.

Photo copy showing overall plant

Chemical treatment facility Biological treatment

Chemical treatment Plants


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Chemical treatment PlantsSources of Effluent

Paint shop Rinsing waste water from all process tanks. DM / R.O Plant rejects and regeneration waste

water Town water entry and exit spray waste water All chemical tanks washing water.

2. Axle shop

De-sludge pit waste water.3. Services. Cooling tower Bleed off / cleaning waste water. Soft water regeneration waste water

4. Cab weld Cooling tower Bleed off / cleaning waste water.

Soft water regeneration waste water5. Vehicle test shop. Vehicle washing water

6. Others Floor washings

RINSING/ DILUTE WASTE TREATMENT SCHEMERINSING/ DILUTE WASTE TREATMENT SCHEME


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SLUDGE

DRYING BEDS

THICKENER

TANK

FLOCCULATION

TANK

pH

CORRECTIONTANK

REACTION

TANK

COLLECTION

CUM

EQUALISATIONSUMP

OIL/

GREASETRAP

CLARI FIER

TANK

P

ACID

(OR)LIME

pH 9.0 To 10.5

OVER

FLOW

OVER

FLOW

TREATED WATER

FOR GARDEN

DRY SLUDGE

FOR DISPOSAL

SULDGE

FILTRATE

RINSING

/

DILUTE

WASTES

pH 9.0 To 10.5

pH 9.0 To 10.5

pH 9.0 To 10.5

pH 9.0 To 10.5

pH 6.0 to 8.5

pH 9.0 To 10.5

PSF&ACF

SUMPACFPSF

RINSING/ DILUTE WASTE TREATMENT SCHEMERINSING/ DILUTE WASTE TREATMENT SCHEME


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Rinsing/Dilute Waste water treatment process

3. The rinsing dilute waste water stream is segregated separately andcollected in a set of collection cum equalization sumps.

4. Prior to collection sump , oil and grease trap is provided to remove free oiland grease from the waste.

5. The equalized waste is then pumped to reaction tank where in lime to havethe required pH value around 10.0. At this optimum pH level, heavy metalsincluding phosphate are effectively precipitated.

6. The reaction mass in then slow mixed in a flocculation tank. The thick flocsfrom the tank are allowed to settle in a clarifier.

7. The sludge from the clarifier is fed to the sludge thickener.8. The over flow from the clarifier and sludge thickener is taken to ph

correction tank.9. The sludge from the thickener is discharged in to drying bed and the dry

sludge is collected and stored.10. The treated waste water from pH correction tank is collected in a sump and

then further polished by pumping through pressure sand filter followed byactivated carbon filter.

11. The final treated waste water along with sewage is collected in a sump andreused for gardening and growing green belt inside the factory premises.


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CONCEN

TRATEWASTE

OIL/

GREASE

TRAP

COLLECTION

SUMP

pH -Above 9.0

PREACTION CUM

SETTLING TANK

ACID(OR)

LIME

SLUDGE DRYING

BED

pH CORRECTIONTANK

SOLAR

EVAPORATIONPAN

CONCENTRATE SLUDGE FOR DISPOSAL

pH 9.0 to 10.5

SLUDGE

FILTRATE

DRY SULDGE FOR DISPO SAL

CONECNTRATED WASTE TREATMENT SCHEME

pH above 9.0

pH 9.0 to 10.5

pH 6.5 to 8.5

pH 9.0 to 10.5

Rinsing Dilute waste water treatment Plant


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Sludge drying beds

Reaction tank Flocculation Tank

Clarifier Tank

Thickener tank

Rinsing Dilute waste water treatment Plant


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SEPTIC TANK A1

S1 S2

POLYSING POND1

COLLE

CTION

SUMP

PUMP

HOUSE

A2 A3

POLYSING POND2

SLUDGE

DRYING BED

FILTRATE

SEWAGE TREATMENT PLANT

A1,A2,A3 - AREATOR

S1,S2 - SETTLING TANK

RETURNSLUDGE

RETURN

SLUDGE

In

coming

canteen/

sewage

water

PSF&

ACF

Sump

TREATED WATER

FOR GARDENACFPSF

Sewage treatment Plant


42/49

Septic tank to remove solids from Canteen & Bath rooms

Collection sump

Aerators

Settling TankPolishing pond

Sewage treatment Plant

Before Zero Discharge Project:


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Sludge Drying

Bed

Reactio

n*

FlocculationTank

Cla

rifier

Thickener

(Clarifier)

Ph Correction

ACFPSF

Equalization

tank

Effluent from

Process

Before Zero Discharge Project:

Process Flow of Industrial Effluent

Excellence in Water Management 2008Excellence in Water Management 2008

To Garden

Usage ofTreated

Effluent

for

PSF : Pressure Sand Filter

ACF : Activated Carbon Filter

Legend:

Zero Discharge Reverse Osmosis (R O )


44/49

Zero Discharge Reverse Osmosis (R.O.)

Plant Process Flow

PRETREATED

WATER FEED

100KL

REVERSE

OSMOSIS-I

(75%)

REVERSE

OSMOSIS-

II (60%)

REVERSE

OSMOSIS-III

(35%)

MULTIPLE

EFFECT

EVAPORATOR

PERMEATE

WATER

STORAGE

(99.67%)

SLUDGE

DRYING

BEDS

PRETRE

ATMENT

(85%)

FEED FROM ETP

TO ETP 25 KL 10 KL 6.5 KL

15 KL 3.5 KL75 KL

93.5KL

6.5 KL6.17 KL

0.33 KL

TO THE PAINT

PROCESS&COOLING

FILTERATE WATER TO

ETP

DRY SLUDGE

TO SLF

FEED

PERMEATE

REJECT

FILTERATE

SLUDGE

BACKWASH

LEGEND :

99.67KL


Zero Discharge Reverse Osmosis (R O )


45/49

R.O.Plant

Boiler

Compressor

R.O.-1R.O. -2

R.O. -3

UF

Multiple Effect Evaporator

Zero Discharge Reverse Osmosis (R.O.)

Plant



46/49

Quality of Effluents

< 3

< 500

< 3

< 500

< 0.5

< 1.0

< 100

< 15< 1000

< 10

6.5 8.5

After

TreatmentThrough

ETP


47/49

Benefits of the Zero Discharge

Project

The entire treated water is being used for the plant paint

process and cooling circuits(100 kl /day present volume).

Rinse water in paint line.

Feed to hot water generator.

Cooling circuits in compressor house & weld shop.

Being 3 stage R.O. Plant, the membrane recovery achieved

is 90-94%.

Lesser the reject quantity the operation of Multiple Effect

Evaporator (Triple Effect) evaporator is less.

The occurred savings :Rs. 12.6 lakhs/annum.


After Zero Discharge Project: Process


48/49

Sludge Drying

Bed

Reactio

n*

Flocculatio

nTank

Cla

rifier

Thickener

Ph Correction

ACFPSF

Equalization

tank

Effluent from Other

Process Process

After Zero Discharge Project: Process

Flow of Industrial Effluent


Usage of

RO

product

for

Zero Discharge R.O.

Plant with Multiple

Effect Evaporator

Cab PaintProcess

Cooling

Circuits


49/49

air & water distribution

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