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Module No: TRM/ Utilities/ Goa/ ver01 dated 11.03.2006

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UTILITIES AVAILABLEUTILITIES AVAILABLE

Chilled WaterChilled Water Warm water Warm water Cooling waterCooling water Compressed airCompressed air SteamSteam Potable WaterPotable Water

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RECOMMENDED WATER QUALITY

TABLE- 1

TEST ITEMSTEST ITEMS CHILLED CHILLED WATERWATER

QUALITY STDQUALITY STD..1) pH1) pH

2) TOTAL (CACO2) TOTAL (CACOээ) PPM ) PPM

HARDNESS HARDNESS

3) TOTAL ALKALINITY 3) TOTAL ALKALINITY

(CACO(CACOзз) PPM) PPM

4) CHLORIDE ION (PPM)4) CHLORIDE ION (PPM)

5) TOTAL ION (Fe) PPM5) TOTAL ION (Fe) PPM

6) SILICA (SiO2) PPM6) SILICA (SiO2) PPM

7) AMMONIUM ION PPM7) AMMONIUM ION PPM

8) TDS8) TDS

7.2 - 8.57.2 - 8.5

MAXIMUM 80MAXIMUM 80

LESS THAN 100LESS THAN 100

LESS THAN 50LESS THAN 50

LESS THAN 0.3LESS THAN 0.3

LESS THAN 30LESS THAN 30

LESS THAN 0.2LESS THAN 0.2

LESS THAN 1200LESS THAN 1200

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1. Chilled water supplied from utility is 1. Chilled water supplied from utility is circulated through chilled water coil of Air circulated through chilled water coil of Air Handling Units.Handling Units.

2. Return air from production area is passed 2. Return air from production area is passed over the chilled water coil to maintain its over the chilled water coil to maintain its temperature and relative humidity.temperature and relative humidity.

3. Return chilled water from the Air handling 3. Return chilled water from the Air handling Units is collected in the Balancing tank and Units is collected in the Balancing tank and then supplied to the chiller evaporator by then supplied to the chiller evaporator by using the pump.using the pump.

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1. Chillers are used to generate chilled water of temperature 5 ºc.

2. YORK Make Centrifugal chillers of capacity 500 TR.

3. Refrigerant used : R-123 (Dichloro Triflouro Ethane)

4. Input Power required : 324 KW

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CHILLERCHILLERChillerChiller::

Chiller is an equipment used to reduce the temperature of a Chiller is an equipment used to reduce the temperature of a Liquid to a lower then its normal temperature like 5ºC.Liquid to a lower then its normal temperature like 5ºC.

Chiller detailChiller detail::

MakeMake : York International Corporation: York International CorporationCapacityCapacity : 500 TR : 500 TR Flow across the evaporator: 1339 USGPMFlow across the evaporator: 1339 USGPMFlow across the condenserFlow across the condenser : 2000 USGPM.: 2000 USGPM.RefrigerantRefrigerant : R-123: R-123Chilled water inlet TemperatureChilled water inlet Temperature : 10º C: 10º CChilled water outlet TemperatureChilled water outlet Temperature : 5º C: 5º CΔ t = 5º CΔ t = 5º C

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CHILLER PARTS:CHILLER PARTS: Compressor:Compressor: Type: Centrifugal Type: Centrifugal

Capacity: 500 TRCapacity: 500 TR

Motor : 324 KW Motor : 324 KW 3 phase,3 phase,

Shaft drivenShaft driven

CondenserCondenser:: Type : Shell and tube type, Type : Shell and tube type, Refrigerant in Shell and water in tube, Refrigerant in Shell and water in tube, Water cooled, Water cooled, Condenser inlet is 32º C and outlet is Condenser inlet is 32º C and outlet is

37ºC37ºC Evaporator:Evaporator: Type : Shell and tube type, Type : Shell and tube type,

Refrigerant in shell and water in tube,Refrigerant in shell and water in tube, Inlet is 10º C and Outlet is 5º C.Inlet is 10º C and Outlet is 5º C.

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WORKING PRINCIPLEWORKING PRINCIPLE Evaporator in the chiller acts as cooler as here Evaporator in the chiller acts as cooler as here

water gets cooled due to heat absorption action of boiling water gets cooled due to heat absorption action of boiling refrigerant. refrigerant.

The chilled liquid at 5º c is then supplied to The chilled liquid at 5º c is then supplied to application area and return water at 10 ºc again comes to application area and return water at 10 ºc again comes to the evaporator via balancing tank to complete the circuit.the evaporator via balancing tank to complete the circuit.

The refrigerant vapour produced in evaporator The refrigerant vapour produced in evaporator flows to compressor where the rotating impeller increases flows to compressor where the rotating impeller increases its pressure and temperature and discharge to the its pressure and temperature and discharge to the condenser. condenser.

The water from Cooling Tower at 30º c flows through The water from Cooling Tower at 30º c flows through the condenser tubes which absorbs heat from the the condenser tubes which absorbs heat from the refrigerant vapour, causing it to condense and then returns refrigerant vapour, causing it to condense and then returns at 34º c to cooling tower for cooling. at 34º c to cooling tower for cooling.

From condenser the refrigerant flows to the From condenser the refrigerant flows to the evaporator through orifice in Liquid form again to cool evaporator through orifice in Liquid form again to cool return chilled water at 10º c from the plants. return chilled water at 10º c from the plants.

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DEFINITION: It is the system which is used to Store the latent heatof water . Latent Heat:

It the name given to the energy either stored or librated when a substance changes in phase take place.Operation:

Thermal energy is stored in the storage tank during charging Mode.

This stored energy can be used as per the requirement by discharging the tank.

In this system brine (Mixture of water and Mono ethylene glycol 28 to 30%) is used instead of water to reduce the freezing point of water.

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DIFFERENT OPERATIONS:NIGHT MODE:

STL tanks are charged during night mode by circulating - 8.5 ºC brine through the tanks.

Brine circulating CIAT MAKE 200 TR Chiller is used for this purpose.

DAY MODE:STL Tanks can be discharged through Plate Heat

Exchangers (PHE) to cool the return Chilled water at 10 ºC to 5 ºC .

BACK UP MODE:It provides power failure back up of 800 TR for 1 hour at

5.1 º chilled water temperature at Balancing tank.

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BENIFIT OF THERMAL STORAGE SYSTEM.

1. It meet the additional HVAC load 311 TR to maintain chilled water temperature to 5.1º C in the balancing tank.2. System to operate with existing 3× 500 TR and new 2×200 TR Chillers and system keeping 1×500 TR Stand by.3. It avoid part loading of 500 TR chillers to possible extent.4. It provides power failure back up of 800 TR for 1 hour

at 5.1 º C chilled water temperature at Balancing tank.

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DEFINITION:

Water which is used in AHU heating coil is called as warm water.

Parameters:

Warm water supply temp. = 30 to 35 ºc

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DEFINITION:

Cooling water is used for cooling different part of equipments or system.

Parameters:

Cooling water supply temp.= 28 to 30 ºc

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RECOMMENDED WATER QUALITY

TABLE- 2

TEST ITEMSTEST ITEMS COOLING COOLING WATERWATER

QUALITY STDQUALITY STD..1) pH1) pH

2) TOTAL (CACO2) TOTAL (CACOээ) PPM ) PPM

HARDNESS HARDNESS

3) TOTAL ALKALINITY 3) TOTAL ALKALINITY

(CACO(CACOзз) PPM) PPM

4) CHLORIDE ION (PPM)4) CHLORIDE ION (PPM)

5) TOTAL ION (Fe) PPM5) TOTAL ION (Fe) PPM

6) SILICA (SiO2) PPM6) SILICA (SiO2) PPM

7) TDS PPM7) TDS PPM

7.2 - 8.57.2 - 8.5

MAXIMUM 300MAXIMUM 300

LESS THAN 100LESS THAN 100

LESS THAN 200LESS THAN 200

LESS THAN 1.0LESS THAN 1.0

LESS THAN 50LESS THAN 50

LESS THAN 1500LESS THAN 1500

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APPLICATIOAPPLICATIONN

• CHILLER CONDENSER.• COMPRESSOR INTER COOLER AND AFTER COOLER.• DIESEL GENERATOR.• COOLING OF PROCESS VESSELES.• COOLING OF PUMP MECHANICAL SEAL.

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Cooling Tower:

It is a device to cool the continuously flowing hot water with the help of atmospheric air in most economic way.

Cooling Tower Details:

Make : Himgiri Cooling Towers Type : Induced Draft Counter Flow

Quantity : 6 NosCapacity : 600TRWater flow : 363 m³/ hr.

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Components Details:

CasingMotor

Fan Water distribution system

NozzleDrift eliminatorPacking (fills)

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COOLING TOWER (INDUCED DRAFT)

MOTOR

WATER INLET

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Working Principle: Cooling Tower helps to change the phase of water by creating a condition in which hot water evaporates in the presence of moving air. Thus heat is extracted from the water and transferred to the air. This process is called evaporative cooling.

Input dry air comes through the opening at the bottom of the tower. Air is sucked in through the fills. The cooled water meets dry air at the bottom of the tower and hot water meets warm moist air at the top to ensure that evaporative cooling takes place through out the fills.

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COMPRESSED AIR

1.DEFINITION Compressed Air is the air at pressure higher than the atmospheric pressure.

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WORKING PRESSURE OF COMPRESSOR : 8.5 To 10.0 Kg/Cm²

SUPPLY PRESSURE FROM UTILITY THROUGH CONTROL AIR SYSTEM:

UNIT - I,III & IV : 7.2 Kg/Cm²

UNIT – II : 8.45 Kg/Cm²

FILTRATION OF COMPRESSED AIR:

Compressed air which is supplied from utility is filtered at service floor to 20μ and 5μ. It is further filtered before supplied for process to 1 μ and 0.1 μ.

WORKING PARAMETERS

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Sr.NoSr.No  

TestsTests AcceptanceAcceptance

   CriteriaCriteria

11 Carbon dioxide(ppm)Carbon dioxide(ppm) NMT 1000 ppmNMT 1000 ppm

22 Sulphur dioxideSulphur dioxide NMT 1 ppmNMT 1 ppm

33 Oil mist Oil mist 1.0 mg /cun.met1.0 mg /cun.met

44 NO + NO2NO + NO2 NMT 2 ppmNMT 2 ppm

55 Carbon monoxideCarbon monoxide NMT 5 ppmNMT 5 ppm

66 Water vapourWater vapour NMT 10 ppmNMT 10 ppm

77 OxygenOxygen Between 19.50% Between 19.50% and 23.50%and 23.50%

PARAMETERSPARAMETERS

NMT-NOT MORE THENREF SOP NO: QCP-55

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APPLICATIONAPPLICATION

• Cleaning of equipment & vessels.• Operation of pneumatic valves & cylinders• Coating pans and spray guns• Filter cleaning.

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Details of Air Compressor:-

There are total three Nos. of Air Compressors installed in utility Cipla – I.

Make : Kirloskar Pneumatic Company Ltd.Quantity : 3 NosCapacity : 600CFM (Cubic feet per minute)Type : Balanced opposed reciprocating

Double Cylinder, double acting.Motor Rating : 200 H.P.

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Details of Air Compressor:-

Free Air Delivery : 16.98 M³/min (600 CFM)Suction Pressure : 1.033 kg/cm²Working pressure : Load-8.5 kg/cm² Unload-10kg/cm²

Media of cooling : Water cooled

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Working of Air Compressor:-Working of Air Compressor:-

Air is sucked from atmosphere in L.P Cylinder Air is sucked from atmosphere in L.P Cylinder through the filter during the suction stroke of the through the filter during the suction stroke of the compressor. compressor.

This air entered through suction valve is Compressed This air entered through suction valve is Compressed and delivered through discharge valves to H.P and delivered through discharge valves to H.P Cylinder via Water cooled intercooler. Cylinder via Water cooled intercooler.

In H.P Cylinder the air is again compressed and In H.P Cylinder the air is again compressed and delivered to through Air Dryer via water cooled after delivered to through Air Dryer via water cooled after cooler and stored in Air receiver. cooler and stored in Air receiver.

From air receiver it is supplied to the different Plants.From air receiver it is supplied to the different Plants.

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Air dryer:- The air from compressor passes through the air dryer before going to the Air Receiver. In Air dryer, air is cooled to dew point of 2 to 4 º c thereby removing the moisture content in the compressed air by condensation.

Dryer Details:- Make : Ultratroc. Types : Heatless, Refrigerant type Refrigerant: R 134 a. Capacity : 1200 CFM (2 Nos.) Dew point Range: 2 to 4 º C

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Air Receiver:- Air Receiver is a vessel in which air is stored. The air receiver takes care of load variation and allows water in compressed air to accumulate at the bottom. This accumulated water is drained by automatic drain valves located at the bottom of receiver.

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STEAMSTEAMSteam Boiler: -Steam Boiler: - Steam Boiler is equipment which generates Steam Boiler is equipment which generates

steam by heating of water.steam by heating of water.

IBR Boilers :-IBR Boilers :- As per the Indian Boilers Act, 1923, and Indian As per the Indian Boilers Act, 1923, and Indian

Boilers Regulations, 1950 issued by Government of Boilers Regulations, 1950 issued by Government of India, Ministry of works, Mines and power – central India, Ministry of works, Mines and power – central Boilers Board, “BOILER” means any closed vessel Boilers Board, “BOILER” means any closed vessel exceeding 22.75 liters (5 Gallons) in capacity exceeding 22.75 liters (5 Gallons) in capacity which is used expressively for generating steam which is used expressively for generating steam under pressure and includes any mounting or other under pressure and includes any mounting or other fitting attached to such vessel which is wholly or fitting attached to such vessel which is wholly or partly under pressure when steam is shut OFF.partly under pressure when steam is shut OFF.

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Non ‘IBR’ BoilersNon ‘IBR’ Boilers

Boilers which having water holdingBoilers which having water holding capacity less than 22.75 liters ( 5 Gallons) is capacity less than 22.75 liters ( 5 Gallons) is called Non ‘IBR’ Boiler.called Non ‘IBR’ Boiler.

Our BoilerOur Boiler

But our Revomax RXD-850 boiler isBut our Revomax RXD-850 boiler isoutside the preview of IBR Act, as its capacityoutside the preview of IBR Act, as its capacity is 21.4 liters which is less than 22.75 liters. is 21.4 liters which is less than 22.75 liters. So, It comes under the category of non-IBR .So, It comes under the category of non-IBR .

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Working pressure : 8.5 to 10 Kg/Cm² Working Temperature : 160 to 180 ºc Type : Wet Saturated. Dryness fraction : 78% Feed water hardness : below 5 PPM Feed water PH : 8.5 to 9.5 Final filtration : 5 μ

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• Pure steam generator.• Multi column distilled water plant.• Sanitation of DM water and WFI water storage tank.• Manufacturing vessels.• Bottle washing.• Coating machines.• Fluid bed equipments.

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Boiler Details:

Make : Thermax LtdType : Vertical water tube boiler.Fuel : Furnace oilWater : Soft water (Hardness below 5 ppm)Capacity : 850 Kg/ Hr.Steam working pressure : 8.5 to 10 kg/ cm²Steam Temperature : 160 to 180 º C

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STEAM OUT

SOFT WATER TANK

FEED WATER PUMP

INNER SHELL

BOILER SHELL

BURNER ASSEMBLY

FURNACEOIL

FLUE GASES EXHAUST TO CHIMNEY

FLAMES

STEAM BOILER ARRANGEMENT

F.OPUMP

BOILER COIL

UNIT 1

UNIT III

UNIT IV

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Major parts of the Boiler:Major parts of the Boiler:

•Feed Water PumpFeed Water Pump•Fuel oil pumpFuel oil pump•BlowerBlower•EconomizerEconomizer•OptimizerOptimizer•Burner AssemblyBurner Assembly•CoilCoil• Inner shell / Outer shellInner shell / Outer shell•Top RefractoryTop Refractory• Wegmann ConeWegmann Cone•Chimney etc.Chimney etc.

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Working of the Boiler :-

REVOMAX PLUS is a once through, coil type, instant steam generator.

The furnace section of the boiler consists of a membrane coil where fuel is burnt.

Fuel is burnt in the membrane coil by the pressure jet burner using air from the combustion air fan.

Water from feed water tank circulates through the coil and converts into steam.

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WaterWater softenersoftener

Water Softener :Water Softener :Softener is an equipment which is used to Softener is an equipment which is used to

convert the potable water into soft water.convert the potable water into soft water.

Softener Plant Details:Softener Plant Details:

► MakeMake : Ion Exchange Ltd.: Ion Exchange Ltd.► TypeType : S- 400/U –up flow: S- 400/U –up flow► CapacityCapacity : 4 M³ /Hr.: 4 M³ /Hr.► Hardness of water : Below 5 ppm.Hardness of water : Below 5 ppm.

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WORKING OF SOFTNER:The softener contains a bed of ion

exchange material through which hard water passes, and in the process it exchanges Sodium ion for the hardness forming calcium and Magnesium ions present n hard water.

All the hardness salts in the water are thus converted to their equivalent Sodium salts which have no scale forming properties.

This softening process continues till the ion exchange material has no more sodium ions available for exchange.

Ion exchange material is then regenerated with sodium chloride to replenish the sodium ions.

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Potable waterPotable water

Definition: Potable water is treated raw water .

Parameters:

Pathogens - NilColony forming units - NMT 500 CFU/ML

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Application:Application: Potable water is being used for DM plant andPotable water is being used for DM plant and for canteen and toilets.for canteen and toilets.

Generation: There are two sources of potable water i.e., i) Bore well

ii) IDC water (Industrial Development Corporation)

Both water sources are being collected in epoxy lined RCC underground tanks (100000 liters) by means of two separate pipe lines.

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Water treatment:Water treatment: To control the microbial growth in To control the microbial growth in

potable water sodium hypochlorite is potable water sodium hypochlorite is being dosed.being dosed.

120 ml of 2.5% sodium hypochlorite 120 ml of 2.5% sodium hypochlorite solution is required to maintain 3 ppm solution is required to maintain 3 ppm free chlorine in 1000 ml of water. free chlorine in 1000 ml of water.

The free chlorine ppm in the potable The free chlorine ppm in the potable water should be in the range of 2.5 to 3 water should be in the range of 2.5 to 3 ppm at underground level.ppm at underground level.

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Distribution:

• Potable water is collected in underground tank of capacity 100,000 liters.

• Then it is pumped to over head tanks, (capacity 12500x2 each) after filtered through quartz filter.

• From over head tanks, potable water is getting distributed to various production and non production areas.

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ANY ANY QUESTIONS?QUESTIONS?

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Thank YouThank You