Observation Report (Maral Overseas Ltd.) -- by Amarnath Pandey (Sr. G.M.

Engineering)

Points to evaluate condition / capacities of Engg installations & their suitability for the existing
production plan.Following are the observations & suggestions :

i) Air humidification units Spg (Unit 1-5)

Air balancing & air changes of Prep, RF & Autoconer adjusted to cater machine heat.
- There is no ahu control system installed /working condition. Adjustment is being
done manully based on complain from prdn deptt. In exisitng system it is very
difficult to ensure consistent deptt conditions and may influence production yield
alonwith quality variations.
- Condition of air washers nozzles / eleminators is needs improvement & plant
efficiency seems to be low. Nozzles need immediate repair /replacement.
- Ahu are not having rotary air filters, existing screen filters may be replaced for better
plant efficiency and clean air circulation.
- Ahus fan housing conditions is poor at some of the area need immediate replacement,
Air capacity / air changes observed to be on lower side.
- Its better to re-calculated ahus installed air capacity, max permissible deptt load &
expected deptt heat load by proposed spin plan and corrective action can be taken
accordingly
It is suggested :
- In JASML Savio Polar Winding area immediate alternative arrangement has to be
made to cater existing heat load which may lead fly genration and failure of
electronics and electrical components.
- Immediate action required to operate ahus as per installed capacity. Detailed action
plan to be made in consultaion of plant manufacturer / other competent vendor to
optimize and start the possible repair activities.
- It is recommended to have ahu revamping plan with electronic control system as per
the m/c layout & deptt heat load for the proposed spin plans. Expected investment can
be evaluated with expert agency providing services in this area.
- Nozzles to be replaced & It is recommended to replace screen filters by installing
rotary air filters with plush type filter media / filter seal.

ii) Fire Hydrant system:

Existing fire Hydrant and sprinkler system inside the factory premises not comply accord
alliance specification. Design of Fire Hydrant, hose reels and extingushers have to be
evaluated and desired changed has to be implementd along with new Project.

iii) Electronics Repair Center:

Existing Electronics repair center has to be modified to efficiently cater our exiting and
future expansion and rack isolation will be made with subsection for Spinning, Knitting,
Power Plant, Dyehouse, Utilities and Power Plant.All the changes would be made
considering 5s practice of housekeeping for reliable and prompt repairs.

iv) Engineering Workshop: To optimized restructring for effcient and prompt work
delivery.
v) Power Plant : Fuel to steam ratio to be calculated, helath of Boilers and turbine to be
checked, condensate recovery, auxiliary power cost analysis.

vi) Boilers : Losses like stack, condensate recovery, blowdown etc.

vii) ETP: Per KL Treatment cost, sludge disposal cost.

viii) STP & Waste Disposal: To review feasibility of food waste disposal and implement
proposals

ix) Compressd Air System

All compresssors are oil flooded screw type & maintained as per std maintenance
practices. Compress air network, reservior design & compressor condition found
satisfactory. Existing system is sufficient to meet the plant requirement w/o any major
investment / changes.
Following are the recommnendations:
- Compress Air pressure to be optimised at 7.0 Kg/cm2 Vs existing 9.5 Kg/cm2 to
reduce compressor power by 15%. Expected savings are US$ 40,000 p.a without any
major investment.
- To install flowmeters for each Spg to optimise & control the compress air
consumption in first phase to optimised compress air consumption.
- Oil & dust filters in compress air lines to be replaced to ensure oil free compress air.
- Shifting of Compressor Room at JASML 2nd Floor is a wise decision and will
improve compressor efficiency and operating performance.
- Compressed air distribution network and piping has to be reviewd for further saving
scope.
- Seprate cleaning line will improve compressor efficiency and saving in power by
2%.Expected saving US$ 6,000 per annum.

x) Electrical system
- Existing electrical system in combination to Gas Power Plant & BDT 11 kV power is
capable to handle the existing power plan. But few area to be revamped to improve
the system reliability. Details as follows:
- 11kV metering box has observed high moisture, we have to connect panel heater
along with silica gel to prevent the same.
- existing transformer need silica change in breather with oil test (BDV, Flash point,
KOH & Water content) and filtration based on test report result.
- We have to schedule yearly magger of all 11KV and 0.4kV Incomer cables from
transformer and Gas Generators with records to avoid any possible breakdown and
change in insulation value due to aging.
- Condition of power factor correction panels is very unsafe. Recommend to use
automatic power factor panel with adequate capacitor in combination to harmonics
filters in phased manner to improve the reliability of electrical system.
 - It is recommended to check all joints and put straight joint ferule low voltage heat
shrinkable kit during Eid holidays where ever required.
- No Metering has installed in the panels it is recommended to install metering at every
DB to monitor power consumption and control the losses if any.

xi) Plant Lighting System:

Existing lighting system can be enhanced by optimizing adequate lighting lux in various
deptt to improve visibilty and product quality latest energy efficeint LED lighting may be
considered for balancing of lux at working areas. Lux meter can be procured to measure
lighting level at various plant area. We can add high lumen energy efficient cool day
lights for better vision and minimal payback period.

Gas Generator : Waste Heat can be used for chilling or heating water. Overall genrator
efficiency can be be improved by minimizing heat losses.

xii) Energy Efficiency:

- We are not adequately practicing for energy efficiency.It has been observed that
lighting is on at many outside area in day time also, which can be switched off by
training and education at shop floor level people. Lighting inside plant area also
remains on which may be kept off while not working. Expected saving per annum is
$3500.
- All motors rewind greater than five times can be replaced in phased manner with
energy efficiency motor for Ring frame and humidification area first. Expected pay
back 2 years.
- All the material transport fan can be optimized and suitable frequency drives can be
connected for saving purpose.
- Motor Load and suction of all waste collection system including fibre deposit plants
to be optimised for energy saving purpose.
- All Autoconer machine suction pressure can be optimise for different count.
Expected saving $5000 per annum.
- All Blow Room, Carding, Draw frame, Autoconer leakage can be regularly arrested
to save energy losses.
- RF Exhaust trench can be used for Elgi yarn conditioning machine water pre
heating. Possibilities to be optimized.
- All Power distribution board live wiring & component which are not in use to be
removed to avoid distribution losses.

xiii) Civil Infrastructure:

- Building construction seems to be strong. All plant building is supported by columns.

RCC ceiling & RCC roof is ok, vibration observed at few places and resonance also
appears at top roofs need to be rectified
 - All support functions i.e. electrical, utility, workshop, stores are having adequate size
good condition buildings except SFTML existing transformer room which is very
compact.
- Plant floor is having cement finish but in little area level is not good, also having
vibrations. Checked floor design, found concrete floor strength suitable
- Top slab of Return Air trenches creates vibration at many of the production area,
action to be taken to rectify the same.
- Water drainage system seems to be undersized to cater rainy season water
requirement, in phased manner rectification can be planned.

Following are recommendation:

Suggested to have detailed civil audit by competent structural engineering agency
including the health of beams, column, Return Air trenches, floors and roof top. Action
plan to be made on the basis of report. It is also suggested to have epoxy levelled flooring
to have max efficiency of m/cs.

Best Regards……………Amarnath Pandey Date : 04th April 2019