*

Module No: TRM/ Utilities/ Goa/ ver01 dated 11.03.2006
1

2

UTILITIES AVAILABLE
      Chilled Water Warm water Cooling water Compressed air Steam Potable Water
3

o

o o

4

RECOMMENDED WATER QUALITY
TABLE- 1

TEST ITEMS
1) pH 2) TOTAL (CACOэ) PPM HARDNESS 3) TOTAL ALKALINITY (CACOз) PPM 4) CHLORIDE ION (PPM) 5) TOTAL ION (Fe) PPM 6) SILICA (SiO2) PPM 7) AMMONIUM ION PPM 8) TDS

CHILLED WATER QUALITY STD. 7.2 - 8.5
MAXIMUM 80 LESS THAN 100 LESS LESS LESS LESS LESS THAN THAN THAN THAN THAN 50 0.3 30 0.2 1200
5

1. Chilled water supplied from utility is circulated through chilled water coil of Air Handling Units. 2. Return air from production area is passed over the chilled water coil to maintain its temperature and relative humidity. 3. Return chilled water from the Air handling Units is collected in the Balancing tank and then supplied to

6

7

1. Chillers are used to generate chilled water of temperature 5 ºc. 3. YORK Make Centrifugal chillers of capacity 500 TR. 5. Refrigerant used : R-123 (Dichloro Triflouro Ethane)

7. Input Power required : 324 KW

8

Chiller:

CHILLER

Chiller is an equipment used to reduce the temperature of a Liquid to a lower then its normal temperature like 5ºC. Chiller detail: Make : York International Corporation Capacity : 500 TR Flow across the evaporator: 1339 USGPM Flow across the condenser : 2000 USGPM. Refrigerant : R-123 Chilled water inlet Temperature : 10º C Chilled water outlet Temperature : 5º C Δ t = 5º C
9

CHILLER PARTS:
Compressor: Type: Centrifugal Capacity: 500 TR Motor : 324 KW 3 phase, Shaft driven

Condenser:

Type : Shell and tube type, Refrigerant in Shell and water in tube, Water cooled, Condenser inlet is 32º C and outlet is 37ºC Type : Shell and tube type, Refrigerant in shell and water in tube, Inlet is 10º C and Outlet is 5º C.

Evaporator:

10

11

WORKING PRINCIPLE
Evaporator in the chiller acts as cooler as here water gets cooled due to heat absorption action of boiling refrigerant. The chilled liquid at 5º c is then supplied to application area and return water at 10 ºc again comes to the evaporator via balancing tank to complete the circuit. The refrigerant vapour produced in evaporator flows to compressor where the rotating impeller increases its pressure and temperature and discharge to the condenser. The water from Cooling Tower at 30º c flows through the condenser tubes which absorbs heat from the refrigerant vapour, causing it to condense and then returns at 34º c to cooling tower for cooling. From condenser the refrigerant flows to the evaporator through orifice in Liquid form again to
12

13

14

DEFINITION: It is the system which is used to Store the latent heat of 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 15 reduce the freezing point of water.

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.

16

BENIFIT OF THERMAL STORAGE SYSTEM. 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.

17

``
18

DEFINITION: Water which is used in AHU heating coil is called as warm water. Parameters: Warm water supply temp. = 30 to 35 ºc

19

20

DEFINITION: Cooling water is used for cooling different part of equipments or system. Parameters: Cooling water supply temp.= 28 to 30 ºc

21

RECOMMENDED WATER QUALITY
TABLE- 2

TEST ITEMS
1) pH 2) TOTAL (CACOэ) PPM HARDNESS 3) TOTAL ALKALINITY (CACOз) PPM 4) CHLORIDE ION (PPM) 5) TOTAL ION (Fe) PPM 6) SILICA (SiO2) PPM 7) TDS PPM

COOLING WATER QUALITY STD. 7.2 - 8.5
MAXIMUM 300 LESS THAN 100 LESS LESS LESS LESS THAN THAN THAN THAN 200 1.0 50 1500
22

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

23

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 Type Quantity Capacity Water flow : Himgiri Cooling Towers : Induced Draft Counter Flow : 6 Nos : 600TR : 363 m³/ hr.

24

Components Details:
Casing

Motor Fan Water distribution system Nozzle Drift eliminator Packing (fills)

25

COOLING TOWER
(INDUCED DRAFT)
MOTOR

WATER INLET

26

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.

27

CO MPR ES SED AI R
1.DEFINITION
Compressed Air is the air at pressure higher than the atmospheric pressure.

28

WORKI NG PARA MET ERS
WORKING PRESSURE OF COMPRESSOR : 8.5 To 10.0 Kg/Cm²

SUPPLY PRESSURE FROM UTILITY THROUGH CONTROL AIR SYSTEM: UNIT - I,III & IV UNIT – II 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. : 7.2 Kg/Cm² : 8.45 Kg /Cm²

29

PARAMETERS
Sr.No   1 2 3 4 5 6 7 Tests   Carbon dioxide(ppm) Sulphur dioxide Oil mist NO + NO2 Carbon monoxide Water vapour Oxygen Acceptance Criteria NMT 1000 ppm NMT 1 ppm 1.0 mg /cun.met NMT 2 ppm NMT 5 ppm NMT 10 ppm Between 19.50% and 23.50%
NMT-NOT MORE THEN
30

REF SOP NO: QCP-55

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

31

32

Details of Air Compressor:There are total three Nos. of Air Compressors installed in utility Cipla – I. Make Quantity Capacity Type Kirloskar Pneumatic Company Ltd. 3 Nos 600CFM (Cubic feet per minute) Balanced opposed reciprocating Double Cylinder, double acting. Motor Rating : 200 H.P. : : : :

33

Detail s o f Air Comp ressor:Free Air Delivery Suction Pressure Working pressure Media of cooling : 16.98 M³/min (600 CFM) : 1.033 kg/cm² : Load-8.5 kg/cm² Unload-10kg/cm² : Water cooled

34

Working of Air Compressor:Air is sucked from atmosphere in L.P Cylinder through the filter during the suction stroke of the compressor. This air entered through suction valve is Compressed and delivered through discharge valves to H.P Cylinder via Water cooled intercooler. In H.P Cylinder the air is again compressed and delivered to through Air Dryer via water cooled after cooler and stored in Air receiver. From air receiver it is supplied to the different Plants.
35

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
36

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.
37

STEAM
Steam Boiler: Steam Boiler is equipment which generates steam by heating of water.

IBR Boilers :As per the Indian Boilers Act, 1923, and Indian Boilers Regulations, 1950 issued by Government of India, Ministry of works, Mines and power – central Boilers Board, “BOILER” means any closed vessel exceeding 22.75 liters (5 Gallons) in capacity which is used expressively for generating steam under pressure and includes any mounting or other fitting attached to such vessel which is wholly or partly under pressure when steam is shut OFF.

38

Non ‘IBR’ Boilers Boilers which having water holding capacity less than 22.75 liters ( 5 Gallons) is called Non ‘IBR’ Boiler. Our Boiler is outside the preview of IBR Act, as its capacity is 21.4 liters which is less than 22.75 liters. So, It comes under the category of non-IBR .
39

But our Revomax RXD-850 boiler

Working pressure Working Temperature Type Dryness fraction Feed water hardness Feed water PH Final filtration

: : : : : : :

8.5 to 10 Kg/Cm² 160 to 180 ºc Wet Saturated. 78% below 5 PPM 8.5 to 9.5 5μ

40

• 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.

41

Boiler Details: Make : Thermax Ltd Type : Vertical water tube boiler. Fuel : Furnace oil Water : Soft water (Hardness below 5 ppm) Capacity : 850 Kg/ Hr. Steam working pressure : 8.5 to 10 kg/ cm² Steam Temperature : 160 to 180 º C

42

STEAM BOILER ARRANGEMENT
F.O PUMP BURNER ASSEMBLY STEAM OUT
UNIT 1

UNIT III UNIT IV

FURNACE OIL

SOFT WATER TANK

BOILER COIL

FLAMES

BOILER SHELL

FLUE GASES EXHAUST TO CHIMNEY

INNER SHELL

FEED WATER PUMP 43

Major parts of the Boiler:

• Feed Water Pump • Fuel oil pump • Blower • Economizer • Optimizer • Burner Assembly • Coil • Inner shell / Outer shell • Top Refractory
• Wegmann Cone

• Chimney etc.

44

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.
45

Water softener
Water Softener :
Softener is an equipment which is used to convert the potable water into soft water.

Softener Plant Details:
► ► ► ►

Make : Ion Exchange Ltd. Type : S- 400/U –up flow Capacity : 4 M³ /Hr. Hardness of water : Below 5 ppm.
46

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.
47

Potable water
Definition: Potable water is treated raw water . Parameters: Pathogens Colony forming units Nil NMT 500 CFU/ML

48

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

49

Water treatment:  To control the microbial growth in potable water sodium hypochlorite is being dosed.

 120 ml of 2.5% sodium hypochlorite

solution is required to maintain 3 ppm free chlorine in 1000 ml of water.  The free chlorine ppm in the potable water should be in the range of 2.5 to 3 ppm at underground level.
50

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.

51

52

ANY QUESTIONS?

53

Thank You

54