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Module No: TRM/ Utilities/ Goa/ ver01

dated 11.03.2006

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 UTILITIES AVAILABLE

 Chilled Water
 Warm water
 Cooling water
 Compressed air
 Steam
 Potable Water
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 RECOMMENDED WATER QUALITY
TABLE- 1
TEST ITEMS CHILLED
WATER
1) pH QUALITY
7.2 - 8.5 STD.
2) TOTAL (CACOэ) PPM MAXIMUM 80
HARDNESS
3) TOTAL ALKALINITY LESS THAN 100
(CACOз) PPM
4) CHLORIDE ION (PPM) LESS THAN 50
5) TOTAL ION (Fe) PPM LESS THAN 0.3
6) SILICA (SiO2) PPM LESS THAN 30
7) AMMONIUM ION PPM LESS THAN 0.2
8) TDS LESS THAN 1200
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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
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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

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 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

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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

Evaporator: Type : Shell and tube type,

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

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 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 12

evaporator through orifice in Liquid form again to

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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
reduce the freezing point of water. 15
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.
• 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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``

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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 ITEMS COOLING
WATER
1) pH QUALITY
7.2 - 8.5 STD.
2) TOTAL (CACOэ) PPM MAXIMUM 300
HARDNESS
3) TOTAL ALKALINITY LESS THAN 100
(CACOз) PPM
4) CHLORIDE ION (PPM) LESS THAN 200
5) TOTAL ION (Fe) PPM LESS THAN 1.0
6) SILICA (SiO2) PPM LESS THAN 50
7) TDS PPM LESS THAN 1500

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APPLICATION

• 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 Nos
Capacity : 600TR
Water flow : 363 m³/ hr.

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Components Details:

Casing
Motor
Fan
Water distribution system
Nozzle
Drift eliminator
Packing (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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 CO MPR ES SED
AI R

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

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 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 : 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.

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 PARAMETERS
Sr.No Tests Acceptance
    Criteria
1 Carbon dioxide(ppm) NMT 1000 ppm

2 Sulphur dioxide NMT 1 ppm

3 Oil mist 1.0 mg /cun.met
4 NO + NO2 NMT 2 ppm
5 Carbon monoxide NMT 5 ppm
6 Water vapour NMT 10 ppm
Between 19.50%
7 Oxygen
and 23.50%

NMT-NOT MORE THEN

REF SOP NO: QCP-55 30
APPLICATION

• 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 Nos
Capacity :600CFM (Cubic feet per minute)
Type :Balanced opposed reciprocating
Double Cylinder, double acting.
Motor Rating : 200 H.P.

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Detail s o f Air Comp ressor:-

Free Air Delivery : 16.98 M³/min (600 CFM)

Suction Pressure : 1.033 kg/cm²
Working pressure : Load-8.5 kg/cm²
Unload-10kg/cm²

Media of cooling : Water cooled

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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.

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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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 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.
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Non ‘IBR’ Boilers

Boilers which having water holding

capacity less than 22.75 liters ( 5 Gallons) is
called Non ‘IBR’ Boiler.
Our Boiler

But our Revomax RXD-850 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 .
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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 : 5μ

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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 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

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

UNIT IV

FURNACE
SOFT WATER
OIL
TANK

BOILER FLAMES
COIL

FLUE GASES
EXHAUST TO
BOILER SHELL
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.
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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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 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.
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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 water

Definition:
Potable water is treated raw water .

Parameters:

Pathogens - Nil
Colony forming units - NMT 500 CFU/ML

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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.

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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.
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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
QUESTIONS?

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Thank You

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