Air & Water Distribution
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Transcript of 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
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Air Compressor
Air Compressor is a machine, which
takes in air at certain pressure
compresses the same and delivers
the air at higher pressure.
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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
http://www.energytechpro.com/Demo-IC/Images/AirRecipUnit.jpghttp://www.energytechpro.com/Demo-IC/Images/AirRecipUnit.jpghttp://www.energytechpro.com/Demo-IC/Images/AirRecipUnit.jpghttp://www.energytechpro.com/Demo-IC/Images/AirRecipUnit.jpghttp://www.energytechpro.com/Demo-IC/Images/AirRecipUnit.jpghttp://www.energytechpro.com/Demo-IC/Images/AirRecipUnit.jpghttp://www.energytechpro.com/Demo-IC/Images/AirRecipUnit.jpghttp://www.energytechpro.com/Demo-IC/Images/AirRecipUnit.jpg -
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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
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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
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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 )
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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
Excellence in Water Management 2008Excellence in Water Management 2008
Zero Discharge Reverse Osmosis (R O )
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R.O.Plant
Boiler
Compressor
R.O.-1R.O. -2
R.O. -3
UF
Multiple Effect Evaporator
Zero Discharge Reverse Osmosis (R.O.)
Plant
Excellence in Water Management 2008Excellence in Water Management 2008
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Quality of Effluents
< 3
< 500
< 3
< 500
< 0.5
< 1.0
< 100
< 15< 1000
< 10
6.5 8.5
After
TreatmentThrough
ETP
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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.
Excellence in Water Management 2008Excellence in Water Management 2008
After Zero Discharge Project: Process
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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
Excellence in Water Management 2008Excellence in Water Management 2008
Usage of
RO
product
for
Zero Discharge R.O.
Plant with Multiple
Effect Evaporator
Cab PaintProcess
Cooling
Circuits
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