Thermal Checklist Epyllion

7/30/2019 Thermal Checklist Epyllion

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Promoting Cleaner Production in textile Washing/Dyeing/Finishing Sector in Phase II Bangladesh

GAS FIRED BOILER

Boiler# 1 23 (DieselBoiler)

4

Running StatusRunning(EKL)

Running(EFL)

Standby

MakeCleaverBrooks

(USA)

CleaverBrooks

(USA)

Daelim(Korea)

ModelCB-700-600-150

ICB-700-600-150

Type (Fire tube /Water tube) Firetube Firetube

Capacity (tons/hr) 9.4 9.4 8

Max. Pressure (Psi) 150 150

Heating surface (Sq. ft.) 139

No. of tubes

Stack temperature (C) 195 190

Steam Pressure (running) 6.2 bar 6.3 bar 4 kg/cm2

Burner type

Blow down details(frequency, amount, TDS,etc)

ManualBlow DownDia: 4Per day 6timesTemp: 64 CTDS: 1300ppmDO: 5.3mg/LConductivit

y: 3840 S

ManualBlow DownDia: 4Per day 6timesTemp: 65 CTDS: 910ppmDO: 5.6mg/LConductivit

y: 2560 S

ManualBlow DownTemp: 67 CTDS: 730ppmDO: 5.4mg/LConductivity: 2310 S

WASTE HEAT RECOVERY BOILER AT GENERATOR

Boiler# 1 2 3 4

Recovery Source

Make

Type

Model

Capacity (kg/hr)

Checklist 3C Mechanical Concerns-Mechanical Page 1 of14

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CHECKLIST 3C - ENERGY CONCERNS-MECHANICAL

Name of Organization Epyllion Fabrics Ltd

Boilers & Hot Water System


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Average Generation

Max. Pressure (Psi)

Heating surface (Sq. ft.)

No. of tubes

Stack temperature (C)

After WTP Water:

Temp: 25.3 C

DO: 8.6 mg/L

TDS: 80 ppmConductivity: 210 S

Feed Water temp: 80 C


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Boiler# 1 2 3 4

Burner

Blow down details

FEED TANK DETAILS

Dia Width Length HeightTemperat

ureInsulatio

n

Gas fired 8 8 8 43 C Insulated

DieselBoiler

6 6 8 90 CNotinsulated

WHR

Boiler

ECONOMIZER (/)Boiler# 1 2 3 4 5

Working status x x x

Boiler Exhaust Temp

Water Temp In

Water Temp Out

DEAD/LEAK STEAM TRAPS

Total no of steam traps 30 Nos

Type of traps (inverted bucket/ballfloat/thermodynamic)

Checked 30 nos

Found OK 30 Nos

Found failed 0 Nos


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STEAM & CONDENSATE DISTRIBUTION LAYOUT

Will be provided with the report after drawn in cad or visio software.


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STEAM TRAPS FAILED

No. Size. Location

STEAM LEAKAGES LOCATIONS

# Location Extent of Leakage

1 Dyeing M/C - 15 High

2

34

5

6

7

8

9

10

11

12


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LACK OF INSULATION

STEAM DISTRIBUTION SYSTEM

Steam pressure:..

#Pipe

locationDia &length

No. of Valve &Location

Valve Dia Remarks

1Dyeing m/c 42Nos

1.5

2Dyeing m/c 8nos

2.5

3Dyeing m/c 4nos

2

4Dyeing m/c 16nos

3

5Dyeing m/c 14nos 4

6 Header- 6 Nos 8

7 Header 2 Nos 6

8 Header 1 Nos 4

9

10

CONDENSATE RETURN SYSTEM

#Pipe

location

Dia &

length

No. of Valve &

Location

Valve Dia Remarks

1MainDistribution Line

4 & 640 ft

2Dyeing m/c 30Nos

2

3Distribution Line 2 Nos

4

4

5

6

7

8

9

10


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CONDENSATE RECOVERY SYSTEM

Recovery System (/)Recovery through gravity or pump (details) pump

Machines draining condensate

Machines Returning Condensate Dyeing machines from 10No to 24 No

Condensate Flow Returning (m3/hr)

STACK ANALYSIS & BURNER TUNING

Schedule present(frequency,results, action)

()

Last stack analysisand Action taken


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Heat recovery at Exhaust (/)No of Genset 2

Genset capacity 1.34 MW

Genset average load

Exhaust temperature

Air flow

Air density at exhaust temperature

Details

90% load- 560 C70~80% load 586C

(/)No of Genset 2

Genset capacity 1.34 MW

Genset average load

Exhaust temperature

Water flow

Details


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HEAT RECOVERY FROM GENERATORS


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Compressor # 1 2 3 4

MakeWorthingtonCreyssensac(2 Nos)

WorthingtonCreyssensac(3 Nos)

Sanlion

Model RLR40BX6 RLR75B7 SK50VS-B-1.0

Type Screw Screw Screw

No of Stages

Discharge Capacity 281 m3/hr 508 m3/hr1.2-6.2m3/min

Discharge PressureMax. Pressure (bar) 10.5 bar 10 bar 0.6~1.0 MPa

Speed (RPM) 3000 2975

Receiver Capacity

Shaft Power (kW) 30 55 37

Flow Rate (m3/min)

Details

Air Receiver

(Quantity, Volume)

2 Nos

Receiver Pressure: 7 barReceiver 1: length-74 & dia-311Receiver 2: length-611 & dia-410

Air

Main line Size

# Location of Air leaks Intensity Number


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COMPRESSED AIR


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# Location of Cleaning Points Number

Header 1

Hydro Extractor m/c 1De-water m/c 1

Slitting m/c 2

Stenter m/c 6

Dryer 1

Final inspection m/c 1

Bag sewing 1

Air turning 1

Grey Slitting m/c 1

Ultrasoft m/c (brushing) 2

Compactor 2

Utility-2 room 1


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Distribution Layout


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1 2 3

Location Utility-2 Room

MakeDaelim Royal(Korea)

Type

Capacity (liters)

Maximum Pressure (bar) 1 MPa

Maximum Temperature (C) 300 C

Heat Capacity 600,000 Kcal/hr

Minimum flow rate (m3 /hr)

Manufacture (year) 2011

Heating Surface 94 m2

Fuel Consumption233 Nm3/hr (228kg/hr)

Hot oil tank

Main receiving line 6 pipe, temp: 198 C

Main delivery line 6 pipe, temp: 206.7 C

Schedule for burner tuning present (/)Last stack monitoring/details

Log sheets available for monitoring

# Location of Oil leaks Intensity Number


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HOT OIL BOILERS


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(/)

# Machine SteamCompressed

AirNatural Gas Hot Oil

Dyeing m/c (#1 to24) Hydro Extractor De-water Slitting Stenter (LK&LH

and ACC)

Stenter(Monforts) Dryer (entema) Compactor(Tubetex) Ultra soft(Brushing) Raising m/c Final Inspectionm/c Air Turning Bag Sewing


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Resource Utilization


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(/)# Machine

Steam FlowMeter

Air FlowMeter

Natural GasFlow Meter

Water FlowMeter

Total


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Monitoring and Evaluation of the System


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Possible Concerns /Thermal System

Bare hot surfaces at Steam

Bare hot surfaces at Condensate Pipes

Bare hot surfaces at Hot Water System

Bare hot surfaces at Hot Oil System

Steam Leaks

Steam Traps Failure

Condensate Drain

Energy Dissipation at Boiler Stack

(Economizer)

Tuning at gas fired Boiler

Steam Flow meters

Gas Flow meters

Compressors

Compressed Air Leaks

Compressed Air Nozzles

Air Flow meters

Misuse of Compressed Air

Power Generators

Waste Heat Recovery Boiler

Heat recovery at Jacketing Water

Hot Oil Boiler

Lack of Insulation

Oil Leak

Tuning missing at gas fired Boiler

Gas flow meter missing


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Name of CP Assessor / Engineer:

Date:

Thermal Checklist Epyllion

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