Air & Water Distribution

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 to temperature. • Relatively clean and non pollutant. • High speed operations are possible.Speed and forces can be varied.

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.

Basic Compressed Air System

Compressor

Air Compressor

Air Compressor is a machine, which takes in air at certain pressure compresses the same and delivers the air at higher pressure.

Types of Compressor Types of compressors

Reciprocating compressors

Piston

Rotary piston compressors

Diaphragm

Sliding Vane rotary

Flow compressors

Radial Flow

Two axial Screw

Roots Blowers

Axial Flow

Reciprocating Piston Compressor

Piston Compressor

Power Transmission

Electric Motor For Distribution

Air Receiver

Line Diagram of Piston Operation

Reciprocating Compressor – Side View Two stage Reciprocating Air Compressor Air inlet

Connecting Rod Water Inlet

Air Filter

Piston

Piston rod Piston

LP Cylinder

HP Cylinder

After Cooler

Piston rod

Compressed Air outlet

Inter Cooler Water Inlet Water Outlet

Reciprocating Compressor – Front View Two stage Reciprocating Air Compressor

HP Cylinder Piston

LP Cylinder Piston

Driven Pulley

V Belts

Lubrication Pump

Drive Pulley

Drive Motor

Reciprocating Piston Compressors  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 are commercially 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.

Ashok Leyland, Unit-2 layout Compressor House

D G

A A S

S M P

F A S

C A P

C A W

TC

CS

CANT.

V T S ETP

K D C

CAS WO

C P S

LC

STP SY

Compressor House Layout 500CFM C4

R 4

R 3

500CFM C3

D: C3 & C4

1250 CFM C2

R 2

D2: C2

1: CAS,CAW,VTS&KDC

1250 CFM C1

R 1

1250 CFM C5

D2: C1

R 5

D2: C5

Demand Controller

2:CAP,Eng.Dressing. 3&4: FAP,FAS,SMP&AAS

1

4

3

2

1250 CFM C6

R 6

D2: C6

Compressed Air Receiver Pressure Relief Valve

 The Compressed air receiver serves to

Air Out

stabilize the compressed air supply. It smoothens pressure fluctuations in the network where air is consumed. Heat exchange to assist air cooling and thus Air In

produce condensate drop out before the air enters distribution line.

M anho le

Dryers •

There are three drying methods used for industrial systems: 2. Refrigeration drying. 3. Adsorption drying. 4. Absorption drying.

Refrigeration Drying 1.Refrigeration Compressor 2.Refrigerant Condenser 3.Electric Fan 4.Liquid Receiver 5.Thermostatic Expansion Valve 6.Air -to- Air heat Exchanger 7.Freon -to- Air Heat Exchanger 8.Centrifugal Condensate Separator 9.Accumulator 10.Moisture Removal Filter 11.By-Pass Valve 12.Automatic Condensate Trap i. e. autodrain 13. Press for Fan (AC only )

Ashok Leyland, Unit-2 layout Compressor House

D G

A A S

S M P

F A S

C A P

C A W

TC

CS

CANT.

V T S ETP

K D C

CAS WO

C P S

LC

STP SY

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

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.

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.

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 the pressure drop caused by turbulence and friction. • Cut-in / Cut-out pressure differential is governed by compressor demand controller.

4. Air Leakage Hole diameter

Air Power required for leakage at compression 6bars

mm

mm3/min.

hp.

kW

1

0.06

0.4

0.3

3

0.6

4.2

3.1

5

1.6

11.2

8.3

10

6.3

44

33

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. in min. • T = time taken between cut-in and cut-out. In min. • QL= Qc x t (T+t)

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

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.

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.

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.

Schematic Diagram of Ring Circuit

Sources of water for AL-H2 • Sipcot Bore well • Sipcot Dam • Private/Tanker

Month Apr-08 May-08 Jun-08 Jul-08 Aug-08 Sep-08 Oct-08

Dam 7580 6530 4309 7114 7659 2637 5325

Borwell 904 1117 833 893 972 738 836

Private 11980 16275 12700.6 15091 13540.4 12113.4 10919.6

Total Water Recived (KL) 20464 23922 17842.6 23098 22171.4 15488.4 17080.6

Water consumption Vs. Production. Daily Water consumption Vs monthly production ( April ' 08-Sep ' 08 ) 2155

1947

1807

1888

2017

Values

1262 494.6

561.0

493.2

543.2

544.6

510.0

Apr-08

May ' 08

June '08

July ' 08

Aug ' 08

Sep '08

Month

Month

Water Consumption per day

Vehicle Produced

Linear (Vehicle Produced)

Water Consumption

Month Apr-08 May-08 Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Average

Industrial Cooling( Domestic (KL) (ETP KL) (KL)(Cant total (DG,Com een+ Cooling p & Cool Toilet Garden( water) Tow) Tank) KL) 1563 468 1935 16498.0 1215.40 469.4 1933.5 20303.7 1450.8 468.1 1848 14075.7 1550.3 646 2020.0 18881.7 2190.5 511.5 1995.0 17474.4 1940.5 796.2 1911 10840.7 1912.46 218.98 1943 13006.6 1689 511 1941 15869

Water Distribution Lay Out

Photo copy showing overall plant

Chemical treatment facility Rinsing dilute waste water Capacity-250 KLD Consented for – 225 KLD

Concentrated waste water Designed – 10 KLD Consented for –6 KLD

Biological treatment Canteen waste water Designed –150 KLD Consented for- 75 KLD

Multi grade filter and Activated carbon filter To improve outlet quality.

Chemical treatment Plants Sources of Effluent •

2. 3. 4. 5. 6.

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. Axle shop • De-sludge pit waste water. Services. • Cooling tower Bleed off / cleaning waste water. • Soft water regeneration waste water Cab weld • Cooling tower Bleed off / cleaning waste water. • Soft water regeneration waste water Vehicle test shop. • Vehicle washing water Others • Floor washings

RINSING/ DILUTE WASTE TREATMENT SCHEME ACID (OR)LIME RINSING / DILUTE WASTES

COLLECTION OIL/ CUM GREASE EQUALISATION TRAP SUMP

REACTION

P

FLOCCULATION TANK pH 9.0 To 10.5

TANK pH 9.0 To 10.5

CLARI FIER TANK pH 9.0 To 10.5

FILTRATE

OVER FLOW

SULDGE

SLUDGE DRYING BEDS

THICKENER TANK

pH 9.0 To 10.5

pH 9.0 To 10.5

DRY SLUDGE FOR DISPOSAL TREATED WATER FOR GARDEN

PSF

OVER FLOW

pH 9.0 To 10.5

ACF

PSF&ACF SUMP

pH 6.0 to 8.5

pH CORRECTION TANK

Rinsing/Dilute Waste water treatment process 3.

The rinsing dilute waste water stream is segregated separately and collected in a set of collection cum equalization sumps. 4. Prior to collection sump , oil and grease trap is provided to remove free oil and grease from the waste. 5. The equalized waste is then pumped to reaction tank where in lime to have the required pH value around 10.0. At this optimum pH level, heavy metals including phosphate are effectively precipitated. 6. The reaction mass in then slow mixed in a flocculation tank. The thick flocs from 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 by activated carbon filter. 11. The final treated waste water along with sewage is collected in a sump and reused for gardening and growing green belt inside the factory premises.

CONECNTRATED WASTE TREATMENT SCHEME ACID(OR) CONCEN TRATE WASTE

pH above 9.0

LIME OIL/ GREASE TRAP

COLLECTION SUMP pH -Above 9.0

REACTION CUM SETTLING TANK pH 9.0 to 10.5

P

pH 9.0 to 10.5

FILTRATE

pH CORRECTION TANK

pH 9.0 to 10.5

SLUDGE DRYING BED

SLUDGE

pH 6.5 to 8.5

SOLAR EVAPORATION PAN

DRY SULDGE FOR DISPO SAL CONCENTRATE SLUDGE FOR DISPOSAL

Rinsing Dilute waste water treatment Plant

Reaction tank

Flocculation Tank

Clarifier Tank

Thickener tank

Sludge drying beds

In coming canteen/ sewage water

SEWAGE TREATMENT PLANT COLLE CTION SUMP

SEPTIC TANK

PUMP HOUSE

A1

A1,A2,A3 - AREATOR

FILTRATE

A2

RETURN SLUDGE

A3

SLUDGE DRYING BED RETURN SLUDGE

S1

S2

S1,S2 - SETTLING TANK POLYSING POND1 TREATED WATER FOR GARDEN

PSF

ACF

PSF& ACF Sump

POLYSING POND2

Sewage treatment Plant

Settling Tank

Polishing pond

Collection sump

Aerators Septic tank to remove solids from Canteen & Bath rooms

Before Zero Discharge Project: Process Flow of Industrial Effluent Reaction * Equalization tank Flocculation Tank

Effluent from Process Usage of Treated Effluent for

To Garden

Clarifier

Ph Correction

PSF

ACF

Thickener Sludge Drying Bed

(Clarifier)

Legend:

PSF : Pressure Sand Filter ACF : Activated Carbon Filter

Excellence in Water Management 2008

Zero Discharge Reverse Osmosis (R.O.) Plant Process Flow TO ETP

25 KL

PRETRE ATMENT (85%)

REVERSE OSMOSIS-I (75%)

FEED FROM ETP

75 KL

10 KL

REVERSE OSMOSISII (60%)

6.5 KL

15 KL

REVERSE 3.5 KL OSMOSIS-III (35%)

PRETREATED WATER FEED 100KL

93.5KL DRY SLUDGE TO SLF

SLUDGE DRYING BEDS

PERMEATE WATER STORAGE (99.67%)

6.17 KL

MULTIPLE 6.5 KL EFFECT EVAPORATOR

99.67KL

0.33 KL LEGEND :

FILTERATE WATER TO ETP

TO THE PAINT PROCESS&COOLING

FEED PERMEATE REJECT

Excellence in Water Management 2008

FILTERATE SLUDGE BACKWASH

Zero Discharge Reverse Osmosis (R.O.) Plant R.O.Plant

Multiple Effect Evaporator

UF R.O. -3 R.O. -2

R.O.-1

Compressor Boiler

Excellence in Water Management 2008

Quality of Effluents S l.N o

Parameter

1

pH

2

TNPCB Tolerance limit

After Treatment Through ETP

After Treatment Through R.O.

5.5 – 9.0

6.5 – 8.5

7.0

TSS (mg/l)

100

< 10

<1.0

3

TDS

2100

< 1000

52.0

4

BOD

30

< 15

<1.0

5

COD

250

< 100

<1.0

6

Copper (as Co) mg/l

3

< 1.0

<0.05

7

Zinc (mg/l)

1

< 0.5

<0.01

8

Chlorides (as Cl) mg/l

1000

< 500

13.0

9

Oil & Grease

10

<3

<1.0

10

Sulphates (as SO4) mg/l

1000

< 500

<0.2

11

Dissolved phospate mg/l

5

<3

<0.05

Excellence in Water Management 2008

Benefits of the Zero Discharge Project The occurred savings :Rs. 12.6 lakhs/annum.  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. Excellence in Water Management 2008

After Zero Discharge Project: Process Flow of Industrial Effluent Reaction * Equalization tank Flocculation Tank

Effluent from Other Process Process

Cab Paint Process Cooling Circuits

Zero Discharge R.O. Plant with Multiple Effect Evaporator

Usage of RO product for

Clarifier

Ph Correction

PSF

Sludge Drying Bed

Thickener

Excellence in Water Management 2008

ACF