training report - brandix lanka (pvt) ltd
TRANSCRIPT
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PREFACE
This training report reflects the 6 months of industrial training I spent at the Brandix Lanka
Ltd.
The report has details of the practical experience and the academic knowledge I have gained
from Brandix Lanka Ltd during these 6 moths as a mechanical and management engineering
trainee. And also it is included details of many projects that I have conducted and involved.
The first chapter contains a preface about the Brandix Lanka Ltd. while the second chapter
consists of the training experience received and also the summarized details of the projects I
involved at the Brandix Lanka Ltd while the third and final chapter contains conclusion of the
training experience I have gained from Brandix Lanka Ltd.
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ACKNOWLEDGEMENTS
First, I would like to thank Eng. N.A. Wijeyewickrame and Eng. P. Gunawardena at the
Industrial Training Division at the University of Moratuwa for handling my placement at the
Brandix Lanka Ltd.
Next, I would like to thank the National Apprentice and Industrial Training Authority
personnel, who had coordinated our industrial training program properly.
Specially I would like to thank Mr.IreshaSomarathna (Head of Environment and Energy
Management Department) at the Brandix Lanaka Ltd. for recruiting me as a management
engineering trainee, planning my training period and accommodating us suitably.
Further, I should really be thankful for Mr.E.M.A.Ekanayake, Mr.ChaturaCabraal, Miss.
PunsalaRanasinghe and Miss. SunaliYatagama who are the engineering staff of our
Environment and Energy team for instructing and advising me always to make my training
period successful.
Finally, I would like to thank my batch-mate from our University who were at Brandix Lanka
Ltd. with me and kept me company and helped me develop practical skills and social skills
on how to interact with working class people.
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Table of Content
PREFACE i
ACKNOWLEDGEMENTS ii
CHAPTER 1 1
1 INTRODUCTION TO THE BRANDIX LANKA LTD. 1
1.1 Background of the Brandix Lanka Ltd.: 1
1.2 Brandix India Apparel City 1
1.3 Brandix Group Companies 2
1.4 Vision of the Brandix Lanka Ltd.: 2
1.5 Mission of the Brandix Lanka Ltd.: 2
1.6 Energy and Environmental Division β Brandix Lanka Ltd 3
1.6.1 Green achievement of environmental division 3
1.7 Profile of the Brandix Lanka Ltd.: 3
CHAPTER 2 4
2 TRAINING EXPERIENCES 4
2.1 Projects Followed during Training Period 5
2.1.1 AutoCAD Drawing βBradix Casualwear Seethawaka 5
2.1.1.1 Introduction 5
2.1.1.2 Job role 5
2.1.1.3 Description 5
2.1.1.4 Improved Skills 5
2.1.2 AutoCAD Drawing β Plumbing Drawing for Brandix Seeduwa Factory 6
2.1.2.1 Introduction 6
2.1.2.2 Preparation of Plumbing Layout 7
2.1.2.3 Improved Skills 9
2.1.3 Electrical Drawing β LutronLighting System 10
2.1.4 Drawings for Brandix Lanka Ltd β For A/C Replacing Project 10
2.1.5 Grease Trap Modification Project 14
2.1.5.1 What is a grease trap? 14
2.1.5.2 Condition of Grese Trap at Brandix Seeduwa 15
2.1.5.3 Observations and failures 15
2.1.5.4 Analysis 16
2.5.5 Solutions 18
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2.1.6 Water Management Project 19
2.1.6.1Drinking Water Problem 19
2.1.6.1.1 Introduction 19
2.1.6.1.2 Observations 19
2.1.6.1.3 Analysis 19
2.1.7 Lighting Simulation Projects 20
2.1.7.1Introduction 20
2.1.7.2 Project 1- Batticlao Brandix Sport Complex 21
2.1.7.2.1 Introduction 21
2.1.7.2.2 Simulation β Sodium Vapour Lights 23
2.1.7.2.3 Luminaire Detail 23
2.1.7.2.4 Calculation Results of each court 24
2.1.7.2.5 Lighting Energy consumption 25
2.1.7.2.6 Simulation β LED Flood lights 25
2.1.7.2.6 Results 29
2.1.7.2.7 Finalizing and Implementation 30
2.1.8 Skylight Project β Brandix Awissawella 31
2.1.8.1 Design Criteria 31
2.1.8.2 Details of skylights 32
2.2 Study of Boilers 34
2.1.1 Structure of Basic Boiler System 34
2.2.2 Types of Boilers 35
2.1.5 Deaerator 37
2.2.6 Economizer 38
2.9 Tri Generation Power Plant (MCP) Project β Textured Jerzy (Seethawaka) 39
2.9.1 Introduction 39
2.9.2 Calculations 40
2.10 Basic Project Design & Main Equipment 44
2.10.1 SYSTEM SPECIFICATIONS 45
2.10.1.1Boiler 45
2.10.1.2 Steam Turbine 45
2.10.1.3 Generator 47
2.10.1.4 Absorption Chiller 47
2.10.1.5 Electro-Static Precipitator 47
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Maximum permissible emissions of ESP are as follows, 47
2.11 Solar net metering project - Mr. Feroz Omarβs house 48
2.11.1 Project Description 48
2.11.2 Observations, Measurements and Analysis 49
Generation Data: 49
2 52
2.11.3 Conclusions 52
2.11.4 Recommendations 53
2.12 Waste Management Project 57
2.12.1 ETP Sludge Co- Processing Project 57
2.12.1.1 Introduction 57
2.12.1.2 Heat Calculation 57
2.12.1.3 Recovery 58
2.12.1.4 ETP Sludge Drying Process 58
2.12.1.5 Proposed Design for the dryer 59
2.13 Energy Audit β Brandix Girithale 60
2.13.1 Introduction 60
2.13.2 Observations 60
2.13.3 Solutions and Implementation 64
2.13.4 Conclusion 66
CHAPTER 3 67
2.12 3 CONCLUSION 67
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List of Tables
Table 2.1 : A/C Types and Qty. ............................................................................................... 13
Table 2.2: Textual Table for Basketball Court ........................................................................ 24
Table 2.3 : Textual Table for Volleyball Court ....................................................................... 24
Table 2.4 : Textual Table for Badminton Court ...................................................................... 25
Table 2.5 : Energy Consumption Analysis .............................................................................. 25
Table 2.6 : Energy Comparison of Two Designs..................................................................... 29
Table 2.7: Skyloght Calculations for Each Section ................................................................. 33
Table 2.8 : Designs of Skylight Calculation for Production Area ........................................... 33
Table 2.9 : CHP Power Plant Enthalpy and Entropy ............................................................... 40
Table 2.10 : Site Condition ...................................................................................................... 43
Table 2.11 : Basic Project Design & Main Equipment............................................................ 45
Table 2.12 : Readings of Power Meters ................................................................................... 50
Table 2.13: Tariff Analysis after Solar System Connected to the Grid ................................... 50
Table 2.14 : saving Analysis .................................................................................................... 51
Table 2.15 : Checklist for Maintenance Engineers .................................................................. 65
List of Figures
Figure 2.1 : AutoCAD Drawing β Bradix Casualwear Seethawaka .......................................... 6
Figure 2.2 : Existing Fire Layout (Damaged) ............................................................................ 8
Figure 2.3 : Proposed Fire Layout ............................................................................................. 9
Figure 2.4 : A/C Layout 1st Floor............................................................................................ 11
Figure 2.5 : A/C Layout 2nd Floor .......................................................................................... 12
Figure 2.6 : A/C Layout 3rd Floor ........................................................................................... 12
Figure 2.7 : A/C Layout 4th Floor ........................................................................................... 13
Figure 2.8 : Untreated Grease Trap.......................................................................................... 14
Figure 2.9 : Treated Grease Trap ............................................................................................. 14
Figure 2.10 : Condition of Brandix Seeduwa Grease Trap ..................................................... 15
Figure 2.11 : Grease Trap Layout ............................................................................................ 17
Figure 2.12 : Lighting Layout of Sport Complex .................................................................... 22
Figure 2.13 : Details of Sodium Vapor Flood Lights .............................................................. 23
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Figure 2.14 : Details of LED Flood Lights .............................................................................. 25
Figure 2.15 : Comparison of SV lights and LED Lights ......................................................... 26
Figure 2.16 : Calculation sheet of Basketball Court ................................................................ 27
Figure 2.17 : Calculation Sheet of Badminton Court .............................................................. 28
Figure 2.18 : Calculation Sheet of Volletball Court ................................................................ 29
Figure 2.19 : Final 3D Model for Sport Complex - Batticaloa ................................................ 30
Figure 2.20 : Deatails of Skylights .......................................................................................... 32
Figure 2.21 : Structure of a Boiler System .............................................................................. 34
Figure 2.22 : Fire Tube Boiler ................................................................................................. 35
Figure 2.23 : Water Tube Boiler .............................................................................................. 36
Figure 2.24 : Package Boiler.................................................................................................... 36
Figure 2.25 : Deaerator ............................................................................................................ 37
Figure 2.26 : Economizer......................................................................................................... 38
Figure 2.27 : 3D Model of the Power Plant ............................................................................. 39
Figure 2.28 : Power Plant Structure ......................................................................................... 40
Figure 2.29 : Proposed Mew Power Plant Layout ................................................................... 42
Figure 2.30 : Structure of Solar System ................................................................................... 48
Figure 2.31 : Placement of Utility Meters ............................................................................... 49
Figure 2.32 : Graph for Solar Generation during Past 30 Days ............................................... 51
Figure 2.33 : Failures in the Solar Panels ................................................................................ 52
Figure 2.34 : Expected Generation after Modifications........................................................... 53
Figure 2.35 : Graph for Energy Consumption of House.......................................................... 54
Figure 2.36 : Graph for Power Generation from Solar Panels ................................................. 55
Figure 2.37 : Graph for Grid Consumption ............................................................................. 56
Figure 2.38 : Structure of Dryer............................................................................................... 59
Figure 2.39 : Steam Pipe Lines ................................................................................................ 61
Figure 2.40 : Steam Barrels for Elastic Boiling ....................................................................... 62
Figure 2.41 : Old and New Flu Gas Chimney of Boiler .......................................................... 62
Figure 2.42 : Skylight Sheets and Roof Sheets ........................................................................ 63
Figure 2.43 : Skylights and Artificial Lights ........................................................................... 63
Figure 2.44 : Utility Area Uncleanliness ................................................................................. 64
Figure 2.45: Brandix Girithale winning M&S Certification.................................................... 66
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CHAPTER 1
1 INTRODUCTION TO THE BRANDIX LANKA LTD.
1.1 Background of the Brandix Lanka Ltd.:
Brandix is the largest exporter of apparel in Sri Lanka. As the holding company of the
Brandix Group of companies, it is engaged in developing, manufacturing and marketing end-
to-end apparel solutions to global fashion super brands. A peek into an exclusive portfolio
reveals Victoria's Secret, Gap, Next and Marks and Spencer, amongst other excellent
company.
The company specialises in casual bottoms, intimate and active wear, woven and knitted
fabrics and a host of apparel industry accessories. Producing its own fabric, threads, buttons
and hangers give us it most tactical edge in textiles and reinforces its core strengths of
advanced research and development, outstanding design, fabric printing, washing, dyeing,
wet processing, finishing, and relentless quality control services with fastest turnaround
times. Embedding and integrating these services into seamless verticality is the value chain it
offers customers.
A single manufacturing facility in 1972 was the springboard to the 34 plants island wide and
supports the Group and employs over 35,000 people directly. Brandix Lanka Ltd was
founded in 2002 and pioneered the concept of holistic apparel solutions from a unique,
customer-centric structure. A concerted initiative to facilitate our vision of achieving
manufacturing and supply chain excellence, and working closely with our partners, we
provide truly inspired solutions.
1.2 Brandix India Apparel City
Brandix India Apparel City (BIAC) is a revolutionary development in the apparel industry; a
unique, integrated apparel supply chain city, managed by Brandix Lanka Ltd. Spread over
1000 acres in the port city of Visakhapatnam in the eastern state of Andhra Pradesh, it brings
alive an avantgarde 'Fibre to Store' concept. BIAC will bring together world class apparel
chain partners from the design table to consumer brands in flawless integration.
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1.3 Brandix Group Companies
Brandix Apparel
Brandix Asia
Brandix Casualwear
Brandix College of Clothing Technology
Brandix Essentials / Brandix Apparel India
Brandix Finishing
Brandix Hangers
Brandix Intimate Apparel
Brandix Lingerie
Brandix Textiles
1.4 Vision of the Brandix Lanka Ltd.:
βTo be the inspiredsolution for brandedclothingβ
1.5 Mission of the Brandix Lanka Ltd.:
TO LEAD in being responsible corporate citizens. Not because we are convinced
that it is a good way of doing business, but because we believe it is the right way
of doing business.
TO STRIVE to make a meaningful difference everywhere we do business.
TO LISTEN and RESPOND to environment challenges that affects our society
and our planet.
TO INSPIRE people to work towards protecting and improving water access and
availability in our communities.
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1.6 Energy and Environmental Division β Brandix Lanka Ltd
Environmental Division is responsible for energy conservation, waste management and
water conservation in all factories of Brandix cluster. There are main functions of this
department.
Oversees engineering functions of the whole group (30 factories)
Supplier evaluation and capex approvals
Maintenance and energy budget controlling
Group sustainability/environmental initiatives ex- controlling resource consumption
(carbon footprint, water footprint, waste production), sustainability report, etc.
Introduction of new technologies and energy efficiency systems
I was recruited to this department as a management engineering trainee. There were 4
engineers working for this department in different fields.
Energy Management
Punsala
1.6.1 Green achievement of environmental division
The worldβs first LEED Platinum rated Apparel Factory
One of three nominees for the Energy Globe World Award in the βAirβ category
Rated Platinum for Corporate Accountability
National Cleaner Production Awards 2008, in recognition of environment friendly
production practices β Gold & Silver awards
1.7 Profile of the Brandix Lanka Ltd.:
Name of the Company:Brandix Lanka Ltd.
Registered Office:409 Galle Road, Colombo 03, Sri Lanka
Telephone Numbers: +94 11 4727222, + 94 11 2 575485
E-mail Address:[email protected]
Website: www.brandix.lk
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CHAPTER 2
2 TRAINING EXPERIENCES
In this chapter, I would explain in detail, the training experience I have received from
Brandix Lanka Ltd. during the 6 month training period. Obviously it was an amazing period
in my life because I could involve with lots of projects regarding Energy conservation and
sustainable engineering that I have already trained when I was a trainee at EnergySolve
International (PVT) Ltd.
Normally there was no any predefined training schedule for us. But during this
training period I could involve and work on various kinds of projects covering mechanical
engineering concepts. Mainly we are conducted by 4 engineers who are specialized in
different areas.
Table 2.1: Engineers at Each Section
Workshop/Section/Division Engineer
Energy Management Mr. D.D.P.M. Gunathilake
Sustainable Engineering Mr.PrabathAbeysinghe
Waste Management Mr. P.M. De Silva
Water Management Mr. V.S.D. Weerasinghe
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2.1 Projects Followed during Training Period
2.1.1 AutoCAD Drawing βBradix Casualwear Seethawaka
2.1.1.1 Introduction
This was the first project that we had to work on after we recruit for Brandix. It was
really amazing because that was the first time we are sent to a Brandix factory too.
Usually in Seethawaka Brandix have two major plants as Denim Plant and Washing
Plant. These are two separate envelops and constructed different time periods though
they are in same brandix casualwear area. These days our energy management section
is planning to locate new boiler and power plant to fulfil the steam demand for both
factories. For this a detail plan of total area was needed for the suppliers and other
parties to proceed with the project. Brandix Denim plant has already got an AutoCAD
plan but washing plant drawing was not that much in detail.
2.1.1.2 Job role
Complete the two AutoCAD drawings and finalize the total plan for Brandix
Casualwear Seethwaka.
2.1.1.3 Description
First dimensions of washing plant have been measured and roughly mentioned them
on a printed plan. Then the AutoCAD plan for washing plant has been modified. The
problem was how to merge these two drawings in to a final drawing. Finally, after
investigation final drawing for Brandix Casualwear Seethawaka has been finished and
submitted to relevant authorities as shown in Annexure.
2.1.1.4 Improved Skills
Though we have practiced AutoCAD software at lectures, practical experiences
havenβt been gained. Therefore after this project I have found lots of problems arising
while observing, analysing and preparing a totally new drawing for a practical
example.
Furthermore I could go through the factory and get an idea of how it performs. There
were various processes regarding mechanical engineering and I was explained about
them for my further knowledge.
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2.1.2 AutoCAD Drawing β Plumbing Drawing for Brandix Seeduwa Factory
2.1.2.1 Introduction
As I mentioned above, the Seeduwa Brandix Casualwear factory is the heart of whole
brandix cluster, because it is the 1st factory which has got the LEED Platinum Award
in Sri Lanka. But the LEED certification is only valid until end of this year. Therefore
it has to be recertified during 3 months validation period. Therefore cluster engineers
have started to work on this. However we have sent to Seeduwa for supporting for
these processes. Mainly we have worked on 3 major functions under the instructions
of maintenance engineers Mr.KasunRaajapakshaand Mr.ShahenAmarathunga.
Prepare a plumbing drawing for whole factory
Find a solution for malfunctioning of Grease Trap
Water Management Project
Figure 2.1 : AutoCAD Drawing β Bradix Casualwear Seethawaka
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2.1.2.2 Preparation of Plumbing Layout
This plumbing layout of the factory I will beindispensable for the LEED certification
under new rules and regulations. Previously it was not that much required and there
was no proper drawing for that.
After exploring the area with the plumbing technician, we concluded that there are 5
major pipe lines laid around the factory.
- Drinking water Line
- Waste Water Line
- Air Conditioning Water Line
- Sewage Line
- Fire Water Line
All water lines are examined separately in each day and marked on a hard copy of a
factory plan. Then the AutoCAD drawing has been drawn including all required
data.Further we had to present to the maintenance engineering staff about the
structure of plumbing layout. After few modifications final drawing has been finalized
and sent to relevant authorities.
The drinking water system had lots of issues. Normally according to LEED
regulations a green factory cannot purchase water supply from national water board or
another external party. If they purchased because of unavoidable reason, the pints
allowed for that criteria would be lost. Because of that for drinking and washing
purposes, 2 deep wells are placed inside the factory area. After using them for long
time, a problem is discovered regarding quality of the water. We could see some sort
of white stones at the outlet of the taps and filters. This will make huge impact on all
parties using this water. Therefore we tired ourselves to find a proper solution for this.
This is explained further in the water management section.
Another thing that we have discovered through investigation, fire system is not
working properly in the plant No.2. Though fire extinguishers and other equipment
have already been fixed inside the plant, water supply is disconnected because of
leaks in the underground pipe. That will be a huge issue for the whole factory if it gets
fired. Therefore we instructed them to fix that problem and connect fire water supply
anyway.
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Figure 2.2 : Existing Fire Layout (Damaged)
This dash line indicates the pipes those are having leaks. Normally for fire pipe lines,
underground pipes should not be used because of the repairing issues. On the other hand this
pipe cannot be fixed as above ground pipe because it has to cross the road. Then they have
been asked to connect this to the fire line ended at the fire wood store room. That was
accepted and now the problem has been totally solved.
Other modifications will be included in the water management section regarding drinking
water line and waste water line.
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Figure 2.3 : Proposed Fire Layout
2.1.2.3 Improved Skills
Form this project I could understand how to design plumbing layout for a factory
and maintenance issues arise. It was a difficult task to work with technicians
because they had some sort of a feeling that they have to leave factory after
letting us to know everything they knew about the plant. But I explained them
that this is only documentation purposes and nothing will be happen
subsequently. That helped me to know how to manage people working under me.
Further I could learn how to draw properly a plumbing layout for a factory.
Further it helped me to improve my presentation skills.
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2.1.3 Electrical Drawing β LutronLighting System
Our customer needed to implement a new lighting system to his home. For the first time I
have heard about this light system which saves energy cost effectively. As we know, today,
energy efficiency is an essential element of every home and business. In fact, lighting can
account for up to 20% of a householdβs yearly electricity usage, and up to 40% a year in
commercial buildings. Lutron has been providing energy-saving light control solutions for
more than fifty years. When considering your options, keep in mind that Lutron dimming
saves energy without sacrificing style or convenience.
I have studied about the Lutron lighting system that will be much helpful for energy auditing
implementation. The drawing I prepared is shown in the annex.
2.1.4 Drawings for Brandix Lanka Ltd β For A/C Replacing Project
Brandix Lanka limited is luxurious, old building but air conditioning system is now not
working properly. Management has decided to replace this A/C packages with new ones.
This whole project is handed over to our department to handle. We visit the site first and went
through the drawings of the building. But drawings were only available for the 2nd floor and
3rd floor. For 1st and 4th floors, only hard copies were available. Therefore I have asked to
prepare drawings for missing floors.
Then we visit the site and marked all the a/c split systems available at the existing layout. We
had to make a list of them because they are going to be sold outside or use internal purposes.
And then new layout has been designed according to the space calculations.
It is shown below.
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Figure 2.4 : A/C Layout 1st Floor
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Figure 2.5 : A/C Layout 2nd Floor
Figure 2.6 : A/C Layout 3rd Floor
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Figure 2.7 : A/C Layout 4th Floor
Description 1st Floor 2st Floor 3st Floor 4st Floor
12,000 BTU/hr 3 1 3 3
18,000 BTU/hr 1 2 1 -
24,000 BTU/hr 3 5 5 4
Total 7 8 9 7
Table 2.1 : A/C Types and Qty.
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2.1.5 Grease Trap Modification Project
2.1.5.1 What is a grease trap?
Grease traps can be found in virtually all food service. By design, a grease trap not
only traps grease, but it also traps other solid food material. The purpose of a grease
trap is the on-site collection of food waste that would otherwise flow directly to the
municipal waste water treatment facility. As the waste collects, the trap becomes less
efficient and finally reaches the point where it becomes clogged and fails. Trap failure
results in drain back-ups and the release of obnoxious odors into the food handling
establishment. Once it has failed, the trap will require pumping and cleaning. The
result is added expense and inconvenience for the management of the food service
facility, and offensive odors for the patrons. As demonstrated, the use of BioLine's
specially selected bacteria will significantly reduce the need for pumping while,
controlling obnoxious odors commonly associated with a grease trap.
Figure 2.8 : Untreated Grease Trap
Figure 2.9 : Treated Grease Trap
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2.1.5.2 Condition of Grese Trap at Brandix Seeduwa
This grease trap was designed during the period the when the factory is striving
for getting LEED certification. I think because of the lack of time, space and
experience, this project havenβt been ended up with a failure. The size and the
location of the waste water tanks are not designed with a proper observations and
analysis. They have just designed only tanks which can flow water under
potential of gravity. When we asked to open the lids of each tank we could see
that as shown below.
Figure 2.10 : Condition of Brandix Seeduwa Grease Trap
2.1.5.3 Observations and failures
- The grease trap in brandix Seeduwa is not working properly
- Waste water is added to the grease trap from kitchen and the canteen wash basins
- Kitchen and Canteen waste water lines are connected to two separate initial tanks
for different processes of filtration and during the process both lines are then
pumped in to 3rd tank.
- Then, after further trapping processes it had been directed to the waste water
treatment plant located at the other side of the factory.
- As I heard, this has been functioning for around 3 months only. They discovered
that grease trap was not working properly and it causes malfunctioning the waste
water treatment plant. Then, management decided to disconnect grease trap
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connection with the waste water treatment plant and pumped it directly to the
drain outside the factory. This will be a huge issue and it breaks the LEED
regulations under the section of waste management. Further I heard that state
environmental authorities have been taken legal actions for this problem because
people living outside the factory have informed relevant authorities.
- At the initial tanks, solid waste filtering process is not functioning properly
because at the peak times during the lunch and breakfast, flow rate would be much
higher and then it would flow beyond the filters. Then it would mix with filtered
water and once again it becomes waste water.
- And when water level of the tanks reached to the maximum level, sludge would
enter into the pipes as shown in figure and would be transferred to the next tank.
- The lids which are used to cover the tanks are heavy and difficult to control
because those are made of some sort of a heavy metals. Normally grease trap lids
are made with transparent and light material for ease of handling and inspection.
- As I heard that the sludge will be removed once a month. But according to
standards this duration should be less than two weeks. If not some chemical
reactions will be occurred and pollute the environment. Nowadays also it emits
polluted air and beings to the environment.
- Lids and top concrete caps of the tank are not fixing well enough. Therefore it
leads to enter the rain water inside and fill tanks with water during rainy days.
Then sludge will sometimes flow out of the tank.
- The concrete starts to react with sludge and strength of the walls cannot be
compromised. Company has used basic concrete mixture to reduce the cost
effects.
2.1.5.4 Analysis
- Though we searched on the total drawing and details of the grease trap project we
could only find the drawings of kitchen water section only. Other part was missing
because that has been done earlier. Therefore using the plans and observations
gained with the help of the technicians, total drawing with dimensions has been
prepared for further proceedings, as shown below.
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Figure 2.11 : Grease Trap Layout
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Then volume of the tanks has been calculated and measured the total volume of the
grease trap.
- After that, technicians are instructed to measure the flow rate of the each inlet
pipeconnected to the initials tanks. We allocated a one person for this task and
asked him to measure the flow rate in 15 minutes intervals during the non-
occupied period and in 5 minutes intervals during the breakfast and lunch time. He
has given a data sheet and end of the day we collect them. We have done this
consecutively 4 days. Then calculated the average values in each time period and
came up with the peak flow rate that will be occurring during the lunch hour. This
will be the key factor to design the grease trap accurately. Reason is that if it is not
designed for the peak flow rate, all the solid waste collected by the filter will be
flushed out to the next tank because of not having enough space to store waste
water.
- Manipulating all the observations grease trap has been redesigned by changing the
volumes and the structure.
2.5.5 Solutions
- For the further proceedings of the project, Dr.Jayasinghe from civil department of
university of Moratuwa has been invited. We were so proud to work with our
lecturer in same project. He visited our site and discovered the condition of the
grease trap and went through the documents we already prepared. He
implemented some instructions to follow for solving the grease trap issue.
Redesigning the tanks (specially initial tanks) according to the peak flow rate
volume calculations
Replace filter nets with newly introduced nets that could filter tiny solid particles.
Previously sludge has been cleared by an outside party per 1 one month or once a
fortnight. But according to flow rate calculations, that duration is not enough to
maintain the tanks properly. According to doctorβs calculations, the sludge should
be cleaned once a week. But there was a problem with that company who buy
them because they are unable to visit brandix only for collecting small amount of
sludge. They explained that it is much expensive to come 4 times per month and
refused to collect sludge. Then factory directors decided to construct a new tank
for collecting sludge for one month and ask the relevant party to collect the sludge
directly.
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2.1.6 Water Management Project
2.1.6.1Drinking Water Problem
2.1.6.1.1 Introduction
As I mentioned before, the condition and the quality of drinking water turning out to be a
huge problem currently. All workers and staff is complaining about this mentioning that
they canβt use this water for drinking purposes because it is hard water. Therefore most of
people use this water only for washing purposes and they used to bring drinking water
from outside. Normally Brandix Seeduwa plant gets water for drinking purposes from 2
deep wells located inside the factory because they cannot be purchased water from outside
according to LEED policies.
2.1.6.1.2 Observations
After listening to the people who are suffering from this problem, we observed the drinking
water line to check out what is the fault. Observations are as follows.
We could observe that big snow white, much stronger stones are collected in filters.
According to the technicians, they would collect about 1kg of these stones per day.
Those stones could be seen at the end caps of the taps which are used for drinking
purposes.
White layer of material has been deposited inside walls of the boiling instruments
such like kettles and hot water bottles.
2.1.6.1.3 Analysis
A sample of this deposit has been sent to Dr.Jayasingheβs testing laboratory. Still they are
being tested to clarify what are the ingredients of the solid material.
Normally water samples are checked per 2 months and check the quality of the water. A test
report of one month has been attached below.
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2.1.7 Lighting Simulation Projects
2.1.7.1Introduction
Lighting is a main component in building designing. If the lighting system is not efficiently
designed, building owners have to allocate large amount of their profit for electricity bills.
Usually architectures design the lighting system according to customer needs but prioritizing
their architectural procedures. Their main intention is to be added beauty to the building
envelop. Because of having limited engineering background, they are not striving for
designing detail lighting system. But bad effects can be experienced after few months when
they are received a huge electricity bill or lighting level is lower or higher for the relevant
task. Sometimes it effects to the A/C system directly because the load levels may be variate
because of inefficient lighting system.
When we visit brandix factories, usually we could see bad effects of inefficient lighting
designing. Less than half of lights are used in each light panelshaving 4 or 6 lights in row.
Reason is that few lights will be given sufficient lux levels needed for the task going on. The
other lights are short circuited or removed. As another example, they are still used artificial
lights in sky lighted areas. Mostly we can see this in factory stores where lux level should be
much lower. Further, in factories halogen lights have been used which are highly electricity
consumable.
Therefore in Brandix Lanka Energy Division always concern about these problems and help
them to solve the energy issues. Normally there are 2 major sections are being focused in our
lighting analysis. That is artificial lighting and natural lighting. For these analysis and
calculations, few software are being used include DIALUX. These steps are followed when
performing detail lighting simulation.
1. Collecting preliminary data (Auto CAD drawing of the building envelop, electrical
and lighting design, Electricity bills, consumption of light bulbs per week etc.)
2. Site visit and further observations
3. 3D modelling the total building envelop with separate room elements
4. Place lights according to the existing lighting drawing
5. Detail Lighting simulation
6. Introducing efficient lighting design with latest technologies, low cost, low pay back
period
7. Implementation with new lighting design
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2.1.7.2 Project 1- Batticlao Brandix Sport Complex
2.1.7.2.1 Introduction
This project is about a proposed sport complex for Brandix Batticaloa. It consists of Netball,
Basketball, Badminton and Volleyball courts. For lighting purposes, normally it is used
special luminaire system for Sport Complexes because the required lux level is much higher.
Therefore usually sodium vapour flood light are used for these kinds of purposes because of
the higher lux levels like more than 30000lm and the high range of spreading. But they can
make a huge effect to the electricity bill because power consumption is much higher. Not
only that, the surrounding is heated up quickly and it will be uncomfortable for the players.
But nowadays, LED technology is vastly developed, and new LED lights have been
introduced for higher lux level requirements with huge power saving. Usually we are updated
with new luminaire products in China and German.
By the way, the lighting designer has sent us the proposal that they are going to implement
lights for this complex using sodium vapour lights. But we have introduced new lighting
design using LED lights and compared with their system. I have given the following structure
as shown in figurethat they are going to implement. And the proposal for the existing lighting
design has been attached with ANNEx.
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Figure 2.12 : Lighting Layout of Sport Complex
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2.1.7.2.2 Simulation β Sodium Vapour Lights
According to the information received the 3D model of the sport arcade has been drawn using
DIALUX. And the lights are located on poles in correct angles and positions as they have
designed and end up with the final simulation. The final report has been attached in the
annex.
2.1.7.2.3 Luminaire Detail
Figure 2.13 : Details of Sodium Vapor Flood Lights
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2.1.7.2.4 Calculation Results of each court
Table 2.2: Textual Table for Basketball Court
Table 2.3 : Textual Table for Volleyball Court
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Table 2.4 : Textual Table for Badminton Court
2.1.7.2.5 Lighting Energy consumption
Table 2.5 : Energy Consumption Analysis
2.1.7.2.6 Simulation β LED Flood lights
In this simulation, all the sodium lights are
replaced with LED flood lights and did
the new simulation keeping the other
parameters constant. The details of the
luminaire are as follows.
Figure 2.14 : Details of LED Flood Lights
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Replacing these lights with sodium vapour lights was not that much easy because we have to
optimize the number of lights, angle of poles and bars and position to get fix with the same
lux levels. In this design we focus on few major targets to achieve.
1. Reduce the power consumption
2. Reduce the heat generation and make comfortable environment
3. Minimize the initial cost for the project or short payback period
For achieving these targets we should not make any effect to the lux levels because then our
main target of constructing the complex will be fail. First I discovered the number of lights
that we have to be used to get the same lux. According to simulation, roughly 5 LED flood
lights have to be located instead of 3 SV lights per pole. And further, no need of changing the
angle of the lights because these types of lights are more dispersal.
Sodium Vapour Light
LED Flood Light
Figure 2.15 : Comparison of SV lights and LED Lights
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Finally better solution has been introduced after the final simulation report. It has been
attached in the Annex.
Calculation Results of each courtae shown in figures below.
Figure 2.16 : Calculation sheet of Basketball Court
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Figure 2.17 : Calculation Sheet of Badminton Court
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2.1.7.2.6 Results
According to tables and iso line graphs indicate that the new design reached to the average
lux level of the existing lighting system. And comparing with the previous simulation, in this
one lux levels become more dispersal.
Table 2.6 : Energy Comparison of Two Designs
Figure 2.18 : Calculation Sheet of Volletball Court
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Energy Comparison
Energy Consumption per month (kWh) β Sodium Vapour System = 92 kWh
Energy Consumption per month (kWh) β LED Flood Lights = 71 kWh
Energy Saving per month = 21 kWh
2.1.7.2.7 Finalizing and Implementation
By considering above calculations and final reports, approval has been received to further
implementation for the new energy efficiency lighting design. After that, a new 3D model has
been designed to get a better view of the new sport complex at Batticaloa.
Figure 2.19 : Final 3D Model for Sport Complex - Batticaloa
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2.1.8 Skylight Project β Brandix Awissawella
Brandix Awissawella factory consists of 2 main plants of washing and denim plant. In denim
plant all the production lines are located and washing plants is used for subsequent processes
after finishing them. Maintenance Engineers have proposed to fix skylights to the denim plant
because they have to spend huge amount from their profit for energy costs. Therefore our
department was asked to handle the project.
In this case the skylight suppliers have sent a proposal for the project mentioning how they
are going to proceed with the project. But we found some mistakes in that proposal. Then that
proposal has been rejected and a new design has been proposed by our department with a
detail daylight simulation. To confirm that the skylight design is suitable, we usually use
following thumb rule.
π¨πππ ππ πππ πππππ πππππππππ
π¨πππ ππ πππ πππππ ππππππππ ππππ X 100 β 3 %
Total Skylight plan β Annex
Using Dialux software, I have calculated lux levels of each area by locating skylights in a
accurate design. Details of skylights used and lux levels of each section are mentioned below.
2.1.8.1 Design Criteria
1 Production Floor
Floor Area - 3,424.63 m2
Required roof area - 130.76 m2
Selected Size - 4' x 4' & 4' x 8'
Required No of Units - 4' x 4β: 22 nos& 4' x 8β: 33 nos
Anticipated Light Level -(400-600) lux on clear sunny day
2 Cutting area
Floor Area - 797.04 m2
Required roof area - 29.72 m2
Selected Size - 4' x 8'
Required No of Units - 10 Nos.
Anticipated Light Level - (400-600) lux on clear sunny day
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3 Raw Material Store
Floor Area - 1,188.18 m2
Required roof area - 32.69 m2
Selected Size - 4' x 8'
Required No of Units - 11 Nos.
Anticipated Light Level -(300-400) lux on clear sunny day
4 Extension - Production Area
Floor Area - 1,102.15 m2
Required roof area - 41.61 m2
Selected Size - 4' x 8'
Required No of Units - 14 Nos.
Anticipated Light Level -(400-600) lux on clear sunny day
2.1.8.2 Details of skylights
U Value - 0.74
Visible Light Transmission - 0.68
Solar Heat Gain Co-efficient - 0.42
Warranty 10 Years for Yellowing including the structure
100% Full spectrum lights, 80%-100% UV is blocked and heat transmittance through
Skylight 50% less than the electrical lighting system.
Can Save Electricity up to 90% during the day time.
Figure 2.20 : Deatails of Skylights
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Floor Area
No. of
Skylights Total
Skylight Area
Area
(mxm) (X)
Skylight
Area (mxm) (Y)
X/Y %
8'x 4' 4'x 4'
Finishing 1102141500 14 0 41606908 1102.14 41.61 26.48938729 4%
Production 3424623400 33 22 130764568 3424.62 130.76 26.1892304 4%
Cutting 797040000 10 0 29719220 797.04 29.72 26.81900804 4%
Raw
Material
Store
1188180000 11 0 32691142 1188.18 32.69 36.34562537 3%
Total 6511984900 68 22 234781838 6511.98 234.78 27.73632303 4%
Table 2.7: Skyloght Calculations for Each Section
We have to cover large area in production floor. Therefore few designs were introduced by
the company and we have analysed what is the best option.
Floor Area
No. of
Skylights Total
Skylight Area
Area
(mxm) (X)
Skylight
Area (mxm) (Y)
X/Y
Avg.
Lux Level 8'x 4' 4'x 4'
Design 1 3424623400 33 22 130764568 3424.62 130.76 3.8% 525
Design 2 3424623400 33 0 98073426 3424.62 98.07 2.9% 405
Design 3 3424623400 22 22 98073426 3424.62 98.07 2.9% 401
Design 4 3424623400 33 6 106989192 3424.62 106.99 3.1% 435
Table 2.8 : Designs of Skylight Calculation for Production Area
Therefore according to our calculations we have chosen the 4th option which gives optimum
lux level and skylight area to floor area ratio is in the acceptable region.
Final Skylight simulation report for Brandix Awissawella is attached to the annex.
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2.2 Study of Boilers
A boiler is an enclosed vessel that provides a means for combustion heat to be transferred to
water until it becomes heated water or steam. The hot water or steam under pressure is then
usable for transferring the heat to a process.Water is a useful and inexpensive medium for
transferring heat to a process. When water at atmospheric pressure is boiled into steam its
volume increases about 1,600 times, producing a force that is almost as explosive as
gunpowder. This causes the boiler to be an equipment that must be treatedwith utmost care.
The boiler system comprises of: a feed water system, steam system and fuel system. The feed
water system provides water to the boiler and regulates it automatically to meet the steam
demand. Various valves provide access for maintenance and repair. The steam system
collects and controls the steam produced in the boiler. Steam is directed through a piping
system to the point of use. Throughout the system, steam pressure is regulated using valves
and checked with steam pressure gauges. The fuel system includes all equipment used to
provide fuel to generate the necessary heat. The equipment required in the fuel system
depends on the type of fuel used in the system.
2.1.1 Structure of Basic Boiler System
For a standard boiler system, following components must be existed.
1. Boiler(Vertical/ Horizontal)
2. Burner
3. Feed water treatment
plant
4. DE aerator
5. Economizer
Figure 2.21 : Structure of a
Boiler System
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2.2.2 Types of Boilers
I have sent many Brandix plants for understand and get familiar with boilers. According to
records, there are many types of boilers in Brandix factories. Most of them are new, but in old
factories still they are using coal steam boilers.
1. Fire Tube boiler
In a fire tube boiler, hot gases pass through the tubes and boiler feed water in the shell
side is converted into steam. Fire tube boilers are generally used for relatively small
steam capacities and low to medium steam pressures. As a guideline, fire tube boilers
are competitive for steam rates up to 12,000 kg/hour and pressures up to 18 kg/cm2.
Fire tube boilers are available for operation with oil, gas or solid fuels. For economic
reasons, most fire tube boilers are of βpackagedβ construction (i.e. manufacturer
erected) for all fuels.
Figure 2.22 : Fire Tube Boiler
2. Water Tube Boiler
In a water tube boiler, boiler feed water flows through the tubes and enters the boiler
drum. The circulated water is heated by the combustion gases and converted into
steam at the vapour space in the drum. These boilers are selected when the steam
demand as well as steam pressure requirements are high as in the case of process cum
power boiler / power boilers. Most modern water boiler tube designs are within the
capacity range 4,500 β 120,000 kg/hour of steam, at very high pressures. Many water
tube boilers are of βpackagedβ construction if oil and /or gas are to be used as fuel.
Solid fuel fired water tube designs are available but packaged designs are less
common.
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In Brandix Girithale plant, steam demand is supplied by these type of boiler.
Figure 2.23 : Water Tube Boiler
3. Package Boiler
This is the most popular type of boilers in Brandix factories. Usually in Brandix
Seeduwa, Katunayake and Rathmalana has got package boilers.
The packaged boiler is so called because it comes as a complete package.
Once delivered to a site, it requires only the steam, water pipe work, fuel supply and
electrical connections to be made to become operational. Package boilers are
generally of a shell type with a fire tube design so as to achieve high heat transfer
rates by both radiation and convection.
Figure 2.24 : Package Boiler
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The features of packaged boilers are:
Small combustion space and high heat release rate resulting in faster evaporation.
Large number of small diameter tubes leading to good convective heat transfer.
Forced or induced draft systems resulting in good combustion efficiency.
Number of passes resulting in better overall heat transfer.
Higher thermal efficiency levels compared with other boilers.
These boilers are classified based on the number of passes - the number of times the hot
combustion gases pass through the boiler. The combustion chamber is taken, as the first pass
after which there may be one, two or three sets of fire-tubes. The most common boiler of this
class is a three-pass unit with two sets of fire-tubes and with the exhaust gases exiting
through the rear of the boiler.
2.1.5 Deaerator
A deaerator is a device that is widely used for the removal of oxygen and other dissolved
gases from the feed water to steam-generating boilers. In particular, dissolved oxygen in
boiler feed water will cause serious corrosion damage in steam systems by attaching to the
walls of metal piping and other metallic equipment and forming oxides (rust). Dissolved
carbon dioxide combines with water to form carbonic acid that causes further corrosion.
Figure 2.25 : Deaerator
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2.2.6 Economizer
In boilers, economizers are heat exchange devices that heat fluids, usually water, up to but
not normally beyond the boiling point of that fluid. Economizers are so named because they
can make use of the enthalpy in fluid streams that are hot, but not hot enough to be used in a
boiler, thereby recovering more useful enthalpy and improving the boiler's efficiency. They
are a device fitted to a boiler which saves energy by using the exhaust gases from the boiler
to preheat the cold water used to fill it (the feed water).
Figure 2.26 : Economizer
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2.9 Tri Generation Power Plant (MCP) Project β Textured Jerzy (Seethawaka)
2.9.1 Introduction
Textured Jersey Lanka PLC is a public listed company,Avissawella, is a joint venture of
Pacific Textiles Holdings Limited and Brandix Lanka Limited. The major intentions of
installing a Combined Heat and Power system are reducing the consumption of grid
electricity and furnace oil whilst reducing the carbon foot print. The main objectives of this
project are,
β’ Replacing existing furnace oil fired boilers to cater the steam demand of production
β’ Generating electricity to reduce the main grid dependency
β’ Catering the Air Conditioning demand of facility
I was asked to involve with this project at the initial stage to compromise the experiences in
power plant projects. This project was initiated during the August. Initial discussions have
been carried out by the head engineers and came up with a rough design structure of the
power plant. Then I have asked to model a 3D design for the proposed structure. Images of
the 3D model are shown below.
Figure 2.27 : 3D Model of the Power Plant
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After modelling this I have been asked to prepare total calculation sheet for the total process
that can be adjustable. That was actually a difficult task because calculations are really
difficult in the liquid phase and the liquid-Steam phase. Nevertheless, enthalpy, entropy and
dryness factors are calculated for each point and prepared a total calculation sheet for the
power plant process. That is shown in figure
Variables
P1 65 bar P2 65 bar P3 7 bar P4 0.1 bar
T1 500 Β°C T2 500 Β°C T3 244 Β°C T4 45 Β°C
h1 3416.4 kJ/kg h2 3416.4 kJ/kg h3 2941.18 kJ/kg h4 2383.45 kJ/kg
s1 kJ/kg-K s2 kJ/kg-K s3 kJ/kg-K s4 7.5199 kJ/kg-K
x4 0.9159
Table 2.9 : CHP Power Plant Enthalpy and Entropy
Figure 2.28 : Power Plant Structure
2.9.2 Calculations
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Boiler Capacity 20 Tons/hour
Boiler Efficiency 80 %
Calorific Value of Coal 26000 kJ/kg
Enthalpy of feedwater (80Β°C, 1 Bar) 334.96 kJ/kg
Boiler Output Steam Pressure 6.5 MPa
Boiler Output Steam Temp 500 Β°C
Boiler Output Steam Enthalpy 3416.4 kJ/kg
Energy Output of Boiler 17119.11 kW
Coal Consumption 0.823034 kg/s
Coal Consumption 71.11015 Tons/Day
Steam consumption per unit of fuel 6.750091 kg/kg
10 Bar steam consumption 3 Tons/hour
Energy output of 10 Bar steam 2567.867 kW
7 Bar Steam Consumption 10 Tons/hour
7 Bar Steam Enthalpy 2941.18 kJ/kg
Energy output of 7 Bar steam 7239.5 kW
Turbine Input Steam 17 Tons/hour
Turbine Input Steam Pressure 6.5 MPa
Turbine Input Steam Enthalpy 3416.4 kJ/kg
Process Tap off Steam 10 Tons/hour
Process Tap off Steam Pressure 0.7 MPa
Process Tap off Steam Enthalpy 2941.18 kJ/kg
Turbine Output Steam 7 Tons/hour
Turbine Outut Steam Pressure 0.01 MPa
Turbine Output Steam Enthalpy 2383.45 kJ/kg
Turbine Efficiency 65 %
Turbine Power Output 2163.57 kW
Absorption Chiller Capacity 650 TR
Absorption Chiller Energy Output 2275 kW
Steam Input into absorption chiller 3 Tons/hour
Steam into cooling tower 4 Tons/hour
System Efficiency 83.21657 %
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After the initial clarifications, Textured Jerzy has officially given the permission to start the
CHP project. But the previous structure of the power plant has been changed bit according to
some technical modifications. I was asked to prepare the new layout using Microsoft Visio
and it is shown below.
Figure 2.29 : Proposed Mew Power Plant Layout
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1.1 Site Condition
β’ Site is around 50km away from Colombo.
β’ Site is located in a BOI Export Processing Zone.
β’ Site coordinates are 6Β°57β²11β³N 80Β°13β²06β³E
β’ Site average weather conditions are as follows
Month
Temperature Β°F Average Rainfall
(mm) Average
snow
days
Average
Fog days Average Absolute Daily Monthly
max min max min
January 89.4 72.3 98.6 58.6 1.1 33.6 0 0
February 90.7 73.0 102.9 52.5 1.9 52.1 0 0
March 90.5 75.0 100.9 46.4 2.2 68.9 0 0
April 90.0 76.6 99.7 71.4 5.8 173.9 0 0
May 88.7 78.8 98.6 68.0 6.3 194.9 0 0
June 86.9 78.8 102.6 68.2 3.4 102.2 0 0
July 86.2 78.3 90.5 52.7 2.4 75 0 0
August 86.7 78.4 96.8 68.4 2.2 67.6 0 0
September 87.1 77.4 103.1 68.2 3.8 113.4 0 0
October 86.5 75.9 100.8 71.2 9.8 302.7 0 0
November 87.1 74.5 102.4 46.0 8.3 247.9 0 0
December 88.0 73.2 95.2 64.4 2.4 75.6 0 0
Table 2.10 : Site Condition
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2.10 Basic Project Design & Main Equipment
Equipment Description Remarks
Boiler Coal fired boiler
Flue gas emission control
Ash control
Coal feeding
A 25TPH (F&A 1000C) AFBC boiler runs
with superheated steam at 45 bar and 5000C. Hot water around 900C shall be
feeding to the boiler. An ESP shall be installed to adhere with
the air quality standards.
Ash control mechanism to be clearly mentioned in the quotation
Coal feeding mechanism with coal crushing method has to be clearly
mentioned in the quotation. Conveying system to be fully covered to avoid the spread of coal dust.
Requirement of intermediate storage to be
provided with all the details.
Steam turbine-generator
Backpressure turbine and no-break generator
Turbine in shall be steam at 45bar and 5000C and saturated steam around 1100C β
1200C to exit from the turbine. 15TPH steam at 8bar to extracted for the
process. Turbine and generator shall be coupled through a gear reduction with appropriate
governing mechanism. Turbine shall be sound proof to adhere
with noise level standards as the attached guidelines
Chiller Absorption chiller runs
on LiBr-Water
Steam exits from turbine shall be directed
through an absorption chiller and hot water around 900C shall be feeding to the boiler. Requirement of a cooling towers to be
verified by the absorption chiller supplier.
Integrated Control System
Boiler
PLC based fully automated control system to be installed to control all the parameters
of the boiler including Pressure and Temperature as per the demand variation in the turbine. This control system should
address from coal feeding to steam out. All the protection alarms should
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Turbine Chillers
Electric System
All the governing mechanism and steam variation to be handled automatically. All the electrical protection including high
protections High voltage / under voltage / differential voltage / phase unbalance / low
frequency / high frequrncy / Critical alarms and general / critical shall
followed by appropriated shut down process.
Table 2.11 : Basic Project Design & Main Equipment
2.10.1 SYSTEM SPECIFICATIONS
2.10.1.1Boiler
A Coal Fired Boiler should be installed.
Boiler is preferred to be an AFBC with 75% or higher efficiency on GCV.
Capacity of the boiler steam generation capacity should be minimum 25TPH (F&A 1000C) at
45bar and 5000C.
Boiler control system shall include but not limited to followings monitoring and controlling
mechanisms:
Coal feeding
Coal bunker level
Feed water temperature and flow rate
ID and FD fans with VSD
Boiler drum water level
Steam out temperature, pressure and flow rate
2.10.1.2 Steam Turbine
System should comprise of a backpressure steam turbine and a driven no break synchronous
generator with a 0.9 or higher power factor.
The system shall include, but is not limited to: generator, coupling, turbine, cooler, piping, valves, governor, control and distribution board, including all control devices, signals, alarm and electrical & mechanical protection devices.
The unit shall be suitable for indoor use in a refinery atmosphere and maximum ambient temperature of 50oC.
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Turbine in is assumed to be at 45bar and 5000C. 15TPH steam to be extracted at 8bar
pressure for the process. Turbine out shall be wet steam at 1100C β 1200C temperature.
The turbine shall be provided with the following protection devices:
Low pressure switch lubricating oil
Low pressure switch regulating oil
High temperature switch lubrication and regulating oil
Low temperature switch regulating oil
Low flow switch cooling water
Over speed turbine
Low oil pressure will close the governor and stops the turbine
Coupling guard.
The turbine shall be provided with the following indicating and alarm devices:
Actual steam pressure and temperature
Steam pressure exhaust
Lubricating oil pressure
Regulating oil pressure
Temperature oil
Differential pressure of filters
Temperature cooling water on both sides of the cooler
Speed indicator
Cooling water flow indicator
The oil cooler shall be provided with the following devices:
Hand control valve cooling water
Thermometer cooling water
Thermometer in oil circuit
The cooling water hand control valve shall be mounted on the outgoing cooling water side of the oil cooler.
The low flow switch cooling water shall be mounted between hand control valve cooling water and outgoing side cooling water oil cooler.
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2.10.1.3 Generator
Generator shall be of the self-ventilated type with curved blade ventilator, mounted within the generator. Exhaust of the air is on the turbine side.
The ambient temperature of the generator will be maximum 50oC.
Voltage regulating equipment shall be mounted in the panel board.
There shall be two regulators: one automatic set and one hand set.
Changing from automatic regulator to the hand one, will be done when unit is in service and
shall stay in service and generator is working on hand control on normal voltage. Panelboard shall be protected in such a way that it is not dangerous to do this change.
2.10.1.4 Absorption Chiller
Absorption chiller shall run with LiBr-Water solution with a cooling capacity of minimum 550TR.
Chilled water out shall be 80C.
On stand-alone basis, it may assume steam in to the chiller shall be at maximum 1100C wet steam
(lower the better) and steam flow rate through the chiller at full load shall be maximum 5,000 kg/hr.
Chiller shall have been designed to withstand steam at maximum 8bar pressure.
Cooling water in shall be assumed at 300C.
Requirement of cooling towers should be provided.
2.10.1.5 Electro-Static Precipitator
Maximum permissible emissions of ESP are as follows,
NOx < 500 mg/cu.m
SO2 < 850 mg/cu.m
Smoking Opacity < 20% PM < 150 mg/cu.m
After clarifying the requirements for the power plant, Mr.Iresha and Mr.Anuruddha have
prepared a bid document to send to bidders for this total project. I was asked to join with with
them to learn how to prepare a Bidding Document for a power plant. These days project is
not running because bidders have been given much time to prepare their documents. During
the next two months I was asked to work for that CHP project.
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2.11 Solar net metering project - Mr. Feroz Omarβs house
2.11.1 Project Description
This project was carried out to observe the performance of the solar photovoltaic system
installed at Mr.Feroz Omarβs house, 29/6, Guildford crescent, Colombo 07. This system has
been operating for two months of period with a net metering system, which is to bill for the
absolutes consumption from the national grid. The observations were carried out on 26 th and
27th June throughout the day.
Here is a brief lay-out of the existing system.
The electricity generation from the PV system is continuously measured by the Web Box. The main objectives of this project are,
1. Verifying the proper working of the system
2. Verifying the accuracy of online metering data through Web Box
3. Verifying the accuracy of CEB billed data
In order to accomplish above objectives, Energy analyzer were installed at three different
places to 1. Measure the electricity generation from PV system (M1)
2. Measure the house electricity consumption (M2)
Figure 2.30 : Structure of Solar System
Electricity consumption from national grid and feeding to the grid (M3)
In addition, temperature readings of PV panels were taken throughout 26 th to confirm the operated efficiency of the system.
WEB
BOX
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Figure 2.31 : Placement of Utility Meters
2.11.2 Observations, Measurements and Analysis
Generation Data:
26th Tuesday was a sunny day. According to the online metering data, 33.6 kWh have
been generated throughout the day. The logged data shows 21.6kWh from 12.00 p.m
till the end of the generation for the day, whilst online data shows 21.0kWh within the
same period.
27th Wednesday was a bit cloudy day, thus generation has been recorded lower than
average figures. Online records shows 22.8 kWh generation and logged data confirms
it by showing 22.6 kWh generation throughout the day.
The summery is as follows,
WE
B
BO
X
M1 M2
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kWhr
26th (12 Hours)
12.00 PM to 12.00
AM
27th (24 Hours)
12.00 AM to 12.00
AM
Solar Generation (Online record) 21.0 22.8
Solar Generation (Logger data) 21.6 22.6
Total House Consumption (Solar +
Grid)
21.3 51.7
Absolute Consumption from Grid 02.8 22.9
Table 2.12 : Readings of Power Meters
After comparing with the logged data, the accuracy of online system readings was
verified for accuracy.
An analysis was done with past 6 months billed data and July billed data to verify the impact
of solar system on July bill.
Units
(kWhr)
Monthly
charge
(LKR)
Monthly
charge
according to
the new tariff
(LKR)
2011 July 1,433 48,212 66,982
2011 August 1,415 47,301 66,075
2011 September 1,708 57,717 80,842
2011 October 1,740 58,869 82,455
2011 November 1,616 54,537 76,205
2011 December 1,239 40,701 57,204
2012 February 1,437 47,961 67,184
Monthly Average 1,513 50,757 70,992
Expected Monthly Generation from Solar Panel 900
Expected absolute consumption from Grid
(after installation of solar panel) per month 613 30,673
Expected absolute consumption from Grid
(after installation of solar panel) per day 20.4 -
Table 2.13: Tariff Analysis after Solar System Connected to the Grid
It can be observed the measured absolute consumption from the grid on 27 th (22.9
kWh) is almost same as the predicted daily absolute consumption from the grid (20.4
kWh)
The daily generation for last 30 days was recorded as follows
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Figure 2.32 : Graph for Solar Generation during Past 30 Days
It can be observed daily generation is being varied between 18 kWh β 33.6 kWh
(maximum expected) depend on the weather condition.
Saving analysis for July is as follows,
Solar system generation for last 30 days 803 kWhr
Home consumption from grid 1,281 kWhr
Given to the grid from solar panel 371 kWhr
Home consumption from solar panel 432 kWhr
Total home consumption 1,713 kWhr
Charged units 910 kWhr
Units saved by Solar panel 803 kWhr
Cost saving for July 40,471 LKR
Table 2.14 : saving Analysis
Shading was observed on over half that panel (closest to balcony) during peak
generation times (shaded by the roof). This will affect the entire string efficiency and
cause a large generation loss.
Another panel was also shaded during the morning hours. This was from the thambili
tree.
0
5
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15
20
25
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35
403
0-M
ay
31-M
ay
1-J
un
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kW
h
Solar Generation During Past 30 Days
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2
Figure 2.33 : Failures in the Solar Panels
2.11.3 Conclusions
1. Online measuring data through web box is correct.
2. No error with the CEB billed data, since June can be a high consumption month like
2011 September and October.
3. The whole system has been affected by the lower generation of shaded panels.
4. System has not been working at 100% efficiency within July, due to extreme weather
conditions.
5. According to the new electricity tariff, around 40,000 β 50,000 LKR of monthly bill
can be saved with the existing system. This is not clearly reflected due to the increase
of tariff.
6. Compared to the same kind of buildings, the consumption is higher than average
values
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2.11.4 Recommendations
Even after the installation of solar PV system, 600 β 700 kWh are consumed monthly. Two types of recommendations can be given to eliminate or to reduce the grid consumption.
1. Increase Production
2. Reduce Demand
To increase the production, following recommendations can be given,
The shading panel to be moved above adjacent panel.
Install 6 new panels in front of the balcony area to increase generation to 40kWh per day (at 100% efficiency). This will add another 1.5kW of generation bringing the total
to 9.5kWp.
Thambili tree branches need to be cut to improve generation.
High pressure washer should be used to clean bird droppings, leaves and other spots
left on the panel.
To reduce the demand, following recommendations can be given,
Electrical water heater to be removed from electric grid to test its performance and establish its functionality. Electrical hot water system consumes unnecessary demand
of 300β400 kWh monthly.
If the existing solar hot water system is not sufficient, it is recommended to install another 1 or 2 units to outfit the hot water demand.
Following results are expected, after implementation of all the recommendations.
Min Max
Monthly demand to be covered 600 700 kwh
Current solar system generation 800 900 kWh
Increase of generation by replacement of panels 2% 3%
Increase of generation by upgrading of panels 15% 18%
Generation after recommendations 938 1094 kWh
Extra Generation 138 194 kWh
Reduction of demand after replacement of hot water
systems 300 400 kWh
Grid consumption after recommendations 162 206 kWh
Electricity Bill 2,923 5,141 LKR
Figure 2.34 : Expected Generation after Modifications
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Figure 2.35 : Graph for Energy Consumption of House
-
1,000.0
2,000.0
3,000.0
4,000.0
5,000.0
6,000.0
7,000.0
8,000.0
WEnergy Consumption of House
26th June 27th June
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-
1,000.0
2,000.0
3,000.0
4,000.0
5,000.0
6,000.0W
Power Generation from Solar Panel
26th June 27th June
Figure 2.36 : Graph for Power Generation from Solar Panels
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Figure 2.37 : Graph for Grid Consumption
-6,000.0
-4,000.0
-2,000.0
0.0
2,000.0
4,000.0
6,000.0
8,000.0W
Grid Consumption
26th June 27th June
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2.12 Waste Management Project
2.12.1 ETP Sludge Co- Processing Project
2.12.1.1 Introduction
Considering that environment and workspace, Brandix Textile Ltd was searching for a
solution for the effluent discharging from the BTL premises. BTL has biological and
chemical treatment plant as effluent treatment unit. With this unit it will generate sludge as a
mixture of biological and chemical waste. In this effluent treatment plant it is treated 2800m3
per day and almost 7000kg of sludge will be generated.
Because of they cannot be used as a land fill as per the standards of CEA it has to be used for
compost or incinerated material.
But in BTL it has a coal boiler. It is used 40,000kg of coal as the fuel for boiler to fulfil the
steam demand of the factory. Therefore this project is about to propose an efficient method to
use this solid sludge waste as a fuel for the boiler instead of coal. Preliminary tests have been
done to check whether it is possible to use this sludge for this purpose because it includes
chemical contents. And reports proved that no effects will be occurred because it is heated
up to higher degrees.
After that, calculations have been done to clarify the amount of coal can be saved if this is
used. Calculations are shown below.
2.12.1.2 Heat Calculation
Daily sludge generation amount
7,000 kg
Moisture content from belt press
80 %
Solid content of the sludge
1,400 kg
Amount of sludge can be generated (with 20% moisture) per day
1,750 kg
Amount of water content included
350 kg
Energy content of sludge (with no moisture content)
11,685 kJ/kg
Amount of heat generation per day from sludge
16,358,580 kJ
Specific heat of water
4.187 kJ/kgoK
Latent heat of evaporation of water
2,270 kJ/kg
Energy needed to evaporate 20% moisture content from sludge
897,082 kJ
Net amount of heat generation per day from sludge
15,461,499 kJ
Higher Heating Value (HHV) of Coal
26,800 kJ/kg
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Energy needed to increase temperature of moisture from 30-100 C
293 kJ/kg
energy needed to evaporate water (Liquid to Vapour phase)
2,270 kJ/kg
Lower Heating value (LHV) of coal (16% Moisture)
24,237 kJ/kg
Amount of coal saving by mixing with sludge per day
638 kg/day
Amount of coal saving by mixing with sludge per day
510 kg/day
2.12.1.3 Recovery
Reduction of coal useage per day
510 kg/day
Reduction of coal useage per month
15 MT/month
Cost of 1 MT of coal
165 USD/MT
Cost of Coal Saving
2,526 USD/month
Operating cost (Labour and Elecricity)
520 USD/month
Savings from project
2,006 USD/month
Total project cost
12,269 USD
Simple payback period
6.12 Months
2.12.1.4 ETP Sludge Drying Process
As per the above analysis there is 80% moisture is present in sludge and this has to reduce at
least 20% before it used in to coal boiler as fuel.
For removing additional moisture content, extra heat energy should be supplied externally.
For this process it is meaningless if we spend for this energy supply. Therefore the heat
sources which are available free to environment without having use of it. There are 4 sources
were found that can be supplied considerable heat for the process.
Thermic Heater (Boiler) exhausts
Furnace oil steam boiler exhaust
Coal fired boiler exhaust
Stented m/c exhaust
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By analysing of flu gas temperatures Stenter out puts are between 100-110 0C and when it try
to use it averagely 10-15 % heat will be loss. Because of that, it cannot give considerable heat
supply to the process. Therefore that method is not applicable for this process.
Further, furnace oil steam boilers are not running continuously and those are only run when
failure of coal fired boiler or if there is sudden increment of steam demand. Therefore this
also cannot be used for continuous operation. Energy output will be negligible.
The most suitable one was the thermic heater boiler exhaust because the output temperature is
about 2100C.
Therefore above calculations shows that the heat generated is enough to the drying of sludge
as per the required level.
2.12.1.5 Proposed Design for the dryer
Figure 2.38 : Structure of Dryer
This project is just started and still under construction. I will be working on this project
during next 2 months.
Dried Sludg
e Out
Sludge
in
Flu Gas In
Flu Gas Out
Belt Drives
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2.13 Energy Audit β Brandix Girithale
2.13.1 Introduction
Girithale Brandix factory is one of main plant in the casualwear cluster having about 500
employers with the corporate staff. Factory area consists of 7 major production lines, packing
area, store and corporate offices. Canteen and training centre are located outside of the plant
but inside the factory premises. This is a one of best profit making factory in casualwear
cluster. Recently it has applied for a green certification issued by Marks and Spencer (M &
S). This M&S green factory certification is their own concept to compromise that the impact
to the environment is low.
The UK-based clothing retailer Marks and Spencer (M&S) has introduced a βcarbon neutralβ
lingerie collection, called Autograph Leaves, which includes four styles of brassieres, three
styles of knickers and one suspender belt design. The company claims that the brassieres in
the collection are the worldβs first carbon neutral brassieres. Therefore, contracts of these
products are only given to the factories having their M&S green certification.
M&S has announced that they would visit the factory for the energy audit and for further
clarifications. Therefore our team was asked to visit the factory earlier for a preliminary
energy audit to make sure that the factory is ready for a green certification. Then team of 3
members including me has sent to the Girithale factory.
2.13.2 Observations
After going through the factory layout, we visit all around the factory to check whether the
factory is under the M&S regulations. Things we have found to be modified or evacuated has
been listed below.
1. Factory Cleanliness is not sufficient.
Dustbins are not used properly and cut waste can be seen everywhere on floor.
Workers are only focussing for achieving day to day targets and not concerning about
the factory cleanliness. Cleaning team in the factory area is not functioning
efficiently.
2. Leaks in Compressed air line
In the fittings and connectors used for supplying compressed air to machines have air
leaks. This may cause to overload the compressor and functioning inefficiently. And
these connectors are very old and need to be replaced with new pipe system.
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3. Steam pipe line and boiler
We could see lots of leaks in the high pressure steam lines. This may cause boiler to
be overloaded and worked inefficiently. And further it will be harmful to the workers
moving nearby leaked areas. And according to further investigations, we found that
the steam pipeline insulation is not sufficient to minimize the heat loss along the pipe
lines.Some areas we couldnβt see Al cladding and pipes are exposed to atmosphere.
Because of these reasons, Steam generated at 3.5 - 4 bar low pressures (no PRV), will
be encouraged to generate condensate.
Figure 2.39 : Steam Pipe Lines
Previously before 2 month a purchase order has been raised by a factory maintenance
engineer for insulation of steam pipe lines. In the documents it is mentioned that 50 kg/m3
insulation material is going to be used. But we got to know that they have used the 30 kg/m3
density material. That is not enough for these pipelines because it has high pressure steam
and no pressure reduction using PRVs.
Further we could see a barrel using to boil elastic for vulcanizing. That barrel is supplied with
a high pressure steam supply. That is not totally covered and the pipe lines are not insulated.
Therefore, instead of direct steam, feed condensate to these barrels. Moreover these barrels
are corroded and hot water leaks are found.
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Figure 2.40 : Steam Barrels for Elastic Boiling
The flue gas duct for tentative boiler is just above head height. Hence there is high
risk of an accident. And the old chimney is not using for emitting flu gas out.
Figure 2.41 : Old and New Flu Gas Chimney of Boiler
4. Artificial Lighting and sky lighting
Recently, skylights have been fixed gain more light during the day time. But the
contractor hasnβt been fixed them properly because the profile of skylight sheet and
roof sheet is not matching. It leads to leaks during the raining period.
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Figure 2.42 : Skylight Sheets and Roof Sheets
Though there is much light from the skylights, still all the artificial lights are occupied
in production lines and even in stores. Reason for that was all the lights in one line are
connected to a one switch.
Figure 2.43 : Skylights and Artificial Lights
Further, for every machine they are given task lights. Therefore no need of using
fluorescent tubes. But all the lights are still occupied.
5. Miscellaneous
Potholes in front pathway and front parking areas add bad look when entering into the
factory. And safety lines are erased. Factory waste should be removed away from the
utility area.
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Figure 2.44 : Utility Area Uncleanliness
In the canteen, though there is a proper waste segregation system, people do not use
them properly. Those dustbins cannot be separately identified because no name tags
are available. And usually monkeys living around the factory area, dirt the kitchen
area by takeout food waste from the dustbins which are not properly covered.
Further there were leaks in waste water lines in the canteen wash basins.
2.13.3 Solutions and Implementation
According to our observations, we held a small presentation for the factory director, factory
maintenance engineers, green ambassador and other relevant parties. And we prepared a
check list to follow up to overcome these problems before M&S certification. All the works
has been listed and asked each party to complete given set of works.
Task Remarks Responsible
person
Steam line insulation to be completed, including piping line to the elastic boiling barrel.
Rectify the leakage in return line.
Contractor agreed to complete within tomorrow
Ajith T
Front area tar layer Will be starting tonight Kasun / Ajith T
Production floor painting to be completed
80% percent of safety lines have been painted.
Kasun / Ajith / Thusitha
Utility area cleaning Has been cleaned for some extend. Remove all unnecessary and unused
equipment.
Ajith D / Ajith T / Thusitha
Arrange a piping to discharge
compressed air dryer condensate directly to the drainage system.
Ajith D
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Remove all the waste piled up in utility are back side and replace
those in cubicles made for waste segregation in canteen back side.
Ajith D
Roof cleaning Clean area roof area for better heat reflection & better look
Ajith D
Turn off all unnecessary lighting. (Especially T8 lights)
Ajith D
Remove all the unnecessary goods piled up in back yard.
(Asbestos sheet, plate sheets, PVC pipes)
Ajith&Thusitha agreed to remove those from factory premises.
Ajith D / Thusitha
Rectify the water leakage in
treatment plant.
This water is coming from
washrooms makes unpleasant situation & unhealthy environment.
Ajith D
Replace remaining 4 plastic
water taps in the canteen
Ajith T
Place 3 new plastic bins at
canteen for Food waste, Paper & Polythene. Name tags are not
clearly visible.
Employees are not discharging waste
properly. Keep a person nearby the bins and inspect for correct segregation.
Ajith D
The cubicles to be used properly
for waste segregation. Place name tags for each.
Ajith D
Remove all the unnecessary
wirings in water tank and other areas
Ajith D
Table 2.15 : Checklist for Maintenance Engineers
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2.13.4 Conclusion
They have followed the instructions as much as possible. Factory become totally changed
with a new good look. Finally after the audit report of M&S, Brandix Girithale has been
announced as a M&S green certified factory.
Figure 2.45: Brandix Girithale winning M&S Certification
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CHAPTER 3
2.12 3 CONCLUSION