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

CHECKLIST 3C - ENERGY CONCERNS-MECHANICAL Name of Organization Epyllion Fabrics Ltd

Boilers & Hot Water System

GAS FIRED BOILER Boiler# Running Status Make Model Type (Fire tube /Water tube) Capacity (tons/hr) Max. Pressure (Psi) Heating surface (Sq. ft.) No. of tubes Stack temperature (C) Steam Pressure (running) Burner type Manual Blow Down Dia: 4 Per day 6 times Temp: 64 C TDS: 1300 ppm DO: 5.3 mg/L Conductivit y: 3840 S Manual Blow Down Dia: 4 Per day 6 times Temp: 65 C TDS: 910 ppm DO: 5.6 mg/L Conductivit y: 2560 S Manual Blow Down Temp: 67 C TDS: 730 ppm DO: 5.4 mg/L Conductivit y: 2310 S 195 6.2 bar 190 6.3 bar 4 kg/cm2 1 Running (EKL) Cleaver Brooks (USA) CB-700600-150 Firetube 9.4 150 2 Running (EFL) Cleaver Brooks (USA) ICB-700600-150 Firetube 9.4 150 139 8 3 (Diesel Boiler) Standby Daelim (Korea) 4

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

WASTE HEAT RECOVERY BOILER AT GENERATOR Boiler# Recovery Source Make Type Model Capacity (kg/hr)
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Average Generation Max. Pressure (Psi) Heating surface (Sq. ft.) No. of tubes Stack temperature (C)

After WTP Water: Temp: 25.3 C DO: 8.6 mg/L TDS: 80 ppm Conductivity: 210 S Feed Water temp: 80 C

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Boiler# Burner Blow down details

FEED TANK DETAILS Dia Gas fired Diesel Boiler WHR Boiler 8 6 Width 8 6 Length 8 8 Height Temperat ure 43 C 90 C Insulatio n Insulated Not insulated

ECONOMIZER ( /) Boiler# Working status Boiler Exhaust Temp Water Temp In Water Temp Out DEAD/LEAK STEAM TRAPS Total no of steam traps
Type of traps (inverted bucket/ball float/thermodynamic)

1 x

2 x

3 x

30 Nos

Checked Found OK Found failed

30 nos 30 Nos 0 Nos

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STEAM & CONDENSATE DISTRIBUTION LAYOUT

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

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STEAM TRAPS FAILED No. Size. Location

STEAM LEAKAGES LOCATIONS # 1 2 3 4 5 6 7 8 9 10 11 12 Location Dyeing M/C - 15 High Extent of Leakage

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LACK OF INSULATION STEAM DISTRIBUTION SYSTEM Steam pressure:.. # 1 2 3 4 5 6 7 8 9 10 CONDENSATE RETURN SYSTEM # 1 2 3 4 5 6 7 8 9 10 Pipe Dia & location length Main Distributio 4 & 640 ft n Line No. of Valve & Location Valve Dia Remarks Pipe location Dia & length No. of Valve & Location Dyeing m/c 42 Nos Dyeing m/c 8 nos Dyeing m/c 4 nos Dyeing m/c 16 nos Dyeing m/c 14 nos Header- 6 Nos Header 2 Nos Header 1 Nos Valve Dia 1.5 2.5 2 3 4 8 6 4 Remarks

Dyeing m/c 30 Nos Distribution Line 2 Nos

2 4

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CONDENSATE RECOVERY SYSTEM Recovery System Recovery through gravity or pump (details) pump ( /)

Machines draining condensate

Machines Returning Condensate

Dyeing machines from 10 No to 24 No

Condensate Flow Returning (m3/hr)

STACK ANALYSIS & BURNER TUNING Schedule present (frequency, results, action) Last stack analysis and Action taken ( )

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HEAT RECOVERY FROM GENERATORS

Heat recovery at Exhaust No of Genset Genset capacity Genset average load Exhaust temperature Air flow Air density at exhaust temperature Details 90% load- 560 C 70~80% load 586C 2 1.34 MW ( /)

( /) No of Genset Genset capacity Genset average load Exhaust temperature Water flow Details 2 1.34 MW

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COMPRESSED AIR
Compressor # Make Model Type No of Stages Discharge Capacity Discharge Pressure Max. Pressure (bar) Speed (RPM) Receiver Capacity Shaft Power (kW) Flow Rate (m /min) Details Air Receiver (Quantity, Volume) 2 Nos Receiver Pressure: 7 bar Receiver 1: length-74 & dia-311 Receiver 2: length-611 & dia-410 Air Main line Size
3

1 Worthington Creyssensac (2 Nos) RLR40BX6 Screw

2 Worthington Creyssensac (3 Nos) RLR75B7 Screw

3 Sanlion SK50VS-B-1.0 Screw 1.2-6.2 m3/min 0.6~1.0 MPa

281 m3/hr

508 m3/hr

10.5 bar 3000 30

10 bar 2975 55

37

Location of Air leaks

Intensity

Number

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Location of Cleaning Points

Header Hydro Extractor m/c De-water m/c Slitting m/c Stenter m/c Dryer Final inspection m/c Bag sewing Air turning Grey Slitting m/c Ultrasoft m/c (brushing) Compactor Utility-2 room 1 1 1 2 6 1 1 1 1 1 2 2 1

Number

Distribution Layout

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HOT OIL BOILERS

1 Location Make Type Capacity (liters) Maximum Pressure (bar) Maximum Temperature (C) Heat Capacity Minimum flow rate (m3 /hr) Manufacture (year) Heating Surface Fuel Consumption 2011 94 m2 233 Nm3/hr (228 kg/hr) 1 MPa 300 C 600,000 Kcal/hr Utility-2 Room Daelim Royal (Korea) 2 3

Hot oil tank Main receiving line Main delivery line 6 pipe, temp: 198 C 6 pipe, temp: 206.7 C

Schedule for burner tuning present Last stack monitoring/details Log sheets available for monitoring

( /)

Location of Oil leaks

Intensity

Number

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Resource Utilization

( /)
# Machine Dyeing m/c (#1 to 24) Hydro Extractor De-water Slitting Stenter (LK&LH and ACC) Stenter (Monforts) Dryer (entema) Compactor (Tubetex) Ultra soft (Brushing) Raising m/c Final Inspection m/c Air Turning Bag Sewing Steam Compressed Natural Gas Air Hot Oil

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Monitoring and Evaluation of the System

( /)
# Machine Steam Flow Meter Air Flow Meter Natural Gas Flow Meter Water Flow Meter

Total

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Possible Concerns
Thermal System Bare hot surfaces at Steam Bare hot surfaces at Condensate Pipes Bare hot surfaces at Hot Water System Bare hot surfaces at Hot Oil System Steam Leaks Steam Traps Failure Condensate Drain Energy Dissipation at Boiler Stack (Economizer) Tuning at gas fired Boiler Steam Flow meters Gas Flow meters Compressors Compressed Air Leaks Compressed Air Nozzles Air Flow meters

Misuse of Compressed Air

Power Generators Waste Heat Recovery Boiler Heat recovery at Jacketing Water Hot Oil Boiler Lack of Insulation Oil Leak Tuning missing at gas fired Boiler Gas flow meter missing

Name of CP Assessor / Engineer: Date:

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