Training Report - Brandix Lanka (PVT) Ltd

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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 – 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 –Bradix 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 – Plumbing Drawing for Brandix Seeduwa Factory 6


2.1.2.2 Preparation of Plumbing Layout 7

2.1.2.3 Improved Skills 9

2.1.3 Electrical Drawing – LutronLighting System 10

2.1.4 Drawings for Brandix Lanka Ltd – 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 – 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 – 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 – 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 – 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 Omar’s 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


2.12.1.2 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 – 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 – 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.:

“To be the inspiredsolution for brandedclothing”

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 – 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 world’s first LEED Platinum rated Apparel Factory

One of three nominees for the Energy Globe World Award in the ‘Air’ category

Rated Platinum for Corporate Accountability

National Cleaner Production Awards 2008, in recognition of environment friendly

production practices – 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 –Bradix 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

haven’t 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 – Plumbing Drawing for Brandix Seeduwa Factory


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 – 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 – 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 household’s 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 – 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 haven’t 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 doctor’s 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 can’t 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.Jayasinghe’s 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 – 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 – 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) – Sodium Vapour System = 92 kWh

Energy Consumption per month (kWh) – 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 – 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.

𝑨𝒓𝒆𝒂 𝒐𝒇 𝒕𝒉𝒆 𝒕𝒐𝒕𝒂𝒍 𝒔𝒌𝒚𝒍𝒊𝒈𝒉𝒕𝒔

𝑨𝒓𝒆𝒂 𝒐𝒇 𝒕𝒉𝒆 𝒕𝒐𝒕𝒂𝒍 𝒐𝒄𝒄𝒖𝒑𝒊𝒆𝒅 𝒂𝒓𝒆𝒂 X 100 ≈ 3 %

Total Skylight plan – 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 4’: 22 nos& 4' x 8’: 33 nos

Anticipated Light Level -(400-600) lux on clear sunny day

2 Cutting area

Floor Area - 797.04 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






4 Extension - Production Area






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 “packaged” 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 – 120,000 kg/hour of steam, at very high pressures. Many water

tube boilers are of “packaged” 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 – 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,

• Replacing existing furnace oil fired boilers to cater the steam demand of production

• Generating electricity to reduce the main grid dependency

• 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 °C T2 500 °C T3 244 °C T4 45 °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 (80°C, 1 Bar) 334.96 kJ/kg

Boiler Output Steam Pressure 6.5 MPa

Boiler Output Steam Temp 500 °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

• Site is around 50km away from Colombo.

• Site is located in a BOI Export Processing Zone.

• Site coordinates are 6°57′11″N 80°13′06″E

• Site average weather conditions are as follows

Month

Temperature °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 –

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 – 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 Omar’s house

2.11.1 Project Description

This project was carried out to observe the performance of the solar photovoltaic system

installed at Mr.Feroz Omar’s 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 – 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

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kW

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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 – 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 – 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 300–400 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


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 – 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 “carbon neutral”

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 world’s 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 couldn’t 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 hasn’t 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

Documents

Training Report - Brandix Lanka (PVT) Ltd