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Blue Star Limited

Blue Star Limited. Cyclopentane Set Up Blue Star , Wada Plant 08 Feb 2019. About Blue Star. The Past…. Founded by Mohan T Advani in 1943 Initially engaged in reconditioning of refrigerators and air conditioners Listed on the Bombay Stock Exchange in 1969

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Blue Star Limited

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  1. Blue Star Limited Cyclopentane Set Up Blue Star , Wada Plant 08 Feb 2019

  2. About Blue Star

  3. The Past… • Founded by Mohan T Advani in 1943 • Initially engaged in reconditioning of refrigerators and air conditioners • Listed on the Bombay Stock Exchange in 1969 • Corporate headquarters in Mumbai

  4. …and the Present India’s leading air conditioning and commercial refrigeration company with 75 years of experience Revenue of Rs 4800 crores (USD 750 million) 2800+ employees Network of 35 offices, 2200 dealers, 600 retailers, 600 service associates and 500 project associates across India Presence in 19 international markets in the Middle East, Africa and South Asia 5 modern manufacturing facilities Comprehensive solutions for corporate, commercial and residential customers

  5. Blue Star – Vision & Credo Vision : “To dream, to strive, to care and, above all to be the best in everything we do.” Credo : “I am Blue Star. I take pride in delivering a world-class customer experience.”

  6. International Business Blue Star International FZCO houses the International Business Group of the Company, comprising The Product Exports business The Joint Ventures in Qatar, Malaysia and Oman Offers AC&R products, MEP projects, after-sales service as well as system integration in global markets, in addition to Original Design & Manufacturing solutions Presence in over 19 countries across the Middle East, SAARC, Africa, and ASEAN regions Focus on building a larger international footprint by enhancing reach of distributors and channel associates in these regions

  7. Global Presence Iran Distributors Kuwait Nepal Bahrain Bhutan Sales Office Qatar Saudi Arabia UAE Bangladesh Sudan Joint Ventures Yemen Oman Vietnam Mumbai Re export Nigeria Sri Lanka Kenya Singapore Malaysia Maldives Tanzania

  8. Products: Blue Star Ltd.

  9. Wada Plant - view

  10. Background Blue Star provides end to end solution for this application. Blue Star started manufacturing insulated panel required for cold storage room way back in 1992 with technical collaboration with M/S Kolpak, USA . The technical collaboration with Kolpak ended in the year 2003. Since then Blue Star is manufacturing insulated panels as per its own design with R141b as blowing agent in polyol chemical

  11. Cyclopentane Recommend due to - • Cyclopentane is a proven technology world wide • In India the major companies such as Godrej, LG ,Voltas ,Samsung Whirlpool have converted to C pentane • C pentane ODP is Zero, GWP is very low and Thermal conductivity is better with respect to other blowing agent

  12. Overview of cyclopentane as chemical : - Cyclopentane of C5 or C pentane as commonly know hydrocarbon,often mixture of 75% cyclopentane and 25% Isopentane are used as blowing agent • Hazard - With low explosive limits cyclopentane posses explosion/fire • Flash Point : -27 Deg C • LFL (Lower flammable limits) : 1.4% volume (1.4gr each 100 ltr of air) • UFL (Upper flammable limits) : 8.0% volume (8 gr each 100 ltr of air) Hazards however it is as dangerous or as safe as petrol if handled rightly • Foaming process Due to its hazardous nature cyclopentane is normally not supplied in premix form with polyol unlike HCFCs, which is commonly supplied as pre blended polyol. Cyclopentane is normally being preblended with polyol before foaming at process site only

  13. Process Parameter Chemical Ratio 1.25 % MDI - 125% of polyol Polyol - 100%

  14. Process flow chart Cyclopentane UG Tank 35KL ISO-cyanate bulk storage Tank (Drums) Polyol bulk storage Tank 25KL Intermediate tank 2.5KL Intermediate tank 2.5KL Premix unit Buffer tank POL 3KL Day tank POL 330Kg Day tank ISO 330Kg Mixing Head Corner Press Door Press Wall Panel Press

  15. PLANT & MACHINERY

  16. 25KL - Polyol storage facility 35KL - C5 storage facility

  17. 2.5KL MDI & Polyol Intermediate storage Premix unit

  18. 3KL Blended (Poly + C5) Tank storage

  19. 100 Kg PU foaming machine Day tank capacity MDI - 330 ltr Polyol - 330 ltr

  20. 12.5 mtr wall panel press Door & corner press

  21. Quality Test - FRD process Take a Bag Shot. Cut a cube of size 50 x 50 mm from the bag shot. Weigh it on the weighing scale and note its weight (0.0035 kg) Fill water in the beaker and note its weight on weighing scale (2.6406 kg) As per Archimedes' principle the change in the weight of water is equal to volume of water displaced. The volume of water displaced is equal to volume of foam cube. Therefore density of foam cube = Mass/Volume = 0.0035/0.1344*1000 = 26.04 Kg/m3 Submerge the foam cube in water and note down the change in weight on weight scale (2.7750 - 2.6406 kg = 0.1344 kg)

  22. SAFETY SYSTEMS

  23. LAYOUT - PROCESS AND SENSORS FOR SAFETY SYSTEMS Safety Panel Storage Premix Production plant Press No.1 P I Press No.2 C5 Storage Underground tank A Sys 100 PT Double ventilator for premix Heat Exchanger Press No.1 I Piping Ring P A Sys 200 PT double With new pol dosing module (Baruch) Press No.2 Premix 20ltr/min Press No.3 3000 lt buffer tank Transfer pump Safety Panel Ventilation ducts (Customer) Safety Panel Infra Red sensors for vapour Liquid sensors

  24. Zones - Zone 0 - Area in permanent contact with explosive product Zone 1 - 250mm around the injection point ( Mix head) and 500mm from the distance of closed press. Degree of protection IP55 Alarm Zone - 1500mm around from zone 1. Degree of protection - IP54

  25. Features - • Ventilation fan,gas detectors, nitrogen valves, monitoring stations, alarms should be powered by UPS or DG sets to guarantee functioning also in case of failure of main power supply • Inbuilt safety function - During foaming cycle unless nitrogen gas is injected as per panel volume, chemical pouring process can not be start.This is mandatory to reduce cyclopentane explosion properties • Use of Nitrogen instead of air to pressurize tanks contain cyclopentane, Blended & MDI chemical. • After the injection of the product, at least 90 secs none of the electric motors installed in classified zone 1 should be powered.

  26. Features - • All parts of the machine should be properly • grounded and should be all set to the same • potential by using copper braids. • All motors used in classified area 1 & 2 must be • explosion proof motors • All motors should have minimum degree of protection IP55 in zone and IP 54 in alarm zone. • Gas detector should be installed in all classified areas connected to monitoring system. • When vapour leakages reach to 10% of LEL power supply to the actuators should be cut off and audio video alarm should be activated • When vapour leakages reach to 30% of LEL power supply to the system should be cut off

  27. CYCLOPENTANE + POLYOL PREMIX UNIT WITH IR SENSOR Infra red sensors detects the cyclopentane vapour leakages during the process and the machine operations are interlock with LFL (lower flammable limit) & UFL (Upper flammable limit)

  28. VENTILATORS INSTALLED ON PRESS MACHINE During foaming process - C5 vapour to exhaust to atmosphere

  29. LIGHTING ARRESTOR WITH SURGE COUNTER Surge counter Lightning arrestor Lightning arrestor installed in 100mtr radius area to ground the high voltage lighting surges 35KL Cyclopentane storage area

  30. FIRE HYDRANT SYSTEM - AUTOMATED OPERATION CAPACITY 273M3/Hr @ 70 mtr HEAD Hydrant point - Shop floor Hydrant point - In campus Total - 16 hydrant points are installed

  31. WIND SOCK - WIND DIRECTION MOBILISER INSTALLED NEARBY TO 35KL CYCLOPENTANE STORAGE TANK 35KL underground chemical (C5) storage tank

  32. Study conducted by NDTEE Services Aurangabad • Hazard & Operability Study - HAZOP • The factory has a total storage capacity of 35 KL of CYCLOPENTANE. • One Tank of 35 KL capacity) CYCLOPENTANE which is highly flammable • and explosive and hence the entire operation of receipt / storage / • distribution / usage of the CYCLOPENTANE is a highly hazardous process. • Quantitive Risk Analysis study conducted - QRA Statutory requirement OF Maharashtra safety council & to access environmental impact, Hence this study is required. To consider various scenarios related to the installation (will be done using current version of ALOHA software for dispersion modeling such as leakage of tanker, rupture (20% of the cross section of the pipe line) during receipt and discharge of the transfer pump lines etc. To calculate risk distances for the above scenarios and determine the MCLS (maximum credible loss scenario) distance for the installation

  33. REGULATORY COMPLIANCE

  34. Memorandum of Agreement • MoA between Ozone cell, Ministry of • Environment & Forests (MoEF) and Blue • Star Limited for HCFC phase out • management plan (HPMP) • HPMP was approved by the executive • committee of the multilateral fund for the • implementation of Montreal protocol • MoEF is the designated authority for • implementing the HPMP on Govt of India • Whereas United Nations Development • Programme (UNDP) is the designated • lead implementing agency in for the • HPMP

  35. Approvals from Govt Authority • PESO - Petroleum & explosive safety organization • DISH - Directorate of Industrial safety and health • Fire & Safety - Approval from Loca fire & safety dept. • MPCB - Maharashtra pollution control board

  36. Petroleum class A installation - PESO License No- P/HQ/MH15/6225(p330476) Valid from 16 Oct 2015 to 31 Dec 2026

  37. THANK YOU

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