Session 2 Water Audit Presentation

National Seminar on Standards
for Quality and Empowerment

Directorate of Standardization
MOD
Dept of Defense Production
New Delhi
Water Audit in
Industry CIIs
Perspective
June 22 2011
Pranab Dasgupta
Confederation of Indian Industry
Agenda for todays presentation

Water Audit Introduction & key drivers
Standardization and Benchmarking
Approach and Methodology supported with case
study
Water Audit in building
Monitoring & Reporting
Typical Scope of Water Savings
Report Card CII Water Audit Program
How to scale up Water Audit
Introduction to CII Triveni Water Institute
Business Communication
8 Keys to Successful Water

Management -water audit being a core
component
WATE
1. Integrated Approach
R
2. Address both Technical + Human side
AUDIT
reqd
3 Accurate baseline data
Steps
4 Logical sequence implementation in phases 3-8
5 Not only how much water but how it is used
6 Quality versus Application matching
7 Considering True Cost of Water
8 Understanding Life Cycle Cost
Water Audit Core Element of Water

Management Program
A Water Audit is a Systematic Approach
of Identifying, Measuring, Monitoring
and Reducing the Water Consumption by
various activities in an Industry
Why Water Audit ?
One should know exactly how the water is
being used in his premises prior to planning
any water management program.
Key Drivers of Water Audit

Legal Requirement
AP, TN, Karnataka, Gujarat, Maharashtra
CREP (Corporate Responsibility for
Environmental Protection) 17 industry sec

Water stress regions Availability / Quality
Corporate image
Business risk involved - Sustainability
Payback options in places of high water
tariff for industry

Standardization and
Benchmarking
Industry are continuously
minimizing their water footprint
thus setting standards for SPECIFIC
WATER CONSUMPTION in their
units.
Objective is to match National and

International Benchmarks
established in each of the sector
Examples on Specific Water

Consumption
Pursuing to match or even parallel with
national and international
benchmarks
Binani Cement
Binani Cement - continue
Vehicles Manufacturing
2007-08
Paper industry - Sripathi Sivakasi

2007-08
JK Tyre & Industries Ltd
2007-08
Steel industry - Vizak Steel

2007-08
Chemicals TATA Chemicals
Approach to Water Audit in

Industry
1. Starts with Training and Awareness
2. Inculcating water saving thoughts
within the employees
3. Establishment of Water Balance within
the premises
4. Application of 3 Rs principle Reduce,
Reuse and Recycle
5. Monitoring & Reporting to Sustain the
Benefits
Training and Awareness

sample sheet
Union
Water Loss
Hourly loss
Annual loss
Min. Annual water only cost
One drop/second
0.5 litres
5 m3
Rs. 7.5
Water Loss
Hourly loss
Annual loss
0.1 litres/minute
6 litres
53 m3
Rs. 80
Water Loss
Hourly loss
Annual loss
0 - 4 litres/minute
0 - 240 litres
0 - 2100 m3
Rs. 0 - 3150
Flang
e
Valve
Pump shaft seal

Water Mass Balance

DM Plant
PMD Humiduct
1730
Boiler -
PMD Process 373
Softener
AC Cooling Tower 465
DG Cooling Tower 533
450
Air Washer CTS 359
Sand
Filter
Dust & Odor 202
327
PMD Cleaning 110
838
Air Washer SMD 105
Fire
Hydrant
Vac Pump, Blower

& Air Comp 33
Domestic 1340 kLD
Backwash 50
Unmetered 327
colony 411
PMD Toilets 120
SMD Toilets 113
Canteen 180
Admin 14
Borewell
Pumps 3800 kLD
Drinking/
Process Water
3790 kLD
Drinking Process
Water
Water
Industrial Cooling/ Process 2450 kLD

270
175
Example: M&M Nashik Plant
Water Management Approach #

4
Reduce at Source
(How much water is really
required?)
Reduction at Source
Better operating controls
Installation of water saving devices
Change of device/ equipment
Process modification
Few case studies are discussed herewith
Avoid use of fire hydrant

system for miscellaneous applications
Case Study 1
Suggested action plan

Immediately avoid use of hydrant water for other
applications
Safety aspects
Mandatory requirement
Create awareness amongst

Plant personnel
Contractors & suppliers
Introduce Work permit system for FH water usage

Continuous monitoring required
Good potential to save process water

Atleast 50 m3/h or 1200 m3/day
Case Study 2 Water use in rinsing

section
Before
Component
s
Fresh
Fresh
Water
Water
To ETP
30 m3/day
pH -5.0, TDS-900
To ETP
30 m3/day
pH -6.5, TDS-100
Fresh Water Consumption = 70

m3/day
Excellent potential to reuse 2nd stage

rinse water in 1st stage rinsing
Reuse 2nd stage rinse as I rinse

After
Component
s
Fresh
Water
To ETP
Fresh Water Saving = 30 m3/day
Benefits
Water Saving
9000 m3/yr
Annual savings
Investment
Rs.1.50 Lakhs
Nil
Payback period
Immediate
Case Study 3 Optimize pump gland

seal water consumption in the plant
Approach for optimization
Throttle the individual valves
Alternatively, further reduce the line size
As a long term option

Install a closed loop seal water circulation system
Provide dedicated cooling towers
Individual plants Can be combined where feasible
Industry best practice

For mechanical seals
Smartflow intelligent control system Safematic
Inc.
Allows water only when cooling is required
Case Study 3 -continue

Benefits
Atleast 15% fresh water savings in gland seals
Fresh water savings ~ 1500 m3/day
Continuous awareness and monitoring

required
Sustain the benefits achieved
Water Savings = 4,95,000 m3/yr

Annual savings = Rs.9.90 lakhs
Investment reqd = Nil

5
Recycle and Reuse
USES OF RECYCLED WATER

LOW END APPLICATIONS
Toilet flushing
Gardening
Floor washing
HIGH END APPLICATIONS

Boiler feed
Cooling water make-up
Process water
Case Study 1 Reuse of Filter Backwash Water in

Beneficial Application
Recommendations
WTP Filtration Cycle

Collect filter back wash only
In Chamber (in Man hole)
Install tube settler
Treat & recycle
In Raw Water Tank
STP Filtration Cycle

Collect all Back wash water in a collection sump
MGF
ACF
Sand Filters (2 Nos)
Input as feed to R.O
Use for Beneficial applications - CT Make up / Gardening
Benefits
WTP Filtration Cycle
Water Saving
50 m3/day
Annual Water Savings - 18250 m3 /annum

Annual Cost Savings
- Rs. 6.0 lakhs
Investment
- Rs. 3 Lakhs
Payback
- 6 months
STP Filtration Cycle

Water Saving
40 m3/day
Annual Water Savings - 14600 m3 /annum

Case Study 2 Install a cooling tower for

vacuum pump seal water and refiner
seal water in paper machine
Seal water consumption
11 vacuum pumps ~ 50 m3/h
Seal water drained to ETP
Fresh water being used for refiner seal

8 refiners ~ 40 m3/h
Both water drained to ETP

Equivalent fresh water consumed
Case study 2 - continue

Fresh water header
Refiner seal
water 8
nos.
M/c
backwater
Fresh
water
makeup
Vacuum
Pump seal
water
11 nos.
Clarified
water
tank
Cooling tower
Case study 2 - continue

Drained seal water quality tested in lab
Vacuum pump - Same as inlet fresh water
Refiner - Same as inlet fresh water
Lab tests conducted by plant team

Oil & grease ~ BDL
Good potential to install a cooling tower system

for seal water
Recirculate after cooling
Fresh water only for cooling tower make-up
Good potential to reduce fresh water

consumption
~ 80 m3/h or 1920 m3/day
Case study 2 - Install a cooling tower

for vacuum pump seal water and refiner
seal water in paper machine
Water savings
= 6,33,600 m3/yr
Annual Savings
= Rs.12.67 lakhs
Investment reqd. = Rs.8.00 lakhs

Simple payback
= 8 months
Case Study 3 Treated Domestic Water

Reuse
Colony domestic wastewater
Generation - 1000 m3/day
Discharged outside after treatment
Treated domestic water characteristic
Treated domestic water
Process water
pH 7.2
pH 7.4
Conductivity - 500 ppm
Conductivity - 400 ppm
Turbidity 10 NTU
Turbidity < 15 NTU
BOD < 10 ppm
COD < 50 ppm
COD < 50 ppm
Good Potential for reuse as DM Plant feed

Treated Sewage Reuse Scheme

Raw
Sewage
Bar
Screen
Chamber
Existing treatment scheme
Sewage
Collection
Tank
Additional treatment
scheme
Aeration tank
Tube settler
Air Blower
Sludge drying Beds
Garden /
DM Plant
Clarifier
Chlorine
Dosing
Case study 4 -Treated Wastewater Reuse

Scheme
Paper stream pH-7.2

TSS < 700 ppm
Inlet
COD < 1000 ppm
TDS < 800 ppm
Primary
Clarifier
PC2
Collection
sump
Secondary
Clarifier
SC1
Aeration tank
pH-7.5
TSS < 60 ppm
COD < 80 ppm
TDS < 800 ppm
Sludge re-circulation pumps
Treated
wastewater
to process
pH-6.8-7.2
TSS < Nil
COD < 30 ppm
TDS < 50 ppm
RO
Micron
Filter
High
Pressure
pump
Activated
Carbon
Filter
Pressure
Sand
filter
Clarified
Water
Tank
Filter Feed
Pumps
Chlorine
Dosing
Benefits
Water Saving
1000 m3/day
3,30,000 m3/annum
Annual Savings
Rs 6.60 Lakhs
Investment
Rs 15.00 Lakhs
Payback
27 months
Case Study 4 Blow Down

Optimization in Boiler
Soda Recovery Boiler
Operating at ~ 90 TPH, 63.5 ata & 450oC
Online Conductivity meter installed
30 mS maintained in boiler drum
Present blow down ~ 4.5%

Low conductivity maintained
Recommend to increase conductivity in steps

Maintain 80 mS in line with CFB
DM Water Saving ~ 1.8 m3/h
Water Audit in building

On-site survey and assessment of
Water using hardware, fixtures, equipment,
landscaping
To develop recommendations for improving
water use efficiency
Typical Water Consumption Pattern in

Building
Cooling tower 30%
Leakages 25%
Domestic 40%
Others 5% -(Irrigation & landscaping /Vehicle
cleaning)
Electronic wash system
Electronic hand wash
Saves up to 70% water in hand

wash
Handles high TDS up to 1800 ppm
Foam spray taps
Saves up to 40% water in

handwash
Electronic flush system

Electronic urinal flush
Saves up to 40% water in flush
Handles high TDS up to 1800 ppm
Flush System
Water less Urinals
100% Water Savings

Rain Water Harvesting
Grey Water Recycling
140 lit/day of fresh water

For Washing and Cleaning

5
Monitoring and Reporting
MONITORING
Monitor daily,
monthly, yearly
Institute specific
format
Introduce as a
part of log sheet
Ashok Leyland Monitoring and

Reporting System
Typical Scope of Water Savings Ex: Hindustan

National Glass & Industries Limited, Nashik
Water Saving Activity
Annual Water Saving

m3
Blow down water from cooling tower is

treated in STP and used in gardening -2009
31025
Reusing treated water from STP in Cullet

washing
7200
All underground lines were replaced with

overhead lines to minimize unidentified
losses
91250
Recirculation of glass gob cooling water
21900
New pit for collection and recirculation to and

from cullet washers
29200
Installation of cooling tower to eliminate

fresh water usage for the hot cullet scraper
during heavy draining of gobs
11880
Report Card CII Water Audit

Water audits & Training
45 audits and training till
date
2 companies facilitated for
Zero Water Discharge
Godrej Industries Ltd, Valia
ITC Ltd, Munger
Annual Water Savings
Equivalent Annual Cost Savings
(m3/year)
(Rs Lakhs/year)
Identified
18 million
1255.00
Achieved*
4.0 million
150.00
(till date)
* Balance under
implementation
What Next ? Scaling up of

Water Audit !!
1.Water Foot Printing in
Industry
2.Blue Rating of
products / organizations
CII Triveni Water Institute The first of its

kind in the world (Government, Industry,
Civil Society coming together)
Jaipur,
Rajasthan
New Delhi
Bangalore
Pune
National & International

Partners
National
State and Central
Government
International Partners
Water Industry Alliance,
South Australia
Cleantech, Switzerland
IFC, USAID,
Netherlands, Israel
Expressed interest
CII Water Activities

Education & Training
Information Dissemination
Centre including Publications
CII Triveni
Water Institute
Advisory
Services
Events & Award Programs
Business Communication
S Raghupathy - Executive Director
Email: s.raghupathy@cii.in
K S Venkatagiri Principal Counsellor
Email: k.s.venkatagiri@cii.in
Pranab Dasgupta Senior Counsellor
Email: pranab.dasgupta@cii.in
THANK YOU

Session 2 Water Audit Presentation

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Session 2 Water Audit Presentation

Încărcat de

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National Seminar on Standards

for Quality and Empowerment

Agenda for todays presentation

8 Keys to Successful Water

Confederation of Indian Industry

Water Audit Core Element of Water

Confederation of Indian Industry

Key Drivers of Water Audit

CREP (Corporate Responsibility for

Environmental Protection) 17 industry sec

tariff for industry

Objective is to match National and

Examples on Specific Water

Confederation of Indian Industry

Confederation of Indian Industry

Binani Cement - continue

Confederation of Indian Industry

Confederation of Indian Industry

Paper industry - Sripathi Sivakasi

Confederation of Indian Industry

JK Tyre & Industries Ltd

Confederation of Indian Industry

Steel industry - Vizak Steel

Confederation of Indian Industry

Chemicals TATA Chemicals

Confederation of Indian Industry

Approach to Water Audit in

Confederation of Indian Industry

Training and Awareness

Pump shaft seal

Water Mass Balance

Confederation of Indian Industry

Confederation of Indian Industry

PMD Process 373

AC Cooling Tower 465

DG Cooling Tower 533

Air Washer CTS 359

Dust & Odor 202

PMD Cleaning 110

Air Washer SMD 105

Vac Pump, Blower

Domestic 1340 kLD

PMD Toilets 120

SMD Toilets 113

Industrial Cooling/ Process 2450 kLD

Example: M&M Nashik Plant

Confederation of Indian Industry

Water Management Approach #

Confederation of Indian Industry

Confederation of Indian Industry

Avoid use of fire hydrant

Suggested action plan

Create awareness amongst

Introduce Work permit system for FH water usage

Good potential to save process water

Case Study 2 Water use in rinsing

Fresh Water Consumption = 70

Excellent potential to reuse 2nd stage

Reuse 2nd stage rinse as I rinse

Fresh Water Saving = 30 m3/day

Confederation of Indian Industry

Confederation of Indian Industry

Case Study 3 Optimize pump gland