1. National Seminar on “Standards for Quality and Empowerment” Directorate of Standardization MOD Dept of Defense Production New Delhi
Water Audit in Industry – CII’s Perspective June Pranab Dasgupta

2. Agenda for today’s 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

3. 8 Keys to Successful Water Management -water audit being a core component
WATER AUDIT reqd
Steps 3-8
Integrated Approach
Address both Technical + Human side
Accurate baseline data
Logical sequence –implementation in phases
Not only how much water but how it is used
Quality versus Application matching
Considering True Cost of Water
Understanding Life Cycle Cost

4. 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.

5. 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 5

6. 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 6

7. Examples on Specific Water Consumption
Pursuing to match or even parallel with national and international benchmarks 7

8. Binani Cement

9. Binani Cement - continue

10. Vehicles Manufacturing – 2007-08

11. Paper industry - Sripathi Sivakasi 2007-08

12. JK Tyre & Industries Ltd 2007-08

13. Steel industry - Vizak Steel 2007-08

14. Chemicals – TATA Chemicals

15. Approach to Water Audit in Industry
Starts with Training and Awareness
Inculcating water saving thoughts within the employees
Establishment of Water Balance within the premises
Application of 3 R’s principle – Reduce, Reuse and Recycle
Monitoring & Reporting to Sustain the Benefits

16. Training and Awareness – sample sheet
Water Loss One drop/second
Hourly loss litres
Annual loss 5 m3
Min. Annual water only cost Rs. 7.5
Union
Flange
Water Loss litres/minute
Hourly loss 6 litres
Annual loss 53 m3
Min. Annual water only cost Rs. 80
Valve
Pump shaft seal
Water Loss litres/minute
Hourly loss litres
Annual loss m3
Min. Annual water only cost Rs
Self Explanatory 16

17. Water Mass Balance
Self Explanatory 17

18. Drinking/ Process Water Industrial Cooling/ Process – 2450 kLD
Borewell Pumps – 3800 kLD
Fire Hydrant
Drinking/ Process Water
Drinking Water
Process Water
Admin – 14
Canteen – 180
SMD Toilets – 113
PMD Toilets – 120
colony – 411
Unmetered – 327
DM Plant
Softener
Vac Pump, Blower & Air Comp – 33
Air Washer SMD – 105
Air Washer CTS – 359
Boiler -
PMD Humiduct
AC Cooling Tower – 465
DG Cooling Tower – 533
Domestic – 1340 kLD
838
1730
270
327
PMD Cleaning – 110
Dust & Odor – 202
PMD Process –373
450
Sand Filter
Industrial Cooling/ Process – 2450 kLD
Backwash – 50
175
3790 kLD 18

19. Example: M&M Nashik Plant

20. Water Management Approach # 4
Reduce at Source (How much water is really required?) 20

21. Reduction at Source Better operating controls
Installation of water saving devices
Change of device/ equipment
Process modification
Few case studies are discussed herewith 21

22. Good potential to save process water
Case Study 1 Avoid use of fire hydrant system for miscellaneous applications
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 22

23. Case Study 2 Water use in rinsing section
Before
Components
Fresh Water
Fresh Water
To ETP
To ETP
30 m3/day
pH -5.0, TDS-900
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 23

24. Reuse 2nd stage rinse as I rinse
After
Components
Fresh Water
To ETP
Fresh Water Saving = 30 m3/day 24

25. Benefits Water Saving 9000 m3/yr Annual savings = Rs.1.50 Lakhs
Investment = Nil
Payback period = Immediate 25

26. 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 26

27. 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 27

28. Water Management Approach # 5
Recycle and Reuse 28

29. USES OF RECYCLED WATER LOW END APPLICATIONS HIGH END APPLICATIONS
Toilet flushing
Gardening
Floor washing
HIGH END APPLICATIONS
Boiler feed
Cooling water make-up
Process water 29

30. 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 30

31. Benefits WTP Filtration Cycle STP Filtration Cycle Water Saving
50 m3/day
Annual Water Savings m3 /annum
Annual Cost Savings - Rs. 6.0 lakhs
Investment - Rs. 3 Lakhs
Payback months
STP Filtration Cycle
40 m3/day
Annual Water Savings m3 /annum 31

32. 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 32

33. Refiner seal water – 8 nos. Vacuum Pump seal water 11 nos.
Case study 2 - continue
Fresh water header
Refiner seal water – 8 nos.
Fresh water makeup
M/c backwater
Vacuum Pump seal water 11 nos.
Clarified water tank
Cooling tower 33

34. 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 34

35. 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 lakhs
Investment reqd. = Rs.8.00 lakhs
Simple payback = 8 months 35

36. Case Study 3 Treated Domestic Water Reuse
Colony domestic wastewater
Generation m3/day
Discharged outside after treatment
Treated domestic water characteristic
Treated domestic water
pH – 7.2
Conductivity ppm
Turbidity – 10 NTU
BOD < 10 ppm
COD < 50 ppm
Process water
pH – 7.4
Conductivity ppm
Turbidity < 15 NTU
COD < 50 ppm
Good Potential for reuse as DM Plant feed 36

37. Treated Sewage Reuse Scheme
Raw
Sewage
Existing treatment scheme
Additional treatment scheme
Bar
Screen
Chamber
Sewage
Collection
Tank
Aeration tank
Tube settler
Air Blower
Sludge drying Beds
Garden /
DM Plant
Clarifier
Chlorine
Dosing 37

38. Case study 4 -Treated Wastewater Reuse Scheme
pH-7.2
TSS < 700 ppm
COD < 1000 ppm
TDS < 800 ppm
Paper stream
Inlet
Collection
sump
Primary
Clarifier
PC2
Aeration tank
Secondary
Clarifier
SC1
pH-7.5
TSS < 60 ppm
COD < 80 ppm
TDS < 800 ppm
Sludge re-circulation pumps
Micron
Filter
Pressure
Sand
filter
Activated
Carbon
Filter
Clarified
Water
Tank
Treated wastewater
to process RO
Filter Feed Pumps pH
TSS < Nil
COD < 30 ppm
TDS < 50 ppm
High
Pressure
pump
Chlorine
Dosing 38

39. Benefits Water Saving Annual Savings - Rs 6.60 Lakhs
1000 m3/day
3,30,000 m3/annum
Annual Savings - Rs 6.60 Lakhs
Investment - Rs Lakhs
Payback months 39

40. 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 40

41. 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)

42. 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 42

43. Electronic flush system
Electronic urinal flush
Saves up to 40% water in flush
Handles high TDS up to 1800 ppm 43

44. Water less Urinals
100% Water Savings 44

45. Rain Water Harvesting 45

46. 140 lit/day of fresh water For Washing and Cleaning
Grey Water Recycling
140 lit/day of fresh water For Washing and Cleaning 46

47. Water Management Approach # 5
Monitoring and Reporting 47

48. MONITORING Monitor daily, monthly, yearly Institute specific format
Introduce as a part of log sheet 48

49. Ashok Leyland – Monitoring and Reporting System

50. 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

51. 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 (m3/year)
Equivalent Annual Cost Savings (Rs Lakhs/year)
Identified
18 million
Achieved*
(till date)
4.0 million
150.00
* Balance under implementation

52. What Next ? Scaling up of Water Audit !!
Water Foot Printing in Industry
Blue Rating of products / organizations

53. CII – Triveni Water Institute The first of its kind in the world (Government, Industry, Civil Society coming together)
Jaipur, Rajasthan
New Delhi
Bangalore
Pune

54. National & International Partners
State and Central Government
International Partners
Water Industry Alliance, South Australia
Cleantech, Switzerland
IFC, USAID, Netherlands, Israel – Expressed interest

55. Information Dissemination
CII Water Activities
Information Dissemination
Centre including Publications
Education & Training
CII Triveni
Water Institute
Events & Award Programs
Advisory
Services 55

56. Business Communication
S Raghupathy - Executive Director
K S Venkatagiri – Principal Counsellor
Pranab Dasgupta – Senior Counsellor
THANK YOU