Blue Star Limited Cyclopentane Set Up Blue Star

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

About Blue Star 2

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 3

…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 4

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. ” 5

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

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

Products: Blue Star Ltd.

Wada Plant - view

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 R 141 b as blowing agent in polyol chemical

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

Overview of cyclopentane as chemical : Cyclopentane of C 5 or C pentane as commonly know hydrocarbon, often mixture of 75% cyclopentane and 25% Isopentane are used as blowing agent Ø Hazard With low explosive limits cyclopentane posses explosion/fire v Flash Point : -27 Deg C v LFL (Lower flammable limits) : 1. 4% volume (1. 4 gr each 100 ltr of air) v 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 Ø 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

Process Parameter Sr. No Parameters Specification 1 N 2 Purity 95% 2 C 5 Ratio 13 - 15% 3 Blended tank temp (Poly + 22 +/- 2 Deg C 5) 5 25000 Kl poly 6 Intermediate tank Temp 23 +/- 2 Deg 6 A MDI 22 +/-2 Deg C 6 B Polyol 22 +/-2 Deg C 7 Chemical pressure 7 A 7 B 8 9 10 MDI Polyol Platen Temp BAG shot FRD Packed density 120 +/-10 bar 45+/-5 Deg C 25+/-2 kg/m 3 40+/-2 kg/m 3 Chemical Ratio 1. 25 % MDI - 125% of polyol Polyol - 100%

Process flow chart Cyclopentane UG Tank 35 KL ISO-cyanate bulk storage Tank (Drums) Polyol bulk storage Tank 25 KL Intermediate tank 2. 5 KL Premix unit Buffer tank POL 3 KL Day tank ISO 330 Kg Day tank POL 330 Kg Mixing Head Corner Press Door Press Wall Panel Press

PLANT & MACHINERY

35 KL - C 5 storage facility 25 KL - Polyol storage facility

2. 5 KL MDI & Polyol Intermediate storage Premix unit

3 KL Blended (Poly + C 5) Tank storage

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

12. 5 mtr wall panel press Door & corner press

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/m 3 Submerge the foam cube in water and note down the change in weight on weight scale (2. 7750 - 2. 6406 kg = 0. 1344 kg)

SAFETY SYSTEMS

LAYOUT - PROCESS AND SENSORS FOR SAFETY SYSTEMS Storage Premix Safety Panel Production plant P C 5 Storage Underground tank Press No. 1 Press No. 2 I A Sys 100 PT Double ventilator for premix Heat Exchanger ng i p Pi Premix 20 ltr/min g Rin P I A Sys 200 PT double With new pol dosing module (Baruch) Press No. 1 Press No. 2 Press No. 3 3000 lt buffer tank Transfer pump Safety Panel Ventilation ducts (Customer) Infra Red sensors for vapour Liquid sensors

Zones - Zone 0 - Area in permanent contact with explosive product Zone 1 - 250 mm around the injection point ( Mix head) and 500 mm from the distance of closed press. Degree of protection IP 55 Alarm Zone - 1500 mm around from zone 1. Degree of protection - IP 54

Features n 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 n 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 n Use of Nitrogen instead of air to pressurize tanks contain cyclopentane, Blended & MDI chemical. n After the injection of the product, at least 90 secs none of the electric motors installed in classified zone 1 should be powered.

Features n. All parts of the machine should be properly grounded and should be all set to the same potential by using copper braids. n. All motors used in classified area 1 & 2 must be explosion proof motors n. All motors should have minimum degree of protection IP 55 in zone and IP 54 in alarm zone. n Gas detector should be installed in all classified areas connected to monitoring system. n When vapour leakages reach to 10% of LEL power supply to the actuators should be cut off and audio video alarm should be activated n When vapour leakages reach to 30% of LEL power supply to the system should be cut off

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)

VENTILATORS INSTALLED ON PRESS MACHINE During foaming process - C 5 vapour to exhaust to atmosphere

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

FIRE HYDRANT SYSTEM - AUTOMATED OPERATION CAPACITY 273 M 3/Hr @ 70 mtr HEAD Hydrant point - Shop floor Hydrant point - In campus Total - 16 hydrant points are installed

MOBILISER INSTALLED NEARBY TO 35 KL CYCLOPENTANE STORAGE TANK 35 KL underground chemical (C 5) storage tank WIND SOCK - WIND DIRECTION

Study conducted by NDTEE Services Aurangabad n 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. n 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

REGULATORY COMPLIANCE

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

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

Petroleum class A installation - PESO License No. P/HQ/MH 15/6225(p 330476) Valid from 16 Oct 2015 to 31 Dec 2026