environmental sustainability calibration tool - zendesk · 5.5 ele mr 4 : power factor correction...

MAS Sustainability Calibration Tool V 1.2

MAS Confidential

Copyright © 2015 MAS Holdings (Pvt) Ltd

All rights reserved


MAS Confidential

Contributing Members

Authors Vidhura Ralapanawe MAS Intimates Hashini Wickramarathne MAS Intimates Shahen Amaratunga MAS Corporate Sajeewa Gunasena Linea Aqua Madumantha Kandepola Linea Aqua Hiru Jayathunga MAS Intimates Akvan Gajanayake MAS Intimates Isira Weerarathne Noyon Lanka Stanley Wijesinghe Bodyline Harsha Deraniyagala MAS Fabric Park Nandana Dissanayake MAS Fabric Park Dhanujie Jayapala MAS Corporate Shehani Gomes MAS Active Udara Logus MAS Corporate Ruwan Nilwakka Trischel Kokila Arandara MAS Intimates Thurulie Sampath Ponnamperuma MAS Intimates Unichela

Version 1.2

Sanjaya Jayawardana Bodyline

Chamila Warathenne MAS Active Contourline

Rohitha Nandasena Silueta

Nadeera Wijesinghe Linea Intimo

Kasun Illangasinghe MAS Fabric Park

Vindyani Jayasinghe MAS Active

Janaka Priyadarshana MAS Intimates Unichela

Prageeth Sarasanantham MAS Fabrics

Suneth de Silva MAS Corporate

Technical Advisors Kelum Perera

Compiled by Shahen Amaratunga

Hashini Wickramarathne

Contributions by the MAS Energy Forum are acknowledged, without which this document

would not have been complete.


MAS Confidential

Table of Revisions

1. SCMR1: Scope defined



4. SCRA1: Best practices changed to Initiatives. Scope re-defined

5. ELEMR3: Over voltage included under protection & safety

6. ELEMR3: Earthing resistance value included

7. ACMR1: Facilities are exempted from this for version 1.2

8. IEQMR1: Indoor CO2 tolerance range defined

9. WMMR3: PHI report if sufficient for piggeries

10. WMMR3: EPL certification not mandatory for fabric waste


MAS Confidential

Introduction

The calibration tool was developed to assess, benchmark rate and subsequently improve existing

infrastructure in all MAS Holdings facilities. This document also aims to standardise and replicate

best practices throughout the group while ensuring efficient operations and continuously

improve the environmental sustainability baseline towards a net zero impact facility.

The calibration tool comes in two parts consisting of the guide document and checklist. The guide

document lists out the road map for each facility to achieve the minimum mandatory

requirements henceforth known as MR for the MAS Sustainability benchmark. It also lists out

additional recommended actions henceforth known as RA that a factory can attempt to

implement and achieve a higher rating in the calibration tool. The guide document provides a

detailed description of the areas covered in each section.

The calibration tool checklist is a detailed self-assessment tool that lists both the mandatory as

well as recommended actions required to successfully pass each section of the tool. Each

requirement comes with a list of parameters to fulfil as well as required documents to be

submitted as part of the assessment process.

The calibration tool is separated in to sections and will cover Sustainability Strategy (SS),

Sustainability Culture (SC), Sewing Machines (SM), Lighting (LT), Electrical Systems (ELE),

Compressors (CMP), Air Conditioning (AC), Boilers (BL), Indoor Air Quality (IEQ), Water Efficiency

(WE), Waste Management (WM), Emissions (EM), Building Site & Envelop (STE) & Chemical

Management (CM).

These sections are further sub-divided and the subsections will receive a Mandatory

Requirement or a Recommended Action rating. All mandatory requirements must be completed

by each facility to achieve the baseline score. Facilities that fail to achieve this baseline score will

not be considered. Recommended actions will be awarded points depending on an allocation

weightage.


MAS Confidential

Table of Contents 1.0 Sustainability Strategy (SS) ..................................................................................................... 10

1.1 SS MR 1 : Long Term Sustainability Strategy ...................................................................... 10

1.2 SS MR 2 : Annual Sustainability Plan .................................................................................. 10

1.3 SS MR 3 : Sustainability KPI Review .................................................................................... 11

1.4 SS MR 4 : Plant sustainability team .................................................................................... 11

1.5 SS MR 5 : Sustainability Awareness for Management ....................................................... 12

1.6 SS MR 6 : Use of Eco Tracker .............................................................................................. 12

1.7 SS MR 7 : Certification ........................................................................................................ 12

1.8 SS RA 1 : Renewable Energy .............................................................................................. 12

2.0 Environmental Sustainability Culture (SC) ............................................................................. 13

2.1 SC MR 1 : Events & Initiatives ............................................................................................. 13

2.2 SC RA 1 : Initiatives ............................................................................................................. 14

2.3 SC MR 2 : Employee Engagement ...................................................................................... 14

2.4 SC MR 3 : Community Engagement.................................................................................... 15

2.5 SC RA 2 : Innovation & Lean ............................................................................................... 15

2.6 SC RA 3 : Training................................................................................................................ 15

3.0 Sewing Machines (SM) ........................................................................................................... 16

3.1 SM MR 1 : Energy Efficient Motors .................................................................................... 16

3.2 SM RA 1 : Direct Drive Motors For New Machines ........................................................... 17

3.3 SM RA 2 : Best Practices ..................................................................................................... 17

3.4 SM RA 3 : On-demand controls for compressed air ........................................................... 18

4.0 Lighting (LT) ............................................................................................................................ 19

4.1: LT MR 1 : Minimum Illuminance level ............................................................................... 19

4.2: LT RA 1 : Lighting power density ....................................................................................... 20

4.3 LT RA 2 : Lighting Controls .................................................................................................. 20

4.4 LT RA 3 : Lamps & Lamp Fittings ........................................................................................ 21

4.5 LT RA 4 : Day lighting .......................................................................................................... 22

5.0 Electrical Systems (ELE) .......................................................................................................... 23

5.1 ELE MR 1 : Mains Metering ................................................................................................ 23

5.2 ELE RA 1 : Sub-Systems Metering ....................................................................................... 23

5.3 ELE MR 2 : Electrical Drawings ........................................................................................... 23

5.4 ELE MR 3 : Protections & safety ......................................................................................... 24

5.5 ELE MR 4 : Power Factor Correction ................................................................................. 25


MAS Confidential

5.6 ELE RA 2 : Load scheduling ................................................................................................. 25

5.7 ELE MR 5 : Testing .............................................................................................................. 25

5.8 ELE RA 3 : EMS Connectivity ............................................................................................... 26

6.0 Compressed Air (CMP) ........................................................................................................... 27

6.1 CMP MR 1 : Calculate Compressor Sizing ........................................................................... 27

6.2 CMP MR 2 : Plant Room Design ......................................................................................... 33

6.3.1 CMP MR 3 : Air Quality Parameters ............................................................................... 35

6.3.2 CMP MR 4 : Refrigerants ................................................................................................. 36

6.4.1 CMP RA 1 : Piping Material ............................................................................................. 37

6.4.2 CMP RA 2 : Distribution System Pressure Management ................................................. 37

6.5.1 CMP MR 5 : Standard Operating Procedure (SOP) .......................................................... 39

6.5.2 CMP RA 3 : Policies .......................................................................................................... 39

6.5.3 CMP MR 6 : Maintenance Schedule ................................................................................ 40

6.5.4 CMP MR 7 : leak detection and prevention program ..................................................... 41

6.6 CMP MR 8 : Health and Safety ........................................................................................... 43

6.7 CMP RA 4 : Training ............................................................................................................ 43

7.0 Air Conditioning (AC) .............................................................................................................. 44

7.1 AC MR 1 : Actual Heat Load ................................................................................................ 44

7.2 AC MR 2 : List of AC Equipment ......................................................................................... 44

7.3 AC RA 1 : Efficiency Calculation .......................................................................................... 45

7.4 AC MR 3 : Standard Operating Procedures (SOP) .............................................................. 46

7.5 AC MR 4 : Preventative Maintenance ................................................................................ 48

7.6 AC MR 5 : Water Treatment ............................................................................................... 51

7.7 AC MR 6 : Training .............................................................................................................. 51

7.8 AC RA 2 : Best Practices ...................................................................................................... 52

8.0 Boilers (BL) .............................................................................................................................. 54

8.1 BL MR 1 : Feed water Quality ............................................................................................. 54

8.2 BL MR 2 : Standard Operating Procedures (SOP) ............................................................... 55

8.3 BL MR 3 : Maintenance Schedule ....................................................................................... 57

8.4 BL MR 4 : Safety Systems ................................................................................................... 58

8.5 BL MR 5 : Operator Training ............................................................................................... 59

8.6 BL RA 1 : Heat recovery & Energy optimising..................................................................... 60

8.7 BL RA 2 : Operational Improvements ................................................................................. 61

9.0 Indoor Environment Quality (IEQ) .......................................................................................... 65


MAS Confidential

9.1.2 IEQ RA 1 : Permanently Installed CO2 Sensors ................................................................ 65

9.1.3 IEQ RA 2 : Automated System For Fresh Air Management ............................................. 66

9.2.1 IEQ RA 3 : Environment Monitoring Test ........................................................................ 67

9.2.2 IEQ RA 4 : VOC Emissions Test ........................................................................................ 68

9.3.1 IEQ MR 2 : Indoor smoking .............................................................................................. 68

9.3.2 IEQ RA 5 : Fume Extraction for specialized functions ..................................................... 69

10.0 Water Efficiency (WE) .......................................................................................................... 70

10.1.1 WE MR 1 : Source Metering .......................................................................................... 70

10.1.2 WE MR 2 : Sub Metering ............................................................................................... 71

10.1.3 WE RA 1 : Additional Sub metering ............................................................................... 71

10.1.4 WE MR 3 : Treatment of raw water .............................................................................. 72

10.1.5 WE RA 2 : Sustainable Sourcing ..................................................................................... 73

10.2.1 WE MR 4 : Treating and Testing of Waste Water ......................................................... 73

10.2.2 WE RA 3 : Reuse of Treated Waste Water .................................................................... 74

10.3.1 WE MR 5 : Water Efficient Fittings ................................................................................ 75

10.3.3 WE RA 4 : Rainwater harvesting .................................................................................... 76

10.3.4 WE RA 5 : Process Water Recovery ............................................................................... 77

10.3.6 WE RA 7 : Drip irrigation for landscaping ...................................................................... 77

10.4.1 WE RA 8 : Ground Water Recharge ............................................................................... 78

10.5.1 WE MR 6 : Training of Maintenance Personnel ............................................................ 78

10.5.2 WE MR 7 : Plumbing drawing & water balance calculation .......................................... 78

11.0 Waste Management (WM) .................................................................................................. 79

11.1.1 WM MR 1 : Centralised Waste Storage ..................................................................... 79

11.2.1 WM RA 1 : Source Segregation ................................................................................. 80

11.2.2 WM RA 2 : Colour Code for Easy Identification of Waste Types ............................... 80

11.3.1 WM MR 2 : Waste disposal Methods ........................................................................ 81

11.3.2 WM MR 3 : Selection of Waste Recyclers ................................................................. 81

11.3.3 WM MR 4 : Selection of Waste Collectors ................................................................ 82

11.3.4 WM MR 5 : Agreements with Waste Collectors ........................................................ 82

11.3.5 WM RA 3 : Transportation of Waste ......................................................................... 82

11.4.1 WM MR 6 : Waste Records ....................................................................................... 83

11.4.2 WM MR 7 : Monitoring of Waste Collectors and Recyclers ...................................... 83

11.4.3 WM MR 8 : Scheduled Waste Management License ................................................ 83

11.5.1 WM MR 9 : Waste Reduction Kaizen / project.......................................................... 84


MAS Confidential

11.5.3 WM RA 4 : Encourage Use of Environmentally Friendly Products ............................ 84

11.6.1 WM MR 10 : Training of Waste Handlers .................................................................. 84

11.7.1. WM MR 11 – Responsibility ..................................................................................... 84

12.0 Emissions Management (EM) ............................................................................................... 85

12.1.2 EM MR 1 : Primary data recording ................................................................................ 86

12.2.1 EM MR 2 : Refrigerants Usage....................................................................................... 88

12.3.1 EM MR 3 : Annual Testing of Flue Gas .......................................................................... 89

12.4 EM RA 1 : Scope 3 Emissions ............................................................................................ 89

12.5 EM RA 2 : Guidelines for Stack Emissions ........................................................................ 90

12.6 EM RA 3 : Emission Reduction Initiatives ......................................................................... 90

12.7 EM RA 4 : Biomass Supply ................................................................................................ 90

12.8 EM RA 5 : Large Scale and Long-Term Supply Partners for Biomass ................................ 91

13.0 Building Site & Envelop (STE) ............................................................................................... 92

13.1 STE RA 1 : Landscape Management Plan ......................................................................... 92

13.2 STE RA 2 : Heat Gain & Thermal Envelop ......................................................................... 93

13.3 STE RA 3 : Asbestos Removal ........................................................................................... 94

13.4 STE RA 4 : Site Maintenance ............................................................................................ 94

14.0 Chemical Management (CM) ............................................................................................... 95

14.1.1 CM MR 1: Chemical Management Team ...................................................................... 95

14.1.2 CM MR 2: Chemical Management Policy ...................................................................... 96

14.1.3 CM RA 1: Chemical Management Plan .......................................................................... 96

14.2.1 CM MR 3: Chemical Inventory....................................................................................... 97

14.2.3 CM RA 2: Additional Information of Dyes/Chemicals ................................................... 98

14.2.5 CM MR 4: Chemical Disposal List .................................................................................. 99

14.3.1 CM RA 3: Positive List .................................................................................................. 100

14.3.2 CM MR 5: Water Testing against the ZDHC 11 Priority Chemical Groups .................. 100

14.3.3 CM RA 4: Action Plan in case of non-compliance ....................................................... 101

14.4 CM MR 6: Chemical Storage, Labelling, Handling and Use ............................................ 102

14.4.7 CM RA 5: Secondary Containment .............................................................................. 103

14.5 CM MR 7: Consumption Monitoring .............................................................................. 103

14.6 CM MR 8: Training .......................................................................................................... 104

14.7 CM MR 9: Chemical Barrel Washing............................................................................... 104

ANNEXURES ............................................................................................................................ 105


MAS Confidential

SS MR 1

SS MR 2

1.0 Sustainability Strategy (SS)

1.1 SS MR 1 : Long Term Sustainability Strategy

The facility should develop a long term (3-5 year) sustainability strategy.

The sustainability strategy should be based on the following:

MAS Holdings Hoshin Kanri and Sustainability Hoshin Kanri

- MAS 5 year Strategy - Customer requirements - Any other related requirements The sustainability strategy should focus on developing plant level performance in key

sustainability related areas, such as energy efficiency improvement, water efficiency

improvement, waste reduction & culture development.

The strategy should be communicated to all employees

1.2 SS MR 2 : Annual Sustainability Plan

An annual sustainability plan should be deduced from the long term (or 5 year) sustainability

strategy. It should include setting KPI targets to achieve the long term strategy.

The annual plan should include;

- Energy reduction projects Energy reduction plan should include energy savings estimated in kWh, cost and payback - Water reduction projects Water reduction plan should include water savings estimated in m3, cost and payback - Waste reduction projects Waste reduction plan should include waste reduction estimated in kg - Sustainability related events (Refer Culture Calibration Tool) Activity Calendar - Other related projects/activities


MAS Confidential

1.3 SS MR 3 : Sustainability KPI Review

Once the overall long term strategy (MR1), the annual plan (MR2) and KPI’s are determined,

quarterly reviews must be conducted and achievements summarised at year end.

Cluster level sustainability KPIs will be set through the Corporate Sustainability Hoshin and

will be passed down to each facility by the head of each cluster. The facility GM will have

ownership for the KPIs while the Sustainability champion of each facility will be responsible

for achieving them.

Plant sustainability champions will be responsible for achieving the action items spelled out

in the sustainability plan and KPI’s. The targets set in the Hoshin must be achieved by the

facility and will be reviewed quarterly by the central sustainability team.

It is recommended to set department level KPIs where appropriate in order to ensure better

results. (Eg: KPIs at sewing floor and bonding area)

1.4 SS MR 4 : Plant sustainability team

A team should be formed to drive sustainability initiatives of the factory and the KPI’s that

have been set.

Team meetings should be conducted on a quarterly basis and meeting minutes must be

documented.

It is recommended to have a cross functional sustainability team representing all the

departments, including the GM of the plant. The sustainability champion can head this

team.

SS MR 3

SS MR 4


MAS Confidential

asd

1.5 SS MR 5 : Sustainability Awareness for Management

Awareness sessions for the management must be conducted at least once every year.

These awareness sessions can also include updates on where the facility stands with regard

to the calibration tool and any improvements that need to be done. Some of the

recommended topics to be covered in the awareness programs.

- General awareness on sustainability

- Current trends and developments in the field

- Customer trends

- What MAS is doing

- LEED / ISO14001 certification updates

Senior management of a plant includes all department managers and their deputies.

Awareness to support staff such as cleaning, security is also recommended.

1.6 SS MR 6 : Use of Eco Tracker

Eco tracker data should be updated on a timely and accurate manner. All data should be

updated by the 20th of every month by the responsible person(s).

1.7 SS MR 7 : Certification

Every facility should have a valid Environmental Protection Licence (EPL), ISO 14001:2004

certification and scheduled waste management licence (where required).

This must be obtained for each site separately in the case the facility has multiple sites

(locations). In the case that the facility does not have these, then measures must be taken to

achieve these targets.

1.8 SS RA 1 : Renewable Energy

Facilities should look at options to incorporate on-site or off-site renewable energy and to

be included in the long term strategy of the facility.

SS MR 5

SS MR 6

SS MR 7

SS RA 1


MAS Confidential

SC MR 1

2.0 Environmental Sustainability Culture (SC)

In order to support the MAS Sustainability Vision it is important that MAS creates a culture of

environmental stewardship. This includes building an employee base who are fully aware of

their roles in a culture of Sustainability and able to take action and support every sustainability

initiative within MAS as well as take the mind-set to their homes. It is also important that MAS

imparts their knowledge and implement initiatives in a wider community to promote an overall

culture of sustainability in a bigger context which would also enhance the image of MAS among

the communities.

2.1 SC MR 1 : Events & Initiatives

Each facility should organise an initiative for each international day mentioned under schedule 1

below. These programs must be conducted once every year.

As desired, a facility may select one of the above three events and celebrate by going beyond

basic awareness and engaging employees or communities or both. The other two events, the

facilities should celebrate atleast with basic awareness to employees or communities or both.

Note: Basic awareness means communicating a message via posters, notice boards, PA system

or electronic media or lecturers without direct interaction.

Note: Examples for going beyond basic awareness: Pledges, competitions, campaigns, dramas

(by employees or school kids), interactive lecturers, symbolic activities, etc.

If plants celebrate the balance two events also beyond basic awareness this will quality for points

in Calibration Tool V2.0.

Schedule 1: International Days

Earth Hour (Last Sat of March)

World Water Day (22nd March)

World Environment Day (05th June)


MAS Confidential

SC RA 1

SC MR 2

2.2 SC RA 1 : Initiatives

Conduct 01 new best practice initiative every year on each of energy, water and waste.

Note: Initiative means: internal short term or long-term projects or programmes that are not

Capex projects. These initiatives should aim at reducing plant’s direct impact.

Examples: standardizing switching off lights when leaving a room, switching off AC half an early,

power saving mode for computers, changing dish washing method at the canteen, plastic

reduced zones, food waste reduction programmes, butterfly gardens, ground water recharge,

tree planting and wetland to purify waste water etc.

An initiative can run across multiple themes which still qualifies. For example Plastic Reduced

Zone will qualify as an initiative under energy, water AND waste.

These initiatives can couple with events mentioned in above schedule 1 or separately or with

employee engagement. If a plant does more than one initiative for each theme they will quality

for points in Calibration Tool V2.0.

2.3 SC MR 2 : Employee Engagement

The facility should conduct at least one program that actively engages employees to develop

their understanding on environmental sustainability.

These projects should reach out to more than 20 people and should not be one off projects but

held on a continuous basis. The facility should conduct at least one such program each year or

should have an on-going programme from previous years. For example; Periodic recycling day

programmes, organic home gardening, knowledge sharing such as interactive guest lectures,

periodic competitions, new skill development, awareness building, training etc.

Note: Key is to get people engaged and inspire behavioural change through education and

activities


MAS Confidential

SC MR 3

SC RA 2

SC RA 3

2.4 SC MR 3 : Community Engagement

The facility should conduct at least one program that actively engages the community to develop

their understanding on environmental sustainability.

These projects should engage more than 20 people and should be long term (more than 6

months) projects. The project could involve any type of community; schools, institutions, villages

etc. The facility should conduct at least one such program each year or should have an on-going

programme from previous years. Example: organic home gardening, clean-up and maintenance

of eco systems, forestry, restoration, waste management, training, awareness building, eco go

beyond projects etc.

Note: Partnerships, education, campaigning, obtaining support, giving support and working

together and inspiring change qualify for engagement.

2.5 SC RA 2 : Innovation & Lean

Innovation: Innovation can be in any areas that will contribute to events, training, knowledge

and awareness, KPIs, products, processes etc.

Lean: Any project done together with or under the guidance of MAS Operating System. The

results of the project should be quantifiable. E.g.: Initiative to reduce fabric waste at source.

2.6 SC RA 3 : Training

It is recommended that relevant employees undergo an external training program related to

environmental sustainability annually.

These programs could include ISO 14001:2004 Lead Auditor, Energy Auditor or Waste Water

Treatment training, etc. This will help develop skills relevant in their job family in the context of

sustainability. The employees sent for training could be in any grade and each year a new person

should be trained.

Training and awareness sessions must be conducted for all Employees.

It is recommended that awareness on environmental sustainability be included in each facility’s

induction or orientation programmes for every level (staff, executives and management)


MAS Confidential

SM MR 1

3.0 Sewing Machines (SM)

This section will cover the improvements expected to be taken to increase machine efficiency in

order to improve sustainability across the group.

3.1 SM MR 1 : Energy Efficient Motors

All sewing machines in the factory must be fitted with servo motors or direct drive motors by

end 2014. Clutch motors can only be used in situations where the sewing operation of a style

deems it mandatory or effective.

In all servo motors, the control box should be equipped with 24/12 V DC Control outlets.

Progressively replace all clutch motors with servo-motors and use direct drive where it is

applicable

The following table shows the machine type with the drive system that should be used.

Machine Type Motor Control Box Additional Options

SNLS/DNLS DDR / BLTDR Servo NA

OL DDR / BLTDR Servo Few Options

CS DDR / BLTDR Servo Maximum Options

FS DDR/ BLTDR Servo NA

ZZ Electronic Servo NA

B/T DDR Servo NA

Sewing Machine Motor Types

Two basic types are common in sewing machines which are listed below.

Motor

Servo

Direct Drive

Belt Drive

Clutch Belt Drive


MAS Confidential

SM RA 1

SM RA 2

3.2 SM RA 1 : Direct Drive Motors For New Machines

It is recommended that new sewing machines be installed with direct drive motors.

Direct-Drive Servo motors are preferred than belt drive servos, but where direct drive is not

applicable belt drive can be used.

Consider the motor efficiency parameters as well when purchasing new equipment.

3.3 SM RA 2 : Best Practices

Have in place the best practice initiatives listed below.

Design or modify the electrical grid so that energy consumption of all machinery can be

measured separately through the centralized EMS. Have in place energy sub-metering

to measure this.

If the facility has Building Monitoring System (BMS) software in place, take measures to

connect the machinery to this. Enable remote switching off through BMS.

Training machine operators to switch off machines during break time (tea/lunch).

Design the lighting and machinery grid so that section-wise switching off can be

accommodated.

Ensure that Total Preventive Maintenance (TPM) is effectively carried out.

Categorize motors based on MTBF (mean-time-between-failure)

Equipment

Sustain

Preventive

Maintenance

TBM (Time Based)

CBM ( Condition Based)

Break down

Maintenance

Improvement

Corrective

Maintenace

Prevention of Maintanance


MAS Confidential

SM RA 3

3.4 SM RA 3 : On-demand controls for compressed air

All sewing machines must use electrically operated solenoids for the foot-lifting operation.

Air lines should be integrated with solenoids and connected to servo motors to control the air

supply.

Uses other than foot lifting must also have on-demand compressed air control systems. No

continuous air output must be given for any operation unless specifically requested.

This will be mandated in the Calibration Tool Version 2


MAS Confidential

LT MR 1

4.0 Lighting (LT)

4.1: LT MR 1 : Minimum Illuminance level

It is required for each facility to maintain illuminance at the prerequisite levels mentioned

below by measuring the LUX level in each area.

Exceptions are tolerated if customer requirements mention a different LUX level.

Task Type1 Range

Roads and pathways (Outside) General 150 - 300

Workstations Localized 200 - 300

Production Floor General 500

Sewing Needle point Local 900 - 1100

Roads and pathways (Inside) General 200

Walkways (outside) General -

Knitting Localized 1000

Dying General 200

Cutting Localized 1000

Ironing & Spreading General 500

Fabric Inspection Localized 1100

Storage General 500

Precision tasks - Define

Local 2000

Based on ILO compliance requirements

1 Refer appendix C : Lighting system types


MAS Confidential

LT RA 1

LT RA 2

4.2: LT RA 1 : Lighting power density

Take steps to meet the requirement for lighting power density.

Building Area Type W/m2

Canteen 15

Factory floor (General) 14

Office 10.8

Machine work shop 15

Gym 12

Warehouse 8.6

Parking (exterior) 1.6

Walkways ( 10 feet wide or greater) 3.3 W / linear m

Walkways (exterior) 0.2

Main entries 100 W/ linear m (door width)

Other entries 66 W / linear m (door width)

Illuminated walls 2.1 Based on SLSEA: Code of Practice for Energy Efficient Buildings in Sri Lanka

Note: Please refer following link for printable/editable format.

http://knet/sites/livinggreen/ESCalibrationTool/Forms/required_documentation

4.3 LT RA 2 : Lighting Controls

4.3.1: Automatic Lighting Shutoff

Interior lighting in buildings larger than 465 m2 (5,000 sq.ft) should be controlled with an

automatic control device to shut off building lighting in all spaces.

This automatic control device shall function on either

- A scheduled basis using a time-of-day operated control device

- an independent program schedule

- an occupant sensor that turn lighting off within 30 minutes of an occupant leaving a

space

Exceptions: The following shall not require an automatic control device:

- Lighting intended for 24-hour operation.

- Medical Centre (during operating hours)

- Lighting provided for security purposes

Lighting 4.3.2: Space Control

Each area enclosed with partitions reaching the ceiling should have at least one control device

to independently control general lighting within the space. Each manual device should be

readily accessible by the occupants.

http://knet/sites/livinggreen/ESCalibrationTool/Forms/AllItems.aspx?RootFolder=%2Fsites%2Flivinggreen%2FESCalibrationTool%2FRequired%20Documentation_Calibration%20Tool%20V1%2E2&FolderCTID=0x01200026D6E94B476C8940B33F112EEB35B39A&View=%7b04FB7BCA-54CD-4348-8ECD-07CEA3261AC3%7d


MAS Confidential

LT RA 3

A control device can be provided to turn off lighting within 30 minutes of all occupants leaving

the space. Control devices could be placed in the following areas; meeting rooms, canteen,

wash rooms, individual rooms (managers’ rooms).

Lighting 4.3.3: Exterior Lighting Control.

It is recommended that all exterior (security) lighting application to have automatic controls

capable of turning off exterior lighting when sufficient daylight is available.

These can be controlled by either

- a combination of a photo sensor and a time switch or

- A time switch.

It is recommended that garden lights (decorative purposes) and security light/perimeter lights

are separately controlled. Garden lights can be switched off after 10 pm or can be permanently

switched off if there is no special requirement.

4.4 LT RA 3 : Lamps & Lamp Fittings

It is recommended that incandescent lamps, halogen spot lamps and fluorescent tube lights

with magnetic ballast to be removed from the facility and replaced with more energy

efficient fixtures.

Lighting 4.4.1: Zero usage of Incandescent lamps

It is recommended to remove all the incandescent bulbs from usage.

Exception: Fabric inspection area and other specialized areas are excluded from scope.

Lighting 4.4.2: Zero usage of halogens lamps

It is recommended to remove all the halogen bulbs from usage.

Exception: any lights intended for specific purpose are excluded from scope.


MAS Confidential

LT RA 4

Lighting 4.4.3: Zero usage of linear fluorescent lights with Magnetic ballasts

It is recommended to remove all magnetic ballasts.

Lighting 4.4.4: Replace fluorescent lights after effective lifetime

It is recommended to replace fluorescent lights after their useful lifetime.

How to identify lights to be replaced

- Flickering

- Black/dark shade developing around two ends (these could be emitting harmful UV

rays)

4.5 LT RA 4 : Day lighting

It is recommended that day lighting options be used for lighting within the facility and that

artificial lighting design be done to incorporate day lighting.

If office areas with day lighting option are available, artificial lighting can be controlled either

manually or automatically.

If skylights are provided for production floors, it is recommended to control artificial lighting

with the day light changes. This will help to maintain necessary illumination levels at the

production floor as well as to optimize savings from the skylight installation.

Lighting 4.5.2: Uniformity of lighting

It is recommended to have uniformity of lighting in order to maintain comfort levels within

occupied spaces.

Note: Uniformity (u) can be obtained by a proper simulation and has to be over 0.5 for the

main production areas.

Lighting 4.5.3: Glare reduction

Use glazing stickers or external shading on windows to reduce glare.

Proper light fixture selection and system design should be considered to reduce glare through

artificial lighting solutions.


MAS Confidential

ELE MR 1

ELE RA 1

ELE MR 2

5.0 Electrical Systems (ELE)

5.1 ELE MR 1 : Mains Metering

All incoming lines from the utility grid (CEB) and generators should be connected to the Energy

Monitoring System (EMS).

5.2 ELE RA 1 : Sub-Systems Metering

It is recommended to install sub meters to measure energy consumption of additional high

usage components.

The following hierarchy could be followed when considering sub systems for sub metering.

1. AC system

2. Lighting system

3. Machinery system

OR

I. Production units/buildings

II. Office block

III. Compressor

IV. Utilities

5.3 ELE MR 2 : Electrical Drawings

A single line diagram (electrical) must be available with the engineer.

It is recommended to display the drawing in the engineer’s office.

In addition the facility may also have a detailed electrical layout drawing.


MAS Confidential

ELE MR 3

5.4 ELE MR 3 : Protections & safety

The facility should have appropriate electrical protection and safety devices.

Having considered the purpose for which the installation is being designed, the safety devices

should address the safety of the users, property and the installation.

Type of protection Description

Protection against electric shock Protection against electric shock shall be provided by the application by completely avoiding direct and indirect contact.

Protection against thermal effects

Protection against fire, burns and harmful thermal effects.

Protection against overcurrent Expect where the overcurrent is limited, every live conductor shall be protected by one or more devices for automatic interruption of the supply in the event of overload current and fault current.

Protection against under voltage / over voltage

Suitable precautions shall be taken where a reduction in voltage, or loss and subsequent restoration of voltage, could cause danger.

Isolation and switching Means shall be provided for non-automatic isolation and switching to prevent or remove hazards associated with the electrical installation or electrically powered equipment and machines.

Protection against lightning Good grounding is essential for adequate protection against damage or injury by lightning (earthing resistance should be less than 10 ohms). The protection system needs to get rid of excess energy from the lightning strike by shunting it into the earth.

The above protections can be obtained through the use of MCB, MCCB devices, earth fault

relays/RCCBs, PFR/UVT coil and fuses.

Lightning protection is obtained through lightning conductor (direct) or surge protector

(indirect).

Electrical installation inspection and testing of the total electrical system must be carried out

every three (03) years and signed off by a chartered electrical engineer.

Note: It is recommended that facilities measure the earthing resistance value.10 ohms will be

mandated in version 2.0


MAS Confidential

ELE MR 4

ELE RA 2

ELE MR 5

5.5 ELE MR 4 : Power Factor Correction

The facility should maintain its power factor at a minimum of 0.98 or better at main feeding

points/main panel room.

It is advisable to use local power factor correction where ever there is a load affecting the total

power factor of the plant. It is also mandatory to conduct routine inspection and maintenance

of the capacitor banks.

It is additionally recommended to maintain the power factor at 0.99

5.6 ELE RA 2 : Load scheduling

Maintain a schedule for switching on sub systems with a high load demand.

The purpose of this is to have the least effect on maximum demand.

The schedule may be made through identifying load pattern demands of the process. Each

schedule must be monitored for consistency on a daily basis.

It is recommended to use automated systems to maintain and monitor equipment within the

facility. Automation should be used to carry out the schedule to optimize the use of electricity

within the facility.

5.7 ELE MR 5 : Testing

The following tests are to be carried out as a part of regular maintenance.

Test Daily Weekly Monthly Biannually Annually

EMS meters inspection (through system) Y

Capacitor banks inspection Y

Lightning protection inspection survey and earthing inspection Y

Surge arrestors inspection Y

Panel boards and wiring terminals inspection Y

MCB / RCCB operation inspection Y

Thermo-graphic survey of electrical sys Y

Electrical test (include safety & earthing) y

Energy audit y


MAS Confidential

ELE RA 3

Electrical Test must include

Earth test

Main panel switch gear

Insulation level

Protective device operation

Apart from these any other inspections / tests recommended by the manufacturers of the

equipment used within the facility should be carried out as per the provided guidelines.

5.8 ELE RA 3 : EMS Connectivity

The facility should have in place an Energy Monitoring System (EMS).

The EMS can be used to monitor electrical loads connected to the system. The system records

key electrical parameters in 15 minute intervals and data can retrieved through the system

itself. (Please refer attached “EMS Report Generation” document for more information on how

to obtain data). The data can be used to;

Analyze energy use patterns and costs

Identify the impacts of energy saving measures taken by the plants

Provide information to plant management in order to maximize efficiency and to

understand load profiles and hotspots

Identify any anomalies in the system and energy wastage

If any anomalies are found, necessary corrective action must be taken immediately and records

must be maintained. Data should be monitored according to the following frequency in order

to improve energy management within the facility.

Daily Weekly Monthly

Main Incomer Load Profile

Main system load profiles

Sub system load profile

Total energy use

Sectional energy use

Compare CEB and EMS monthly data

It is required to maintain a log for meter locations and connection details for future references.


MAS Confidential

CMP MR 1

6.0 Compressed Air (CMP)

6.1 CMP MR 1 : Calculate Compressor Sizing

6.1.1 Method 1 – Using Air Flow meter

Use an air flow meter to accurately measure the air intake requirements of all compressed air

usage devices. Tabulate these CFM values to calculate the total system requirement.

Plug in a data logger to the compressor to monitor loading/unloading times, power consumption

and maximum pressure of the compressor.

6.1.2 Method 2 – Hand calculation method

Calculate the total compressed air requirement of the factory in CFM by tabulating the individual

requirement of all equipment as mentioned in its instruction manual.

Compile a list of all machines in the factory based on whether the machines use compressed air.

(E.g. 1)

Example 1: List of machines that use and do not use compressed air.

No Compressed Air Users Compressed Air Non Users

1 Over-lock Single needle

2 Cover-seam / Flat-seam Double needle

3 Hem cutter Zig zag

4 Binding Bar-tag

5 Elasticater

6 Air gun NOTE: Include other types of chain stitch machines, lock stitch machines and specialised machine.

Tabulate the CFM requirements for the machines using compressed air. Two separates tables

are required one for sewing machines and another for specialised non sewing machines. (E.g. 2)


MAS Confidential

Example 2: List of Sewing Machines

NO Type of Machine No of Machines

CFM per M/C

D factor Total CFM

1 Over-lock machine 1 2.3 0.4 0.92

2 Cover seam machine 1 2.3 0.4 0.92

3 Flat seam machine 1 2.3 0.4 0.92

4 Air gun 1 2.8 0.2 0.56

5 General attachments 1 0.7 1.0 0.70

Tot NOTE: This table could be adjusted when more accurate data is available.

Example 3 : List of specialised machines.

No Type of machine No of Machines

CFM per M/C

D factor Total CFM

1 Cutting table 1 TBC TBC TBC

2 Molding M/C 1 TBC TBC TBC

3 Specialised sewing M/C 1 TBC TBC TBC

Tot

**D Factor – States the actual compressed air usage time in a fraction.

Eg: 0.4 D factor equates that a machine running for 60 seconds will use air for 24 seconds.

TBC – To be calculated

6.1.3 Calculate compressor requirement

Based on the demand analysis carried out, calculate the size of compressor required.

Based on either method 1 or 2 estimate the compressed air volume required for the factory.

Compressors are sized at 8 bar as most sewing machines require air compressed at 6 bar.

Consider pressure drop losses, contingency for future expansions and a safety buffer when sizing

the compressor.

It is recommended to split the air volume requirement and opt for 2 smaller compressors as

opposed to 1 large compressor. The reason being that 1 compressor can run on full load, while

the other can run on part load using a variable speed drive to increase overall efficiency. This

also gives leverage to the production process in the case a compressor fails. The same principle

of having 2 units can be followed for dryer and air receiver as well. All these can be connected to

the same header.


MAS Confidential

Example 4: Sizing the compressor

Equipment Quantity(nos) Utilization(cfm) D factor

Total(cfm) Full total (cfm)

Overlock 100 2.3 0.4 92

427 Coverseam 100 2.3 0.4 92

Air guns 60 2.8 0.2 33

Specialized Machines

300 0.7 1 210

According to this example the chosen compressor must have FAD of 450cfm considering demand

fluctuation. The most suitable product will be one that can provide this FAD at the lowest

horsepower rating.

6.1.4 Evaluate with current system

Once the ideal compressor sizing has been calculated, it should be compared with the existing

system. Any major deviation between the two systems must be documented and justified.

6.1.5 System Optimisation

It is recommended to have in place as many system optimisations as possible. A few such

methods are given below.

If the current system is over designed or under designed steps must be taken to either introduce

VSD or install new compressors, fulfil short term demand load by installing additional air

receivers closer to the end use location and using multiple smaller compressors to match

different loads/ times/pressures.

Consider the auto condensate drain for compressor, dryer & receiver tank. The temperature at

the air end element of the compressor should be below 100OC, while the temperature at the

dew point of the dryer should be below 7OC.

Paint the compressed air line. Have electronic air controlling solenoids for sewing machines.

Compressor system layout drawing must be available with the engineer.


MAS Confidential

6.1.6 Calculate Compressor Efficiency (optional)

Efficiency could be calculated using the power output to power input ratio.

𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =𝑉 × 100 × ln (𝑃)

𝑃𝑜𝑤𝑒𝑟

V = Flow rate (L/s)

P = Pressure (bar)

Power = Input power (watt)

This ratio should be compared with the rated efficiency of the compressor and should be

presented in the form of a table.

6.1.7 Calculate size of air receiver tank

The air receiver forms a buffer storage area for the compressed air, balances compressor

pulsations, cools air and collects condensate. The air receiver must be fitted with an automatic

condensate drainage device.

The sizing of the air receiver should follow the following equation.

𝑉𝑅 =𝑄 × 5

𝐴𝐼 × ∆𝑃

VR = Volume of receiver tank (m3)

Q = FAD of compressor (m3/min)

5 = Constant factor

AI = Allowed Motor Cycles

ΔP=Pressure Difference (Cut out pressure – Cut in pressure) (bar)

Table : Figured of constant AI values

Motor power rating (KW) Allowed cycles/h

4-7.5 30

11-22 25

30-55 20

65-90 15

110-160 10

200-250 5

Reference : Compressed air compendium

Note: If 2 or more compressors of different sizing is used chose the lower corresponding AI

value. FAD of variable speed compressor should not be considered when calculating the Q

value. 1 CFM = 0.02831 m3/min.


MAS Confidential

This equation may also be used; 𝐴𝑖𝑟 𝑅𝑒𝑐𝑒𝑖𝑣𝑒𝑟 𝑆𝑖𝑧𝑒 (𝑚3) = 𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟 𝐹𝐴𝐷 𝑖𝑛 𝑚3/𝑚𝑖𝑛

3

Air receiver sizes corresponding to compressor type & size;

Modulating Control: 0 to 1 gallon per CFM

On line/ Off line: 3 to 4 gallons per CFM

Stop-start/Variable speed: 4 to 6 gallons per CFM

6.1.8 Calculate the size of the refrigerated air dryer

The compressed air system must be fitted with a refrigerated air drying unit matching the free

air delivery rate of the compressor/s. A contingency factor may be considered for future

expansions. It is also recommended to have an exhaust duct for the dryer unit.

𝐷𝑟𝑦𝑒𝑟 𝑠𝑖𝑧𝑒(𝑐𝑓𝑚)

= 𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟 𝐹𝐴𝐷 ∗ 𝐼𝑛𝑙𝑒𝑡 𝑎𝑖𝑟 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝐶𝐹 ∗ 𝐼𝑛𝑙𝑒𝑡 𝑎𝑖𝑟 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝐶𝐹

∗ 𝐴𝑚𝑏𝑖𝑒𝑛𝑡 𝑎𝑖𝑟 𝐶𝐹

Refrigerated dryers consume around 3% of total power requirement of a compressor, while

desiccant dryers require 10-25% more power. Therefore refrigeration dryers are recommended,

except in the case where extremely dry air with a low dew point is required.

Manufacturers rate their compressed air dryers in accordance with recommended Standard

CAGI Standard No. ADF100 for 33ºF-39ºF (.5ºC - 3.8ºC) pressure dew point. This is based on 100

psig inlet air pressure, 100ºF (37.7ºC) inlet air temperature, 85ºF (29.4ºC) cooling water

temperature (water cooled units) and 100ºF (37.7ºC) ambient air temperature (air cooled units).

The maximum airside pressure drop allowed is 5 psi.

Inlet air CF / Inlet air temperature CF / Ambient air CF refer to Correction Factors which are

annexed below in ANX CMP B.


MAS Confidential

6.1.9 Meet best practice filter parameters

Use appropriate filter sizing to adhere to the earlier mentioned air quality standards. It is

mandatory that micro filters (at minimum) are installed in the compressed air system. An

appropriate inlet filter and secondary filter are also required.

Table :

Name Code Description Other Names

Bag filter THNF Cleans dust and contaminated intake air Air filter

Centrifugal separator

ZK Separated accumulating condensate

Eco drain ED Electronic level controlled condensate drain

Pre filter FB/FC Separates aerosol oil and solid particles Line Filter (before dryer)

Micro filter FE/FF Separates aerosol oil and solid particles Line Filter (after dryer)

Activated carbon filter

FG Adsorption of oil vapours

Activated micro FFG Activated carbon and micro filter combination

Activate carbon adsorber

ACT Adsorption of oil vapours

Sterile filter FST For sterile compressed air

Aqua-mat Condensate treatment system

AMCS Air main charging system

Reference : Basic principles, tips, suggestions (Kaeser) / ISO 8573-1

Filter placement example;

(air dryer can be placed before or after the receiver tank)


MAS Confidential

CMP MR 2 6.2 CMP MR 2 : Plant Room Design

6.2.1 Plant Room Spacing Conditions

All equipment in the compressor room should be arranged taking into consideration minimum

spacing requirements as mentioned in the machine manual, while also considering accessibility

during emergency.

The temperature inside the compressor room should vary by not more than 2O Celsius in

comparison to the outdoor ambient air temperature, measured between 12noon and 2pm on a

warm sunny day, 10 feet away from the plant room air vents. This should be measured on a

quarterly basis. If the location is unable to provide enough fresh air at the recommended

temperature, an air intake fan should be installed to facilitate ventilation, taking care not to

exceed 4m/s air velocity inside the room.

It is recommended that the compressor room be situated in a separate location central to the

plant and designed to promote ventilation without cross-circulation. The compressor should be

preferably placed on a raised platform, plinth or concrete slab foundation. The air intake and the

air exhaust must not be blocked by any permanent or temporary structures.

The compressor room should have a minimum of 1 meter bare space in front and on the sides

with a minimum 6 inches of space at the back, unless otherwise stated in the machine manual.

It is recommended that the compressor room be built to a height of 3m, with wall thickness of

25mm and a well-insulated roof. Direct solar radiation infiltration to the room must be at a

minimum level.


MAS Confidential

Image 1: Correct plant room arrangement

Fresh air vent is common to compressor & dryer air intake location.

Exhaust air duct is available, situated opposite the intake and close to the dryer.

Compressor exhaust is ducted out of the west side wall.

Air receiver tank is before the refrigerated dryer units.

Each compressor has an individual exhaust duct.

6.2.2 Fresh Air Intake

The compressor intake air temperature / separator element temperature must be within the

recommended manufacturer ratings. The humidity of the air entering the compressor should

meet the minimum criteria mentioned in the machine manual.

Compressor’s intake air must be clean and free from solid / gaseous contaminants / corrosive

gases. It is said that a 4oC increase in inlet air temperature increases energy consumption by 1%.

A pre filter must be used in installations where surrounding air has high dust content or has a

remote air intake from an area with clean air.

The fresh air intake should not be close to the following;

Washroom / Kitchen exhaust / Cooling towers

Parking garages/roads/highways

waste collection / water treatment areas / landfill zones

Loading areas / generator & boiler rooms / Incineration areas/ cooling towers

Fume/VOC generation sources & Chemical stores exhausts / Other exhaust ducts

Or any other areas which have a high ambient temperature or high ambient dust

content.


MAS Confidential

CMP MR 3

6.2.3 Exhaust Systems

All heated air generating sources must be exhausted out of the room without causing cross-

circulation of the fresh air intake.

In the case where multiple compressors are used it is recommended to have separate ducts for

each unit. A common duct maybe used for compressors with similar rated capacities. It is also

recommended to have a mechanically ventilated (Forced Draft) fan inside the exhaust duct if it

has many bends or runs for a fairly long distance. It is further recommended to look into

exhausting the hot air generated from the refrigerated air dryers.

6.3.1 CMP MR 3 : Air Quality Parameters

Meet best practice air quality parameters

The compressor system must include the following;

Dust Separator

Pre-filter

After-filter

Refrigerated air dryer

Receiver tank

Every compressor regardless of type draws in compressed air, concentrating the contamination

by compression, and if no measures are taken to remove it, passes it on to the compressed air

network. Neither oil free nor fluid/oil cooled compressors alone can provide oil free air without

some kind of air treatment.

Table: Compressed Air Quality Standards

CLASS SOLID / DIRT Particle size in micron

WATER @ 7 bar / 100 psi Pressure Dew point

OIL (including vapour)

0.10<d<0.5 0.5<d<1.0 1.0<d<5.0

Max number of particles per m3 Â° C Â° F Mg /m3 PPM

0 As specified As specified As specified

1 100 1 0 -70 -94 0.01 0.008

2 100.000 1.000 10 -40 -40 0.1 0.08

3 - 10.000 500 -20 -4 1 0.8

4 - 1.000 +3 +38 5 4

5 - 20.000 +7 +45 25 21

6 Â - +10 +50 - -

Reference : ISO standard from air-compressor-guide.com


MAS Confidential

CMP MR 4

It is recommended that the outlet air quality from the compressor meet these minimum criteria.

The classes range from 1 to 6 where class 1 has the highest quality. It is determined that apparel

factory requirement is categorized under pneumatic tools, which would need the following air

quality standards.

Oil – Class 1

Particle – Class 1

Water – Class 4

To acquire these air quality standards the compressed air system should include a dust separator,

pre filter, refrigerated dryer and micro-filter as per the below mentioned table reference from

compressed air compendium.

6.3.2 CMP MR 4 : Refrigerants

Use CFC free Refrigerants

The refrigerant used in the air dryer must be CFC free / have a Zero ODP (Ozone Depleting

Potential).

It is recommended to use HFC type refrigerants instead of CFC’s. A list of the refrigerants used in

the facility needs to be available.


MAS Confidential

CMP RA 1

CMP RA 2

6.4.1 CMP RA 1 : Piping Material

Select the best type of pipe material based on pressure drop and internal smoothness.

Type Max Press

Max Press Advantages Disadvantages

Steel-Threaded 10-80 120 Inexpensive flow resistance

Quick installation high leakage Easy removal corrosion(un-galvanised)

Steel-Seamless 12-25 120 Inexpensive Skilled job

Wide selection corrosion(un-galvanised)

less Leakage

Stainless Steel 80 above 120 Corrosion proof Skilled job

low flow resistance Expensive

less Leakage Limited availability

Plastic 12.5 max N/A Corrosion proof Instability

Lightweight Skilled job

Smooth inside surface Cheap imitations

low flow resistance resistance to condensate

The material must meet the different criteria in protecting against corrosion and ensure

maximum operating temperature, maximum operating pressure, deliver low pressure loss and

low cost installation.

6.4.2 CMP RA 2 : Distribution System Pressure Management

Ensure that pipe sizing has been done so as to reduce losses due to pipe diameter changes. The

maximum pressure drop between the compressor and the end user should be no greater than 1

bar (including filter, dryer).

The pressure drop can be verified by connecting a pressure gauge to the furthest end user and

measuring the actual pressure drop.

∆𝑝 = 450 ×𝑞𝑐

1.85 × 𝑙

𝑑5 × 𝑝

Δp = Pressure Drop (bar)

qc = Air flow, FAD (l/s)

D = Internal pipe diameter (mm)

L = length of pipe (m)

P = Absolute initial pressure (a)


MAS Confidential

A larger compressed air network can be divided into four main parts: risers, distribution pipes,

service pipes and compressed air fittings. The risers transport the compressed air from the

compressor plant to the consumption area. Distribution pipes split the air across the distribution

area. Service pipes route the air from the distribution pipes to the workplaces.

Table : Typical pressure drop in compressed air line for different pipe sizes considering 100cfm

Pipe nominal bore (mm) Pressure drop (bar) per 100 meters

Equivalent power loss (kW)

40 1.80 9.5

50 0.65 3.4

65 0.22 1.2

80 0.04 0.2

100 0.02 0.1

Reference : Sri Lanka Energy Audit Manual

Table: Pressure drop across other devices.

Description Pressure Drop(Bar)

Final Filter 0.1-0.5

Pipe System 0.2

Dust Filter 0.1-0.5

Dryer 0.1

Reference : Compressed Air Manual 2010 (Atlas Copco)

Table : Maximum Pressure drop across a distribution system

8 Bar and above 3 Bar and below

A Pipe System ΔP≤0.04 ΔP≤1.5% Pmax

1 Main Line ΔP≤0.04

2 Distribution Line ΔP≤0.04

3 Connection Line ΔP≤0.03

Reference : Compressed air compendium BOGE

The system must also have in place pressure regulating and pressure reducing valves where

appropriate. The pressure drop can be further reduced by using long curves and Y pieces instead

of knee joints and T pieces. Try to avoid abrupt changes in pipe diameter and consider isolating

some sections using non return valves for better access during a breakdown. Sufficient proof

must be shown that attempts have been made to optimize the compressed air network. This

network must be designed on a closed loop system to reduce losses. Separate sub-circuits to

facilitate emergency repair work.

All compressed air lines should be painted blue and marked showing the direction of flow (British

Standard 1710:1984).

Maximum air flow velocity of a compressed line should be less than 20 m/s to avoid excess noise

and turbulent flow. The distribution system can be designed with a 1.5-2% downward gradient

in the direction of the flow to capture condensate, though this is not very important for systems

that include refrigerated dryers.


MAS Confidential

CMP MR 5

CMP RA 3

6.5.1 CMP MR 5 : Standard Operating Procedure (SOP)

The SOP for compressed air system must be displayed at the plant room. All operators must be

aware of the contents of the SOP.

The SOP for the compressed air system must follow the format shown below. Slight variations

are allowed depending on compressor model and manufacturer.

Standard Operating Procedure – Compressor

Prior To Starting

Make a visual inspection (secure guards, proper ventilation, free access to unit)

Check coolant level.

Make sure main discharge valve is open.

Turn the power on. (indicator will light)

Check direction of rotation at initial start or following power interruptions.

Starting Switch the ON/OFF switch to ON position. (Compressor will then start and load)

Normal / Emergency Stop

Switch the ON/OFF switch to OFF position. (compressor will unload and stop)

Press EMERGENCY STOP button. (compressor will stop immediately)

Turn off electrical isolator or disconnect.

Standard Operating Procedure – Dryer

1. Check the by-pass.

2. Activate current supply and switch the ON/OFF switch to ON.

3. Wait 5-10 minutes until machine has achieved its standard operating parameters.

4. Slowly open the air outlet valve and successively open the air inlet valve.

5. Close the by-pass (if available).

6. Check if the condensate drain is working properly.

7. Check if all connecting pipes are properly tightened and fixed.

8. Switch the ON/OFF switch to OFF position.

Caution : Dryer must be switched ON or OFF after first switching the compressor unit ON or OFF.

6.5.2 CMP RA 3 : Policies

A policy covering the compressed air system should be in place for the factory and should

cover the following topics.

New air line connections

Using compressed air for non-value addition processes.


MAS Confidential

CMP MR 6 6.5.3 CMP MR 6 : Maintenance Schedule

The factory must have a maintenance schedule that covers all of the below mentioned topics.

The standard maintenance checklist can be found in the annexures section. Slight variations are

allowed depending on compressor model and manufacturer.

Table : Maintenance Schedule

Daily or before each operation Check for oil leaks.

Check lubricant level and fill as when necessary.

Drain receiver tank condensate.

Check for unusual noise and vibration.

Ensure belt guards and covers are in place.

Ensure area around unit is clean

Weekly Observe operation of safety valve.

Inspect air filter elements and clean as when necessary.

Monthly Inspect for air leaks (visually).

Check tightness of screws and bolts.

Inspect drive belts.

Clean exterior.

3Months/500Hours Change lubricant.

Drain compressor oil and clean oil sight glass.

Conduct comprehensive leak detection survey.

12Months/2000Hours Install maintenance pack/conduct service.

Change synthetic lubricant.

Replace filter element.

Reference: Ingersoll Rand O&M Manual

Table : Maintenance schedule for Dryer

Weekly Verify temperature on the control panel display.

Visually check if condensate is drained regularly.

Check the dew point temperature.

Monthly Clean the condenser. (with compressed air)

Ensure that unit is working properly after cleaning.

12Months/2000Hours Check if flexible tube used for condensate drainage is damaged.

Ensure connecting pipes are properly tightened & fixed.


MAS Confidential

CMP MR 7

6.5.4 CMP MR 7 : leak detection and prevention program

Periodically check and rectify any compressed air leaks within the system in order to stop leakage

of air in the main network. The air leakage loss in the total system should be calculated before

searching for individual leaks in the network.

Studies show that 70% of leaks from an air main occur in the last few meters of the network

including T joints, switch couplings and air filter joints in sewing machines.

Simple Calculation

The simplest way of quantifying leakage (VL) is by using the following equation.

𝑉𝐿 =𝑉𝑇 × (𝑃𝑠 − 𝑃𝐹)

𝑡

VL = Volume of leakage (l/min)

VT = Volume of Receiver (l)

PS = Receiver pressure at start (bar)

PF = Receiver pressure at end (bar)

T = Time measured (min)

Firstly empty the compressed air receiver and plug in the supply line to the receiver after

making sure all consumer devices in the system are switched off. If there is a leak, the

receiver pressure will drop and the time taken for this could be measured.

Secondary Calculation

The consumer devices in the network should be switched off. The leaks in the system consume

compressed air and the network pressure will drop and the compressor must replace this

volume. The total running time of the compressor is measured over a period of time. Measuring

time should be for at-least 5 cycles for accurate readings.

Example:

A compressed air receiver with a pipe system has a volume of 1000L. Within 2 minutes

the pressure drops from 8 bar to 7 bar.

𝑉𝐿 =1000 × (8 − 7)

2= 500𝑙/𝑚𝑖𝑛


MAS Confidential

𝑉𝐿 = 𝑉𝐶 × ∑𝑡𝑥

𝑇

VL = Leakage (m3/min)

VC = Free air delivery of the compressor (m3/min)

∑x = t1+t2+t3+t4+t5 (min)

T = Total time (min)

*∑t = average compressor loading (running) times.

Certain levels of leakage could be tolerated as per the below schedule.

Table : Accepted leakage percentage

5% Small networks (below 250 CFM)

7% Medium sized networks (250-300 CFM)

10% Large networks (300-500 CFM)

15% Very Large networks (above 500 CFM)

Reference : Compressed air compendium_BOGE

A leak detection survey should be carried out quarterly depending on the results of the past

surveys (persistent leaks should result in more frequent leak detection surveys). This survey

should be carried out preferably on a day the plant is shut down.

How to conduct a leakage test

Step 1: Close all the end user valves.

Step 2: Make note of the volume of the air receiver and piping. Start the compressor.

Step 3: Measure time taken to pressurize the system to the set pressure.

Step 4: Measure loading/unloading cycle time. Total volume of system divided by time

taken for unloading time will give you the leak rate.

Step 5: By conducting a walk-around audit make note of places where leaks are taking

place and mark accordingly (mark on separate drawing if action is planned for a later

date).

Step 6: Prioritize the leaks and attend to larger air flow leaks first.


MAS Confidential

CMP MR 8

CMP RA 4

6.6 CMP MR 8 : Health and Safety

Comply with safety regulations mentioned in the factory ordinance and any other customer

requirements.

All pressure vessels should have safety valves and pressure gauges. Maximum pressure must be

displayed, along with Tested pressure and the next inspection date. Personal Protection

Equipment (PPE) must be available in the plant room and should be worn by the operator. The

following inspections should be carried out by a certified independent inspector.

Pressure vessel inspection – Every year

Internal Examination – Every 5 years

Pressure Test – Every 10 years

6.7 CMP RA 4 : Training

Systematic training programs must be conducted for maintenance team and compressed air end

users.

The factory must have at-least 2 qualified and sufficiently trained persons to operate the

compressed air system.

All designated compressor operators must take part in external training sessions conducted by

the supplier/manufacturer at least annually.

Training sessions should also be conducted for compressed air end users, such as sewing machine

operators and cleaning staff, on the correct uses and applications and creating awareness on the

ill effects of using compressed air incorrectly.


MAS Confidential

AC MR 1

AC MR 2

7.0 Air Conditioning (AC)

7.1 AC MR 1 : Actual Heat Load

Conduct a heat load calculation. Refer annexed excel calculation sheet.

This can also be done using simulation software.

The first step is to calculate the total heat load demand for the facility. This demand calculation

should be available with the factory engineer. Calculation method is attached in the annexures.

The demand calculation must be separately calculated for each section (Eg: Sewing floor, HR

office, etc.).

Current AC systems must be listed (Eg: 24000 BTU AHU, 2 Ton split, etc.)

Calculate Air Changes per Hour (ACH) based on the different sections identified above.

Example Table:

No Section Name Heat Load Demand (W) Current AHU/AC Size (KW) ACH

1 Sewing Floor

2 HR Office

Note: Facilities are exempted from ACMR1 for version 1.2

7.2 AC MR 2 : List of AC Equipment

The facility should have an updated list of all Air Conditioning equipment. The following points

must be included.

AC type

AC size

Age of the unit

Refrigerant Type / Charge

Make / Model / Year of Manufacture

Service agreements available (Y/N)

No Type Size(BTU) Make Model Year(age) Refrigerant Ref Charge( Kg)

EXAMPLE

1 Split 12000 Midea MC-XYZ 2000(13) R-123 2

* Same should be included for pumps, cooling towers & AHU’s.


MAS Confidential

AC RA 1 7.3 AC RA 1 : Efficiency Calculation

Running efficiency for the existing air conditioning system should be calculated. This should be

conducted for chillers and package units larger than 10RT.

Performance of refrigeration equipment is indicated using different bases. The most commonly

used bases are Coefficient of Performance (COP), Energy Efficiency Ratio (EER) and Kilowatt per

Ton (kW/TR) rating.

𝐶𝑂𝑃 = 𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑒𝑓𝑓𝑒𝑐𝑡 𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑 (𝑘𝑊)

𝐸𝑛𝑒𝑟𝑔𝑦 𝐼𝑛𝑝𝑢𝑡 (𝑘𝑊)

𝐸𝐸𝑅 = 𝑂𝑢𝑡𝑝𝑢𝑡 𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 (𝐵𝑡𝑢 𝑜𝑟 𝑘𝐶𝑎𝑙)

𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 𝐼𝑛𝑝𝑢𝑡 𝑃𝑜𝑤𝑒𝑟 (𝑘𝑊)

𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝐸𝑛𝑒𝑟𝑔𝑦 = 𝐼𝑛𝑝𝑢𝑡 𝑃𝑜𝑤𝑒𝑟 (𝑘𝑊)

𝑂𝑢𝑡𝑝𝑢𝑡 𝐶𝑜𝑜𝑙𝑖𝑛𝑔 (𝑇𝑅)

Energy Efficiency Ratio (EER) method is recommended for window, split and package type air

conditioning devices.

This kW/TR rating is widely used to express the performance of chillers. It denotes the power

input required to produce one tone of cooling input.

Typical COP and kW/RT of different Air Conditioner types are given below. Make sure the

system at each facility closely matches these values.

Type COP kW/RT @ full load

Window AC units 1.2 TO 1.3

Split AC units 1.25

Multi Split AC Units 1.2 TO 1.25

VRV AC Units 1.0

Package Units – Air Cooled 1.2-1.25

Package Units – Water Cooled 1.0-1.05

Chillers – Air Cooled 3.7-4.1 1.0-1.2

Chillers – Water Cooled 4.6-5.3 0.5-0.6

Pump Efficiency

𝑃𝑢𝑚𝑝 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =(𝑄 × 𝐻)

(𝑃𝑜𝑤𝑒𝑟 × 𝑀𝑒 × 𝐷𝑓)

Q = Flow rate (L/s) H = Pressure head + Suction lift (m) Me = Motor Efficiency Df = Transmission loss

Pump efficiency should be above 80% (rated), refer attached calculation excel sheet to

determine pump efficiency.


MAS Confidential

AC MR 3 7.4 AC MR 3 : Standard Operating Procedures (SOP)

The SOP for cooling systems must be displayed at all times in plant room at all times. All

operators must be aware of the contents of the SOP.

The SOP must follow the below mentioned format. Slight variations are allowed depending on

compressor model and manufacturer.

7.4.1 SOP – Water Cooled Package Units

Prior to starting

1. Make a visual inspection (dampers, piping, fan belt)

2. Compressor oil should be visible through sight glass.

3. Check voltage.

4. Ensure sufficient load.

Starting

1. Turn on the power switch.

2. Turn on the condenser water supply.

3. Check the fan for rotation direction.

Normal/Emergency Stopping

1. To interrupt operation, press STOP button.

7.4.2 SOP – Water Cooled Chiller

Prior to starting / starting

1. Verify the chilled water pump and condenser water pump starter are ON.

2. Verify cooling tower is ON.

3. Check oil tank oil level.

4. Check the chilled water set-point.

5. Check the current limit set-point.

6. Press AUTO.

Normal/Emergency Stopping

1. Press STOP

2. After compressor and water pumps shutdowns turn pump contactors to OFF.


MAS Confidential

7.4.3 SOP : Air cooled chiller

Prior to Starting

1. Visual Inspection (Oil level, Oil and chilled water leakage, Panel board and

cleanliness)

2. Check Voltage

Starting

1. Switch on all the AHUs

2. Turn on the chilled water pump (this will automatically start the chiller unit)

3. Check and make sure the working condition of the condenser fans.

Normal Stopping

1. Turn off the chilled water pump (automatically shut down the chiller)

2. Switch off the all AHUS

3. Clean the AHU filters

Emergency stopping

1. Turn off the chiller main switch

7.4.4 SOP : Air cooled package

Starting

1. Switch on the main panel

2. Switch on the blower fan from the compressor

3. Check the condenser fan

4. Check suction and discharge indicators, and make sure they are at the acceptable levels

stated by manufactures

5. Ensure there is no leakage of gas or oil of any kind

6. Check all unit’s ampere ratings and make sure they meet the requirements


MAS Confidential

AC MR 4 7.5 AC MR 4 : Preventative Maintenance

A daily log sheet must be kept to monitor certain parameters

7.5.1 Water Cooled Package Unit (WCP)

Table : Maintenance Schedule – WCP

Weekly Check liquid line sight glass.

Check temperature drop across the filter driers.

(Replace if necessary)

Monthly Inspect unit air filter.

Clean/Replace if necessary

Inspect coils for excess moisture or icing.

Check condensate flow through drain pipe.

Check tension and condition of fan belts.

6 Months Inspect fan motor for proper lubrication.

Disconnect power & manually check fan rotation.

Check alignment of fan assembly sheaves.

Inspect, clean, tighten all electrical connections.

Inspect TXV sensing bulbs.

Drain & inspect the condenser water system.

Clean the condensers.

Reference: Trane water cooled package

7.5.2 Water Cooled Chiller (WCC)

Table : Maintenance Schedule – WCC

Daily Check chilled water entering & leaving temperatures.

Check condenser water entering & leaving temperatures.

Current drawn by compressor.

Oil level in oil sump.

Condenser pressure.

Evaporator pressure.

Check for unusual noise and vibration.

Annual Check setting and operation of control & safety devices.

Conduct refrigerant leak test.

Check starter contactors. Replace if required.

Check motor winding insulation.

Check motor amps draw.

Perform oil analysis.

Perform vibration analysis.

Check & adjust water flow.

Check & adjust interlocks.


MAS Confidential

Clean condenser tubes.

Check evaporator insulation for condensate/leakage

Check refrigerant gas discharge pressure

Reference: Trane water cooled chiller

7.5.3 Air Cooled Package Unit (ACP)

Table : Maintenance Schedule – ACP

Daily Remove Filters & wash

Monthly Service Evaporator & condenser coils

Check blower motor belt tension

Check blower & fan motor bearings

Check suction & discharge pressure

Check compressor unit current

Check contactors, thermostat, sensors

Clean drain lines

Annual Carry out insulation test for compressor & fan motor

Service contactors


7.5.4 Air Cooled Chiller (ACC)

Table : Maintenance Schedule – ACC

Weekly Clean filters

Monthly Check chiller operation

Check fan bearing

Clean cooling coils with high pressure water

Check pump gland

Check liquid & oil level in sight glass

3 Months Calibrate with computer program

6 Months Check all controls

Annual Sample compressor oil and replace if necessary

Leak check chiller

Check wiring connections


7.5.5 Split Air Conditioner

Table : Maintenance Schedule – Split AC

3 Months Check Current

Check gas pressure

Check blower condition

Clean filters

Clean coil & drain pan

Clean/wash indoor/outdoor unit

Check & service compressor

Reference: Fujicool split AC


MAS Confidential

7.5.6 Cooling Tower

Table : Maintenance Schedule – Cooling Tower

Daily Check for abnormal noise and vibration

Check for abnormal temperature differences

Monthly Check water distribution & sprinkler

Clean tower pan & drain

Apply protective coating if required

Quarterly Check belt tension & pulley alignment

Check fan guard, inlet louvers & fan blades

Check operational level of pan and adjust if required

Annual Clean the strainer of the tower

Reference: King Sun cooling tower

7.5.7 Air Handling Unit (AHU)

Table : Maintenance Schedule – Air Handling Unit (AHU)

Monthly Check belt tension, motor current, damper function

Check air filter & service

Quarterly Clean coil & drain pan

Check & adjust pulleys, V belts & motor base

Lubricate fan & motor bearings

Check and clean electrical components, panel service

Check exhaust fan

Wash filters

Annual Check and correct earth fault settings

Reference: York AHU

7.5.8 Fan coil Unit (FCU)

Table : Maintenance Schedule – Fan Coil Units (FCU)

Monthly Clean Filters

Quarterly Check electrical wiring & tighten

Clean drain pipes

6 Months Check condenser coil and clean if necessary

Reference: Uni-master FCU

7.5.9 Pumps

Table : Maintenance Schedule – Pumps

Daily Check abnormal noise and vibration

Check for cleanliness

Check contact points for wear & tear

Monthly Conduct visual inspection

Quarterly Apply grease to pump & motor bearings

Check loading amperage

Check electrical system


MAS Confidential

AC MR 5

AC MR 5

7.6 AC MR 5 : Water Treatment

The following water purification steps are mandatory for an effective chilled water system.

Testing should be conducted monthly.

Table : Water quality at cooling tower basin

Parameter Recommended Levels

1 pH 7.20 – 8.50

2 Electrical Conductivity, µS/cm Below 2000

3 Total Dissolved Solids, mg/l Below 1000

4 Total Hardness, CaCO3 mg/l Below 500

5 Total Alkalinity, CaCO3 mg/l 150-750

6 Phosphate, PBTC mg/l 3-8

Reference : Willpower Analysis Report

Table : Water quality at chiller make-up water

Parameter Recommended Levels

1 pH 6.9-7.5

2 Electrical Conductivity, µS/cm Below 100

3 Total Dissolved Solids, mg/l Below 50

4 Total Hardness, CaCO3 mg/l Below 25

5 Total Alkalinity, CaCO3 mg/l 50-100

6 Chloride, Cl, mg/l Below 20

7 Silica Below 5

Reference : Willpower Analysis Report

To achieve these values it is recommended that the chilled water system has a softener plant &

sedimentation filter depending on the quality of raw water. In addition corrosion & scale

inhibitors, dispersants and algae (Biocide & micro-biocide) inhibitors should also be used to

control the water quality.

7.7 AC MR 6 : Training

All operators running AC systems must be sufficiently trained on AC operations. It is further

recommended that an annual refresher training course be conducted for the operators by a

verified 3rd party trainer.

Training should include at least one or more of the following;

- Energy efficiency

- Effective maintenance

- Best practices

- Safety / refrigerant handling


MAS Confidential

AC RA 2 7.8 AC RA 2 : Best Practices

An AC evaluation for each facility should be carried out once in 2 years.

7.4.1 Best Practices – General Systems

Make sure the facility is running with the most suitable AC solution. Submit a shot write

up with relevant details.

Have in place efficient cooling systems in order to reduce the energy consumption after

first conducting a feasibility study.

A centralized Building Monitoring System (BMS) should be in place, which can remotely

monitor and control the AC system. It is recommended to control and display

temperature, humidity, CO2, AHU return air temperature, damper position & valve

position. It can also display chiller parameters such as load percentage, chilled water

temperature and loading amperes.

Conduct performance tests on equipment such as chillers, package units, AHU’s, pumps,

cooling towers and distribution systems every 2 years.

All heat generating equipment should be installed with heat extraction, isolation or

separation devices.

Heat recovery systems such as desiccant wheels should be installed.

For areas that produce high amounts of dust and fumes, it is recommended to carry out

a calculation to determine the optimum air exchange rate. This rate could typically be 8-

10 ACH.

Partitions must be in place to separate AC areas from non AC areas. These partitions can

be air curtains, plastic curtains or automatic speed (polythene) doors.

Make sure the building envelop is well insulated and has minimum air infiltration. 50mm

thick (density-32 kg/m3) glass-wool insulation along with double sided aluminium foil is

recommended for the roof.

7.4.2 Best Practices – Chiller System

Have in place VSD pumps for chilled water systems.

Ensure that the chiller is running at the highest corresponding efficiency loads based on

the recommended part load values. Conventional screw chillers are most efficient at 70-

80% of full load and VFD chillers are most efficient below 60% of full load, depending on

manufacturer specifications.

Optimum filters must be used to ensure good air quality. Flow velocity across the filters

should not be more than 2.5m/s. Filters should have a classification of MERV 9 or better.

Energy efficiency of the chiller could be improved by regulating the water temperature.

As the chilled water temperature in the chiller is usually between 7OC (leaving) and 12OC

(entering), it is recommended to increase the temperature of the water leaving the

system above 7OC. The incoming water to the condenser should be 3OC- 5OC lower than

the temperature of the outgoing water.


MAS Confidential

Water cooled chillers should be installed with a by-pass system so that the cooling tower,

chiller & AHU has the option of being by-passed independently. This is useful during

chemical flushing of individual components of the system without impacting the other

components.

7.4.3 Best Practices – Water cooled condenser systems

It is recommended to install a VSD motor or twin speed fan for the cooling tower.

A chemical management plan that meets the water conservation objectives and controls

corrosion, scaling, sediment and biological growth should be implemented. Mineral content is

typically managed through a combination of bleed-off and chemical treatment that prevents

precipitation of dissolved solids. Water conservation can be optimised by ensuring that bleed-

off and chemical strategies are aligned.

Consider increasing the conductivity concentration ratio of the cooling tower from 4 cycles per

bleed-off to 12 cycles, thus reducing the amount of water that is bled out. Other water leaks

resulting from drift loss and leaks should be minimised.

2.4.4 Best Practices – AHU (air side)

Air Handling Units (AHU) above 15kW should be installed with temperature sensors and variable

speed drive motors. It is also recommended to use 2 way motorised valves for VSD AHUs and 3

way motorised valves for non VSD AHUs.

Condensate water from AHUs should be recovered thus enabling higher water savings & chiller

efficiency. Condensate water runoff should flow in to a single tank taking into consideration the

quality of the water collected. Collection in a single tank will make it easier for the water to be

pumped back into the cooling tower. It is recommended to use an insulated line to pump back

the water.

All chilled water ducting lines must be sufficiently insulated by using appropriate material,

correct thickness and suitable U values (Heat transfer coefficient). Piping material must be

chosen considering the temperature range of chilled water.


MAS Confidential

BL MR 1

8.0 Boilers (BL)

Steam is used in a wide variety of application throughout the facility. Steam is produced in a

closed vessel in which water under pressure is transformed into steam by the application of heat.

In the boiler furnace, the chemical energy in the fuel is converted to heat which then heats the

contained water.

This document is focused on the operation and maintenance of boilers. Even though boilers can

cover a very broad area depending on the design, fuel type and application, this document mainly

focuses on bench marking best practices. Mini boilers will not be covered in this version.

8.1 BL MR 1 : Feed water Quality

The standards mentioned below must be met for boiler water quality.

Table : Feed water parameters

Parameter Recommended level

Total Dissolved Solids (TDS) 3500ppm

pH 10-11

Hardness 0-5ppm

M – Alkalinity (total) 500-700

P – Alkalinity (Hydroxyl) 200-400

Sulphite 30-70 ppm

Phosphate 30-70 ppm

Refer list of problems caused by impurities of water BL ANX A.


MAS Confidential

BL MR 2

8.2 BL MR 2 : Standard Operating Procedures (SOP)

The factory should have Standard Operating Procedures for boiler operation.

Example 1 : (Furnace Oil)

Start the boiler operation ½ hour before starting the distillation process based on the following

sequence,

Check the feed water tank & lines. Feed water tank needs to be ¾ full.

Check the make-up water line. A solenoid valve will control the minimum water level of

the tank.

Blow down the boiler to remove the precipitants & contaminants accumulated from the

last operation.

Open the diesel valve to let diesel into the burner. (Burning is started using diesel)

Turn on the Main breaker after making sure there are no faults.

Turn on the Burner switch. (Boiler will start at Low fire mode).

After few minutes (after verifying that the boiler is running smoothly), turn on the Auto

mode. This will enable the High fire mode.

When the boiler is pressurized to 0.5 bar, open the Air valve for few seconds (until steam

comes through the valve) to remove the air filled in the boiler.

When the boiler is pressurized to 2 bar, open the main valve at the steam header.

After 2 minutes, close the header bypass line.

At 4 bar, high fire will cut off and open the biogas supply manually. (Only for

Diesel+Biogas boiler).

Pressure set points are set at 4 bar – 5 bar

System Shut-down

Boiler is turned down 20 minutes before the distillation process ends. Shutting down sequence

is as follows

Turn off the burner switch.

Cut off the diesel valve

Let the boiler run at no load mode for 5-6 minutes.

Close the main valve at Steam header.

Open the bypass line. (Header pressure goes down)

Fill up the boiler up to the recommended level

Turn off the main breaker.


MAS Confidential

Example 2 : (Bio mass)

Verify that the main steam valve is closed.

Ensure that the feed water level is at the correct level.

Make sure that the valves in the feed water line are opened.

Test for right functionality of both the feed water pumps.

Make sure that all blow-down valves are closed properly.

Air venting valves of the boiler need to be kept opened during initial firing for some time

and then should be closed.

Fill softener water through feed water pump into boiler until it reaches the correct level.

During this operation, make sure switches of both feed water pumps are in the AUTO

position. Also verify that the feed water pump stops automatically when the water level

reaches the set level.

During the initial feeding of fire wood logs to fire chamber, make sure the fire wood is

dry and the size is of the fire wood is less than 5inch diameter.

Make sure fire wood is weighed and that the quantity does not exceed the quantity

recommended by the manufacturer.

Small pieces of dry firewood should be stacked close to the doors of the fire wood

chamber and pour kerosene oil (half a litre) before firing.

After small fire wood pieces are burned over switch on IDF fan and maintain speed at

300rpm.

Make sure scrubber is working together with the IDF fan.

Switch on the FD fan as other fire wood is started to be burnt

Switch on the saw dust feeding system after whole firewood bed catches fire.

Open blow down valve for 90 seconds, when the steam pressure crosses 5bar

Verify that the firing stops when steam reaches 9 bar.

Communicate with steam consumers and open valve as and when they require steam.

Ensure that the main safety valve of the boiler is functioning at set pressure.


MAS Confidential

BL MR 3 8.3 BL MR 3 : Maintenance Schedule

Have in place a daily log sheet and preventative maintenance checklist for the boiler system.

The following parameters need to be measured on a daily basis. Some parameters need to be

measured more than once a day depending on the requirement. Running hours of the boiler

must be logged along with the fuel consumption & water consumption. Fuel consumption data

should also include any solid fuels used in bio mass boilers.

Parameter

1 Fuel Temp

2 Fuel Pressure

3 Cylinder Pressure

4 Header Pressure

5 Flue Gas Pressure

6 Gauge Glass Level

7 Feed Water Level

8 Blow-down

9 Condensate Return

10 Feed Water Temp

11 Flue Gas Temp

12 Pre Heater Temp

13 Supply Steam Pressure

Maintenance Schedule

Table : Maintenance Schedule – Boiler

Daily Blow-down boiler as per TDS readings

Blow-down water gauge glass

Check fuel pressure

Check fuel pre-heated temperature

Weekly Remove photocell to check flame failure circuit

Clean ignition electrode

Check solenoid valves

Monthly Clean feed water tank

Clean water strainers

Clean fuel strainers

Check safety valves

Clean electrical controllers

2 Months Blow of soot in fire tubes

3 Months Check water pump output pressure

Check all motors

6 Months Tune burner

Inspect refractory

Inspect & clean water side

Annual Test safety valves, Repair is necessary

Chemical cleaning of water side

Overhaul water level controllers

Reference: SLEA Energy Managers Training


MAS Confidential

BL MR 4 8.4 BL MR 4 : Safety Systems

Periodic inspection of boiler must take place every 12 months.

Periodic inspection of steam receivers must take place every 24 months.

Inspection must be conducted by an authorised person and reports should be filed.

Scope of Boiler Inspection

A boiler inspection must be carried out annually by an authorized boiler inspector, while the

system is in shutdown.

Cold stage

Conduct hydraulic test.

Check water report and quality

Check condition of internal part of the boiler visually and hammer test.

Check external part.

Check refractory work.

Check all safety instruments for functionality.

Check all fittings.

Check tubes for scaling. Hot stage

Check and set safety relief valves.

Check water level sensors.

Check all gauges for functionality.

Check safety and warning alarms.

The following controls and safety measures must be in place;

Safety Interlocks

Unsafe conditions Instrument Action

High water level Level controller no 1 Feed water pump trip

Low water level Level controller no 2 Alarm and burner shut down

Extra low water level Level controller no 2 (overriding controller) Alarm & lock-out

Flame failure Photocell Alarm & burner trip

Boiler high pressure Safety valve Lift & discharge

Table : Safeties and Controls


MAS Confidential

BL MR 4

.

Oil temperature indictor 1 no Local cum panel mounted to indicate oil temperature

Pressure switch 2/3 nos For firing positions of burner

Photo resistant cell 1 no Flame failure and audio visual alarm

Temperature controller 1 no To control oil temperature in burner heater before nozzle

with audio visual alarm and burner trip

Sequence controller 1 no To control sequence of firing, pre-purging etc.

Modulating mechanism 1 no Stepped/three stage modulating

Low oil pressure switch 1 no To trip burner with audio visual alarm

Level controller 2 nos To regulate feed water pump operation and trip burner in

case of very low level with audio visual alarm

8.5 BL MR 5 : Operator Training

Boiler should be operated by an authorised person who holds a boiler attendant’s certificate.

Class III– up to 2000lb/hr

Class II – up to 6000lb/hr

Class I – Any capacity.

Annual refresher training programs should be conducted for the boiler operator focusing on

energy saving and systems optimisation. The factory must have at-least 2 qualified and

sufficiently trained persons to operate the boiler.


MAS Confidential

BL RA 1 8.6 BL RA 1 : Heat recovery & Energy optimising

8.6.1 Boiler Blow-down

Blow-down is a necessary task in boiler operation intermittently reducing the concentration of

solids in the boiler. The frequency of blow-down depends on the quality of the feed water, the

use of the live steam and the quality of the make-up water.

In practice we see a blow-down of 0 % to 15 % of feed water. The consequence of too much

blow-down is an increase in fuel consumption. Too little blow-down also increases fuel

consumption, because it may lead to scale formation at the water-side of the boiler.

8.6.2 Reducing surface losses

It is important to sufficiently insulate the boiler to avoid heat losses. Regular maintenance must

also be conducted to reduce soot deposit on heat transfer surfaces and scale deposit on the

water-side. Both these could reduce the boiler efficiency by 5 to 10.5%. An additional 70% of

heat losses can be avoided by floating a layer of 45mm poly-propelyn balls on the surface of the

condensate.

8.6.3 Air pre-heating

A 1% fuel saving could be obtained by pre-heating the incoming air by 20OC more than the

ambient temperature, using the waste heat recovery unit. This can be done by forcing the

incoming air through a heat exchanger that passes through the heated flue gas. This saving is

achieved by fuel which would otherwise have had to be burned to raise the air temperature.

Air-fuel ratio

The objective of good combustion is to release the total energy in the fuel. Complete combustion

is only possible in the presence of an adequate supply of oxygen. If the supply of oxygen is lower,

incomplete combustion takes place. On the other hand if the supply of oxygen is more,

combustion efficiency is reduced as heat is absorbed from the combustion.

Table : Recommended excess air levels for various fuels

Fuel Excess air (% by wt) Efficiency (%)

1 Furnace oil, Diesel 17-22 85

2 Fire wood 25-40 70

3 Baggases 25-35 70

4 Gas 5-7 88

5 Paddy Husk 25-35 70

Reference : SEA Energy Auditor Program


MAS Confidential

BL RA 1

Maintaining the correct air fuel ratio at the combustion stage is very important; a 5% reduction

in excess air increases the boiler efficiency by 1%. This ratio can be kept at the optimum level

using a flue gas analyser, oxygen analyser or through effective maintenance.

8.6.4 Economiser & condensate recovery

It is recommended to recover condensate and to insulate the recovery lines to ensure minimum

heat loss. When feed water is kept above 80OC, the dissolved oxygen escapes from the water,

resulting in a corrosion free environment inside the boiler. Flash steam can be recovered from

blow-down water and used to pre heat boiler feed water.

The function of the economiser is to increase the temperature of the feed water before it enters

the boiler by passing it indirectly through the flue gas. This would save on fuel energy that would

be required to heat this water. A 6OC rise in feed water temperature corresponds to a 1% saving

in boiler fuel consumption.

8.7 BL RA 2 : Operational Improvements

8.7.1 Monitor operational performance

It is recommended to analyse the performance of boiler operations on a daily basis.

1. Boiler fuel yield. (Steam tons/fuel ton/Wood).

2. Makeup water (water cubic meters / Steam ton)

3. Electricity (Kwh/Steam tone)

For calculating above performance indicators, it is necessary to measure fuel consumption, water

consumption, steam generation and electricity consumption daily.

Automatic combustion air controlling system with flue gas oxygen analyser.

It is recommended to install a flue gas oxygen analyser to control combustion air motor speed at

set oxygen levels; 11-12% for biomass boilers and below 5% for HFO boilers. This ensures

efficient combustion and reduces electricity consumption.


MAS Confidential

8.7.2 Instrumentation

It is recommended to have the following instrumentation in place.

No. Item Qty Description

1 Water level controllers 2nos For feed pump operation and low water level alarm

2 Over-ride controller 1nos For lockout under extra low water level alarm

3 Steam pressure gauge with cock 1nos For display of boiler steam pressure

4 Water level gauge assembly 2nos For display of water level in the boiler

5 Switch gears, relays connectors 1set For individual controls of equipment through control panel (for lockout)

6 Audio visual alarm 1set In case of unsafe operation for lockout under extreme conditions

7 Pressure and temperature gauge with thermostat

1set For burner operation

8 Control panel 1set For housing above instruments and switch gears

9 Steam to fuel ratio monitoring system

1set To monitor and display the boiler efficiency on-line, using necessary meters, instrumentation and hardware

10 Main valves for boiler 2nos For safety (isolation valve)

11 Automatic blow-down control 1set

12 Water flow meters 1set

13 Steam flow meters 1set

14 Biomass weighing system 1set

15 Blow-down heat recovery 1set

Flow meters are necessary to measure water, fuel and steam generation. These three

measurements are needed in calculating boiler efficiency.

Temperature monitoring at stack is a mandatory requirement for boilers that run on

fossil fuel.

Temperature at the following locations has to be measured as they are critical for

calculating boiler efficiency.

o Temperature of combustion air.

o Temperature of makeup water.

o Temperature of exhaust air at inlet and outlet of APH. (Air Pre Heater)

o Temperature of exhaust air at inlet and outlet of WPH. (Water Pre Heater)


MAS Confidential

Variable Speed Drives (VSD or VFD) need to be in place to control combustion air so as

to maintain the optimum air to fuel ratio. This will help increase combustion efficiency

and to reduce electricity consumption.

Piping

Ensure correctly sized pipes are used. (do not oversize / undersize)

The distribution system should be setup so that sections can be isolated or branched off

if required.

Components of a steam system must include a steam pipe, flange, isolation valve, control

valve, expansion joint, strainer and pressure reducing stations.

Insulation & cladding

Pipes must be insulated with correct material and thickness, and be covered with

cladding.

Thermal insulation is used to reduce heat loss, provide protection from damage/burns

and to provide weather proofing. The insulating material must be temperature resistant,

have low conductivity, shock resistant, porous and inert. The most commonly used

materials are mineral wool, glass wool, calcium silicate and magnesia.

Minimum heat gradient across insulation.

Table : Economic thickness of insulation

TEMP Dia<50 Dia>50 Dia>150 Flats

50 25mm 25mm 25mm 25mm

100 25mm 25mm 40mm 50mm

150 25mm 40mm 50mm 65mm

200 40mm 50mm 50mm 80mm

300 40mm 50mm 65mm 80mm

400 50mm 50mm 80mm 80mm

Steam Traps & bellows

Ensure steam traps are sufficiently available and are in good working condition.

Generated steam must pass through a main header unit.

A steam trap is a device used to discharge condensate and non-condensable gases with

a negligible consumption or loss of live steam. When steam first enters the circuit from

the boiler it will encounter the cold surfaces of the distribution pipework and process

equipment. This temperature difference causes condensate to form. During the

installation of the trap; stop valve, strainer, spiratec chamber, non-return valve and

diffuser must be connected.


MAS Confidential

8.7.3 Reducing emission

The facility is recommended to install a dust collector and wet scrubber for biomass boilers.

In a wet scrubber, the polluted gas stream is brought into contact with the scrubbing liquid; by

spraying it with the liquid, by forcing it through a pool of liquid, or by some other contact method.

A wet scrubber removes pollutants from the flue gas generated by a furnace.

A dust collector is used to enhance the quality of air released from industrial and commercial

processes by collecting dust and other impurities from air or gas. Designed to handle high-

volume dust loads, a dust collector system consists of a blower, dust filter, a filter-cleaning

system and a dust receptacle or dust removal system.

Necessary steps must be taken to ensure that the flue gases meet the best practice parameters.

These regulations are covered in the Emissions Calibration Tool.

8.7.4 Calculate efficiency

Direct Method Calculation

Boiler Efficiency η =𝐻𝑒𝑎𝑡 𝑂𝑢𝑡𝑝𝑢𝑡

𝐻𝑒𝑎𝑡 𝐼𝑛𝑝𝑢𝑡× 100 =

𝑄×(ℎ𝑔−ℎ𝑓)

𝑞 ×𝐺𝐶𝑉

Q: Quantity of steam generated per hour (kg/hr)

Q: Quantity of fuel used per hour (kg/hr)

hg: Enthalpy of saturated steam (kcal/kg of steam)

hf : Enthalpy of feed water (kcal/kg of water)

GCV : Gross calorific value of fuel (kcal/kg of fuel


MAS Confidential

IEQ MR 1

IEQ RA 1

9.0 Indoor Environment Quality (IEQ)

9. 1 CO2 / Fresh Air Management

9.1.1 IEQ MR 1 : Indoor CO2 Management

The Carbon dioxide concentration inside the factory should not exceed 1500ppm. An annual CO2

audit may be carried out to monitor these values.

The normal concentration of CO2 in outdoor air is between 300-400 ppm. CO2 level in office

buildings typically range between 350 – 2500 ppm. It has been demonstrated that levels above

1000 ppm tend to result in health complains and above 5000 ppm is considered a health hazard.

LEED EBOM V3 stated that the maximum allowable indoor CO2 concentration cannot be greater

than 530 ppm above corresponding outdoor levels or 1000 ppm absolute.

Carbon dioxide test must be conducted on an annual basis to ensure building continues to adhere

to the indoor air quality standards. These levels must be checked in all occupied areas. This can

be carried out as an in-house audit. A portable Non-Dispersive Infrared (NDIR) CO2 sensor is

recommended for this (A NDIR sensor is a simple spectroscopic device often used as gas

detector).

Control methods for CO2 concentration through fresh air are given in the annexures.

Note 1: The maximum tolerance level for V1.2 will be 1500 ppm

Note 2: All new / upgrade AC projects must include a design criteria for CO2 to be below

1000ppm or follow ASHRAE 62.1 (Given in Version 2.0)

9.1.2 IEQ RA 1 : Permanently Installed CO2 Sensors

Install permanent C02 sensors to measure CO2 concentrations in order to maintain adequate

outdoor air ventilation rates inside the building.

CO2 concentrations are an indicator of air-change effectiveness where increased levels suggest

inadequate ventilation. With this information ventilation systems can be designed for actual

conditions thus saving on energy usage.

The building should have CO2 sensors in densely occupied spaces.

The sampling location must be between 3 and 6 feet above floor level, which known as the

breathing zone. Test and calibrate the sensors to have an accuracy of 75ppm or 5% of the

reading, whichever is greater.


MAS Confidential

IEQ RA 2

The calibration of the sensors must be carried out once every 5 years or as per the

manufacturer’s recommendation. Monitor and trend the CO2 concentration in intervals of 30

minutes and calibrate the system to generate an alarm visible to the systems operator if the CO2

concentration rises more than 15% above the corresponding minimum outdoor rate specified in

ASHRAE standard 62.1-2007.

Sensors connected to the BMS system are recommended to have audio visual alarms for high

CO2 concentrations.

9.1.3 IEQ RA 2 : Automated System For Fresh Air Management

Have in place a Building Management System (BMS) which is connected to at-least the AC

system. Connecting machinery, lighting and heat generation is recommended based on

feasibility.

OR

Availability of demand controlled dampers that can control the fresh air flow in to the building.

The purpose of this is to provide the capability for monitoring the ventilation system in order to

sustain occupant comfort and well-being. It is recommended to install a continuous monitoring

system that provides feedback on the performance of the ventilation system to ensure that it

maintains the minimum outdoor airflow rates and be capable of measuring and controlling the

conditions within 15% of the design rates. Monitoring should also be performed for at least 80%

of the buildings total outdoor air intake (LEED EBOM V3).


MAS Confidential

IEQ RA 3

9.2 Particle Management / Volatile Organic Compounds

9.2.1 IEQ RA 3 : Environment Monitoring Test

Facility is required to conduct an Indoor Environment Monitoring Test annually. This will cover

Dust, Noise, Light and Heat levels within the facility. Ensure the readings are below

recommended values.

Use MERV 09 (Bag filter 70-90%) or better filters in Air Handling Units (AHU’s).

It is necessary to have in place filtration media for all the outdoor air intakes. The strength of the

filtration, known as the Minimum Efficiency Reporting Value (MERV) shall depend on the

national guidelines and building best practice schemes. Pre-filters can also be used where

necessary. As per LEED-EB guidelines the filtration should have MERV 09. This translates to a

normal (bag) filter with an efficiency of 70-90%.

Establish and follow a regular schedule for maintenance and replacement of these filtration

media according to the manufacturer’s recommended intervals.

It is also recommended to have in place a permanent entryway system at least 10 feet long in

the primary direction of travel to capture dirt and particles entering the building (LEED NC V3).

Adhere to the maximum permissible levels stated in the National Environmental (Ambient Air

Quality) Regulations, 1994, published in Gazette Extraordinary, for particulate matter. (This is

covered in the environment monitoring test.)

The indoor noise level should not exceed the permitted levels mentioned in the National

Environmental (noise control) Regulations, 1996. (This is covered in the environment monitoring

test.)

Required parameters are listed in annexures. These requirements will be mandated in

Calibration Tool Version 2.


MAS Confidential

IEQ RA 4

IEQ MR 2

9.2.2 IEQ RA 4 : VOC Emissions Test

It is recommended that the facility conduct a Volatile Organic Compound (VOC) test.

The VOC test may be carried out in the bonding, moulding & printing sections. The purpose of

this is to make sure no VOC’s are present in the indoor atmosphere. If VOC’s are found then it is

recommended to conduct this VOC test annually. It is also recommended to conduct a VOC test

at the introduction of new product or process that may contain VOC’s.

It is also recommended to use low VOC products for applicable operations such as cleaning

chemicals and painting. Use green seal certified products where applicable. Avoid products

containing formaldehyde, for example in carpets, wall panels and cabinetry. Measures need to

be taken to control and mitigate random build-up of VOCs.

9.3 Fume Extraction / Contaminant Management

9.3.1 IEQ MR 2 : Indoor smoking

Smoking indoors is banned in all facilities.

Environmental tobacco smoke is both the smoke given off directly from ignited tobacco products

and smoke inhaled by smokers. This smoke contains a wide amount of carcinogenic chemicals

which can lead to asthma, bronchitis, pneumonia, lung cancer and heart disease. To minimize

exposure to building occupants, smoking is strictly prohibited in all indoor areas. Due to these

negative health effects indoor smoking is strictly prohibited in the buildings.

Plan for outdoor Smoking

If there is a designated smoking area, proper signage should be displayed and the area should be

located at least 25 feet away from building entrances, windows and air intakes. The purpose of

this is to reduce the exposure of building occupants to the harmful effects of environmental

tobacco smoke.


MAS Confidential

IEQ RA 5 9.3.2 IEQ RA 5 : Fume Extraction for specialized functions

Specialized machines emitting known toxins such as VOC’s and carcinogens must be extracted

from source. No recirculation of this air should be allowed.

Equipment such as photo process machines, clothes driers, and grinding machinery may have

exhaust duct collars for connecting ductwork that collect and remove contaminants. The

Standard requires that the discharge from such equipment be ducted directly to the outdoors.

This is also applicable for bonding & molding machines, soldering & stain removing operations

and other specialized operations within the facility.

In addition a total VOC audit should be conducted in the identified area and total VOC limit

should not exceed 500 µg/m3. This audit should be carried out annually and is conducted in Sri

Lanka by ITI and SGS.


MAS Confidential

WE MR 1

10.0 Water Efficiency (WE)

10.1 Water Sources

All water entering the site must be metered, monitored and sufficiently treated to meet the end use criteria. In addition, drinking water must also be tested.

The main consumption of water at each location comprises of process water directly linked to the production and non-process water which used for all other requirements. Raw water may enter the facility premises in one or more of the following methods

- City water(Pipe Bourne) - Surface water - Ground water - Rainwater - Other (water bowsers, external tankers, water dispensers)

This water is used for Process Consumption, Human Consumption, Utilities and Gardening.

The quality of waste water discharge must be analysed on a quarterly basis and should be within the limits stipulated by the National Environmental Act and BOI environmental guidelines.

Quality measurements must be carried out for Potable Water at all facilities on a Quarterly basis.

These measurements must be carried out by an accredited third party laboratory. For example: University of Moratuwa, Industrial Technology Institute (ITI), National Water Supply and Drainage Board (NWSDB) etc.

Any deviation from the respective standards should be addressed immediately and adequate corrective and preventive action should be taken.

10.1.1 WE MR 1 : Source Metering

Each plant must have Main Flow Meters for all incoming sources to measure the total water

input to the facility.

This would enable each facility to keep track of their water usage patterns and easily identify if

any discrepancies take place. The recording of these meters must take place on a daily basis.

Accurate, timely and complete reporting to Eco Tracker on a monthly basis must be executed

by facility representatives.


MAS Confidential

WE MR 2

WE RA 1

10.1.2 WE MR 2 : Sub Metering

Water used for Process and Non-process must be able to be identified separately.

The main measurement of water is based on Process Water and Non-Process Water (Human

Consumption, Utilities and Gardening). Therefore, it is required to measure these separately to

facilitate the analysis of water usage.

Water consumption should be measured and reported on the following bases:

Process water – Litres per kg of production. (Process water is relevant to Fabric and Apparel other facilities: Silueta, Linea Intimo & Prym)

Non Process water – litres per Full time equivalent.

It is recommended that facilities implement a sub-metering system most meaningful to its consumption structure.

Accurate, timely and complete reporting to Eco Tracker on a monthly basis must be executed by facility representatives by the 20th of every month.

10.1.3 WE RA 1 : Additional Sub metering

It is recommended that the following sections are also Sub-metered to ensure effective management of resources and reduction of wastage.

Apparel Plants Fabric Plants / Apparel Other Plants

Cooling tower Process users (Dyeing , Washing and Finishing)

Toilets Utilities (Boilers, AC)

Canteen & Kitchen Toilets

Irrigation & outdoor usage Canteen & Kitchen

Treated Waste Water discharge Irrigation & outdoor usage

Recycled Waste Water for Reuse Treated Waste Water Discharge

Accurate, timely and complete reporting to Eco Tracker on a monthly basis must be executed by facility representatives by the 20th of every month.


MAS Confidential

WE MR 3

10.1.4 WE MR 3 : Treatment of raw water

The raw water used at the facility must be treated appropriately and adequately as per the Water Source to ensure it meets the quality parameters for its designated usage. Drinking water quality must meet the parameters set in Drinking Water Standards of Sri Lanka (SLS 614:1983):WE ANX A

10.1.4.1 Treatment for Process Water

Treatment will occur as per the requirement of the Process , Machinery and other equipment used. However a Softener plant is recommended to keep the Total Hardness below 5 PPM. pH of the treated water must be 7 +/- 0.5.

10.1.4.2 Treatment for Non Process Water

Non-process water used for drinking, cooking and in washrooms may be treated in order to achieve the required quality. The treatment schemes for non-process water may include the following steps depending on the quality of the raw water.

Step 1 Multimedia filter / Rapid sand filter

Step 2 Activated carbon adsorption

Step 3 Softener plant (depends on raw water hardness)

Step 4 Advanced membrane filter (depends on raw water quality)

Step 5 PH correction

Step 6 Disinfection (Ultra violet, Chlorination, Ozonation)

In the case of multimedia & UV filters, it is mandated to have a standby unit. Pipe borne Drinking Water parameters must meet SLS 614:1983 standard and Bottled Drinking Water Shall meet the SLS 894 Standard.

Sample Table: Different Water Sources and their recommended treatment schemes. (Based on Raw Water Quality)

No. Water Source Final Use Treatment Steps

1 Well water Drinking Depending on the water quality, all the above steps may stay the same or reduced. (Ex: Avissawella Vs. Kilinochchi)

Gardening None (as it is).

2 City water Drinking None for online. But if an in-house sump is used, Step 6 should be incorporated.

Gardening None


MAS Confidential

WE RA 2

WE MR 4

Drinking water quality parameters must be monitored monthly.

10.1.5 WE RA 2 : Sustainable Sourcing

Existing Wells

If the facility receives its water from a tube well, the ground water availability of the respective

well must be monitored (depth & yield) in order to ensure the water yield and water tables are

not depleted. For this, a pumping test can be carried out by the National Water Supply &

Drainage Board (NWSDB) annually and a nearby open well can be used as the year-on-year

reference for the water level.

New Wells

In the case of constructing a new tube well, a hydro-geological survey and a pumping test (24

hours test) must be carried out by consulting the hydro-geological division of the National

Water Supply and Drainage Board (NWSDB).

10.2 Waste Water

There are two broad categories of waste water discharged from MAS facilities :

Industrial Waste Water (Effluent) – Liquid discharge from all processes and utilities (Dye house ,

Utility drains , Labs etc.)

Non-Industrial Waste Water (Sewage) – Liquid discharge due to human consumption (Canteen,

Kitchen, Toilets , Washrooms etc.)

10.2.1 WE MR 4 : Treating and Testing of Waste Water

All waste water must be treated within the factory premises before being discharged.

In the case that the facility is situated in a BOI zone that has a central waste water treatment plant the discharge must meet the BOI influent requirements. (WE ANX D). The discharge water must meet the tolerance limits stated in the National Environmental Act (NEA) No.47 of 1980. (WE ANX B,C,D)

The treated discharge water must be tested once in every 3 months for pH, BOD, COD, TSS, Oil & Grease, Amonical Nitrogen and once a year for all the parameters specified in the NEA. Test reports should be filed for future reference. (WE ANX B,C,D)


MAS Confidential

WE RA 3 10.2.2 WE RA 3 : Reuse of Treated Waste Water

Treated waste water may be re-used within the facility premises in order to reduce the potable water consumption, thereby reducing the water footprint and the cost of water.

Treated Non-industrial Waste Water (Sewage) can be used for toilet flushing and gardening. Water that is being re-used should be colourless, odourless and free of microorganisms. The treatment standard needed for each usage is given below. A separate plumbing system and adequate signage is mandatory.

Further treatment of waste water should be done only for the required quantity that will be re-used within the facility. For example if only 35% of treated waste water is needed for flushing, only 35% has to be further polished for re-using.

Table : Treatment if using treated waste water

No Usage Mandatory Treatment

1 Toilet Flushing Multimedia Filter /Activated Carbon Adsorption /Disinfection

2 Gardening Sprinklers - same as above.

Other – No treatment required if standards are met (refer WE ANX C)

3 Cooling Towers Membrane (Ultra, Nano, RO). But this is not feasible in this context

Harvested rainwater can be used for Toilet Flushing, Gardening and Cooling Towers. The treatment standard recommended for each usage is given below.

Table : Treatment if using harvested rain water

No Usage Mandatory Treatment

1 Toilet Flushing First Flow Diverter + Gravel filter + Disinfection

2 Gardening First Flow Diverter

3 Cooling Towers First Flow Diverter + Multimedia Filter + Disinfection.

It is recommended to analyse the inlet water quality prior to finalizing the treatment scheme for each end use.

Adequate signage must be allocated to identify reclaimed water distribution points for the benefit of the users.

It is recommended to use recycled waste water or harvested rain water for gardening activities, while avoiding the use of potable water. Using non-potable water for gardening will be a Mandatory Requirement in the Calibration Tool Version 2.


MAS Confidential

WE MR 5

10.3 Reduction Water Consumption

Steps must be taken within the facility to reduce the consumption of potable water.

10.3.1 WE MR 5 : Water Efficient Fittings

Water Fittings used in the factory must follow the Standard as mentioned in the MAS Water Policy (derived from LEED V3-EB for O&M 2009). It is mandated that a minimum of 25% of all water fittings in every facility meet this criteria.

Please refer IPC/UPS standards for further efficiency details. Refer WE ANX E

Type of Fittings MAS Recommended Standard

Faucet (Canteen) <6.0 LPM

Faucet (Toilet) <1.9 LPM

Faucet (self-closing) <0.96 per cycle

Urinal Flush <3.85 LPF

WC Flush (cistern) <6.0 LPF

WC Dual Flush 3 / 4.8 LPF

Showers <9.6 LPM


MAS Confidential

WE RA 4

10.3.2 Recommendation - Water Efficient Fittings (100%)

It is recommended that ALL water fittings adhere to the LEED 3.0 guidelines.

It is also recommended for facilities to exceed the MAS standard for fittings as given above.

The use of water efficient fitting will help to further reduce the water footprint of the facility. This section will become mandatory in the Calibration Tool Version 2.

Type of Fittings Recommended Fittings

Faucet (Canteen)

Push taps, Peddle taps, Eco aerators for existing aerated taps, Lever and Mixers with inbuilt efficiency

Faucet (Toilet) Sensor taps, Eco aerators for existing aerated taps, Lever and Mixers with inbuilt efficiency

Faucet (self-closing)

Push taps, Sensor taps

Urinal Flush Sensor and Push type or Complete unit with inbuilt efficiency

WC Flush Sensor, Dual Flush and Cisterns, Flush Valves, Conceal, Push Type, Wall Plate etc with inbuilt efficiency

Showers Shower heads with inbuilt efficiency.

10.3.3 WE RA 4 : Rainwater harvesting

Rainwater Harvesting shall be implemented where possible after conducting a feasibility study.

The following components should be available for a feasible rain water harvesting system to be set up at a plant :

Catchment Area (Roof or Roof-top slab)

Gutters and down pipes

Leaf Screens and First Flow Diverters (to remove debris and contamination sources)

Gravel Filters and Storage Tanks (adequately sized)

Gravity fed or Pumped to the end user after dis-infection (UV or Chlorination < 0.20 mg/l)

For Cooling Tower Use, Pumping / Multi-media Filter and UV Dis-infection is recommended.

Refer WE ANX F


MAS Confidential

WE RA 5

WE RA 6

10.3.4 WE RA 5 : Process Water Recovery

Attempts should be taken to recover and reuse process water.

Process water could be recovered from the following sources. Documented proof must be available with relevant persons.

Recovery of steam condensate for boiler feed water

Recovery of AC condensate

Recovery of process cooling water

Reuse cooling water

10.3.6 WE RA 7 : Drip irrigation for landscaping

Use re-cycled treated Waste water (sewage) or Harvested Rain Water for 50% of the total landscape area.

Following measures will ensure no potable water is used for landscaping:

Re-claimed Water Storage tank and feeding system (by gravity or flow actuated pump)

Selected Native Plant Species and zonally plumbing with a sub-flow meter.

LDPE (plastic) micro-irrigation tubing / Adjustable Drip Nozzles.


MAS Confidential

WE MR 7

WE RA 7

WE MR 6

10.4 Water Resource Enhancement

Water resources can be further purified and replenished by using simple mechanisms.

10.4.1 WE RA 8 : Ground Water Recharge

Have in place ground water recharge mechanisms within the facility.

Storm water can be collected to a water collection pond for groundwater recharging.

Landscaping should be carried out to reduce soil erosion and increase water absorption. Consultancy can be obtained from recommended external parties.

Construct wetland system to purify (including treated sewage waste water) and sustain water tables. Consultancy can be obtained from recommended external parties.

Construct percolation pits & bore-wells.

10.5 Training

10.5.1 WE MR 6 : Training of Maintenance Personnel

Employees engaged in the water treatment (raw/waste) and plumbing process shall be trained on the proper usage and maintenance and basic testing of these systems.

The training can include efficient operation and maintenance of waste water treatment processes, efficient operation of Air-conditioning system, best practices and techniques on water-harvesting

All Employees

Periodic training for all staff members, on water conservation and the MAS water policy.

Special training sessions must also be conducted for janitorial and gardening staff.

This section is covered in the Culture Calibration Tool.

10.5.2 WE MR 7 : Plumbing drawing & water balance calculation

Have in place a plumbing layout drawing and water balance calculation.

The plumbing layout drawing must be update and displayed in the engineers office or pump house room. The facility can also do a periodic leak detection test.

Plant water balance calculation shall be available with the plant engineer / sustainability representative.


MAS Confidential

WM MR 1

11.0 Waste Management (WM)

11.1.1 WM MR 1 : Centralised Waste Storage

A centralized waste storage area should be maintained for each factory / site.

11.1.1.1 Size of waste storage area

The size of the facility should be determined according to the amount of waste generated due to the normal operations of the factory and taking into account the frequency of waste collection / disposal. All waste items should be stored within the said facility and no waste material should be stored outside or at any other location.

11.1.1.2 Required infrastructure

The waste storage facility should be properly constructed having a roof to avoid rainwater contamination and effects of direct sun light. Effective spillage control measures such as a secondary container shall be in place for hazardous waste storage. The location of the facility should be determined according to access routes to be used by waste disposal vehicles.

11.1.1.3 Segregation at Waste storage facility

Waste collected at the centralized storage facility should be segregated by using a physical partition so that waste once stored will not get mixed. At a minimum the waste should be segregated as hazardous and non-hazardous waste. Non-hazardous waste should be further segregated according to the following types and taking into consideration the method of disposal.

1. Fabric 2. Paper / Cardboard 3. Plastic / Polythene 4. Bio-degradable 5. Glass / Metal

Signage should be used to identify the segregated waste at appropriate locations.

11.1.1.4 Hazardous waste storage

A separate room should be maintained for the storage of hazardous waste and appropriate warning signage should be used at the entrance. The hazardous waste storage facility shall have the following characteristics;

1. Built in a manner so that no seepage will occur due to a spill 2. Adequate secondary containment should be in place


MAS Confidential

WM RA 1

WM RA 2

3. Adequate spill control kits should be placed nearby in case of an emergency

11.2 Segregation of waste

11.2.1 WM RA 1 : Source Segregation

Segregation of waste at source should be carried out at all possible locations within the factory / office premises. Segregation should be carried out according to the following waste types:

1. Fabric 2. Paper / Cardboard 3. Plastic / Polythene 4. Bio-degradable 5. Glass / Metal 6. Hazardous

If any type of source segregation is carried out, the colour codes mentioned in 11.2.2 should be used for the containers used for segregation.

11.2.2 WM RA 2 : Colour Code for Easy Identification of Waste Types

The following colour code should be adopted for the ease of identification of segregated waste. This colour code should be used on the walls, signage and any other items used for the storage of segregated waste.

Type of waste Colour

Bio-degradable Green

Fabric White

Paper / Cardboard Blue

Plastic / Polythene Orange

Glass Red

Metal / Mixed waste Brown

Hazardous waste Yellow

This section will be a mandatory requirement in the next version.

11.3 Waste disposal

The disposal of all types of waste should be carried out in accordance with the Environmental Protection License of the factory and the waste policy of MAS Holdings. The relevant factory will be responsible for the environmentally friendly disposal of all wastes generated from the factory. The factory is responsible for disposing of all wastes collected in accordance with section 11.3.4


MAS Confidential

WM MR 2

WM MR 3

11.3.1 WM MR 2 : Waste disposal Methods

The final disposal of different types of waste has to be carried out as per the guidelines set out in the MAS Waste Management Policy. No waste type should be burnt / incinerated within the premises or sold to an outside party for burning / incineration, excluding those wastes sold to a CEA approved incineration facility. The waste hierarchy of Reject, Reduce, Reuse, Recycle, Energy recovery, Landfill should be adopted when disposing of waste at all times. Any type of waste that can be reused or recycled as per the Waste Management Policy should not be incinerated. Refer Annexure 1 for full list

Type of waste Mandatory method of disposal

Recommended method of disposal

Garments – Logo(Garments with Customer' Logo, Unique Prints or designs)

Should be shredded and sold to a recognized waste fabric collector for reuse / recycle. Items that are not recyclable should be sent to Geocycle

Garments – Non logo (Garments which do not carry Customer Logo, Unique Prints or Designs)

Stocks must be transferred to BPU

Recommended disposal methods mentioned in this section may be made mandatory in future versions of the calibration tool.

11.3.2 WM MR 3 : Selection of Waste Recyclers

A suitable waste recycler must be selected while following the criteria given below. The final disposal of waste may be carried out by an outsourced company (in accordance to section 11.3.5) competent with the disposal of such wastes. Any party identified by a factory for disposal of waste should be selected after verifying the suitability of the manner in which waste is disposed. The company carrying out the final disposal should possess the following documentation, copies of which should be kept at the factory.

1. A valid Environmental Protection License for the specified operation* 2. A Scheduled Waste Management License (for hazardous waste recyclers)

In the case where a waste recycler carries out collection of waste from the factory, requirements of section 11.3.3 will apply. * An EPL / certification from the Public Health Inspector is sufficient for a piggery. * EPL certification is not a Mandatory Requirement for fabric waste.


MAS Confidential

WM MR 4

WM MR 5

WM RA 3

11.3.3 WM MR 4 : Selection of Waste Collectors

A suitable waste collector must be selected while following the criteria given below. The collection and transportation of waste from the factory could be outsourced to a third party by either the factory or the recycler. In such an instant the third party identified for the collection of waste should possess the following documentation, copies of which should be kept at the factory.

1. Business registration / local authority approval to carry out the collection of waste 2. Sale records or documentation proof of how each type of waste is sold to a recycler 3. A Scheduled Waste Management License (for the transportation of hazardous

waste) Waste collectors are obligated to sell / transfer the collected waste to a qualified recycler. If the waste collector reuses or recycles any type of waste collected from the factory requirements of 11.3.2 will apply. In case a particular type of waste cannot be recycled or reused it should be sent for incineration to a CEA approved incineration facility.

Note: Please refer following link for printable/editable format for was disposal list. http://knet/sites/livinggreen/ESCalibrationTool/Forms/required_documentation

11.3.4 WM MR 5 : Agreements with Waste Collectors

The factory will sign an agreement with all waste collector/s who have been assigned to collect and transport waste out of the factory. The agreement shall include the following details;

1. The time period the agreement is valid for 2. Obligations of the factory and the waste collector (in accordance with section 11.3.3) 3. The types of waste the collector is responsible for collecting 4. The frequency of collection

11.3.5 WM RA 3 : Transportation of Waste

The transportation of waste out of the factory can be carried out using factory owned vehicles or vehicles of a contractor selected for this purpose. The vehicles used for transportation of waste should be specifically identified for this purpose and preferably should be a closed truck so that no spillage will occur during transportation.



MAS Confidential

WM MR 6

WM MR 7

WM MR 8

11.4 Monitoring

11.4.1 WM MR 6 : Waste Records

Records of all types of waste collected within the factory and the method of disposal for each waste type should be maintained within the factory. The following data on each waste type should be recorded on a monthly basis and needs to be updated on EcoTracker.

1. Type of waste 2. Quantity of waste collected (in Kgs, meters or any other unit as appropriate) 3. Method of disposal 4. Name of collector and recycler

11.4.2 WM MR 7 : Monitoring of Waste Collectors and Recyclers

An audit of the waste collectors and recyclers should be carried out at least annually in order to confirm that the collector / recycler is carrying out the activities as prescribed in the agreement with the factory. The following records should be maintained at the factory;

1. Site visit report 2. Photographs 3. Cusdec document if waste is being exported 4. Records of quantity of waste transferred by the collector to Holcim for incineration

More frequent audits may have to be carried out depending on customer or other requirements.

11.4.3 WM MR 8 : Scheduled Waste Management License

Applicable factories must obtain a scheduled waste management license. Any factory generating hazardous waste (as listed in schedule VIII of the National Environmental Regulations No. 1 of 2008) due to it being used in the normal manufacturing operations of the factory should possess a Scheduled Waste Management License from the Central Environmental Authority. This is also applicable for plants where a third party is conducting support manufacturing operations using hazardous materials (e.g. printing, embellishment etc.) If no hazardous waste is generated by the factory due to the normal operations of the factory a Scheduled Waste Management License is not necessary.


MAS Confidential

WM MR 9

WM RA 4

WM MR 10

WM MR 11

11.5 Waste reduction programs

11.5.1 WM MR 9 : Waste Reduction Kaizen / project

A minimum of 1 Kaizen / project must be implemented with the objective of reducing the waste generated and/or to dispose of waste in a more environmentally friendly manner. It is recommended to conduct 5 kaizens annually. Records of the waste reduction programs should be maintained and should include;

1. Baseline 2. Target reduction level 3. Time period 4. Methods to be used 5. Actual reduction within the time period 6. Environmental benefit

11.5.3 WM RA 4 : Encourage Use of Environmentally Friendly Products

The management may take steps to encourage the use of recyclable / recycled / bio-degradable products within the factory and/or encourage the use of such products amongst its employees. Methods used for this purpose could include but not limited to;

1. Eliminating the use of non-recyclable products 2. Purchasing environmentally friendly products for the use in the factory 3. Subsidize environment friendly products for employees

11.6 Training

11.6.1 WM MR 10 : Training of Waste Handlers

Employees engaged in the waste disposal process (from generation to final disposal) shall be trained on the proper methods of waste disposal and on the use of personal protective equipment when handling hazardous waste. Records of such training programs should be kept at the factory. In addition one program must be conducted annually for all employees on waste related topic. This will be covered in more detail in the MAS_SCT_Culture Document.

11.7 Responsibility

11.7.1. WM MR 11 – Responsibility

The senior management shall appoint a competent employee who will be responsible for the management of waste within the factory and its disposal with any outside party. He/She will also be responsible for the maintenance of the records mentioned in earlier sections. Said person can also be included in the facility sustainability team.


MAS Confidential

12.0 Emissions Management (EM)

12.1 Greenhouse Gas Emissions Management

12.1.1 Introduction

As per the Kyoto Protocol established in 1997 by the United Nations Framework Convention for

Climate Change (UNFCCC), a global treaty was accorded to reduce Greenhouse Gas (GHG)

emissions in order to prevent potentially drastic impacts on long term global climate trends.

Accordingly, time-bound emission reduction targets are to be achieved at regional and country

level to support this global goal.

The following is the list of gases mandated for measurement under the Kyoto Protocol

1. Carbon Dioxide (CO2)

2. Methane (CH4)

3. Nitrous Oxide (N2O)

4. Hydrofluorocarbons (HFCs)

5. Perfluorocarbons (PFCs)

6. Sulpher Hexafluoride (SF6)

Scope for GHG Measurement

The scope of measurement for greenhouse gases is mandated as per the six Kyoto gases

mentioned above. Further, reporting of GHG emissions are to be classified under scope 1,2 &3

as per level of control the operating facility has on such emissions.

Calculation Methodology

For calculation of GHG emissions the following guidelines are to be strictly adhered to and no

alternative methods are to be used for the purpose. The method shown below is to be used for

calculating emissions for fuel combustion & purchased utilities and Refrigerant use at Facilities.

Fuel combustion and Purchased utilities at Facilities

Activity data : electricity in kWh or fuel data in litres or kgs

Emissions factor : CO2 equivalent kg per kWh or litre or kg (Refer annexure EM ANX 01 for

applicable emission factors)

Refrigerant use at Facilities

Preferred Method: Mass Balance

The preferred method for emissions related to refrigerant use at facilities is the mass balance

method which requires taking account of actual refrigerant refill volume on a periodic or need

basis. Accordingly, the applicable formula is as follows:

GHG emissions (CO2e kg)= Activity data * Emission factor

GHG emissions (CO2e kg) = Refrigerants used (kg)* GWP


MAS Confidential

EM MR 1

Nature and Scope of GHG Emissions

The following table provides the prescribed scope for measurement. While scope 3 emissions

measurement is not mandatory, please consider this as a recommended course of action for

good practice.

Nature of emissions Scope Reporting Status

Use of fossil fuels for stationary combustion within processes controlled and owned by the facility: Diesel/LPG/Kerosene/HFO (Control of process includes machinery and equipment hired/owned equally.

1 Mandatory

On-site combustion of waste or other processes not related to production

1 Mandatory

Diesel/Petrol/LPG used for company owned vehicles

1 Mandatory

Refrigerants from AC and freezer units which are not ODGs (Please refer annexure 02 for GHG emitting refrigerants)

1 Mandatory

Purchased electricity from the National Grid 2 Mandatory

Non-renewable energy purchased for use in the facility (steam/heat/other)

2 Mandatory

12.1.2 EM MR 1 : Primary data recording

Make sure the below mentioned items (quantity) are recorded and uploaded on eco tracker.

Purchased electricity

Fuel (Diesel/Kerosene/LPG/HFO)

Fuel : Company owned Vehicles

Purchased non-renewable energy (Steam/heat)

Purchased refrigerants


MAS Confidential

12.2 Refrigerant Management

12.2.1 Introduction

Inventory of ODGs

An inventory of ODG emitting refrigerants is to be compiled by each operating facility as per the

guidelines set by the Montreal Protocol which was ratified by the Government of Sri Lanka. A

list ODGs is provided in annexure 03 for reference and completion of the same.

In order to establish an ODG baseline for reduction and phase-out facilities can calculate their

ODG impact as per the methods explained in the following section.

Calculation Methodology

Preferred Method: Mass Balance

The preferred method for emissions related to refrigerant use at facilities is the mass balance

method which requires taking account of actual refrigerant refill volume on a periodic or need

basis. Accordingly, the applicable formula is as follows:

Secondary Method: Annual Leakage Rate

In the event that the plant does not have access to actual refrigerant data, the following method

could be used for completeness of reporting. However, this method is to be used only as a “last

resort” and not as an alternative to the mass balance method.

For chillers as per IPCC guidelines

For packaged units as per IPCC guidelines

For packaged units as per IPCC guidelines

GHG emissions (CO2e kg) = Capacity of unit*15% * GWP

GHG emissions (CO2e kg) = Refrigerants used (kg)* GWP

GHG emissions (CO2e kg) = Capacity of unit*5% * GWP


MAS Confidential

EM MR 2

ODGs banned by the Government of Sri Lanka

As per the guidelines set by the Government of Sri Lanka the following gases are banned.

Accordingly, the use of such is a violation of the emission calibration standards. Full list available

in EM ANX C.

Planned Strategy for Phase out of ODGs

In accordance with the expectations set under the Montreal Protocol, all new units purchased

within MAS Holdings with effect from January 2014 should not use ODGs. Therefore, the

emission calibration standards will aim to make MAS Holdings’ refrigerant use ODG-free by 2024.

This directive is subject to change depending on any forthcoming local or/and international

regulations.

12.2.1 EM MR 2 : Refrigerants Usage

The purchases of new equipment using CFC refrigerants are banned (refer table: Banned ODG

with effect from Oct 2003).

Existing equipment using CFC refrigerants purchased prior to Jan 2000 must be phased out and

converted to CFC free refrigerants by 2024. (Refer Annexure EM ANX 3)

The facility must have an updated list of all refrigerants used.

Table : Ozone Depleting Gases Banned

Code Symbol Substance

CFC -11 CFCl3 Trichlorofluoromethane

CFC- 12 CF2Cl2 Dichlorodifluoromethane

CFC- 113 C2F3Cl2 Trichlorofluoroethane

CFC- 114 C2F4Cl2 Dichlorodifluromethane

CFC- 115 C2F5Cl Chloropentafluroethane

Halon- 1211 CF2BrCl Bromochlorodifluoromethane

Halon- 1301 CF2Br Bromotrifluoromethane

Halon- 2402 CF4Br2 Dibromotetrafluroethane

CFC- 13 CF3Cl Chlorotrifluromethane

CFC- 111 C2FCl5 Pentachlorofluroethane

CFC- 112 C2F2Cl4 Tetrachlorodifluroethane

CFC- 211 33FCl7 Heptachlorofluropropane

CFC- 212 C3F2Cl6 Hexachlorodifluropropane

CFC- 213 C3F3Cl5 Pentachlorotrifluropropane

CFC- 214 C3F4Cl4 Tetrachlorotetrafluroprone

CFC- 215 C3F5Cl3 Trichloropentafluropropane

CFC- 216 C3F6Cl2 Dichlorohexafluropropane

CFC- 217 C3F7Cl Chloroheptafluropropane

Source: Gazette Extraordinary No 850/4 of Dec 1994


MAS Confidential

EM MR 3

EM RA 1

Air conditioner units

AC Type Refrigerant

Type

Annual recharge quantity of refrigerants (kg)

LG 9000 BTU R-22 0.5 kg

Refrigerators, Freezers & water dispensers

Refrigerator

type

Refrigerant

Type

Annual recharge quantity of refrigerants (kg)

Freezer R-134a 0 kg

12.3 Stack emissions

12.3.1 EM MR 3 : Annual Testing of Flue Gas

All facilities are expected to conduct a stack emissions test on an annual basis.

Stack emission tests must be conducted for boilers, generators & incinerators. Please refer

annexure EM ANX 4 for accredited third parties who could provide the said services. Stack height

measurements must also be available with the factory Engineer.

12.4 EM RA 1 : Scope 3 Emissions

Following sources of scope 3 emissions are recommended to be reported for good practice and

identification and influence of emission sources not within the direct control of the organization.

Nature of emissions Methodology for measurement

Stationary combustion: Use of fossil fuels within processes but not controlled or owned by the facility: Diesel/LPG/Kerosene/HFO

Please refer section 11.1.3

Mobile combustion: Diesel/Petrol/LPG used in hired vehicles for raw material, finished goods and employee commute. (Travel includes both surface and air)

Please refer section 11.1.3


MAS Confidential

EM RA 2

EM RA 3

EM RA 4

12.5 EM RA 2 : Guidelines for Stack Emissions

Facilities are recommended to meet the interim standards and guidelines set by the Central

Environmental Authority (CEA) on flue gas emissions and stack height.

Please refer annexure EM ANX 05.

12.6 EM RA 3 : Emission Reduction Initiatives

The following reduction opportunities are recommended. At least one initiative per year.

Identification of efficiency measures to reduce electricity and stationary energy use.

Generation or/and purchase of renewable energy (Solar, hydro, biomass and wind)

Generation or/and purchase of waste to energy sources such as biogas

Use of hybrid and electric vehicles for owned-fleet at facility level

Implementation of owned and/or community-based afforestation projects for offset of

emissions impact.

12.7 EM RA 4 : Biomass Supply

12.7.1. Use of Biomass Residue

Facilities which are currently using or intending to use biomass in their in-house stationary

combustion are encouraged to use biomass residue.

Following is the list of recommended composition of biomass residue.

Saw dust/saw dust briquettes

Paddy husk/paddy husk briquettes

Trimmings (Rubber, Cashew, Cinnamon, Pine, Acacia)

Residue approved by respective authorities such as the Forest Department and State

Timber Corporation

12.7.2. Use of Fuel wood

Facilities which are currently using or intending to use biomass in their in-house stationary

combustion are expected to consider using the following in their biomass composition:

- Gliricidia

- Caliandra

12.7.3 Maintaining a record of biomass supply


MAS Confidential

EM RA 5

Operating facilities are requested to maintain a consistent and updated supplier register for each

batch of biomass.

DATE BATCH NO

SUPPLIER

VEHICLE NUMBER

CLEARANCE DETAILS

TYPE

QUANTITY

REGION

REMARKS

12.7.4 Facilities are recommended to keep a checklist of biomass used with respect to the hours

run.

NO Date Running Hours Biomass Used (kg) Remarks

11.7.5 Facilities’ database with types and vendors will be subject to spot checks throughout the

year which will include the following for verification:

- Sourcing sites will be checked against plants’ database

- Spot samples will be checked for consistency in composition highlighted above

12.8 EM RA 5 : Large Scale and Long-Term Supply Partners for Biomass

Plants with an existing or a future biomass requirement are expected to maintain at least 20% of

its total supply through long term and large scale suppliers.

This is applicable for facilities that use 10 tons of biomass or more per day.

To qualify as a long term and large scale supplier the following conditions must be met:

- Meet at least 10% of the total daily requirement of the plant

- Provide biomass types recommended in section 11.7 of this document

- Sign an agreement to provide disclosure into vendor’s supply chain and support spot audits.

- Provide a stable supply and enter into an agreement to that effect for at least a year.


MAS Confidential

STE RA 1

13.0 Building Site & Envelop (STE)

13.1 STE RA 1 : Landscape Management Plan

A landscape management plan for the facility covering the following details (minimum) should be available.

a. Landscape map with storm water discharge lines/points b. Quantity of water used for irrigation c. List of landscape equipment

The landscape management plan should be prepared so as to reduce impervious cover, promote infiltration, capture and treat storm water run-off and to limit all site disturbances beyond the building perimeter, walkways and roadway curbs. It is recommended to use percolation pits and sedimentation traps with proper maintenance. Consider bird safe landscaping, façade treatment and glazed surfaces.

A system should be implemented to calculate the quantity of water used for gardening. If there is no separate water meter for this purpose a log sheet should be maintained indicating the time, duration of watering, dates and locations. This data can be used to estimate the quantity of water used for gardening each month. This is mandatory for facilities that use potable water for irrigation and recommended for those who use recycled water.

The list of equipment should also specify the frequency of usage of the equipment and the types and quantity of the fuels used.


MAS Confidential

STE RA 2 13.2 STE RA 2 : Heat Gain & Thermal Envelop

A thermal audit of all air conditioned buildings by using an IR camera should be carried out at

least once a year.

Abnormal heat/thermal spots should be identified by using an IR Thermal Camera. Windows, doors, walls etc. that are exposed to direct sunlight should be treated accordingly in order to reduce solar radiation into the facility.

Thermal heat gain from roofs can be reduced by insulating the roof or planting vegetation on the top of flat roofs.

Iinfiltration should be reduced via sealing cracks in a building's envelope, and for new construction or major renovations, by installing continuous air retarders.

Roof: Material of roofing sheets should have at least SRI78 or SRI29 depending on the slope of the roof, a green roof or a combination of both. Please see STE ANX A & B for more details of insulation types and their parameters.

Non-roof: Provide shading by introducing a tree canopy and have open grid paving. It is recommended to use materials with at least SRI29 rating or more.

Microclimate: A layout plan for existing paving, roads, courtyards etc. should be available. It is recommended for more than 50% of such areas should be shaded.

Shading: Windows exposed to direct sunlight (East-west oriented) should be adequately

shaded from the outside.

One or more of the following recommendations could be implemented as appropriate.

a. Shade to be provided through the of recesses in the external envelope of the building b. Shade to be provided by static or moveable external blinds or louvers c. Transient shading to be provided by the orientation of the building on one or more of

its external walls d. Permanent or transient shading to be provided by the surrounding buildings, screens or

vegetation. e. Shading of roofs by rolling reflective canvass, earthen pots, vegetation etc.


MAS Confidential

STE RA 4

STE RA 3 13.3 STE RA 3 : Asbestos Removal

It is recommended not to use asbestos as construction material when building new roofs.

It is also recommended that existing asbestos roofing material be phased out gradually.

13.4 STE RA 4 : Site Maintenance

A landscape map with tree location and list of species should be available.

Consider using native species in new garden projects.

As built drawings of the factory, a building material checklist and schedules should be available.

It is recommended to have a Certificate of Conformity issued by the Factory Inspection

Engineer.

Have the following checklists / schedules in place;

Cleaning maintenance

Garden maintenance

Onsite composting and organic fertilization


MAS Confidential

Facility should form a Chemical Management Team to coordinate the development and

implementation of the facility Chemical Management System

CM MR 1

14.0 Chemical Management (CM)

Many chemicals, dyes and raw materials are used in manufacturing processes. However, their

toxicity to human and to the environment is not always fully known. The MAS Chemical

Management Work Stream (CMWS) was initiated in 2013 with the intention of making ‘MAS and

its products free of toxic chemicals by 2020’. We will ensure the safety of our people, our

consumers and our environment through proactively understanding and prudently selecting

every chemical and raw material used within MAS.

The ‘Chemical Management’ forms a key part of our work stream. Effective chemical

management within the facility will ensure concrete benefits such as reducing costs and

environmental impact, becoming more competitive and improving worker health and safety.

14.1 Chemical Management System

14.1.1 CM MR 1: Chemical Management Team

A team approach to chemical management in a facility has been found to be the most effective strategy for long term planning and implementation. A team creates institutional memory, and the success of the team’s work continues even if one member leaves the facility. Also, a team representing all aspects of chemical use in the facility will develop a chemical management system that represents the entire facility, and helps to coordinate common responsibilities across departments.

Key stakeholders for your team; • Senior manager (GM/HRM/Dye house manager) • Department representatives (Dye house, Printing, QA lab, Maintenance, HR and

Finance) • Purchasing officer • Safety officer/ Compliance (Restricted Substances List/RSL) point person

• Representatives from chemical handling

Team meetings should be conducted (refer the following table) and meeting minutes must be

documented. A ‘Champion’ will be required to drive these initiatives.


MAS Confidential

The facility should adopt the MAS Chemical Management Policy

The facility should have a written chemical management plan

CM MR 2

CM RA 1

Table : Meeting frequency

Type of the business Meeting frequency

Cut and sew Quarterly

Dyeing, Printing Monthly

Note: Can be combined with any other committee/team

14.1.2 CM MR 2: Chemical Management Policy

The MAS Chemical Management Policy will address the following areas;

Chemical Purchasing Procedure

Chemical Handling and Use Procedure

Chemical Storage Procedure

Chemical Labeling

Note: For the Calibration Tool Version 1.2 facilities must adopt the MAS Chemical Procedure or

show progress of adoption. The MAS Chemical Management Policy will be shared with SBU’s

within the year.

14.1.3 CM RA 1: Chemical Management Plan

It is important that the facility set new targets and areas for action in order to make further

improvements in the management of hazardous chemicals. The facility can incorporate

programs in place to phase out the intentional use of the Zero Discharge of Hazardous Chemical

(ZDHC) priority chemical groups.


MAS Confidential

The facility should maintain a Chemical Inventory list

CM MR 3

14.2 Information of chemicals/dyes

14.2.1 CM MR 3: Chemical Inventory

14.2.1.1 Prepare a Chemical Inventory

A Chemical Inventory is a comprehensive list of chemicals/dyes used in a facility including;

Dye house

Printing

Production

Maintenance (thinners, coolants, machine oil, etc.)

Effluent Treatment Plant

Janitorial services (soap, detergents, etc.)

Laboratory, etc.

This enables facilities to easily respond to request on any use of hazardous chemicals for

production.

Information of all chemicals used in the facility should be filled in the ‘Chemical Inventory Form’

developed by the MAS Chemical Management Work Stream.

Note: Facility must complete the chemical inventory by 2 months prior to the assessment date

and send it back to the MAS Chemical Management Work Stream to carry out the ‘Hazard

Assessment’.

Note: Please refer following link for printable/editable format.

http://knet/sites/livinggreen/ESCalibrationTool/Forms/required_documentation

Figure : Chemical Inventory Form



MAS Confidential

The facility should collect additional information on dyes/chemicals including;

Technical Data Sheet (TDS)

Certificate of Analysis (CoA)

CM RA 2

14.2.1.2 Update the Chemical Inventory

Maintaining a chemical inventory should be a continuous process. Therefore, the chemical

inventory should be revised/updated due to,

Addition of new chemicals/dyes, new suppliers, etc.

Deletions

The MAS Chemical Management Work Stream will review the chemical inventory biannually.

Facility should clearly highlight the above changes (ex: use two color codes for addition and

deletions) and the quantity in the chemical inventory for the existing chemicals/dyes should also

be updated biannually.

14.2.1.3 Maintain MSDS

Material Safety Data Sheet (MSDS) or Safety Data Sheet (SDS) of all chemicals should be less than of 3 year old. The facility must communicate the requirement to chemical suppliers in order to obtain the most updated MSDS. If the existing MSDS does not meet the criteria, the facility must obtain a verification from the supplier to confirm that it is the most up-to-date version.

Although MSDS can vary in format, the facility should require their chemical suppliers to provide MSDS similar to the preferred examples in the CM ANX A. Restricted substances issues could be prevented when MSDS equipped with good information.

Each department of the facility should maintain MSDSs in a file for all chemicals/dyes used by them.

14.2.3 CM RA 2: Additional Information of Dyes/Chemicals

14.2.3.1 Technical Data Sheet (TDS)

Technical Data Sheet (TDS) or Technical Information (TI) sheet gives important information such as product description (application field, storage info, shelf life, etc.) and chemical nature (claims like APEO-free, metal-free, etc.).

The facility should collect TDSs for all chemicals from chemical suppliers and document them.

Note: TDS is not available for dyes


MAS Confidential

The facility should maintain a Chemical Disposal List (MR)

CM MR 4

14.2.3.2 Certificate of Analysis

The Certificate of Analysis is a document generated for each run or batch of a product shipped. This may contain a list and percent composition of active ingredients, and results of analytical tests that were performed on the product, such as tests for contaminants (e.g., lead, cadmium).

Dye houses and QA (Quality Assurance) labs should collect this document for all chemicals/dyes used in their processes. Electronic version of this document should be available with the relevant person in the department.

Refer CM ANX B for more information.

14.2.5 CM MR 4: Chemical Disposal List

Completing the chemical disposal list will help the facility to identify chemical management problems or cleanout issues that need immediate attention or action (e.g., situations that might pose health and safety concerns to workers and staff, such as potential explosions or fires). It also helps to rank and prioritize departments and areas of the facility needing cleanout. Using this list, the facility could estimate the types and quantities of chemicals for removal in the cleanout. The facility can also identify activities that need the expertise of a qualified professional (e.g., removing and disposing of chemicals) when using a chemical disposal list.

Chemicals that are no longer being used, outdated, in poor condition, or otherwise in line for disposal should be included in this list. The facility should incorporate the following format to create the chemical disposal list.

Table 1: Chemical disposal list (Example)

Storage date

Product name

Information on

ingredients

CAS numbe

r

Expiry date

Estimated amount

Task owner

Action plan

Date of disposal

14/02/ 2013

RUCOGEN FWK

Nonionic surfactants (25-50%)

N/A 24/04/2014

20 kg

Propan-2-ol (1-5%)

67-63-0


MAS Confidential

The facility should gather positive lists from chemical suppliers

Facility should test both incoming water and raw effluent against the ZDHC 11 priority chemical

groups

CM RA 3

CM MR 5

14.3 Restricted Substances Compliance

14.3.1 CM RA 3: Positive List

Positive List (Refer CM ANX C) is a signed and dated declaration made by chemical suppliers which confirm that the formulations supplied to the facility are compliant with the ZDHC MRSL (e.g. no intentional ingredients of any ZDHC 11 priority chemical groups or as impurities above the limit specified in the MRSL). The facility should communicate this requirement to all chemical suppliers who are supplying

chemicals (all chemicals including dye house, effluent treatment plant/ETP, quality assurance

and maintenance and bulk chemicals) regarding this requirement in order to ensure their

commitment on the ZDHC targets. The facility should check whether any of these declarations

are renewed at least annually. This would enable facility to choose suppliers based on their

environmental performance.

Note: This requirement will be mandated in Calibration Tool Version 2. The facility should be

able to produce proof (ex: e-mail) of communications with suppliers.

14.3.2 CM MR 5: Water Testing against the ZDHC 11 Priority Chemical

Groups

Facility should test both incoming water and raw effluent against the ZDHC 11 priority

chemical groups. Please refer the Table 3 for the testing frequency.

Table : Water testing frequency

Type of the business Testing frequency

Fabrics Alliance Bi-annually

Silueta and Linea Intimo Annually

Wet process entities Annually (Exempted for Version 1.2)

Cut and Sew plants without wet processing Exempted

Testing incoming water will confirm whether the facility’s incoming water already contains any of the 11 ZDHC chemical groups. If it does, then it could be that the plant is using clean chemicals, but the facility incoming water is not clean. Raw effluent is the wastewater before conducting any treatment. Testing raw effluent identifies which of the 11 ZDHC chemical groups are being used in production.


MAS Confidential

The facility should have an action plan in the case of non-compliance with the ZDHC MRSL

CM RA 4

Water samples should be tested against the following priority chemical groups.

1. Alkylphenol ethoxylates and Alkylphenols (APEOs and APs) 2. Phthalates 3. Brominated and chlorinated flame retardants 4. Azo dyes 5. Organotin compounds 6. Perfluorinated chemicals (PFCs) 7. Chlorobenzenes 8. Chlorinated solvents 9. Chlorophenols 10. Short-chain chlorinated paraffins (SCCPs) 11. Heavy metals: Cadmium, Lead, Mercury and Chromium (VI)

These testing must be carried out by Bureau Veritas, Sri Lanka and the Compliance Point Person should share the results only with the MAS Chemical Management Work Stream upon request. Refer the following table for testing frequency.

Note: This requirement will be mandated for Wet Processing facilities from Calibration Tool Version 2.0 onwards.

14.3.3 CM RA 4: Action Plan in case of non-compliance

There are instances of non-compliance of chemicals/dyes due to intentional addition of

ingredients specified in the ZDHC 11 priority chemical groups or as impurities above the limit

specified in the ZDHC MRSL. In such cases, facility should build business relationships with their

suppliers to respond to such situations and overcome non-compliance.

Facility should be able to provide a copy of the corrective action process if there is any non-

conformance in the supply of the chemicals found by the facility.

Note: The MAS Chemical Management Work Stream will guide the facility to evaluate safer

alternative substances in the case of non-compliance with the ZDHC MRSL.


MAS Confidential

The facility should ensure the chemicals stored, labelled, handled and used in a proper

manner including;

Provide personal protective equipment

Containers must be capped and sealed

Segregation according to hazards

Storage of chemical waste

HMIS Rating

PPE Index

CM MR 6 14.4 CM MR 6: Chemical Storage, Labelling, Handling and Use

14.4.1 Availability of Personal Protective Equipment (PPE)

It is the responsibility of the facility to provide separate personal protective equipment (PPE) kits

for people who handle chemicals and they should be trained on the use of PPE. Personal

protective equipment must use properly when handling chemicals.

14.4.2 Storage of chemical containers when not in use

All chemical containers should be kept closed tightly when not being used. Facility should also

ensure that the excess chemicals are stored back in the main barrel soon after the addition

especially if jugs are used to transfer chemicals from the main drum/barrel. This is useful to

maintain the quality of chemicals.

14.4.3 Segregation according to Hazards

Chemicals should be stored according to chemically compatible families (chemical class/ reactive group). Compatibility on shelves should be vertical as well as horizontal. Storage recommendations given in the MSDS of the chemical should be followed.

14.4.4 Storage of Chemical Waste

Chemicals listed in the ‘Chemical disposal list’ under the section 14.2.5 should be stored

separately until a proper disposal method is determined. Follow the guidelines specified in the

section 14.4.4 when storing these chemicals.

14.4.5 HMIS Rating

A Hazardous Material Identification System (HMIS) is a numerical hazard rating that incorporates

the use of labels with color developed by the American Coatings Association as a compliance aid

for the OSHA Hazard Communication Standard.

The HMIS rating is found in the MSDS of the chemical. HMIS labels must be displayed to all

chemicals/dyes in the chemical storage area and the place of use. Refer CM ANX D.

14.4.6 PPE Index

The PPE Index must be posted in the chemical storage area and the place of use. Refer CM ANX

D.

http://en.wikipedia.org/wiki/Occupational_Safety_and_Health_Administration


MAS Confidential

The facility should

Monitor and document its chemical usage

Report the consumption of ‘Red’ and ‘Amber’ chemicals

Secondary containment should be available at all locations where chemicals are stored

CM RA 5

CM MR 7

14.4.7 CM RA 5: Secondary Containment

Facility should provide sufficient secondary containment for containers of any chemicals,

hazardous materials, solvents, etc. in the workplace. Capacity of the secondary containment

should be minimum of 110% of the primary container.

This requirement will be mandated in Calibration Tool Version 2.

14.5 CM MR 7: Consumption Monitoring

The facility should document the monthly consumption of all chemicals. The electronic version

of the monthly consumption report should be available with the purchasing officer.

The MAS Chemical Management Work Stream (CMWS) will carry out the ‘Hazard Assessment’ after the chemical inventory is submitted by the facility. This assessment will include a close and thorough inspection of the chemicals used within the business, cross reference them against our own MAS MRSL (Manufacturing Restricted Substances List) and classify them as either Red, Amber or Green.

Monthly consumption of the ‘Red’ and ‘Amber’ classified chemicals should be reported to the MAS CMWS by the first week of following month.


MAS Confidential

Employees directly exposed to chemicals should be trained annually

Empty chemical containers should be washed before being disposed from the factory premises

(MR)

CM MR 8

CM MR 9

14.6 CM MR 8: Training

Training topics should include and may not be limited to the following:

Safe handling, transportation, use and storing of chemicals

Chemical hazards

Toxicities of chemicals

Training on MSDS handling

Spillage prevention practices

Spill response plan

All trainings need to be documented (Signature sheets, photographs, training materials, etc.

should be available).

14.7 CM MR 9: Chemical Barrel Washing

All chemical cans and barrels need to be washed in house before being sold to a waste vendor.

100% of the washing effluent should be diverted to an effluent treatment plant.

The chemical containers refer to any container that was used to store / transport any

hazardous substances into the factory. These could be any type of barrels and cans used for

dyes, dyes, chemicals, printing ink, glue etc.


MAS Confidential

ANNEXURES

LT ANX A: Measurements and Units

Measurement Unit Description Relationship

Luminous Intensity Candela (cd) Radiant power from source. =1/683 W/sr

Luminous flux Lumen (lm) Quantity of light emitting from source

= 1cd/4*π*r2

Illuminance Lux (lx) Luminous Intensity = lm/Area

Luminance cd/m2 Perceived Brightness

Irradiance W/m2 Power of electromagnetic radiation per unit area

Lighting Power Density W/m2 Power of lights used per unit area on floor

Characteristic Dimensional Unit Equipment

Light

Wavelength Nanometer Spectrometer

Color None Spectrophotometer/Colorimeter

Flux density (Illuminance) Lux Photometer

Degree of Polarization % Polarization photometer

Light Sources

Energy radiated J/m2 Calibrated radiometer

Color temperature Kelvin(K) Colorimeter or photometer

Luminous Intensity Candela Photometer

Light output Lumen Sphere photometer

Lighting Materials

Reflectance % Reflecto-meter

Transmittance % Photometer

LT ANX B: Lighting Systems


MAS Confidential

LT ANX C: Typical Lamp Types and their Parameters


MAS Confidential

LT ANX D: Table of data to be filled out by each facility

Area Type Area

Type of light Wattage

Quantity of lights Lux LDP

Lighting controls

Daylight available

Production Floor General

Sewing Needle point Local

Office

Office Workstations Localized

Machine work shop

Knitting Localized

Dying General

Cutting Localized

Ironing & Spreading General

Fabric Inspection Localized

Storage & Warehouse General

Canteen

Gym

Roads and pathways (Inside) General

Walkways (outside) General

Parking (exterior)

Roads and pathways (Outside) General

Main entries

Other entries

Illuminated walls

CMP ANX A

Policy Documents

Maintenance check sheet


MAS Confidential

CMP ANX B

Refrigerated Compressed Air Dryer Correction Factors

Inlet Air Pressure

Psig (bar) Correction Factor

50 (3.4) 1.29

75 (5.2) 1.10

100 (7) 1.00

150 (10.3) .86

250 (17.2) .79

Inlet Air Temperature

ºF ºC Correction Factor

80 26.6 .61

90 32.2 .79

100 37.7 1.00

110 43.3 1.23

120 48.8 1.51

Ambient Air Temperature

ºF ºC Correction Factor

80 26.6 .80

90 32.2 .89

100 37.7 1.00

110 43.3 1.16

120 48.8 1.30

BL ANX A: List of problems caused by impurities of water

Table: List of problems caused by impurities of water

Impurities ( Chemical Formula)

Problems Common Chemical Treatment Methods

Alkalinity (HCO3-, CO3

2- and CaCO3)

Carryover of feed water into steam, produce CO2 in steam leading to formation of carbonic acid (acid attack)

Neutralizing amines, filming amines, combination of both and lime-soda

Hardness (calcium and magnesium salts, CaCO3)

Primary source of scale in heat exchange equipment

Lime softening, phosphate, chelates and polymers

Iron (Fe3+ and Fe 2+) Causes boiler and water line

deposit Phosphate, chelates and polymers

Oxygen (O2) Corrosion of water lines, boiler, return lines, heat exchanges equipment etc. (oxygen attack)

Oxygen scavengers, filming amines and de-aeration

pH Corrosion occurs when pH drops below 8.5

pH can be lowered by addition of acids and increased by addition of alkalis


MAS Confidential

Hydrogen Sulfide (H2S) Corrosion Chlorination

Silica (SiO2) Scale in boilers and cooling water systems

Lime Softening

Source : fact sheet – Boiler Chemicals 101 :North Carolina Department of Environment and Natural Resources (NCDENR)

IEQ ANX A

Table : Maximum Limits for indoor Particulate Matter (PM) volume

SCHEDULE

Pollutant Averaging time

Maximum Permissible Level

Method of measurement

µgm-3 ppm

Particulate Matter – Aerodynamic diameter is less than 10µm in size (PM10)

Annual 50 - High-volume sampling and Gravimetric or Beta Attenuation 24 Hours 100 -

Particulate Matter – Aerodynamic diameter is less than 2.5µm in size (PM2.5)

Annual 25 - High-volume sampling and Gravimetric or Beta Attenuation 24 Hours 50 -

Source: National Environmental (Ambient Air Quality) Regulations, 1994, published in Gazette Extraordinary, for particulate matter.

IEQ ANX B

Table : MERV filter efficiencies

MERV Rating 0.3-1.0 Microns 1.0-3.0 Microns 3.0-10.0 Microns

Dust Spot Efficiency

1 <20% <20%

2 <20% <20%

3 <20% <20%

4 <20% <20%

5 20-35% <20%

6 35-50% <20%

7 50-70% 25-30%

8 >70% 30-35%

9 <50% >85% 40-45%

10 50-65% >85% 50-55%

11 65-80% >85% 60-65%

12 <80% >90% 70-75%

13 <75% <90% >90% 89-90%

14 75-85% <90% >90% 90-95%

15 85-95% <90% >90% >95%

16 <95% <95% >95% N/A


MAS Confidential

17 >99.9%

18 >99.9%

19 >99.9%

20 >99.9%

Reference: Allfilters.com & ASHRAE 52.2

IEQ ANX C

Table: Noise Level


MAS Confidential

IEQ ANX D: Additional Information

Air Exchange Rates

The following air change rates should be followed in any typical factory setup. These values have

been derived from ASHRAE 62.1 to better suite factory working conditions.

Typical Location Air Changes per Hour

1 Factory sewing floor 4-6

2 Kitchen 40

3 Operation Theatres 25-30

4 Workshop / Laundry 16

5 Normal / office room 2-4

6 Public wash rooms 16

7 Office wash rooms 6-12

IEQ ANX E: Ventilation Rate Procedure (VRP) – ASHRAE 62.1

Fresh air should be calculated as per the Ventilation Rate Procedure (VRP) mentioned in ASHRAE 62.1. The VRP is a prescriptive procedure in which outdoor air intake rates are predetermined for various space types (occupancy categories) based on contaminant sources and source strengths. The rates are intended to dilute and exhaust odorous bio effluents from occupants and odorous and sensory irritant contaminants from other sources common to that type of space. The VRP is based on typical spaces, those with contaminant source strengths commonly found in the listed category, and based on achieving reasonable levels of adapted occupant satisfaction with space air quality.


MAS Confidential

IEQ ANX F: Thermal Comfort

Thermal comfort is a condition that expresses satisfaction to the environment around. This has

been evaluated in ASHRAE 55 standard and is one of the important aspects in HVAC design.

The Predicted Mean Vote (PMV) is one of the more recognized thermal comfort models. There

are six primary factors that directly affect thermal comfort that can be grouped in two categories:

personal factors; based on the characteristics of the occupants and environmental factors; which

are conditions of the thermal environment. The former are metabolic rate and clothing level, the

latter are air temperature, radiant temperature, air speed and humidity.

The PMV is measured on a scale of -3 to +3. ASHARAE 55.1-2010 states the value of PMV must

be kept between -0.5 to +0.5 to ensure best thermal comfort.

The Predicted Percentage of Dissatisfied (PPD), which is related to the PMV, is an index that

establishes a quantitative prediction of the thermally dissatisfied people assuming that those

who vote -2, -3, +2 or +3 on the thermal sensation scale are dissatisfied. The model is also based


MAS Confidential

on the simplification that PPD is symmetric around a neutral PMV. ASHARAE 55.1-2010 states

the value of PPD must be kept below 10% to ensure best thermal comfort.

ASHRAE Standard 55-2010 sets an acceptable range of conditions that must be complied in order

to apply this method and draw the comfort zone: occupants’ metabolic rates between 1.0 and

1.3 met, clothing between 0.5 and 1.0 clo, air speeds under 0.2 m/s.

The PMV and PPD can be calculated at http://cbe.berkeley.edu/comforttool/

http://cbe.berkeley.edu/comforttool/


MAS Confidential

IEQ ANX G

Table : List of Low VOC paints in Sri Lanka

Asian Paints

Product Name Coating Type VOC in grams/Litre

Tractor Emulsion - Smooth Wall Finish (White) Flat 24.14

Royale Luxury Emulsion (Regal White) Non-Flat 55.62

Royale Shyne (White) Non-Flat 56.31

Apex Ultima Weather Proof Exterior Emulsion (Brilliant White) Non-Flat 33.67

Apex Weather Proof Exterior Emulsion (Classic White) Non-Flat 32.34

Ace Exterior Emulsion (White) Flat 22.22

Tractor Acrylic Distemper (Snow White) Flat 28.22

Premium Emulsion (White) Flat 41.3

Robbialac

Safecoat, Emulsion , Weathercoat, Ceiling White Flat Less than 50

Non Flat top Coat- Tuffkote Paint Non Flat Less than 50

Gloss -Robbialac Aqua Enamel , Non Flat Less Than 50

Robbialac Enamel, Non Flat Less than 400

Robbialac varnish Non Flat Less than 400

Semi-Gloss -Robbialac Aqua Enamel( Satin) Non Flat Less than 50

- Robbialac egg shell Non Flat Less than 400

Non Flat top Coat - Robbialac Patashop Enamel Non Flat Less than 400

Primer Or Undercoat – Lankem -Wallkote, Primer/undercoat Less than 50

Robbialac Wallfiller, Primer/undercoat Less than 50

Lankem Skimcoat Primer/undercoat zero

Robbialac Crack Bridging primer, Primer/undercoat Less than 50

Robbialac Aquablock Primer/undercoat Less than 400

Robbialac Alkali Resistance Primer Primer/undercoat Less than 400

Floor paint - W/B 2k Kemikote Flat Less than 50

- Kemikote Floor paint Flat Less than 500

Flat top coat - Robbialac Patashop Emulsion , Flat Less than 50

Robbialac patashop W/coat Flat less than 50

Anti-corrosive coating – Robbialac A/C paint, Anticorrosive Less than 400

Robbialac Alkyd Zinc Phosphate, Anticorrosive less than 400

Epoxy ZincPhosphate, Anticorrosive less than 250

Reflective roof coating - Robbialac FlexibleRoofing Reflective Less than 50

Dulux

Dulux Pentalite flat 41

Glidden Max Emulsion flat 50


MAS Confidential

Dulux Light and Space non flat 67

Dulux 3 in 1 non flat 51

Recycle Paints flat 37

Dulux Weathershield flat 26

Dulux MP Weathershield non flat 69

Glidden Duraguard flat 45

Dulux Gloss non flat 415

Dulux MP Gloss non flat 399

Glidden Max Enamel non flat 417

WE ANX A

10.6.1 Drinking Water Standard (for pipe borne water: SLS614:1983)

PARAMETER Highest Desirable level Minimum permissible level

A Physio-Chemical

Electrical conductivity at 25°C µs/cm 750 3500

Total solids (mg/l) 500 2000

Colour (Hazen Units) 5 30

Taste Unobjectionable -

Odour Unobjectionable -

Turbidity (NTU) 2 8

Chloride CL (mg/l) 200 1200

FluorideF (mg/l) - 1.5

Iron Fe (mg/l) 0.3 1

Manganese (Mn) (mg/l) 0.05 0.5

Copper Cu (mg/l) 0.05 1.5

Zinc Zn (mg/l) 5 15

Calcium Ca (mg/l) 100 240

Magnesium Mg (mg/l) 30 150

Total Phosphates (PO4) (mg/l) - 2

Sulphate (S04) (mg/l) 200 400

Total Alkalinity (as CaCO3) (mg/l) 200 400

Total Hardness (as CaCO3) (mg/l) 250 600

Free Ammonia (as NH3) (mg/l) - 0.06

Nitrate (NO3) (mg/l) - 45

Nitrite (NO2 ) (mg/l) - 0.01

pH 7 0 - 8.5 6 5 - 9 0

Arsenic (As) (mg/l) - 0.05

Cadmium (Cd) (mg/l) - 0.005

Chromium (Cr) (mg/l) - 0.05


MAS Confidential

Cyanide CN (mg/l) - 0.05

lead (Pb) (mg/l) - 0.05

Mercury Hg (mg/l) - 0.005

Selenium (Se) (mg/l) - 0.01

Free Residual Chlorine (as Chlorine) (mg/l) - 0.2

Polynuclier aromatic hydrocarbons (mg/l) - 0.0002

Phenolic compounds (as phenolic 0H) (mg/l) 0.001 0.002

Grease & Oil (mg/l) - 1

COD (Chemical Oxygen Demand) (mg/l) - 10

Radioactive materials

Gross alpha radioactivity (pC/l) - 3

Gross beta radioactivity (pC/l) - 30

Bacteriological

Total Coliforms /100 ml Absent in (i) 95% of the samples in year end, and any two consecutive

samples

10

E.Coli/100ml Absent Absent


MAS Confidential

WE ANX B

10.6.2 Tolerance limits for the discharged of industrial waste water into inland surface waters as per BOI-Sri Lanka

No. Parameter Unit (Type of limit) Tolerance Limit Value

1 Total suspended solids mg/l, max 50

2 Particle size of the total suspended µm, Iess than 850

solids

3 pH at ambient temperature - 6.0-83

Biochemical Oxygen Demand mg/l, max 30

(BOD5, in five days at 20°C or

BOD3, in three day, at 27°C)

Temperature Discharge °C. max. Shall not exceed 40°C in any section of the

stream within, 15m downstream from the effluent outlet

Oils and grease, mg/l, max 10

7 Phenolic compounds (as phenolicOH) mg/l, max 1

8 Chemical Oxygen Demand (COD) mg/l, max 250

9 Colour

Wave length range Maximum spectral absorption coefficient

436nm (Yellow range) 7/m

525 (Red rance) 5/m

620 (Mac range) 3/m

10 Dissolved phosphates (as P) mg/l, max 5

11 Total Kjedahl nitrogen (as N) mg/l, max 150

12 Ammonical Nitrogen mg/l, max 50

13 Cyanide (as CN-) mg/l, max 0.2

14 Total residual chlorine mg/l, max 1

15 Fluorides (as f-) mg/l, max 2

16 Sulphides (as s2-) mg/l, max 2

17 Arsenic (as As) mg/l, max 0.2

18 Cadmium (as Cd) mg/l, max 0.1

19 Chromium, total (as Cr) mg/l, max 0.5

20 Chromium, Hexavalent (as C56+) mg/l, max 0.1

21 Copper (as Cu) mg/l, max 3

22 Iron (as Fe) mg/l, max 3

23 Lead (as Pb) mg/l, max 0.1

24 Mercury (as Hg) mg/l, max 0.0005

25 Nickel (as Ni) 3

26 Selenium (as Sc) 0.05

27 Zinc (as Zn) 2.0

28 Pesticides 0.005

29 Detergents/surfactants 5

30 Faecal Coliform 40

31 Radioactive material Between 10-8 and 10-7


MAS Confidential

WE ANX C

10.6.3: Tolerance limits for the discharged of industrial waste water on land for irrigation purpose as per BOI-Sri Lanka

No: Parameter Unit (Type of limit) Tolerance Limit Value

1 Total dissolved solids mg/l, max 2100

2 pH at ambient temperature - 5.5-9.0

3 Biochemical Oxygen Demand mg/l, max 250

(BODs in five days at 20°C or BODs in three days at 27°C)

4 Oils and greases mg/l, max 10

5 Chemical Oxygen Demand (COD) mg/l, max 400

6 Chlorides (as Cl) mg/l, max 600

7 Sulphates (as S04) mg/l, max 1000

8 Boron (as B) mg/l, max 2

9 Arsenic (as As) mg/l, max 0.2

10 Cadmium (as Cd) mg/l, max 2

1 1 Chromium, total (as Cr) mg/l, max 1

12 Lead (as Pb) mg/l, max 1

13 Mercury (as Hg) mg/l, max 0.01

14 Sodium Adsorption Ration (SAR) - 10-15

15 Residual Sodium Carbonate (RSC) mol/l, max 2.5

16 Electrical conductivity µ/cm. max. 2250

17 Fecal Coliform MPN/100ml, max. 40

1 8 Copper (as Cu) mg/l, max 1

19 Cyanide (as CN) mg/l, max 0.2

20 Radio Active Material:

(c) Alpha MIMI'S micro curie/ml, max 10^-9

(d) Beta emitters micro curie/ml, max 10^-8


MAS Confidential

WE ANX D

10.6.4: Tolerance limits for the discharged of industrial waste water into marine coastal areas as per BOI-Sri Lanka – Please refer water policy

10.6.5: WE ANX D1: Tolerance limits for the discharged of industrial waste water into the common waste water treatment plant as per BOI-Sri Lanka

PARAMETERS Max Tolerance Limits

BOD (5 days at 20°) (mg/l) 200

COD (mg/l) 600

pH 6.0-8.5

Total Suspended solids (mg/l) 500

Total dissolved solids (inorganic) (mg/I) 2100

Temperature (°C) 40

Phenolic compounds (as phenolic OH) (mg/l) 5

Oil and grease (mg/l) 30

Total Cluornium (mg/l) 2 (Chromium VI0.5)

Copper (as Cu) (mg/l) 3

Lead (as Pb) (mg/l) 1

Mercury (as Hg) (mg/l) 0.001

Nickel (as Ni) (mg/l) 3

Zinc (as Zn) (mg/l) 10

Arsenic (as As) (mg/l) 0.2

Boron (as B) (mg/l) 2

Ammonical Nitrogen (as N) (mg/l) 50

Sulphides (as S2-) (mg/l) 2

Sulphates (as S04) (mg/l) 1000

Chlorides (as Cr) (mg/l) 900

Cyanides (as CN) (mg/l) 0.2

Free Residual Chlorine (as Chlorine) (mg/l) Nil

Colour - Wave length range Max spectral abs

Coeff

400-499nm (yellow) 7/m

500-599nm (red) 5/m

600-750nm (blue) 3/m

Radioactive Materials

Alpha emitters (µc/ml) 10m-7

Beta emitters (µc/ml) 10m-6


MAS Confidential

Note: WE ANX D2

The quality of waste water discharged into common sewers or collection system should be such

to ensure that the waste water;

1. Does not damage the sewer by physical or chemical action;

2. Does not endanger the health of the workers cleaning the sewer;

3. Does not upset the processes that are normally used in sewage treatment;

4. Does not overload the common treatment plant;

5. Does not damage the crops or affect the soil an case the effluent after treatment is

used for irrigation and,

6. Does not create fire and explosion hazards due to certain constituent present in the

effluent

The industrial effluents not conforming to the specified tolerance limits or containing solids

such as ash, sands, feathers, large floatable items, straw, plastics, wood, lime slurry, residue,

beer or distillery slops, chemical or paint residue, gross solids from cannery wastes, cinder,

sand. tar, hair, rags, metal shavings, garbage and broken glass shall not be permitted to be

discharged directly into the common sewer line leading to the waste water treatment plant.

Such effluents have to be subjected to an in house treatment to bring them to be within the

suggested tolerance limits and or to free them from the undesirable material mentioned above

prior to discharge into the sewer line.

WE ANX E

10.6.6 LEED V3 – EB for O&M

Table : UPC / IPC standards for plumbing fixture water use

Fixture UPC/IPC Stnd EPA water sense Stnd

Water closets (gpf) 1.60 1.28

Urinals (gpf) 1.00 0.50

Shower heads (gpm) 2.50 1.5-2.0

Faucets and aerators (gpm)

Public lavatory 0.5

Private lavatory 2.2 1.5

Kitchen & janitorial sink faucets 2.20

Metering faucets (gpc) 0.25

Public metering lavatory faucets 0.25

1 Gallon = 3.85 Liters. Gallons per flush= gpf. Gallons per minute=gpm. Gallons per cycle=gpc IPC=International plumbing code. UPC=Uniform plumbing code

Reference : LEED V3 EBOM


MAS Confidential

WE ANX F

10.6.7 Rainwater holding provision requirement (Part 2, Schedule 7 of Extraordinary Gazette No. 1597/8 – 2009)

MINIMUM EQUIVALENT RAINWATER HOLDING PROVISION REQUIREMENT

Annual

Rainwater Band

(mm)

Minimum Volume (m3) required per 100 m2 of roof plan area and hard

paved area

Residential

Commercial Industrial Institutional Domestic

Apartments/

Condominiums

750 - 1000 1.5 2.5 5 8 10

1000 - 1500 1.5 2.5 3 8 10

1500 - 2000 1.5 2.5 3 5 10

2000 - 2500 1.5 2.5 3 3 5

2500 - 3000 1.5 2.5 2 2 3

3000 - 4000 1.5 2.5 1 1 2

4000 - 5000 1.5 2.5 0.5 1 1

5000 - 6000 1.5 2.5 0.5 0.5 0.5

Also refer rainwater harvesting guide: 2013


MAS Confidential

10.6.8 Unit Conversions and Some Definitions

Measurement SI Unit Other Related Conversions

1 Volume 1 m3 = ( 1mx1mx1m)

1000 Ltrs ( 1 Ltr = 1000 ml)

35.314 ft3

264.172 US Gallon

2 Weight 1 kg 1000 g (1g=1000mg)

2.205 Pound (lb)

3 Area 1 m2 = (1mx1m)

10.764 sq.ft

0.000247 Acres (1 Acres = 4046.856 m2)

4 Pressure 1 Pa= 1 kg/(m s2)

10-5 bar (1 bar = 105 Pa)

1 N/m2

(1 bar = 0.987 atm)

(1m H2O = 0.0968 atm)

5 Density 1 kg/m3 0.0624 lb/ft3

1 g /ltr

1000 g/m3

6 Flow Rate 1 m3 / s 264.172 gal / s

4.403 gpm

1000 Ltrs / s

7 Length m 1m = 0.001 km

1m = 39.37 inches

1 in. = 25.4 mm = 2.54 cm

8 Temperature 0 C 0 C = (0F - 32) / 1.8

9 Viscosity 1 m2/ s1 1550.003 in2/S

10.753 ft2/ S

Definitions

1 Absolute Pressure Pressure above absolute Vacuum - 0 atm. Used for Cavitation Calculations.

2 Gauge Pressure Over Pressure higher than the normal Atmos. Press. of 1atm. Normal Pressure Gauges show this.

3 Head How High the Pump can lift a Liquid ,(m) and independent of Liq. Density

4 Pump's Energy Power Transferred to the Liquid,(PH) = Power Input to the Pump (Shaft Power) P2 x Pump Efficiency.

P1 = Power Input to the Motor from the Distribution(Consumer pays for) Single Phase : P1 = V x I x CosΦ. Three Phase : P1 = √3 x V x I x CosΦ

Use Bernoulli’s Equation and Friction Factor Calculations for Pipe flow.


MAS Confidential

WM ANX A : Recommended Disposal Methods for All Waste Types

Type of waste Mandatory method of disposal

Recommended method of disposal

Garments – Logo(Garments with Customer' Logo, Unique Prints or designs)

Should be shredded and sold to a recognized waste fabric collector for reuse / recycle. Items that are not recyclable should be sent to Geocycle

Garments – Non logo (Garments which do not carry Customer Logo, Unique Prints or Designs)

Stocks must be transferred to BPU

Rejected Panels (Logo / non-logo)

Should be shredded and sold to a recognized waste fabric collector for reuse / recycle

Fabric /Lace – Logo Should be shredded and sold to a recognized waste fabric collector for reuse / recycle

Fabric / Lace – Solid Stocks must be transferred to BPU

Fabric waste contaminated by chemicals / dye

Send to Geocycle

Foam waste (not molded) Sell to third party for reuse / recycling

Foam waste (molded) Sell to third party for recycling Send to Geocycle

Trims – Logo (including customer labels)

Should be shredded and sold to a recognized waste fabric collector for reuse / recycle

Trims- with no customer identification

Sell to third party for reuse / recycle

Art work used in printing Should be shredded and sold to a third party for reuse / recycle. Items that are not recyclable should be sent to Geocycle

Used Thread cones Send back to supplier for reuse

Plastic and polythene waste contaminated by food / drink

Send to Geocycle

Polythene and plastic Sell to a third party for recycle

Corrugated boxes Send back to supplier (local) for reuse. If supplier is overseas sell for recycling

Paper contaminated by food Send to Geocyle

Cardboard and paper Sell to third party for recycling


MAS Confidential

Food waste Sell as animal feed or compost on site

Cooking waste Sell as animal feed or compost on site

Coconut shells Sell to third party for recycling (manufacture of charcoal)

Gardening waste Compost on site or sell for composting at outside location

Waste needles Sell to a third party for recycling

Other metal waste Sell or handover to third party for recycle or reuse

Glass Sell to a third party for recycling

Toner and Inkjet Cartridges Send for reuse to supplier

E-waste Handover to licensed e-waste collector for safe disposal

Fluorescent bulbs Handover to Asia Recycling for safe disposal

Sludge – Chemical Send to Geocycle for appropriate disposal

Sludge – Biological Use as fertilizer within the factory premises. Not recommended to be used for food crops / home gardening

Chemical Containers / Empty paint buckets

Send to Geocycle. If the plant has an ETP with chemical treatment, the containers could be washed and sold for recycling.

Used Machine Oil Sell to service stations for reuse. Recommended to use as fuel for in-house boilers after proper analysis.

Used Lead Acid Batteries Dispose as per e-waste section

No waste type should be burnt / incinerated within the premises or sold to an outside party for burning / incineration, excluding those wastes sold to a CEA approved incineration facility.

EM ANX A: Emission factors for different types of fuel

Fuel type Emission factor -CO2e kg/unit

Diesel (l) 2.79

Kerosene(l) 2.6

HFO (l) 3.117

LPG (kg) 2.75


MAS Confidential

Purchased electricity Emission factor –CO2e kg /kWh

2010 0.692

2011/2012/2013 (subject to revision) 0.7047

EM ANX B: Refrigerants and GWP

Industrial

Designation or Common Name

Chemical

Formula

Lifetime

(years)

RadiativeEfficiency

(W m–2 ppb–1) GWP

Hydrofluorocarbons

HFC-23 CHF3 270 0.19 11,700

HFC-32 CH2F2 4.9 0.11 650

HFC-125 CHF2CF3 29 0.23 2,800

HFC-134a CH2FCF3 14 0.16 1,300

HFC-143a CH3CF3 52 0.13 3,800

HFC-152a CH3CHF2 1.4 0.09 140

HFC-227ea CF3CHFCF3 34.2 0.26 2,900

HFC-236fa CF3CH2CF3 240 0.28 6,300

HFC-245fa CHF2CH2CF3 7.6 0.28

HFC-365mfc CH3CF2CH2CF3 8.6 0.21

HFC-43-10mee CF3CHFCHFCF2CF3 15.9 0.4 1,300

Perfluorinated compounds

Sulphur hexafluoride

SF6 3,200 0.52 23,900

Nitrogen trifluoride NF3 740 0.21

PFC-14 CF4 50,000 0.1 6,500

PFC-116 C2F6 10,000 0.26 9,200

Perfluorinated compounds

PFC-218 2,600 0.26 7,000

PFC-318 3,200 0.32 8,700

PFC-3-1-10 2,600 0.33 7,000

PFC-4-1-12 4,100 0.41

PFC-5-1-14 3,200 0.49 7,400

PFC-9-1-18 >1,000d 0.56

trifluoromethyl

sulphur pentafluoride

800 0.57

Fluorinated ethers

HFE-125 136 0.44

HFE-134 26 0.45

HFE-143a 4.3 0.27


MAS Confidential

HCFE-235da2 2.6 0.38

HFE-245cb2 5.1 0.32

HFE-245fa2 4.9 0.31

HFE-254cb2 2.6 0.28

HFE-347mcc3 5.2 0.34

HFE-347pcf2 7.1 0.25

HFE-356pcc3 0.33 0.93

HFE-449sl (HFE-

7100) 3.8 0.31

HFE-569sf2 (HFE-

7200) 0.77 0.3

HFE-43-10pccc124

(H-Galden 1040x) 6.3 1.37

HFE-236ca12 (HG-10)

12.1 0.66

HFE-338pcc13 (HG-

01) 6.2 0.87

Perfluoropolyethers

PFPMIE 800 0.65

Hydrocarbons and other compounds – Direct Effects

Dimethylether 0.015 0.02

Methylene chloride 0.38 0.03

Methyl chloride 1 0.01

EM ANX C: Substances controlled by Montreal Protocol

Industrial Designation or

Common Name

(years)

Chemical

Formula

Lifetime

(years)

RadiativeEfficiency

(W m–2 ppb–1) GWP

Carbon dioxide CO2 b1.4x10–5 1

Methanec CH4 12c 3.7x10–4 21

Nitrous oxide N2O 114 3.03x10–3 310

Substances controlled by the Montreal Protocol

CFC-11 CCl3F 45 0.25 3,800

CFC-12 CCl2F2 100 0.32 8,100

CFC-13 CClF3 640 0.25

CFC-113 CCl2FCClF2 85 0.3 4,800

CFC-114 CClF2CClF2 300 0.31

CFC-115 CClF2CF3 1,700 0.18

Halon-1301 CBrF3 65 0.32 5,400

Halon-1211 CBrClF2 16 0.3


MAS Confidential

Halon-2402 CBrF2CBrF2 20 0.33

Carbon

tetrachloride CCl4 26 0.13 1,400

Methyl bromide CH3Br 0.7 0.01

Methyl chloroform CH3CCl3 5 0.06

HCFC-22 CHClF2 12 0.2 1,500

HCFC-123 CHCl2CF3 1.3 0.14 90

HCFC-124 CHClFCF3 5.8 0.22 470

HCFC-141b CH3CCl2F 9.3 0.14

HCFC-142b CH3CClF2 17.9 0.2 1,800

HCFC-225ca CHCl2CF2CF3 1.9 0.2

HCFC-225cb CHClFCF2CClF2 5.8 0.32

EM ANX D: Recommended practice for stack emissions & height based on the

regulations under National Environmental Act

Standard limits for Pollutants:

Fuel Type

Particulate

Matter (PM)

(mg/Nm3)

Sulphur

Dioxide (SOx)

(mg/Nm3)

Nitrogen

Oxides (NOx)

(mg/Nm3)

Excess O2

Content

%

Liquid/Gas 150 1000 500 3

Standards on Stack Height:

Minimum chimney height C (m) in meters of any combustion point source is defined by

the following equation.

C (m) = H (m) + 0.6 U (m)

C : Minimum chimney height

H : Height of tallest building within 5U radius of the chimney

U : Uncorrected height for heat input

U = 1.36Q0.6


MAS Confidential

Where Q is the gross heat input in MW

In any case, chimney height shall NOT be less than 20m.

STE ANX A

Heat Island Effect – Roof (Roofing material SRI vs. Roof Angle)

(Source: http://www.leeduser.com/credit/NC-v2.2/SSc7.2)

STE ANX B

Different types of Insulation materials and their thermal parameters

Walls

Material Description "U" Factor

Flat Metal 0" Fiberglass Insulation 1.20 1" Fiberglass Insulation 0.22 2" Fiberglass Insulation 0.12 3" Fiberglass Insulation 0.09 4" Fiberglass Insulation 0.07 6" Fiberglass Insulation 0.05 8" Fiberglass Insulation 0.041 12" Fiberglass Insulation 0.027 Masonry 8" Brick 0.41 12" Brick 0.31 16" Brick 0.25


MAS Confidential

8" Conic Block, Solid 0.39 12" Conic Block, Solid 0.36 4" Conic Block, Hollow 0.51 8" Conic Block, Hollow 0.39 12" Conic Block, Hollow 0.37 Poured Concrete 2" Thick 0.99 (140 lb. / ft3) 4" Thick 0.86 6" Thick 0.75 8" Thick 0.67 10" Thick 0.61 12" Thick 0..55 Poured Concrete 2" Thick 0.62 (80 lb. / ft.3) 4" Thick 0.42 6" Thick 0.31 8" Thick 0.25 10" Thick 0.21 12" Thick 0.18

Doors


Steel No Fiberglas Insulation 1.20 Insulated 0.65 Wood 1" Thick 0.64

Roofs


Flat Metal - Roof 0" Fiberglass Insulation 0.90 1" Fiberglass Insulation 0.26 2" Fiberglass Insulation 0.16 3" Fiberglass Insulation 0.11 4" Fiberglass Insulation 0.071 6" Fiberglass Insulation 0.05 8" Fiberglass Insulation 0.039 12" Fiberglass Insulation 0.027 Wood - Roof 0" Fiberglass Insulation 0.48 1" Fiberglass Insulation 0.21 2" Fiberglass Insulation 0.12 3" Fiberglass Insulation 0.10 4" Fiberglass Insulation 0.075


MAS Confidential

6" Fiberglass Insulation 0.052 8" Fiberglass Insulation 0.04 12" Fiberglass Insulation 0.027 Concrete Deck - Roof 2" Thick 0.30 3" Thick 0.23 4" Thick 0.18 Sky Lights Single Wall 1.15 Double Wall 0.70

Floors - Exterior Exposure


Floor - Exterior exposure Insulated 0.55 Un-Insulated 0.81

Windows


Glass Single Pane 1.22 Double Pane 0.70 Fiberglass Panels 1.09


MAS Confidential

CM ANX A: Material Safety Data Sheet (MSDS)

Preferred MSDS


MAS Confidential

Non-Preferred MSDS


MAS Confidential

CM ANX B: Additional Information of Dyes/Chemicals

Technical Data Sheet (TDS)


MAS Confidential

Certificate of Analysis (CoA)


MAS Confidential

CM ANX C: Positive List


MAS Confidential

CM ANX D: Chemical Storage, Labeling, Handling and Use

HMIS Rating

PPE Index