Table of Contents

Declaration………………………………………………………………………………………………..............................................i
Acknowledgment..............................................................................................................ii
Abstract.............................................................................................................................iii
Objective...........................................................................................................................iv
Methodology.....................................................................................................................v
Literature review...............................................................................................................vi
Chapter one
Company background
1 company profile (B.G.I)...................................................................................2
1.1 Historical background.....................................................................2
1.1.1 Mission of (B.G.I)...........................................................................2
1.1.2 Vision of (B.G.I).............................................................................3
1.2 Objective of (B.G.I).....................................................................................4
1.3Major services granted by the company (B.G.I)...........................................5
1.4 Overall work flow........................................................................................6
Chapter two
Energy management in bottling department
2.1Problem statement & Justification.....……………………………………...9
2.2 thermal insulation………………………………………………………....10
2.3 Reason for insulation..................................................................................10
2.4 Common insulation material………….......................................................12
2.5 Super insulators…………………………………………………………...12
2.6 Bottle washer inputs……………………………………………………....13
2.7 Operating principles……………………….................................................14
2.8 Motorization………………………………….…………………………...15
2.9 Bottle loading…………………………………………………….……….15

Chapter three
Design of thermal insulation for steam pipelines
3.1 Cost analysis by steam leakage……………………………………..….…..16
3.2 Cost analysis by convection..........................................................................18
3.3 Cost analysis by radiation.............................................................................19
3.4 Cost analysis by bottle washer……………………………………………..20
3.5 The R-value of Insulation ………………………..………………………..22
3.6 Optimum thickness of insulation…………………..……………………....23
3.7 Design of insulation…………………...........………..…………………….24
Chapter four
Conclusion and recommendation
4.1 Conclusion.................................................................................................27
4.2 Recommendation..........................................................................................28
4.3 Reference………………………………………………………………...29

1
 Declaration
I, the undersigned, declare that the following report paper of the internship period is my original
work, has not been presented earlier after a completion of the period and that all sources of
material used for the report have been duly acknowledged.

Declared by:

Daniel Berhanu
Signature:___________________
___________________
Intern

Confirmed by
Tamerat

Signature: ____________________
____________________
Mentor

Mesfin
Signature: ____________________
____________________
Company Supervisor

2
 ACKNOWLEDGEMENT
I thank my company Human resource manager Mr.Mesfin and Mr.Tamerat he is the deputy
production head for they relentless support, advice and provision of motivation throughout the
internship period, which made my stay at the company as an intern a good time of experience.
Special thanks to all employees of B.G.I Ethiopia Machine operators, Technical assistance and
Engineers, of the B.G.I Bottling Department for their hospitality and guidance that they gave me
constantly throughout the internship period.

Also my gratitude goes to my teacher Mr. Meseret for his friendly support, advice and inspiration
during the internship period.

3
ABSTRACT

This paper is aimed at discussing the overall activity in the internship period that I am engage with
it. With a reference and reliance on the outline for an internship report, generally this paper will try
to discuss about the brief history of the internship hosting company, B.G.I Ethiopia (St. George
division) the overall internship experience including work task I have been executing, challenges I
have been executing, measures I have been taken in order to overcome the challenges and benefits
I gained from the internship and other related topics Although the internship period was only four
month, I got a lot of important things like I develop practical skills, how to manage myself if I
want to do private task in addition to being employee, how to react with the employers in the
company and to develop communication skill, organizational skill, responsibility in the task-
fulfillment, cooperation with colleagues and other issues. The main idea behind this internship
semester is that the student should know the outside environment before he/she graduated and after
graduation he/she might have the chance to create ideas which is vital for the people around the
country or develop his/her theoretical skill with the practical skill.

4
OBJECTIVE

GENERAL OBJECTIVE

 THE MAIN OBJECTIVE OF THE PROJECT IS TO AUDITE THE ENERGY OF THE STEAM

PIPELINE FROM THE OUTLET OF THE THE BOILER TO THE INLET OF THE BOTTLE WASHER

SPECIFIC OBJECTIVE

The specific objectives of this project:-

 Is to calculate the cost analysis due to poor steam leakage.in the steam pipeline

 Is to calculate the cost analysis due to the action of convection heat transfer mechanism on
the steam pipeline.

 Is to calculate the cost analysis due to the action of Radition heat transfer mechanism on
the steam pipeline.

5
 Methodology
In order to achieve the project both primary and secondary data will be used.
 Primary data is the data which is the first hand data through interview, questioner from
both manual operators and staff through direct observation.

 Secondary data also be used from written materials which describes the project those are
reports ,plans ,and documents.

6
Literature review
During the period of working the project I get only the reports and documents that helps me to get
the data which I use in my paper. but I didn’t get the documents that exactly deals about project.
And some of the data’s are taken from the case study’s which I get from Mr. Tamerat who is the
vice production head of the bottling department the case studs are deals about the energy auditing
and recovery mechanisms .

7
Chapter one

Background of Hosting Company (B.G.I)

1.1 Historical Background

Ethiopia’s pioneer brewery saint George, founded in 1922 is located in central Addis Ababa at a place
locally known Mexico square. The owning French BGI group is engaged in production, distribution
and retail of beverage products mainly beer in three breweries located in Addis Ababa, Kombolcha
town and currently started production at Hawassa. Its products include St. George Bottled Beer, St.
George Draft, Bati Beer and Castel Beer

The management and its capacity

The management of the Company is made up of

• The Board of Directors
• CEO and Deputies: Utility department, bottling department, marketing department who are
managing the operation offices
•Finance, Human Resource and Property Administrator
 • BGI Ethiopia PLC has currently 785 employs working permanently in all the
three factories full time and currently total Production capacity Of the company is about 1.67
million hectoliter per annum while the new production including the imminent expansion in
Hawassa increased the company’s total production to two million hectoliters.

1.1.1 B.G.I Mission

Provide the market with the highest quality of different brand Bottled Beer and genuine Draft and change
the image to center of excellence that would enhance competitiveness in the Beer Industry and profitability
for the company thereby ensuring the desired benefits for the owners and for its employers.

1.1.2 B.G.I Vision

Ensure that the services granted by the company have achieved a breakthrough to the satisfaction of our
customers and to see the society charming and enjoying by choosing our Brand products.

8
 1.2 Objectives of B.G.I

B.G.I Ethiopia being a profitable Beverge company and a center of excellence in brewing different
brand Bottled beer and genuine draft and also disterbute this product locally through the country
and abroad (in united stataes, Canada, Australia and united kingdom in mass beside other country)
B.G.I is a self sestaning private company that promote economic growth, sustainable development
by working with different governmental program and by working in cooperation with varies
brewery company in share.
- strength and promote the capability through human resource and by making technology
transfer
-build nice image for Ethiopia in competing on brewery industry locally and globally
through out then world
-ensures that it is self-sustaining and profitable through rendering quality services for its
customer.

9
 1.3 Major Services granted by the company

St. George beer factory is the pioneer beer factory producing a variety type of beer with different
Genuine Beer tastes the following are the products of the company with different brand and taste

♦ St. George Named for the patron saint of Ethiopia, Ethiopia's oldest brewery Saint found in
1922 is located in central Addis Ababa. The website of Lalibela U.K. a British company that
distributes Ethiopian beer in Europe, says that “St. George is a lively beer bursting with warm
flavors and aromas.” On ratebeer.com, a British drinker writes, “Golden beer with a strongest
frothy head. The aroma is gently malty, and the flavor is nicely dry with a hint of yeast. Overall a
reasonable lager.”And Sweet flavor, slightly rough and grainy flavor. To it in the sun but. . ”

♦ Castel. Another lager from Kombalcha and thus another product of BGI – it’s“known as Queen
of Beers,” and it “perfectly balances fresh and fragrant flavors in light, sparkling lager that is
recognized across Africa and Europe for its excellence.” the reviews vary. One reviewer from
British Columbia writes: “Golden-straw color with lots of sparkle. Grainy, slightly industrial nose
with aged herbal happiness. Malty start, finishes slightly tart. Quite sweet throughout, with some
very light herbal hop flavor but no bitternes

10
♦ Bati. Yet another lager from Kombalcha and BGI, with mixed reviews. From Maryland:
“Pours a small, off-white head, clear, golden color. Thin palate, typical lager taste. Nothing
really compelling about this beer other than it’s from Ethiopia.” And from France: “A golden
beer with a thin white head. The aroma has notes of malt and straw. The flavor is sweet malty
with primary notes of straw,”

11
 1.4 Over all work flow of bottling department

The process of making the beer available for market is taken care at the bottling section of the company.
Thus, after it has gone the process making the beer it is transported to the bottling section in this section
there are a number of processes taken care of to the bottle where the beer is packed and supplied to the
market.
Before the process starts every bottle and crates should be washed and clean from any kind of dust
before
it is used therefore the processes starts from big store where the empty bottles in a crate is put, thus from
this store number of sorted crates are taken using man operated forklift trucks to the Depaltising
machine where the machine operating mechanically with the help of pneumatically actuated crate
holders. This machine takes up seven crates at a time to the idle rollers and conveyers which are used to
transport the crates to the next stage. The crates pass through a simple general wash using water before
the bottle is separated from the crate.

The next stage will be separating the bottle from the crate for further washing and inspection of
the bottle.Therfore using Decamatic machine the bottle is separated from the crate and driven to
different conveyer to which it leads to the bottle washer. This machine is operated pneumatically to
separate the bottles from the crate in which it can processes 96 bottles at a time i.e. form one movement
we have this number of bottles taken up to the next conveyer but not only the bottles are taken to be
washed but also
the crates. The crate is taken to its washer which is spread highly pressurized water. The bottles that are
separated are taken to the bottles washer which is a big machine that operates with only one electrical
motor.

And this has its own advantage that is since it’s a bottling unit there might be a problem that
may occur thus in order to prevent the loss of just only working separate motor while the other is not
working. So it can be noticed that there are a number of power transmission mechanisms like chain and
shafts with gear boxes.
So as the bottles are aligned to their position there is a mechanism that pushes the bottles to the washing
sockets. Thus as it goes in to the socket it is transported to the inside of the washer as it passes different
stages i.e. the first stage it experience is the pre wash which removes some solid materials inside the
bottle and that can be washed away with spraying water over it. The next stage is to remove the labels
from the bottle since it has been used it has to be changed. Therefore as it passes this stage it is washed
with the chemicals like caustic Soda, water and steam is spread to the bottles through different nozzles.

As the bottles are ready to be filled with beer that is as it finishes the washing process it goes to
the filler machine but before getting there it passes through the inspecting machine called the E.B.I
machine (empty bottle inspector) this machine inspects if the bottles have broken bottle neck and if it
has any kind of residue in the bottle it automatically rejects that particular bottle that has problem. Thus
a bottle that has no problem goes directly to the filler machine. The filler machine is used to fill the
empty bottles with the beer to its appropriate level. This machine has 72 nozzles that are per one
revolution it fills 72 bottles and goes to the capping machine this machine directly works with filler as
the bottles are filled with going any distance it is capped with a metal cap.
The machine can do 18 bottles of beer per revolution of the machine. The caps that are used to seal the
beer bottle have their own system entering to the filler machine i.e. there is cap holder on the other side
of the machine operators feedlots of caps to it as the conveyors are magnetic they are stacked on the
conveyor belt to pass to the capping machine that’s how the caps are transported.

12
 The next part is the F.B.I machine (Full bottle inspection), this machine is used to inspect if bottle
have excess foam and not capped, and it is synchronized machine that it automatically rejects the bottle
with problem. Now this is done bottles that are to the correct level are sent to the pasteurizer. This
machine uses steam from the big boiler in order to increase the life span and sterilize the bear or in other

words when the beer is pasteurized it can be put and used after some time that’s advantage of the
machine. In this machine the bottle of beer passes different stages to go on it has its own temperature
that each stage has to go on.

As this process is done and bottle of beer comes out from the pasteurizer goes to the next stage
that is the labelling process. The labelling machine is other machine found in the bottling department,
this is machine is used to attach the trade mark of the company bottles come from the pasteurizer come
directly
to this machine so that it will have the sticker on it. After it passes this stage goes to the Incamatic
machine this machine is the exact opposite of the decimatic machine that is bottles that are ready to the
market are conveyed and an arranged as it reaches to the machine then after it reaches machines
automatic arrangement will pick up bottles to the crate but at the same time the crates also be conveyed
from their washer. By this process it is the end of the bottling group and ready for market.

In this overall process or the bottling there are number of sensors available at some distance, the
purpose of this sensors is since this machines are synchronized i.e. no machine works alone while the
other is not working thus this sensors at each places are necessary. The following figure shows the
simple flow chart of the bottling of beer.

13
 Depalletizer Decrater
New bottles

Washer
Filled bottles
To warehouse

Empty Bottle
Inspection

Palletizer

Crater Filler

Pasteurizer
Labeler

Fig: 1, overall flow diagram of the Bottling department

14
 Chapter two

Energy management in bottling department

Steam pipelines

A steam pipeline is a pipe which carries steam from the boiler outlet to the desired location in our case
to the inlet of the bottle washer

Bottle washer

A bottle washer is a machine which is used for washing empty bottles in the bottling industry of all
brewing company

2.1 Problem statement & Justification

The steam pipeline from the outlet of the boiler to the inlet of the bottle washer has been insulated the
main problem of this pipeline is the leakage it made because of the usage of poor steam pipeline material
and poor insulation.

The other problem is the bottle washer machine, then manual of this machine says the performance of
this machine is 40,000 bph (bottle per hour) but, nowadays the bottle counter of this machine shows
that the performance of this machine is 38,000 bph.

In this project I will try to put how much money does this problem cost the company annually.

15
 2.2 Thermal insulators

Thermal insulations are materials or combinations of materials that are used primarily to provide
resistance to heat flow. You are probably familiar with several kinds of insulation available in the
market. Most insulation is heterogeneous materials made of low thermal conductivity materials, and
they involve air pockets. This is not surprising since air has one of the lowest thermal conductivities and
is readily available. The Styrofoam commonly used as a packaging material for TVs, VCRs, computers,
and just about anything because of its light weight is also an excellent insulator Temperature difference
is the driving force for heat flow and the greater the temperature difference, the larger the rate of heat
transfer. We can slow down the heat flow between two mediums at different temperatures by putting
“barriers” on the path of heat flow. Thermal insulations serve as such barriers, and they play a major
role in the design and manufacture of all energy-efficient devices or systems, and they are usually the
cornerstone of energy conservation projects.

2.3 Reasons for Insulating

If you examine the engine compartment of your car, you will notice that the firewall between the engine
and the passenger compartment as well as the inner surface of the hood is insulated. The reason for
insulating the hood is not to conserve the waste heat from the engine but to protect people from burning
themselves by touching the hood surface, which will be too hot if not insulated. As this example shows,
the use of insulation is not limited to energy conservation. Various reasons for using insulation can be
summarized as follows:

• Energy Conservation conserving energy by reducing the rate of heat flow is the primary reason for
insulating surfaces. Insulation materials that will perform satisfactorily in the temperature range of
-268°C to 1000°C (-450°F to 1800°F) are widely available.

• Personnel Protection and Comfort A surface that is too hot poses a danger to people who are
working in that area of accidentally touching the hot surface and burning themselves To prevent this
danger and to comply with the OSHA (Occupational Safety and Health Administration) standards, the
temperatures of hot surfaces should be reduced to below 60°C (140°F) by insulating them. Also, the
excessive heat coming off the hot surfaces creates an unpleasant environment in which to work, which
adversely affects the performance or productivity of the workers, especially in summer months.

16
 • Maintaining Process Temperature some processes in the chemical industry are
temperature-sensitive, and it may become necessary to insulate the process tanks and flow sections
heavily to maintain the same temperature throughout.

• Reducing Temperature Variation and Fluctuations the temperature in an enclosure

may vary greatly between the midsection and the edges if the enclosure is not insulated. For example,
the temperature near the walls of a poorly insulated house is much lower than the temperature at the
midsections. Also, the temperature in un insulated enclosure will follow the temperature changes in the
environment closely and fluctuate. Insulation minimizes temperature non uniformity in an en- closure
and slows down fluctuations.

• Condensation and Corrosion Prevention Water vapor in the air condenses on surfaces
whose temperature is below the dew point, and the outer surfaces of the tanks or pipes that contain a
cold fluid frequently fall below the dew-point temperature unless they have adequate insulation. The
liquid water on exposed surfaces of the metal tanks or pipes may promote corrosion as well as algae
growth.

• Fire Protection Damage during a fire may be minimized by keeping valuable combustibles in a
safety box that is well insulated. Insulation may lower the rate of heat flow to such levels that the
temperature in the box never rises to unsafe levels during fire.

• Freezing Protection Prolonged exposure to subfreezing temperatures may cause water in pipes
or storage vessels to freeze and burst as a result of heat transfer from the water to the cold ambient. The
bursting of pipes as a result of freezing can cause considerable damage. Adequate insulation will slow
down the heat loss from the water and prevent freezing during limited exposure to subfreezing
temperatures.

• Reducing Noise and Vibration an added benefit of thermal insulation is its ability to dampen
noise and vibrations. The insulation materials differ in their ability to reduce noise and vibration, and the
proper kind can be selected if noise reduction is an important consideration.

17
 2.4 Common insulation material

There are a wide variety of insulation materials available in the market, but most are primarily made of
fiberglass, mineral wool, polyethylene, foam, or calcium silicate. They come in various trade names
such as Ethafoam Polyethylene Foam Sheeting, Solimide Polimide Foam Sheets, FPC Fiberglass
Reinforced Silicone Foam Sheeting, Silicone Sponge Rubber Sheets, fiberglass/mineral wool insulation
blankets, wire-reinforced mineral wool insulation, Reflect-All Insulation, granulated bulk mineral wool
insulation, cork insulation sheets, foil-faced fiberglass insulation, blended sponge rubber sheeting, and
numerous others.

2.5 Super insulators

You may be tempted to think that the most effective way to reduce heat transfer is to use insulating
materials that are known to have very low thermal conductivities such as urethane or rigid foam (k =
0.026 W/m • °C) or fiberglass (k = 0.035 W/m • °C). After all, they are widely available, inexpensive,
and easy to install. Looking at the thermal conductivities of materials, you may also notice that the
thermal conductivity of air at room temperature is 0.026 W/m • °C, which is lower than the
conductivities of practically all of the ordinary insulating materials. Thus you may think that a layer of
enclosed air space is as effective as any of the common insulating materials of the same thickness. Of
course, heat transfer through the air will probably be higher than what a pure conduction analysis alone
would indicate because of the natural convection currents that are likely to occur in the air layer.
Besides, air is transparent to radiation, and thus heat will also be transferred by radiation.

The thermal conductivity of air is practically independent of pressure unless the pressure is extremely
high or extremely low. Therefore, we can reduce the thermal conductivity of air and thus the conduction
heat transfer through the air by evacuating the air space. In the limiting case of absolute vacuum, the
thermal conductivity will be zero since there will be no particles in this case to “conduct” heat from one
surface to the other, and thus the conduction heat transfer will be zero. Noting that the thermal
conductivity cannot be negative, an absolute vacuum must be the ultimate insulator, right? Well, not
quite.

The main purpose of insulation is to reduce “total” heat transfer from a surface, not just conduction. A
vacuum totally eliminates conduction but offers zero resistance to radiation, whose magnitude can be
comparable to conduction or natural convection in gases

18
2.6 Bottle washer inputs

1. Water

water is necessary for the final rinsing of bottles and to fill detergent soak for the final rinse water must
be of drinking quality that is according to (WHO)

PH………………………………..7-8

CHLORIDE (mg/l)……………… <50

BROMIDE (mg/l)……………………5

NO FLORIDE & SILCATES

The internal surface of the bottles has the same chemical and microbiological characteristics as drinking
water.

2. SODA

Soda, (NaoH) is used to create the detergent solution in the soaks, soda is the element providing the
chemical action necessary for washing bottles and which ensures the elimination of microbiological
contamination with the help of steam

3.Steam

Steam is used to heat detergent rinse and in some case to sanitize the rinsing area the stem system must
be powerful enough to supply at 3500kg/hr. of saturated dry steam at 4 bars.

4.Air

Clean, dry compressed air is required at 6 bar from the utility department the compressed air system
must be sized to supply the bottle washer at 10Nm3 /h of dry air.

19
 2.7 Operating principal

Washing This is a critical part of returnable bottling. Bottles return to breweries in various states, They
will be dirty and will still have labels attached. The labels may be made of paper or Metallized foils,
which may contain tin or aluminum. Bottle cleaning must remove all The labels, and clean and sterilize
the bottles, which are then presented to the filler. This is An aggressive operation and over time the
bottles will become scuffed and unattractive. This has been a problem in developed markets where the
appearance of the package is so Important. This has led to the rise in popularity of the one-trip non-
returnable bottle, Which can be decorated to a very high standard…….? This type of package, unless re-
cycled, is Less environmentally acceptable than the returnable bottle.

Important factors in bottle washers are:

· Soaking to remove dirt and labels

· Jetting to rinse
· Label disposable
· Detergent

The total time of the operation is normally 10±15 minutes. The sequence of operations
Varies with different washers. A typical system is to soak the dirty bottles in hot water and
Then pass them through a hot caustic soda solution. Bottles are then successively rinsed
With hot caustic solution, hot water, and finally cold fresh water.
Bottles are transported through the machine in row. The bottles are assembled in lines so that
They cannot fall over. Efforts are made to keep the noise as low as possible (<85 dBA).
Propulsion is usually by a slat conveyor chain. In outline we have:

• Soaking. Residues of beer are drained at the first station in the machine There is then usually a pre-
soak at 35±40 C to remove easily soluble dirt And to pre-warm the bottles. The bottles are then
immersed in a bath of caustic soda Solution (2.0 to 3.5%) at 75±85 C. Residence time is extended by
Circulating the bottles in a series of loops. The caustic solution is then jetted over the Bottles to remove
any remaining labels. The effluent solution from these operations is Very dirty and contaminated with
micro-organisms.

• Rinsing/jetting. After soaking, the bottles are rinsed neck downwards several times With hot caustic
solution, hot water and cold water. The temperature of the caustic Solution is 45 C, the hot water is 35 C
and the cold water is 20±25 C The final fresh water rinse will be at around 15 C.

• Label disposal. The major challenge of the operation is the removal of the soggy Mass of denatured
label paper and foil. A label press is used to dewater the label pulp By about 80% and the caustic
solution residue is returned to the bottle washer. Disposal of the `dry' pulp is not always easy.

20
• Detergent. The detergent is normally based on 1% w/v sodium hydroxide solution. It Must have good
wetting power to penetrate the old labels and should not cause foam or Allow scale build-up. Microbes
must be killed. Water with low temporary hardness

2.8 Motorization

The machine is driven by electric variable speed motor with self-breaking system controlled by a
frequency variation which starts up the machine increasing the speed until the desired rate is reached the
motor is connected to gear reducer with cardans and drives the individual worm gear reducers the gear
reducer and main motor can be equipped with a special safety cut-off device which brings the machine
to a halt whenever the shafts are subjected to excessive stress.

2.9 Bottle Loading

The bottles are fed onto the loading platform by means of belt conveyers and from where they are Then
channeled by the accumulation table forms on to the loading slides. Variable adjustable speed motor
drives the belt a lubricating substance is sprayed onto the belt to Help them slide into the loading unit
the movement of the belt is synchronized with loader arm before the bottles reach the lifting stage when
they are transferred into the bottle supporting pocket. The Table belt comes to a halt allowing the bottles
to be directed more easily toward the flow of the Detergent solution carries the label to the net filter
which conveys it to the outside.The label is detached from the net by a brush rotating in the opposite
direction
and the label then falls Outside the flow created by the pump is such that labels are not deposited in the
baths and allows the Labels to be removed without damaging the bath and the solution mix so there are
no variation of temperature and concentration with in the bath.

21
 Chapter Three

3.1 Cost analysis by steam leakage

The stem pipelines from the boiler outlet to the inlet of the bottle washer has served for many years
because of this and other minor reason the pipe has some leakage here by observing and taking data’s
during 4 months of my stay on this company I tried to measure the amount of leaked steam I a
cylindrical object directly from the point of leakage by taking with time and calculate how much money
does this leakage costs the company here, this cost analysis is based on if the steam pipe is leaked ones
in a week in only one point that is the minimum leakage because, the stem pipe line may leak in more
than one point in a week

Radius of the cylinder (R) =8cm

Height (altitude) of the cylinder (H) = 20cm

V=3.142*R2*H

V=3.142*64* 20

in 20 minute
V=1280cm3………………………………………………………………………………

Conversion factor

1000dm3 = 1m3 1000cm3 = 1dm3 1dm3 = 1lit

In 1 hour the volume of leaked steam will be, 1.280 * 3 = 3.84 lit of steam will be leaked in one hour
in one point of leakage if the point of leakage is in two points the total volume will be doubled. In other
word the volume flow rate will be 0.00384m 3/hr. the density of steam will be 880Kg/m by interpolation
from tables

M=V*q

M=0.00384m3/hr.* 880Kg/m3

22
M=3.3821Kg/hr the mass flow rate of the leaked stem.The Boiler will need 11000 liter of oil for operating one full day

that is 24hr; here one liter will cost 14 Birr so the total cost for one day will be 154000 Birr. For one hour the cost of fuel

will be 154000/24 =6416.667 Birr Now, we need 6416.667Birr for producing 3500Kg/hr. flow rate in to the steam pipe

so,

3500Kg/hr. = 6416.667 Birr

3.3821Kg/hr. = X Birr

X = 62.00Birr……………the leaked steam will cost the company this amount of money per week,

The total cost of leakage per year will be Y = X*52weeks

Y = 6.200*52

Y= 3224 Birr .

The company will cost this amount of money per year due to poor leakage in one point of leakage by taking this money

if the point of leakage in the whole pipe is 10 the total cost will be 10 *3224Birr=32240Birr because our first calculation

is based on the minimum cost of one point leakage

23
3.2 Cost analysis by convection
Despite the complexity of convection, the rate of convection heat transfer is observed to be proportional
to the temperature difference, and is conveniently expressed by Newton’s law of cooling as
Q con =h AS (TS - T∞)
where h = 6.0574W/ m2 ·°C, is the convection heat transfer coefficient, As is the surface area through
which convection heat transfer takes place, Ts=80°C is the surface temperature, and T∞=25°C is the
temperature of the fluid sufficiently far from the surface.

Table, 1
Typical values of convection heat
Transfer coefficient
Type of h, W/m2 · °C
Convection
Free convection of 2–25
Gases
Free convection of 10–1000
liquids
Forced convection 25–250
of gases

The surface area of the steam pipe line exposed to convection heat transfer will be
As=π*D*L
= π*0.3m*160
=150.2m2
Q= 6.0574W/ m2.°C *150.2m2*(80-25) °C
Q=50.0402kW this is the heat lost from the steam pipelines because of the action of convection heat
transfer
Q. =1744488.9KW is the heat produced in one hour note that to produce this amount of heat the
company will cost 154,000 Birr so, the lost heat by the action of convection is Q. =50.0402 Kw will cost
44.17Birr in one day that is the company is working 6 days a week and 312 days in a year so, the total
loss of the company due to convection in one year time will be 44.17Birr*312days=13781Birr

24
3.3 Cost analysis by radiation

Radiation is the energy emitted by matter in the form of electromagnetic Waves (or photons) as a result
of the changes in the electronic configurations of the atoms or molecules. Unlike conduction and
convection, the transfer of Energy by radiation does not require the presence of an intervening medium.
In fact, energy transfer by radiation is fastest (at the speed of light) and it suffers no attenuation in a
vacuum. This is how the energy of the sun reaches the earth.
Q. =εσAsT 4
Where σ=5.67 *10-8 W/m2 · K4steafan–Boltzmann constant. The average temperature of the exposed
surface of the steam pipeline is 80°c when the surrounding Temperature is 25°c and the material of the
steam pipeline is stainless steel whose emissivity is 0.17, As is the surface area of the steam pipelines
which is exposed to radiation.

Table, 2
Emissivity of some materials
At 300 K
Material Emissivity

Aluminum foil 0.07

Polished copper 0.03

Polished silver 0.02

Polished stainless 0.17

steel
Black paint 0.98

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Q. = εσAs (Ts-T∞)
= 0.17*5.67*10-8 W/m2 · K4* (π) 0.3m * 60m * [(80+273)4 – (25+273)4] k4
=70.957KW
Is the heat lost by the action of radiation on the steam pipe line
Q. = m cp (T inlet-T outlet)
Where Cp=4195.5 J/kg.k is the specific heat of steam, m=3500Kg/hr. is the mass flow rate of the
flowing steam through the pipe and T inlet =168oc and T outlet=135oc is the temperature of the steam at
the entrance of the steam pipeline and at the end of the pipeline respectively

Q. =3500kg/hr*4195.5 J/kg.k*[(168+273)-(135+273)]k

Q. =484580250J/hr.

Q. =1744488.9KW

Q. =1744488.9KW
this is the heat produced in one hour note that to produce this amount of heat the company will cost
154,000 Birr so, the lost heat by the action of radiation that is Q . =70.957 Kw will cost 62.6 Birr in one
day that is the company is working 6 days a week and 312 days in a year so, the total loss of the
company due to radiation in one year time will be 62.6Birr*312days=19531.2 Birr

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3.4 Cost analysis by Bottle washer

The manual of the Bottle washer says that the performance of this machine is 40,000bph (Bottle per
hour) but, currently the performance of this machine is 38,000 bph, here there is about a big difference
between the designed and the current performance of the machine. Here I tried to calculate how much
money does this company costs because of this gap and to investigate what is the reason behind this
problem. Here, the company works 6 days a week and 24hr per day, in its current performance the bottle
washer will washes this much 24 *38,000 = 912,000 Bottle per day this means there is about 24*2000
=48,000 Bottles are (wasted) rejected in one day without washing because of the poor performance of
the machine. Now in one week time there will be 6 * 48,000 = 288,000 bottle will be ideal without
washing that is the company will not brought 288,000 bottles of beer in one week for market in which
the company has supposed to bring this amount. Here, the company has 1.35 Birr neat profit from one
bottle, due this ideal bottle washer the company will cost 1.35Birr*288,000Bottle = 388,800 Birr per
week, Here note that This means the B.G.I Ethiopia P.L.C is losing 52Week * 512,640 Birr =
20,217,600 Birr in one year According to the data get from the production manager 5% of the faillerity
was this machine is due to the poor performance of the steam pipelines that is the steam pipelines from
the outlet of the boiler to the inlet of the bottle washer will not bring the required amount of steam to the
bottle washer. Here the B.G.I Ethiopia P.L.C will cost 606,528 Birr per year Due to the effect of the
steam pipelines on the bottle washer the other reason which decrease the designed performance of the
bottle washer are beyond the scope of this project they are like

♦ Poor maintenance
♦ the un proper mixing of soda (Naoh)
♦ un proper usage of washing water
♦ Poor performance of the motors which drives the loader arm etc….

3.5 The R-value of Insulation

The effectiveness of insulation materials is given by some manufacturers in terms of their R-value, which is

27
the thermal resistance of the material per unit surface area. For flat insulation the R-value is obtained by simply dividing
the thickness of the insulation by its thermal conductivity. That is,
R-value = L/k (Flat insulation)
Where L is the thickness and k is the thermal conductivity of the material. Note that doubling the thickness L doubles
the R-value of flat insulation. For pipe insulation, the R-value is determined using the thermal resistance relation from
R-value = r2/k ln r2/k (Pipe insulation)
Where r1 is the inside radius of insulation and r2 is the outside radius of insulation.
Once the R-value is available, the rate of heat transfer through the insulation can be determined from
Q = !:1T/ R-value X Area
Where !:1T is the temperature difference across the insulation and Area is the outer surface area for a cylinder.

3.6 Optimum Thickness of Insulation

It should be realized that insulation does not eliminate heat transfer it merely reduces it. The thicker the
insulation, the lower the rate of heat transfers but also the higher the cost
of insulation.Therefore,there should be an optimum thickness of insulation that corresponds to a
minimum combined cost of insulation and heat lost. The determination of the optimum thickness of
insulation is illustrated in Figure

Cost per year

Lost Total cost

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 Heat
Cost

Minimum total cost

Optimum thickness

Insulation thickness

Fig, 2 Determination of optimum thickness of insulation

Notice that the cost of insulation increases roughly linearly with thickness while the cost of heat loss
decreases exponentially. The total cost, which is the sum of the insulation cost and the lost heat cost,
decreases first, reaches a minimum, and then increases. The thickness corresponding to the minimum
total cost is the optimum thickness of insulation, and this is the recommended thickness of insulation to be
installed. If you are mathematically inclined, you can determine the optimum thickness by obtaining an
expression for the total cost, which is the sum of the expressions for the lost heat cost and insulation
cost as a function of thickness differentiating the total cost expression with respect to the thickness;
Setting it equal to zero. The thickness value satisfying the resulting equation is the optimum thickness.
The cost value can be determined from the requirement that the insulation pay for itself within two or
three years. Note that the optimum thickness of insulation depends on fuel cost.
The discussion above on the optimum thicknesses is valid when the type and manufacturer of insulation
The insulation with the lowest annual cost is obviously the most economical insulation, and the
insulation thickness corresponding to the minimum total cost is the optimum thickness []

3.7 Design of Insulation

Here we will see the optimum thickness and type of insulator that the company is using and how much
money does this insulation saves and we cross check whether the company insulation is best or not if the
company insulation is not good enough we will select a new insulation material and thickness.

Material Selection
The material selected for the design of insulation is fiberglass because of
Its widely availability
Its inexpensive cost and
Its easy to install

Analysis
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The average temperature of the exposed surface of the steam pipeline is 80°C when the surrounding
Temperature is 25°C the pipe line is 160m long and 0.30m in diameter the plant operates 24 h a day
313 days a year, and thus 7512h/yr. the type of insulation to be used is fiberglass (kins = 0.038 W/ m
°C), whose cost is 11.9/m2per inch of insulation material thickness, plus 34/m2 for labor regardless of
thickness. The combined heat transfer coefficient on the outer surface is estimated to be ho = 6.0574W/m
• °C. The steam pipeline uses light oil, whose unit cost is 2Birr/therm, and the efficiency of the steam
pipeline is 80 %. Here a cylindrical steam pipeline is to be insulated to reduce heat losses. The optimum
thickness of insulation is to be determined.
The exposed surface area of the steam pipeline is

As = 2Abase + Aside

= 2(π) r 2 + 2(π) r*L = 2*π*0.15m2 + 2*π*0.15 m*160 m

= 150.9 m2

Then the relation above for 1-in thick insulation gives the rate of heat loss to be

• Q in = As (Ts - T) = (150.9 m2)*(80 - 25) °C

T ins + 1 1/12 ft. + 1

Kins ho 0.04153 W/m • °C 6.0574 W/m • °C

= 3824.65 W

Also, the total amount of heat loss from the steam pipelines per year and the amount and cost of energy consumption of

the steam pipeline become

Qins = •Qin*!:1t = (3824.65W) (7512 hr/yr.) = 28,730,803.6 W.h/yr.

Qin, ins = Qins //steam pipe = (28,730,803.6 W.hr/yr.)/0.80

= 35,913,504.6 W.hr/yr. Since 1W=Btu/hr.

= 35,913,504.6 Btu/yr. Since 1 therm = 100,000 Btu.

=359.135046therms/yr. Since 1therm=29.31Kwh

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Annual cost = Qin, ins X Unit cost

= (359.135046therm/yr.)(2/therm)

= 718.27 Birr/yr.

The unit cost of insulation is given to be $2.70/ft2. Then the installation cost of insulate comes
Insulation cost = (Unit cost) (Surface area) = (Birr 45.9/m2) (150.9 m2) = 6926.3 Birr The sum of the
insulation and heat loss costs is the Total cost = Insulation cost + Heat loss cost

= 6926.3 + 718.27

= 7644.58

To determine the thickness of insulation that maximizes the saving we repeat the calculations above for 2-, 3-, and 4-

in.thick insulations, and list the results in Table.

Table,3
The variation of total insulation cost with insulation thickness.
Insulation Heat loss, W Lost fuel, Lost fuel cost, Insulation cost, Total cost, Birr
thickness therms/yr. Birr/yr. Birr

1 in. 3824.6 359.13 718.27 6926.3 7644.58

2 in. 1990.3 186.88 373.77 7143 7497

3 in. 1342 126 252 7583 7835
4 in. 1035 83 145 7920 8065

Note that the total cost of insulation decreases first with increasing insulation thickness, reaches a
minimum, and then starts to increase we observe that the total insulation cost is a minimum at Birr 7497
for the case of 2-in.-thick insulation. So we select the 2-in-thickness fiberglass insulaton

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 Chapter four

4.1 Conclusion

Here, working in the group of B.G.I Ethiopia P.L.C as an intern student gave me a clue about
how my future looks like besides these, knowing and experiencing all work ethics and
procedures was a chance the internship period gave me.

Now a days the productivity and the profit of a company depends on balancing it expenses
with its income, different companies will expense more money for Energy matter but it’s not
more common to audit their energy after the installation of their machinery’s in working on this
project I tried to put how much money does the company cost due to steam leakage in the steam
pipeline from the out let of the boiler to the inlet of the bottle washer, the cost of insulation and
how to select the optimum thickness of insulator by mentioning different type of insulator with
different thermal conductivity and about how much money does the company cost due to the
poor performance of the bottle washer.

In the recommendation part I had put some points and method on how to save the company
money which is wasted improperly.

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 4.2 Recommendation

The table below shows the cost of the company which is wasted for energy matter in steam pipeline
from the boiler outlet to the inlet of the bottle washer and the cost of the company due to the poor
performance of the bottle washer

Table,4
Total cost of the company

cost analysis by steam leakage 32240Birr

cost analysis by convection 13781 Birr

cost analysis by radition 19531 Birr

cost by bottle washer 606,528 Birr

total cost of company 672,304 Birr

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 Here, the company cost a total of 672,304 Birr which is unnecessary waste the bottle washer cost
too much money if the company wants to save this amount of money annually I recommend to see and
take this project into reality.

The cause for the failerity of the bottle washer is the steam from the boiler is not reaching in effective
temperature to the operation of the bottle washer. So, to save the company money due to the bottle
washer first we have to take care for the steam pipeline which is the primary input of the bottle washer.

Reference

1. Yunus A. Cengel, “Heat transfer a practical approach”,(2003),Second Edition,

2. Frank P. Incropera and David P. Dewitt. “Introduction to heat transfer”,(2001),Third Edition
3. www.B.G.I Ethiopia.com (date 17-09-2003)
4. Simonazi H. “ Bottle washer manual oceanic”,(1995), Second edition

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