29-08-2014, 02:40 PM
Six Months Industrial Training Report Done At Reliance Industries, Hoshiarpur Manufacturing Division
CHAPTER 1 INTRODUCTION Reliance Industries Limited (RIL) is an Indian conglomerate holding company headquartered in Mumbai, Maharashtra, India. The company operates in seven major segments: Exploration Production Refining Marketing Petrochemicals Retail Telecommunications. RIL is the second-largest publicly traded company in India by market capitalization and is the second largest company in India by revenue after the state-run Indian Oil Corporation. The company is ranked No. 107 on the Fortune Global 500 list of the world's biggest corporations, as of 2013. RIL contributes approximately 14% of India's total exports HISTORY The Reliance Group, founded by Sh. Dhirubhai H. Ambani (1932-2002), is India's largest private sector enterprise, with businesses in the energy and materials value chain. Group's annual revenues are in excess of US$ 66 billion. The flagship company, Reliance Industries Limited, is a Fortune Global 500 company and is the l
CHAPTER 1
INTRODUCTION Reliance Industries Limited (RIL) is an Indian conglomerate holding company headquartered in Mumbai, Maharashtra, India. The company operates in seven major segments: Exploration Production Refining Marketing Petrochemicals Retail Telecommunications. RIL is the second-largest publicly traded company in India by market capitalization and is the second largest company in India by revenue after the state-run Indian Oil Corporation. The company is ranked No. 107 on the Fortune Global 500 list of the world's biggest corporations, as of 2013. RIL contributes approximately 14% of India's total exports HISTORY The Reliance Group, founded by Sh. Dhirubhai H. Ambani (1932-2002), is India's largest private sector enterprise, with businesses in the energy and materials value chain. Group's annual revenues are in excess of US$ 66 billion. The flagship company, Reliance Industries Limited, is a Fortune Global 500 company and is the largest private sector company in India. Backward vertical integration has been the cornerstone of the evolution and growth of Reliance. Starting with textiles in the late seventies, Reliance pursued a strategy of backward vertical integration - in polyester, fiber intermediates, plastics, petrochemicals, petroleum refining and oil and gas exploration and production - to be fully integrated along the materials and energy value chain. The Group's activities span exploration and production of oil and gas, petroleum refining and marketing, petrochemicals (polyester, fiber intermediates, plastics and chemicals), textiles, retail, infotel and special economic zones. VISION & MISSION MUKESH AMBANI, chairman of RELIANCE INDUSTRIES Ltd, India’s largest private company, laid down a roap map for business transformation and value creation for the company at its 35th annual general meeting .This has been a truly transformational year at RELINACE INDUSTRIES (RIL). Our Vision To be amongst the most admired and most trusted integrated utility companies in the world, delivering reliable and quality products and services to all customers at competitive costs, with international standards of customer care- thereby creating superior value for all stakeholders. To set new benchmarks in standards of corporate performance and governance through the pursuit of operational and financial excellence, responsible citizenship and profitable growth. Our Mission • To attain global best practices and become a world-class utility. • To create world-class assets and infrastructure to provide the platform for faster, consistent growth for India to become a major world economic power. • To achieve excellence in service, quality, reliability, safety and customer care. • To earn the trust and confidence of all customers and stakeholders, exceeding their expectations and make the Company a respected household name. • To work with vigour, dedication and innovation with total customer satisfaction as the ultimate goal. • To consistently achieve high growth with the highest levels of productivity. • To be a technology driven, efficient and financially sound organization. • To be a responsible corporate citizen nurturing human values and concern for society, the environment and above all people. • To contribute towards community development and nation building. • To promote a work culture that fosters individual growth, team spirit and creativity to overcome challenges and attain goals. • To encourage ideas, talent and value systems. • To uphold the guiding principles of trust, integrity and transparency in all aspects of interactions and dealings. Growth through Commitments We care about Quality Research & Development Health, Safety & Environment Human Resource Development Energy Conservation For Reliance… • Growth is care for good health • Reliance's occupational health centers carry out pre-employment and periodic medical checkups as well as other routine preventive services. Specialized tests like biological monitoring, health risk assessment studies and audits for exposure to various materials are also performed. Health education and awareness form an integral part of the health care programme at Reliance • Growth is care for safety • We believe that the safety of each employee is the responsibility of the individual as well as of the whole community of employees • Growth is care for the environment • Reliance believes that a clean environment in and around the workplace fosters health and prosperity for the individual, the group and the larger community to which they belong. Environmental protection is an integral part of the planning, design, construction, operation and maintenance of all our projects. • Growth is betting on our people • Reliance builds with care a workplace that proactively fosters professional as well as personal growth. There is freedom to explore and learn; and there are opportunities that inspire initiative and intrinsic motivation. We believe that people must dream to achieve, that these dreams will drive the company's excellence in all its businesses. Reliance thinks, behaves, lives and thrives with a global mindset, encouraging every employee to reach his / her full potential by availing opportunities that arise across the group. • Growth is thinking beyond business • As corporate citizens, we invest in social infrastructure, believing strongly that our business strength fuels our social contributions. To this end, Reliance encourages, funds and develops numerous education, health, human capital and infrastructure initiatives. These initiatives are undertaken through partnerships with non-governmental organizations, corporates and trusts. RIL-Hoshiarpur Manufacturing Division RIL-Hoshiarpur Manufacturing Division is located in Hoshiarpur, Punjab. It manufactures a wide range of PSF, PFF, POY and polyester chips. On 29th March, 2001 this division of JCT was purchased by RELIANCE INDUSTRIES and Hence the Hoshiarpur Manufacturing Division came into existence. The Plants at Hoshiarpur Manufacturing Division Name of Plant Commissioned Year PSF-I 1989 PSF-II 1995 POY 1995 PFF 2004 TABLE 1.1:- YEAR OF COMMISSIONING VARIOUS UNITS AT RIL-HMD In addition to the regular products, Hoshiarpur Manufacturing Division has added the following differentiated value added products: 1. Dope Dyed Olive Green & Khaki Fiber 2. Recron 3s for Construction & Paper Industry 3. Polyester Fiber Fill 4. Cluster Fiber 5. Conjugate Fiber Divisions of RIL-HMD • Health, Safety, and Environment • Mechanical Utility • Poly Area • Spinning • Fiber Line Area • POY Area • PFF Area The key features of our Health, Safety and Environment Policy are: • Plants designed to highest standards of safety. • Effective use of safe working procedures and practices. • Effective HSE training of employees as well as contractors' personnel in the Complex. • Total & strictest compliance with statutory requirements in all respects as a Minimum • Learning from failures in the complex, major or minor, to eliminate Recurrence • Learning from the experiences of others in the industry. • Rigorous and regular audit of work procedures and practices, internal as well as external bodies. • Constantly following the leading edge international HSE practices. • Ensuring a clean and safe environment in and around the complex. • Pre-employment and periodic medical check-ups of employees for early Identification of occupational health hazards. CHAPTER 2 POLY Polyester is defined by the International Standards Organization (ISO) as a polymer comprising of synthetic linear macromolecules having a chain with at least 85% (by mass) of an ester of a diol and Terephthalic Acid. The Poly section at RIL-HMD is responsible for the production of the raw material for the Fiber Line, Spinning, PFF, etc. 1) The RAW MATERIALS being used in the manufacturing of POLYESTER are : INPUT o PTA ( Pure Terephthalic Acid ) o MEG ( Mono Ethylene Glycol ) o Antimony Trioxide o Titanium dioxide 2) OUTPUT o Poly condensed in chips or melt form 3) Specifications of RAW MATERIALS : PTA (PURE TEREPHTHALIC ACID) Basic Raw Material Appearance—White Powder Moisture—0.2% MEG (MONO ETHYLENE GLYCOL) Chain Terminator Appearance — Colorless Transparent Liquid Boiling Range – 195-199 degree Celsius ANTIMONY TRIOXIDE Catalyst Appearance – White Free Flowing Liquid , Free from Contamination Moisture – 0.50% TITANIUM DIOXIDE Delusteranting Agent Water <0.5% 4) MANUFACTURING PROCESS : a) FEEDING THE RAW MATERIALS AND AGENTS:- The process line starts with continuous preparation of the monomer paste. The monomer paste continuously prepared in the PTA slurry preparation vessel which consists of a homogenous mixture of PTA, MEG and catalyst. b) ESTERIFICATION SECTION:- The PTA paste is discharged continuously from the paste mixing vessel to the esterification reactor. The esterification is carried out in two reactors under graduated pressure and with rising temperature to form terepthalic diglycol Easter while water is split off. The esterification reactors are provided with heating jackets, internal heating coils and agitator. c) PREPOLY CONDENSATION :- The product coming from Esterification reactor is then transferred to the prepoly reactor. Here we are increasing vacuum and elevated temperature to the Desired final viscosity glycol is withdrawn immediately under a High vacuum and rapid poly condensation reaction takes place in the product. d) FINAL POLY CONDENSATION :- The product leaving the Prepoly condensation is finally poly condensed in the disc ring reactor I & II under increase vacuum and elevated temperature to the desired final viscosity glycol is withdrawn immediately under a high vacuum and rapid poly condensation reaction takes place in the product. e) The supply from DRR-I &DRR-II is given to the chips, Spinning, POY f) CHIPS PRODUCTION :- The chips production system is Installed to produce solid PES out of PES melt. For chips production, the polymer is passed through the cooling water where it changes into long wires and then it is cut by a cutter in small pieces. This chips is than dried. Fig 2.1:- FLOW DIAGRAM OF POLY AREA PSF SPINNING (POLYESTER STAPLE FIBRE SPINNING) • INPUT MATERIAL :- Polymer in melt or chips form from poly section • OUTPUT MATERIAL :- • Polyester Tow • MANUFACTURING PROCESS :- 1. Polymer is discharged from DRR (Disc ring reactor) to spinning through discharge pumps. There are two discharge pumps running continuously. If one pump trips then speed of second pump shoots up to double. These pumps also maintain required pressure. 2. Through discharge pumps melt polymer comes into manifolds. Beams are having spin pumps and spin packs. Firstly melt enter into spin pump then it goes to spin pack having spinnerets with different holes as per the requirements. 3. Melt coming out of spinneret’s is quenched by air to decrease its temperature and to change it into semisolid state for take up’s. 4. In take up section finish application is applied with kiss rollers. Which act as a antistatic agent and binds the filament. In take up drawing and stretching is also given to filament. 5. From take up section material is taken into cans to form a creel for the fibre line. 6. This tow in form of creel act as a raw material for fiber line. Fig 2.2:- FLOW DIAGRAM OF SPINNING AREA Process Flow Chart of Spinning Area Fig 2.3:- Process Flow Chart of Spinning Area FIBRE LINE OR DRAW LINE This is the area which holds the maximum amount of production at RIL-HMD. There are total of 4 lines for product manufacturing known as Draw Machine (DM) Lines. The DM lines are numbered as DM 1, DM 2, DM 3, and DM 4. All the four lines have common set up. PARTS OF DM:- 1. Can 2. Tow Guiding frame 3. Dip Bath 4. Draw frame 1 5. Draw Frame 2 6. Steam chest 7. Thermo setting unit OR Annealer 8. Tow Cooler 9. Draw Frame 3 10. Tow convergence unit & Dancing Roller 11. Steam Box 12. Crimper Unit 13. Dryer Unit 14. Cutter Tension Unit 15. Cutter and Bailing Press • INPUT :- Tow in form of creel from spinning department. • OUTPUT :- Polyester staple fibre Polymer Drawing At Fiber Line In this section, all the DM lines are used as per requirement for the manufacturing of the fiber. Undrawn tows from the spinning section are brought in the cans and are placed at can handling area of the DM line depending upon the tow requirement by the line. These are collected in the form of sheet and passed through the Tow Guiding Frame which helps the tow of different cans to mesh and then it is further passed onto a tough of hot bath known as Dip Bath. In the dip bath the temperature of the polymer is raised to approximately 70 degree Celsius with the help of hot water, so that the polymer can be easily drawn into the final products on the draw frames on the DM line. In the next two zones, the polymer is drawn approximately 4 times. The actual draw also known as pull takes place either in the steam camber or in the hot water trough. After the drawing is complete each filament has the required denier and has all the sub microscopic chains aligned parallel to the fiber axis, thereby improving the crystal structure and imparting the strength required. The next step is to set up the strength by annealing the filaments by passing them under tension on several steam heated cylinders at temperature rating between 180 to 220 degree Celsius. Also the filaments may be shunk during the first phase of annealing by over feeding and imparting higher strength by stretching 2% or during the final annealing phase. Then the fiber is quenched in a hot water batch. Textile spin finish is applied either before crimping by kiss roll technique or after crimping by a bank of hollow cone sprays mounted on the both sides of tow. From the dryer the tow is then guided to cutter and the cut fibers are then pass out onto the bailing press for packaging and dispatching. The cutter reel having slots at intervals equal to the cut desired generally of 32, 38, 44 or 51 mm. each slot has a sharp stainless steel or tungsten carbide places on it. The tow is wound on the blades and tow is cut. The cut fiber falls down by gravity and is usually partially opened by several air jets and finally the fiber us baled. Balers have preset weighting arrangement which enables the baler to produce bales of predetermined bales. • Fiber Specifications DENIER: It is a unit of measure for the linear mass density of fiber. It is defined as the mass in gram per 9000 m. Usually the actual denier is a little on the finer side i.e. for 1.2 D it will be 1.16 D and for 1.4 D it will be 1.35 D. Denier specifies the fineness of the fiber and in a way control the spinning limit. In order to form yarn or ring spinning there must be 60 to 62 fibers in the yarn cross section. • Crimper The crimper is used to feed the continuous tows into stuffer box from a pair of crimper rollers and the pressure of the stuffer box to confirm the even crimping and acquire the qualified tows. Specifications:- • Type : Squeezing • Fiber : Polyester • Crimper roller width : 300 mm • Diameter Of Roller Crimper : 253 mm • Tow Speed : Max 300 m/min • Tow Temperature at Surface of the roller : 80 to 130 deg Celsius • Stuffer box Dimensions : 350*300*24 mm • Pressure of Air Supplied : 0.6 MPa • Tow Height Above ground :1350 mm • Gear Box Ration 1: 4.19 • Over All dimensions : 3848*1400*1838 mm • Machine weight : 4500 kg • Structure The machine consists of various parts such as gear box, pneumatic system, crimper head which consists of stuffing box, pressure arm, crimper holder, rotary joints, pressure parts etc. The stuffing box consists of upper and lower crimper blades and left and right hand plates. The two blades maintain a fix distance combining the side plates installed in the lower blade to from the stuffeing box. The upper blade rolls as fulcrum. The cylinder can adjust the pressure applied on the tow. The rotate blocks on the bottom of the side plates seal the rollers and blades. The steam can move through the clearance between the blades. The upper and lower crimper rollers push the tow into the stuffing box. The upper roller is installed on the rockers which rocks with the pin shaft as fulcrum. The upper and the lower rollers are unstalled on the holder. Fig 2.4:- LINE DIAGRAM OF CRIMPER • MANUFACTURING PROCESS 1. The undrawn tow is brought together via a creel to a combined tow for further processing. 2. The tow is passed through water (dipping bath), giving preliminary heating and taken for drawing. Drawing is the process of stretching the tow so that molecules in the fiber get an orientation in a regular fashion. 3. Then the tow is made to pass through draw frame I (DF-I). It consist of seven rollers out of which six are jacketed for flow of hot water. Seventh is called as pinch roller whose unction is to pinch the tow and remove the excess water. 4. Then the tow is made to pass through drawing bath where it is heated with hot water. Here temp. is kept about 361K to 368K. 5. After drawing bath tow is made to pass through draw frame II (DF-II). NOTE: - One thing is to be noted that the speed of DF-II is three times than the DF-I and main tension to tow is given in between this region. 6. After draw frame II tow is passed through TSU (thermo setting unit) where properties like elasticity module are controlled. TSU consist of 12 rollers through which steam is circulated. Tow that comes out of the TSU unit is passed through cooling tower where water at normal temp. is sprayed on tow to decrease its temperature. 7. After cooling tower the tow is passed through tow stacker where its width is decreased and thickness is increased. Width and thickness are changed by three times. 8. After tow stacker tow is made to pass through steam box where it’s temp. Is again raised to 373K. 9. After it tow is passed through crimper (to make crimps on the fiber like natural fiber and so that fiber sticks to each other with great force when clothes are formed). 10. The crimped tow obtained is continuously moved forward through a chyte called tow plaiter and placed on conveyor belt which carries the tow through dryer. Where it is dried. 11. Then the crimped tow is passed through the cutter section. In cutter unit, there is one tension unit, pressure wheel and cutter reel. Cutter reel has several grooved iron rods through which blade is inserted. The tow is wrapped around the cutter reel. When it rotates the tow is cut into required length. 12. After cutting PSF is taken to the bailing machine. A hydraulic press is used in the bailer. A pump is used to fill the oil in the press then it make the press down and when the oil enter from the bottom side then it lift the press upwards. Temp. of oil rises during each revolution so it is decreased by chilled water. Fig 2.5 FLOW DIAGRAM OF FIBRELINE AREA PFF (POLYESTER FIBRE FILL PLANT) RECYCLE PLANT • It is interesting to know why it is called as recycle plant. The reason behind is that reliance is using pet bottles for making fibre also. The plastic bottles are crushed and treated to make fibre which is then used in many fields. • The process of manufacturing is divided into main three parts i.e. 1. Flakes conveying and drying 2. spinning/take up 3. Fibre line Process description is as follows:- 1. FLAKES CONVEYING AND DRYING • INPUT :- Pet flakes • OUTPUT :- Dried flakes • PROCESS :- Flakes are conveyed to storage silo by pneumatic conveying system. From this silo it goes to five driers where flakes are dried to required level. In these driers the flakes are kept for six hours and then this is transferred to two storage hoppers with the help of conveying trolleys. 2. PFF SPINNING • INPUT :- Dried flakes • OUTPUT :- Polyester tow • MANUFACTURING PROCESS :- a) Dried flakes are charged to the extruder where it is melted. Extruder consists of heaters around the pipe through which flakes are conveying. These heaters are of 3.5 watt power and produce a temperature of about 523K which is enough to change the flakes into water. b) After extruder melt is made to pass through CPF (continuous poly filter) which remove the impurities of the melt. It consists of a filtering material called CANDLES. Material move from the bottom of the candle and comes out of the upper end. The melt escaped from the CPF is free from every impurity. c) After passing through CPF the melt enter into spin beams each having eight positions. Beams are having spin pumps and spin packs. Firstly the melt enters into the pump and then to the spin pack having spinnerets with different holes as per the denier required. d) Melt coming out of the spinnerets is quenched with air to bring it into semi solid state and then it is taken to take up unit. e) In the take up unit, spin finish is applied to the semi solid melt to remove its dullness in color. It is applied while melt is touching the kiss roller. f) After it melt is passed through sunflower to make creel of its tow. 3. FIBRE LINE :- • INPUT :- Tow in creel form from spinning • OUTPUT :- Polyester fiber fill/ Recron • MANUFACTURING PROCESS :- a) The undrawn tow is brought together via a creel to a combined tow for further processing. The tow is first passed through the tow guiding frame. b) Then the tow is made to pass through the dipping bath where it is washed properly. c) After it tow is made to pass through the draw frame I (DF-I). it has a pinch roller which remove the excess water from the tow. d) Before proceeding to DF-II the tow is made to pass through drawing bath for heating up the material in wet state to enable the drawing process. e) After this the tow is stretched in between DF-I & DF-II. The main drawing is done in between DF-I & DF-II. The difference in between the speeds of DF-I & DF-II is about three times. f) After DF-II the tow is passed through steam chest where it is again heated for better draw ability. g) In the DF-III the tow is also cooled by spraying water at normal temperature. After it the tow is passed through the tow stacker, which divides it into three parts which are then placed on one after other. After this the tow is made to pass through the steam box. h) After steam box steam is passed through the crimper which produces the crimps in the tow like in natural fiber. i) After crimper the tow comes out with three dimensional effect and gets collected in collecting tray from there tow goes through drier that gives it soft and slippery feel. After this tow is cut in required length. j) After cutting, it is transferred to the bailer. Where it is packed by a hydraulic press. MECHANICAL UTILITY UTILITY Utility is the department which fulfill all the necessary Requirements of the plant. Utility is divided into following Main branches. • Air condition plant • Cooling tower • Nitrogen plant • Plant air supply • Boiler house • Water treatment plant • H.T.M(Heat transfer media plant) Details of each process are given as follows….. 1. BOILER HOUSE :- Its main function is to supply steam to the entire plant as steam is used everywhere. But the main supply of steam is to fiber line as it is used to heat the tow at many stages. The description of plant is as follows:- • It consists of four boilers out of which two are fire tube boilers and two are water tube boilers. These are also called as internal fired boilers and external fired boilers respectively. MATERIAL OF BOILER: - Boiler is made of C.S. on which insulation is made to decrease the temperature loss. FIRE TUBE BOILERS: - In fire tube boiler the fuel is burnt inside the tube. The boilers are called as I.A.E.C boilers. The fuel used in these boilers is furnace oil. When fuel burn in the tube, then it heat the water in outside vessel. It consist of following mountings a) Steam stop valve: - its function is to stop the steam to flow when there is less consumption of steam in the plant. b) Steam safety valve: - Its function is to escape the steam when the pressure inside the boiler increases beyond the safety level. Then it rises up and allows steam to escape until it reaches the safety point. c) Man hole: - It is provided on the top of the boiler for the man to enter in the boiler for cleaning. d) Mud hole: - It is provided at the bottom of the boiler to remove the sludge from the boiler. Fig 2.6:- FIRE TUBE BOILERS 2) WATER TUBE BOILER: - It is the boiler in which fuel is burnt in the Outside vessel and the water flows in the inside vessel. The boiler is known as thermal boiler. It also consists of same mountings as in fire tube boiler. Fig 2.7:- WATER TUBE BOILER • In spite of mountings it also consists of accessories which are used to increase the efficiency of the boiler. Mainly mounting is economizer ECONOMISER: - The economizer is used to pre heat the water. When the flue gases escape through the chimney on the way it is made to pass through the economizer and water is also flowing in the tubes in the economizer and it is heated by the high temperature of flue gases in this way the temp. Of the gases escaping is also used. Thus it increases the efficiency of the boiler. WATER TREATMENT PLANT It is also known as D.M water plant. Its function is to change raw water into mineral water. Water is treated at various stages to purify it. The description of plant is explained below. The various components of plant are:- • Mixed bed tower • SAD unit • DEGASSED unit • SBD unit • Mixed unit • Storage tank MIXED BED TOWER: - In mixed bed tower there are several layers of sand, concrete through which water is made to pass and after it the impurities in the water stay in the bed where as pure water flow outside the tank. This water is pure and can be used for drinking purpose. SAD unit: - In SAD unit water is treated with HCl (Hydro chloric acid) acid and then it removes all the anions present in the water. Here water is treated with FFIP resin. Here the ph of water is 3 to 4. DEGASSED UNIT: - During passing through the SAD unit certain gases like CO2 are produced in the water. To remove these gases water is treated with blow of air which made these gases to escape through water. SBD unit: - In SBD unit water is treated with NaOH and NIP resin. This remove all the cations present in the water. Here the ph of water is achieved at 8-10. MIXED UNIT: - In the mixed unit water is treated with both NaOH and HCl. This is done so that all the remaining anions and cations present in water are removed. Here both FFIP and NIP resins are used. Here the ph of water is maintained at 6-7. HEAT TRANSFER MEDIA It is the area under utility which provide the heat for various processes in the main plant. Here santotherm(heat transferring medium) is heated and is then transferred to various parts where it is required. Working of the plant is as shown below:- It consist of a vessel in which six coils are there and in these coils santotherm is rotating and this santotherm is heated by a flame at the base of the vessel. To spread the flame throughout the vessel superheated steam at high pressure is used. The temperature of the vessel is about 700k and the temperature of santotherm is about 599k. And this santotherm is transferred to various parts by gear pumps. To maintain the temperature of santotherm constant throughout the tubes through which santotherm is flowing are insulated. NOTE: - to extract moisture from the steam, steam traps are used which extract the moisture from the steam so that it does not extinguish the fire in the furnace. DIESEL GENERATOR (D.G) HOUSE To provide the electric power to the plant in case of power cut D.G sets are used can produce power and supply to whole plant. There are six D.G sets out of which four are vertical cylinder engines and two are v-engine cylinder engine. The D.G sets are started on air at 30 Kg pressure. Main parts of Diesel generator are explained below:- • VERTICAL CYLINDER ENGINE: - In vertical cylinder there are nine cylinders out of which one at a time is working. The main parts of vertical cylinder engine are:- a) Cylinder: - It is the main part of cylinder which contains all the parts of the cylinder. b) Piston: - It is the part which causes the suction and compression of air and fuel. c) Piston rings: - There are two sets of piston rings the upper portion of rings do not allow the gases to enter at the bottom side and the lower rings do not allow the upper oil to enter on the upper sides. d) Crank shaft:- The function of crank shaft is to give movement to the piston once so that so that engine can be started easily by air of Turbocharger. It has four strokes 1. Suction stroke: - In suction stroke air from the turbocharger is made to hit the piston of cylinder and the piston moves down due to which air is sucked in the cylinder 2. Compression stroke: - In the compression stroke the piston move from B.D.C to T.D.C and air is compressed due to which temperature of the air is increased. 3. Working stroke: - In the working stroke the fuel is made to enter in the cylinder and due to high temperature of air it burns and lot of heat is produced. 4. Exhaust stroke: - In the exhaust stroke the piston move from B.D.C to T.D.C and the exhaust valve opens and flue gases escape to the atmosphere. For the cooling of the engine water is continuously made to rotate in the engine so that cylinder does not have effect of heat on it. Also lubrication is done by a oil which is pumped in the engine at high temperature so that friction can be decreased in various parts of the engine. • V-Type engine cylinder: - In V-type cylinder engine there are twelve cylinders but these cylinders are small in size than in vertical cylinder engine. The parts and working of these cylinders are same as that of vertical cylinder engine. The only difference is that the turbocharger is made to run by the flue gases before these are escaped to atmosphere. AIR COMPRESSOR To supply air to the whole plant, natural air is compressed and is supplied to whole plant. It consists of following main parts:- A) AIR FILTER: - Its function is to filter the natural air which is sucked from the atmosphere so that the dust particle may not enter into the system and blockage of various parts can be avoided. B) LOW PRESSURE COMPRESSOR: - In low pressure compressor there are four inlet valves and four outlet valves. The suction and discharge are done in both forward and return stroke. During this the temperature of air is raised to high value. D) HIGH PRESSURE COMPRESSOR: - After cooling system air is sucked by high pressure compressor. It has two inlet valves and two outlet valves. Suction and compression both are done in both forward as well as return stroke. Here also the temperature of air is raised to high value such that it can destroy various parts. f) AIR RECIEVER: - This air is collected in a tank which is known as air receiver. From this receiver the air is supplied to various parts where it is required. CHILLING DEVICE It is the device used to cool the water circulating in A.H.U (Air Handling Unit). It contains three main parts:- • Chiller • Centrifugal pump • Condenser First of all hot water coming from A.H.U is supply to chiller in tubes. In chiller dichlorofloromethane gas is circulating which absorb heat from water and get converted into vapors. Then these vapors get suck by impeller of centrifugal pump. These vapours then after compressing supply to condenser. In condenser chilled water coming from cooling tower circulated in tubes. When vapors get in contact with these tubes get cool and converted into liquid. Then this liquid is supplied to chiller through float valve. Float valve controls the supply of cool liquid. It closes when the liquid level reaches its highest level and stops the supply of cooling liquid again when the liquid level decreases it opens and again liquid starts flowing through it and reaches to chiller. This cool liquid when get in contact with water tubes decrease the temperature of water and this water is again supplied back to the A.H.U through pump. MECHANICAL EQUIPMENTS USED CENTRIFUGAL PUMPS Fig 2.8:- CENTRIFUGAL PUMPS Centrifugal pump works by the conversion of the rotational to kinetic energy, typically from an electric motor or turbine, to an increased static fluid pressure. This action is described by Bernoulli's principle. The rotation of the pump impeller imparts kinetic energy to the fluid as it is drawn in from the impeller eye (center) and is forced outward through the impeller vanes to the periphery. As the fluid exits the impeller, the fluid kinetic energy (velocity) is then converted to (static) pressure due to the change in area the fluid experiences in the volute section. Typically the volute shape of the pump casing (increasing in volume), or the diffuser vanes (which serve to slow the fluid, converting to kinetic energy in to flow work) are responsible for the energy conversion. The energy conversion results in an increased pressure on the downstream side of the pump, causing flow. Fig 2.9:-PARTS OF CENTRIFUGAL PUMPS MULTISTAGE CENTRIFUGAL PUMP A centrifugal pump containing two or more impellers is called a multistage centrifugal pump. The impellers may be mounted on the same shaft or on different shafts. A multistage centrifugal pump has the following two important functions: • To produce a high head • To discharge a large quantity of liquid. If a high head is to be developed then the impellers are mounted on same shaft (series) while for large quantity of discharge of liquid, the impellers are mounted on different shafts (parallel). Mechanical seals feature: Fig 2.10:- DIFFEREN PARTS OFMECHANICAL SEALS *Invisible leakage *Less friction/power loss *No to little wear on the shafts or sleeves *Flexibility - to accommodate shaft deflections and End play *No period maintenance *Long Life MECHANICAL SEAL It consists of two basic parts a rotating element attached to Shaft and a stationary part attached to casing. Both are highly polished. Process to Assemble the Mechanical Seal Positions the shaft sleeve with its thread facing upwards on a work bench. Coat the sleeve surface and o ring of inner seal with TEG (tri-ethylene glycol). Clean seat and seal surface with alcohol. Push the inner stationery seal seat first and then the inner rotating seal over the sleeve. Check that the groove in the shaft sleeve is aligned with the groove in the rotating seal. Insert the woodruff key by compressing the seal. Slide the ring over the rotating seal so that seal seat and the inner seal are centered against each other. Surface of woodruff key must be parallel to shaft sleeve. GEAR PUMP Fig 2.11:- FLOW IN A GEAR PUMP As the gears rotate they separate on the intake side of the pump, creating a void and suction which is filled by fluid. The fluid is carried by the gears to the discharge side of the pump, where the meshing of the gears displaces the fluid. The mechanical clearances are small—on the order of a thousandth of an inch (micrometers). The tight clearances, along with the speed of rotation, effectively prevent the fluid from leaking backwards. The rigid design of the gears and housing allow for very high pressures and the ability to pump highly viscous fluids Many variations exist, including; helical and herringbone gear sets (instead of spur gears), lobe shaped rotors similar to Roots Blowers (commonly used as superchargers), and mechanical designs that allow the stacking of pumps. The most common variations are shown below (the drive gear is shown blue and the idler is shown purple). Fig 2.12:- DIFFERENT PARTS OF GEAR PUMP Suction and pressure ports need to interface where the gears mesh (shown as dim gray lines in the internal pump images). Some internal gear pumps have an additional, crescent shaped seal (shown above, right) PACK BODY SYSTEM Spin pack will contain in some heating devices in case of melt spinning. For melt spinning these refers to spin beams. Several ways of holding these packs into these heating devices: - by jackscrews, bolts or threads. Selection of construction material for pack body is critical. Metal should be subjected to high temperature, high machine ability. It has to be properly designed because it will disassemble and reassembled where damage of pack occur. METAL POWDER AND SILICA SYSTEM Filter media for polymer filtration are metal powders, silica sand, aluminum oxide, metal screens. Ideal characteristics required for efficient polymer filtration includes inert to polymer, compaction, high void volume and long life. MONOMETER SYSTEM Every spinning position there is a monometer suction nozzle which removes the monomer vapor through bottom of the spinnerets. Consists of water jet pipe connected to exhaust from every spinning positions. Circulated water collected in monometer tank with circulating pump. Monomer vapor needs to remove as this may lead to powder generation during textile fiber processing. CRIMPER Fig 2.13:- BASIC DIMENSIONS OF CRIMPER It is the most important part of the fiber line. In this crimper crimps are made in the tow coming from the stem box. These crimps in the tow help to bind the yarn strongly and properly. In this crimper there are two rollers (one is fixed and other is moveable) through which tow is allowed to pass and then through the stuffer box. The rollers are jacketed in which hot water is always flow to give proper temperature to the tow. In stuffer box there is steam at 0.6bar and 80’c temperature flows through it to give proper softness so that crimp can be easily drawn out through it. Pneumatic cylinder provided for both roll pressure and stuffer box. Fig 2.14 PRODUCT PRODUCED AFTER CRIMPPING CRAFT WINDER Fig 2.15:- CRAFT WINDER It is a machine used for winding the yarn on the bobbins. It consists of following parts:- 1) CAM SHAFT – It is the shaft consisting of several grooves in it, these grooves guides the yarn which is to be winded on the bobbin. 2) TRANSFER TAIL – The yarn coming from cam shaft pass through this transfer tail which allows yarn to wind up on the bobbins. 3) CHUCKS – These act as a spindle for the bobbins. It rotates at a high speed. In it there is gripping device which grip the bobbins on to the chuck. It is operated with the pneumatic pressure. When pressure is released it tighten the bobbins and when pressure is applied it frees the bobbins. 4) PUSHING DEVICE – This device used for pushing out the bobbins from the chuck when winding get completed. It is operated with pneumatic cylinder. 5) BAILING DEVICE – It is used for pressing the yarn on the bobbins so that yarn can’t slip away while winding. 6) ROTER MOTER – It used to give instant rotation to the chuck plate. 7) CREEP MOTER – It is used to give uniform creep rotation to the chuck plate so that the two chucks do not make any interference and winding remains smooth. Chapter 3 PROJECT: Maintenance of agitators and to prepare the daily check list while agitators are working. AGITATORS: AGITATORS are machines used in industries that process products in the chemical, food, pharmaceutical and cosmetic industries, in a view of: • Mixing liquids together. • Promote the reactions of chemical substances. • Keeping homogeneous liquid bulk during storage. • Increase heat transfer (heating or cooling). DIFFERENT TYPES OF AGITATORS: Mechanical agitators are divided into eight basic groups depending upon their design and application. These are: 1. Paddles. 2. Turbines. 3. Propellers. 4. Helical screw. 5. Cones. 6. Radial propellers. 7. High speed disc. 8. Aerators. Fig 3.1:-AGITATOR USED IN POLY AREA Fig 3.2:- General arrangement of the vessel with agitator Maintenance of agitators: Maintenance basically contains two parts list of spares of an agitator, and the lubrication schedule for its various parts which also mention the specifications of lube oil required. Spares of agitators: The various parts of an agitator are listed below. An agitator unit consists of: 1. Blades (these are either bolted to the agitator or are integral with the shaft, depending upon agitator size) 2. Transmission system 3. Coupling to connect the driven shaft with the driving shaft. 4. Bearing etc. 5. The rotor shaft. 6. An electric motor to drive shaft. Maintenance Procedure: Maintenance mainly includes the following jobs: 1. Checking the lubrication. It includes the following: • Checking the oil level in oil sump for worm gear and thrust bearings. • Checking that the chain used in driving mechanism is properly lubricated. • Periodic lubrication of the bearings etc. with the right quantity of lubricant. 2. Checking the alignment of driving and driven shaft. 3. Checking the surface of mating parts and the parts rotating in contact e.g.: the meshing gears teeth. 4. LLF checking for vibration, sound and any abnormality. 5. Checking the condition of v-belt or chain or coupling whichever is applicable, of the driving mechanism. Lubrication Of agitator Parts: Lubrication of an agitator, just like any other rotating equipment, is of foremost importance as it determines the efficiency , in terms of quality and effectiveness of the work done as well as the power consumption; and life of the equipment. Thus, it is essential to determine the right type of lubricant for an agitator and its frequency of lubrication. Procedure Of Lubrication: The following parts of agitators require lubrication 1. Worm, worm gear and worm gear bearings. 2. Countershaft bearings 3. Roller chain • Worm, worm gear and worm gear bearings: Worm gear and ball bearings should be submerged in oil bath. The proper oil level in the worm gear housing is determined by plugged overflow elbow at side of oil sump. The recommended oil is: SAE140. • Countershaft bearings: The bearings of the shaft can lubricated either by natural lubrication or by pressurized lubrication. • Roller chain: In some cases, roller chains are used in place of v-belts or couplings. These chains need regular lubrication. Lubricant to be used : SAE60 TROUBLESHOOTING IN AGITATOR S.NO PROBLEM REASON SOLUTION 1. Gear heating up Use of wrong lubricant. Use correct lubricant as specified by The supplier. Excessive churning Use lubricant of lower viscosity. Check that the oil sump is not overfill -ed. Bearing clearance not Proper Adjust the bearing clearance using shims. Misalignment between the gear shaft and prime mover Align properly 2. Gear-box leakage Excessive oil in the sump Fill oil up to the upper oil level mark 3. Gear-box noise Worn out bearings Clearance can be adjusted using shims and pushing in the bearing caps from one or both ends. If this is not possible, replace the bearings caps from one end or both. If this is not possible, replace the bearings. Worn out worm or worm wheels. Replace them in pair if both are worn out. Foreign particles in the bearings. Clean. Take precautionary so that it is not repeated again. Excessive backlash Replace worm and worm wheel. Tooth contact not proper. Align worm worm wheel properly. If damaged replace them. Worm shaft or wheel running eccentrically. If worm shaft is bent replace it and align it properly. Care should be taken while assembling the bearing on the worm shaft. 4. Gear-box vibrations. Improper foundation. If worm shaft is bent replace it and align properly. Care should be taken while assembling the bearing on the worm shaft. Improper alignment Align properly. 5. Oil seal whistling Dry oil seal lips Lubricate. TABLE 3.1:- TROUBLESHOOTING IN AGITATOR FIG 3.3:-CHECKLIST PREPARED FOR AGITATOR Project: - Maintenance of boilers and to know the different problem which occurs while their working and to know the maintenance procedure. 1-STARTING OF BOILER a. Switch ON the main power supply. b. Start boiler feed water pump and open the discharge valve, confirm that the discharge pressure is around 30kg/cm2 if abnormal vibration is observered then regulate spill back water valve. c. Open the boiler feed water line. confirm the level of water in boiler steam drum, it should be ¾ on gauge glass. d. Start FD fan. Open inlet and outlet damper as much as indication of combustion air pressure disappears and pressure on furnace pressure gauge is around 50mm wg. e. Open the atomizing air/steam valve. The atomizing media pressure should be around 10 kg/cm2 on pressure gauge. Remove condensate if atomizing media is steam. f. Open hand shut off valve of oil and air/steam. Open the purging valve for two mins. To flush oil line, close the hand shut off valve. g. Open inlet and outlet valves of oil pump. Start the oil pump. Oil pressure should be around 8 kg/cm2. h. Switch on the burner panel power supply, supply on, limit OK, and burner ready to start; indications will come on burner panel. Now press the sequence controller switch and after that press burner start switch. Now the indication `burner ready to start disappears from burner panel`. After some seconds atomizing media solenoid valve automatically opens. Adjust approx. 1kg/cm2 air/steam differential pressure through differential control valve. i. Open LPG gas hand shut off valve immediately after atomizing media solenoid valve opens. After few seconds solenoid valve of LPG gas operates in ON position. At the same time the electrodes give spark and pilot flame starts. It can be soon through sight glass. Now immediately open the oil hand shut off valve. Within few seconds solenoid valve in oil line operated in `open` position. Now main flame is started in boiler furnace and indication of `pilot on` disappears from burner panel and solenoid valve of LPG gas closes. Now there is no indication on main panel annunciator. Now raise the required oil pressure and open wind box air dampers and adjust these dampers according to oil pressure. Check flue gas of the chimney. If smoke is black it means air is less. Adjust the dampers so that the smoke color is light brown. j- Start LP and HP dosing systems. 2-STOPPING Switch off the burner off push button from burner panel; confirm that the oil pump is ‘OFF’. After around 15 min stop the following:- (a) Boiler feed water system. (b) L.P & H.P dosing system. © F.D fan. (a) Feed water pump discharge : 25 to 40 kg/cm2 (b) Deareator water level : 3/4 on the water level gauge. © Atomizing media pressure : 9 to 11 kg/cm2. (d) Pressure difference b/w atomizing media& fuel oil : approx. 1 kg/cm2 (e) Boiler steam pressure : max 27 kg/cm2 (f) Blow down sample ph : 9to 11 Hardness : max 5ppm Alkalinity : max. 600 ppm TDS : max. 3000 ppm 3- BOILER RUNNING PARAMETERS Table 3.2:- BOILER RUNNING PARAMETERS 4 – BOILER SAFETIES DESCRIPTION TRIP ALARM i. DE aerator level Very low(25%) Low (40%) ii. Atomising air/steam pressure low 4 kg/cm2 4kg/cm2 iii. Combustion air pressure Low 40mm WC 40mm WC iv. Furnace pressure high 250mm WC 250mm WC v. Steam pressure high 28kg/cm2 28kg/cm2 vi. Limit switch on dampers Contact open vii. Drum level high 70% of water level viii. Drum level low 50% of water level ix. Safety level(set point) PSVI 27kg/cm2 X Safety valve (set point) PSV2 27.5kg/cm2 Table 3.3:- BOILER SAFETIES. 5-TROUBLE SHOOTING (maintenance problems) DEFECTS CAUSES REMEDIES Drum levels falls rapidly Controlled valve jammed Feed water pump pressure low Leakage through some tubes. Blockage in feed water system Open water by pass system, then repair control valve. Clean suction filter Shut down the boiler check, e