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Alihaider 12-MT-21
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SUBMITTEDBY:ALIHAIDER
ROLLNO:12-MT-21
SUBMITTEDTO:PROF.ZAFARABBAS
NFC INSTITUTE OFENGINEERING AND FERTILIZER RESEARCH FSD
INDUSTRIAL TRAINING REPORT
CENTURY PAPER & BOARD MILLS
BSc ENGINEERING AND
TECHNOLOGY MECHANICAL
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INDUSTRIAL TRAINING
REPORT
First of all I am gratefultothe Allah Almighty the most gracious,most mercifuland most beneficent whoenabledme to complete this
Internship. I pray to Allahhoping myjourney is inHis bliss.
I offer my thanksto the Holy Prophet (PBUH) whoisthe beaconofenlightenment andthe greatest benefactor,the mankindeverhad.
ThenI offer tothe thanksto Engr. Prof. Dr. Syed AmjadAhmad(HeadofDepartment ofMechanicalEngineering inNFCIE &FRFSD) &
Engr. MuhammadNaheed Javed[Assistant Professor in MechanicalDepartment inNFCIE& FRFSD) for including the Industrial Training in our
Degree andinspiring me for Industrial Training. I also would like tothank herfor showing me and my classmate some example and also techniques
about the industrythat relatedtothe industrial training and how we can serve inthe industry.
The time I spent inCentury Paper and Board Millsas an internee Engineerfrom (2nd
Feb2016to2nd
June 2016)was amemorable one for
me as it was rich inexperience sharing and helpedme discovermy potential.I have had so many richexperiencesandopportunitiesthat I personally
believe willforevershape and influence my professional life while fostering personal growthand development.
The industrial training Ihad withCenturyPaper and Board MillsLtd. great chance for learning and professional development. Therefore, I
consider myselfas a veryluckyindividualas I was provided withan opportunity tobe a part of it.I am also gratefulfor having a chance tomeet so
many wonderful people and professionals who ledme though thisinternshipperiod.
Bearing inmind previous I am using thisopportunity toexpress mydeepest gratitude andspecialthanksto the GeneralManager&
Mangersand who inspite of being extraordinarily busywithhis duties, tooktime out tohear, guide and keepme on the correct pathand allowing me
tocarry out myproject at theiresteemedorganizationand extending during the training.
Specialthanksto Mr.Nadeem-Ullah-Sheikh[GeneralManagerofEngineering inCPBM],Mr. NadeemDenial[Managerof mechanical
Maintenance inCPBM],Mr. Zahoor Saleem [ManagerofmechanicalinCPBM],Mr. GhulamQadar[Assistant ManagerofmechanicalMaintenance
in CPBM],Mr. Waqas Wakeel [SeniormechanicalEngineerinCPBM]& Mr. TariqYaseen [MechanicalEngineerinCPBM] fortaking part in useful
Acknowledgement
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decision, giving necessaryadvices,guidance and valuable suggestionsand affectionate supervision. I
choose this moment toacknowledge hiscontributiongratefully.
CPBM Introduction:
 CenturyPaper & Board MillsLimited(CPBM) ispart ofLakson Group of Companies
Pakistan. The Lakson Groupof Companies is one the leading groupsof the countrywith
diversifiedinterestsin industriessuch as Paper &Paperboard, Printing & Packaging,Soaps
&Detergents,Instant Fruit Drinks, Fast Food Restaurant , Textiles,SurgicalGoods,
Information Technology,Insurance, Travel& Tours, Print & Electronic media,Investments
and Software Development.
 Lakson Group of Companies has built up Strategic BusinessRelationshipsand Business
AllianceswithMulti-NationalCorporations which includesTetleyTea,Colgate-Palmolive,
McDonalds and Kraft Foods.
Profile:
 CenturyPaper & Board MillsLimited(CPBM),establishedin1984.The Company started
commercialproduction in1990 and establishedits name as major producerof quality
Packaging boards in the country.It has attaineda positionof Market LeaderinPackaging
Boards in particular.
 The plant iscapable to caterlarge continuousorders for different typesof boxestoserve
multifarious sectorsincluding Soaps &Detergents,Home Appliances, DairyProducts, Ice
Cream, Food and Beverages,CigarettesandTobaccoand Lubricants etc.
The plant comprising of SevenPaper Machines(PMs),a Complete CorrugatedCartons Manufacturing
Plant, IntegratedPulpMills(MajorInputs Wheat Straw), inhouse Engineering Workshop, Captive
Power GenerationPlant, and ChemicalHouse etc.is situatedon162 Acres close tomajor business city
(Lahore) of the country.
CONTENTS
1. CPBM Introduction
 Profile
 Vision & Mission
 Core Values
2. Century Policies
 Environmental
 Quality
 Safety
3. Mile Stone
4. Board of Directors
5. Pow er Generation
6. Paper Production
7. Products
8. Financial
9. Technical Wing
 Mechanical
 Electrical
 Instrumentation
 Condition Monitor
10. Assignments
11. Practical’s
12. Conclusion
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Vision:
 To be the market leaderand an enduring force in the paper, board and packaging industry,positivelyinfluencing and providing value to
our stakeholders, societyandour nation.
Mission:
 To strive for excellence
 Teamwork environment
 Customer focusedstrategy
Core Values:
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Century Policies:
1. EnvironmentalPolicies:
 Ensure environment friendly operations, products and services.
 Mitigate environmentalimpactsthrougheffective implementationofISO14001:2004inorder to achieving conformance toapplicable
laws and regulations.
 Promote environmentalawareness to allemployeesand the community.
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2. Quality Policies:
 Century, a customerfocusedCompany, is always ready toaccept challengesforachieving itsmission.
 Century’squalityobjectivesare designedforenhancing customersatisfaction and operational efficiencies.
 Century,with itsprofessional and dedicatedteam,ensures continualimprovement inqualityand productivitythrougheffective
implementationof QualityManagement System(QMS) ISO9001:2008;
3. SafetyPolicies:
 Improve OccupationalHealthand Safety(OHS) performance continuously inall areas of operations.
 Promote OHSpracticesthroughtraining of employeesforhealthyand safe work environment.
 Communicate SafetyPolicyto allstakeholdersand reviewit periodicallyfor ensuring adequacyand compliance withOHSAS
18001:2007 standards.
Milestone:
Productioncapacity
 1990Commencedcommercialproductionwiththree machineshaving capacityof30,000Metric Tonsperannum.
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 1996Started12.3MW Captive PowerGenerationPlant as CenturyPower GenerationLimited(aformer subsidiary Company).
 1997 Enhancedproductioncapacityto50,000Metric Tonsthroughaddition of a three layersBoard Machine (PM-4).
 2003Enhancedproductioncapacityto80,000Metric Tonsperannum after installationof twin layerBoard Machine (PM-5).
 2006Enhancedproductioncapacityto110,000Metric Tonsperannum after installationof Paper Machine (PM-6).
 2008 EnhancedCaptive PowerGenerationcapacityto30MW asnew18 MW CogenerationPlant startedcommercialoperations.
 2009Enhancedproductioncapacityto240,000Metric Tonsperannum as CoatedBoard DuplexPlant (PM-7) starteditscommercial
operations.
 2011EnhancedBoxMaking capacityto30,000Metric Tonsperannum after aNewBoxMachine isadded with capacityof8,000Metric
Tons per annum.
 2012InstallednewCoal/BiomassFired Boilerwithcapacityof30ton perhour of steam.
 2014Inkedanagreement forinstallationof 18 MW CoalBased Co-GenerationPowerPlant.
Board of Directors:
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Power Generation:
CoGen-1
 Establishedin 1995
 3dieselgenerator
 Manufacture by “WATSILA”
 Production Capacity12.3 MW
CoGen-2
 Establishedin 2007
 4Dual-fuel GasTurbines
 Manufacture by “KAWASAKI”
 Production Capacity22MW
 Power along with54tons of Steam/hr.
CoGen-3
 The company on anInvestment of Rupees3.2 billion18 Megawatt CoalBased Co-Generation PowerPlant.
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Paper Production:
RawMaterials
 MW (MixedWaste)
 ONP(OldNewspaper)
 SOP (Sortedoffice paper)
 BKP(BleachKraft Pulp)
 Wheat Straw
Paper Machine (PM)
SPP:
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 Raw material
 Pulper
 Hole screen
 Slot screen
 H.D press
 Pre Heating screw
 Disperser/Disparager
 Storage tank
B.M:
 Wire part/sheet
 Head Box
 Press part/Felt
 Press 1
 Press 2
 Shoe press
 Smooth press
 Dry part
 Calendaring (Hard)
 Coating (pre, Top &Middle)
 IR Heater
 Calendaring (Soft)
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 Tunnel Dryer
 Rewinder
 Finishing House
 Cutting
 Counting
 Packing
Products:
Category
Description Substance Range
(g/m2)
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Packaging
Boards
One Side Clay Coated Boards with
100% virgin Fibers
205 - 350
One Side Clay Coated Boards with
recycled fiber in middle ply
230 – 400
Un-Coated Multi-layer Boards 125 – 350
Papers
Machine Finished Writing Printing
Papers
55 – 150
Machine Glazed Papers 22 – 70
Financial:
 Sales 14,667,669
 Cost of sales 12,646,230
 Gross profit before taxation/other charges 2,021,439
 (Loss)/profit of year 629,849
Profit and Loss in 2015
 Sales 13,186,182
 Cost of sales 12,308,379
 Gross profit before taxation/other charges 877,803
 (Loss)/profit of year 205,398
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Pumps:
 Pumps
 Typesof Pump & itsapplication
 Centrifugalpump
 Positive Displacement pump
 Rotary pump
 Gearpumps
 Screwpumps
 Reciprocating pump
 Piston pumps
 Diaphragm pumps
 VacuumPump
 Pump Assembly
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 Pedestal: Bearingsonshaft
 Stuffing Box: sleeve,glandpacking andpusher, sealing water,gas kit
 Casing: Impeller, eye,vanes, wearring
Coupling:
 Coupling
 Types& Application
Rigid(ForAlignedshaft)
 Flange coupling
 Split muff coupling
Flexible (ForNon-alignedshaft)
 Gearcoupling
 Gridcoupling
 Jaw coupling
 Universal coupling
Bearings:
Types& Application:
1. FrictionalBearing
 BallBearing
 DeepGroove bearing
 Self-Aligning bearing
 Thrust ballbearing
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 RollerBearing
 CylindricalRoller bearings
 SphericalRollerbearings
 TaperedRoller bearing
2. Non-FrictionalBearing
 BushBearing
Bearing Number Define:
Bearing Mounting / Dismounting:
 Hot
 Cold
Bearing Failure Reasons:
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 Improper Bearing Lubrication
 Contamination
 Improper Mounting
 Bearing Misalignment
 HighTemperatures
 ForeignMatter
 Corrosion
Power Transmission:
Typesof Belts:
 Flat belts
 Vbelts
 Ribbedbelts
 Timing belts
TypesofChain:
 Rollerchain
 Silent Chain
 Timing chain
Types of Gears:
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 Types& Application
 Spur gear
 Helicalgear
 Rackand pinion
 Externaland Internal gear
 Bevelgear
MCC (MotorControlCenter):
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Motors:
DC Motors:
AC Motors:
 Single Phase
 Three Phase
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PLC (Program Logic Control):
DCS (Distribution Control System):
• Instrumentation
• Instrument air
• Pneumatic /Hydraulic cylinder
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ControlLoops (Flow, Temperature, Consistency& Level):
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What is Maintenance?
• Purpose of Maintenance
TypesofMaintenance
• BreakDown Maintenance
• Preventive Maintenance
• Predictive Maintenance
• Pro-active Maintenance
• RCM (ReliabilityCenterMaintenance)
Condition monitoring:
• History
• Techniques
• Vibrationanalyze
• Thermography
• Stroboscope
• Stethoscope
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Heat Exchanger:
 Heat exchanger is a device used to transfer heat between one or more fluids
 The fluids may be separated by a solid wall to prevent mixing or they may be in
direct contact
Uses:
1. Spaceheating
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2. Refrigeration
3. Air conditioning
4. Power stations
5. Chemical plants
6. Petrochemical plants
 Internal combustion engine in which a circulating fluid known as engine
coolant flows through Radiatorcoils and air flows past the coils
Induction Heater Working Principle:
 An induction heater can be compared to a transformer using the principle of a
primary coil with a large number of windings, and a secondarycoil with a few
windings, on a mutual iron core. The input/output voltage ratio is equal to the ratio
of the windings, while the energy remains the same
 The secondary coil will provide a low voltage at high amperage
 The bearing is a short circuited
 Secondarycoil through which a low A.C. voltage flows at high amperage, thus
generating high heat
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What is Shaft coupling?
 A coupling is a device used to connect two shafts together at their ends for the purpose
of transmitting power
 The primary purpose of couplings is to join two pieces of rotating equipment while
permitting some degree of misalignment or end movement or both
Shaft coupling types:
1. Jaws coupling:
 A jaw coupling is a type of general purpose power
transmission that also can be used in motion control applications
 Consiston jaws and spiderwhich is used for more friction and
power transmission purpose
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2. Gear coupling:
 A gear coupling is a mechanical device for transmitting torque
between two shafts that are not collinear.
 It consists of a flexible joint fixed to each shaft. The two joints are
connected by a third shaft, called the spindle
3.Rigid coupling:
 Rigid couplings come in two parts and fit together around the shafts to form a
sleeve.
 They offer more flexibility than sleeved models, and can be used on shafts
that are fixed in place.
 They generally are large enough so that screws can pass all the way through
the coupling and into the second half to ensure a secure hold
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Difference between Tapping & Threading?
1.Tapping:
 Is drilled by hand or drill machine
 It consiston three drill method
 1-Bottoming -2- Plug -3- Tapper
2. Threading:
 Can be done easily on the lathe machine
 Die and Tap are used for threading
 There are -1- Internal threading -2- External threading

Mechanical Tool
File:
A file is a metalworking, wood working and plastic working tool used to cut fine
amounts of material from a work piece.
Types of Files:
Mill Files:
 Mill files are the most common shape
 They are rectangular in cross section and taper
 Slightly in both width and thickness from tang to end.
 They are all single-cut
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Hand or Flat File:
 Hand files are parallel in width and tapered in thickness
 They are used for general work.
Half Round Ring Files:
 Half round ring files taper in width and thickness
 Used for filing inside of rings
Barrette File:
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 Barrette files are tapered in width and thickness
 Only the flat side is cut, and the other sides are all safe
 For doing flat work.
Round File:
 It has circular cross section
 Used to file inside of holes
Bearing?
 Is a machine element which is used for Support the rolling elements
 For easily Rotation
 Overcome the friction
Bearing parts:
1. Outer race
2. Inner race
3. Rolling elements
4. Cage
Types of bearings:
1. Anti-frictional Bearing
2. Frictional Bearing
Anti-frictional Bearing:
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 Ball bearing
 Cylindrical bearing
 Spherical bearing
 Tapper bearing
1-Ball bearing:
 A ball bearing is a type of rolling-element bearing that uses balls to maintain the
separation between the bearing races
 The purposeof a ball bearing is to reduce rotational friction and
support radial and axial loads
2-Cylinderical roller bearing:
 Common roller bearings use cylinders of slightly greater length than diameter
 Line contactis more than ball rollers
 Can bear more axial load
 If the inner and outer races are misaligned, the bearing capacity often drops
quickly compared to either a ball bearing or a spherical roller bearing
3-Spherical roller bearing:
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 Spherical roller bearings have an outer ring with an internal spherical shape
 The rollers are thicker in the middle and thinner at the ends
 Spherical roller bearings can thus accommodate both static and dynamic
misalignment
 However, spherical rollers are difficult to produceand thus expensive, and the
bearings have higher friction than an ideal cylindrical or tapered roller bearing
since there will be a certain amount of sliding between rolling elements and rings
4-Tapper roller bearing:
 Tapered roller bearings use conical rollers that run on conical races
 Most roller bearings only take radial or axial loads, but tapered roller bearings
supportboth radial and axial loads
 Generally can carry higher loads than ball bearings due to greater contact area
Mechanical tool
Screw driver:
A screw driver is a tool used to turn a screw. It is a feature that allows the screw
driver to apply a torque on screw
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Types of Screw Driver:
External Types:
 Square
 Hex
 Pentagon
Hex:
 A hex screw drive uses six-sided fastener heads
 The fastener is known as a hex head cap screw.
 The hex drive is better than square drive for locations where
surrounding obstacles
Pentagonal:
 A pentagon screw drive uses five-sided fastener heads
 The fastener is known as a penta screw.
 They require a special five-point socket in order to be turned.
 A pentagon screw drive uses five-sided fastener heads.
 The fastener is known as a penta screw. They require a special five-point socketin
order to be turned.
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Circumference Types:
Phillips:
 A screwdriver having a cross-shaped tip rather than the rectangular tip of a
standard screw driver
 Useful on automated production lines that use powered screwdrivers.
Frierson:
 The Friersonscrew drive, also known as the Reedand Prince screw drive
 Similar to a Phillips but the Frierson has a sharp tip and larger angle in the V shape
 sharp cross, allowing for higher applied torque
 Unlike the rounded, tapered Phillips head
Flat:
 Used to drive flat heads
 It is commonly used screw drives
 Designed to turn slotted screws
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INDUSTRIAL TRAINING
REPORT
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Filtration:
Filtration is commonly the mechanical or physical operation which is used for the separation of
solids from fluids (liquids or gases) by interposing a medium through which only the fluid can
pass.
SAMPLING:
Take subject to be filter
Like (Vacuum Pump Storage Tank Water) e.g.
PROCEDURE:
Shake well before subject to proceed further so contamination which is present in bottom mix up
properly with H2O
Take some quantity of water in the beaker (1000ml)
Now take a filter paper which is already dried (remove moisture) in oven at 135c0
temperature
and weighted (1.002g) e.g.
Now wet the both sides of filter paper with water
Fix the filter paper at the top of the Sucker which is called Funnel
Now turn on the (vacuum pressure or negative pressure) valve
After that start pouring the subject in to the funnel through filter paper until subject quantity is
finished
Remove the filter and take it to the oven (for 10-15 min) so it can be dry
In the end note weight of filter paper [with contamination-like (1.04g)] and get your values by
applying following formulas
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FORMULAS:
For weight: - Dry contaminated filter paper - Dry filter paper weight (1.04-1.002=Ans) e.g.
For %age:- Dry contaminated filter paper / Wet contaminated filter paper *100
PRECAUTIONS:
All the apparatus must be well cleaned
They are accurate or work properly
Shake the subject 5 to 6 times for better results
Don’t fill the funnel pan full with subject pour it slowly slowly
Take weight of filter papers quickly after dry in oven because of moisture contents
What is Engine?
 Is a device whichconverts the energy one form to another form
 Is a device converts the Chemicalenergy into Mechanicalenergy
What is I.C Engines & E.C Engines?
I.C Engines:
 Stands for INTERNALCOMBUSTION Engines
 Combustion procedure occurs inside the cylinder
 Examples: 1- Diesel -2 Petrol -3 Gas Engines
 1860-1920
 Generally using cycles 1- Otto cycle -2 Diesel cycle
E.C Engines:
 Stands for EXTERNALCOMBUSTION Engines
 Combustion procedureoccurs outside the cylinder
 Example: Steam Engine
 3rd century on wards
 Generally using cycles 1- Organic rankine cycle -2 Carnot cycle
Classification of I.C Engine?
 Reciprocating
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 Rotary
Reciprocating:
By number of strokes:
1. Two-stroke Engine
2. Four-stroke Engine
3. Six-stroke Engine (over view)
By type of ignition:
1. Spark ignition
2. Compressionignition
Generally used cycles:
1. Otto Cycle
2. Diesel Cycle
Rotary:
 Wankel Engine
What is Stroke?
 Piston covers a distance from TDC to BDC
 Top dead center(TDC)
 Bottom dead center(BDC)
What is Two- Stroke Engine?
 It completes a power cycle with Two strokes (up and down movements) of the
piston during only one crankshaft revolution
 It is also consist on Diesel& Petrol Engines
Working:
Intake:
The fuel/air mixture is first drawn into the crankcase by the vacuum that is created
during the upward stroke of the piston. The illustrated engine features a poppet
intake valve which is drawn open by the vacuum produced bythe intake stroke.
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Compression:
During the downward stroke, the poppetvalve is forced closed by the increased
crankcase pressure. The fuel mixture is then compressed in the crankcase during
the remainder of the stroke.
Power:
At the top of the stroke, the spark plug ignites the fuel mixture. The burning fuel
expands, driving the piston downward, to complete the cycle. (At the same time,
another crankcase compressionstroke is happening beneath the piston.)
Transfer/Exhaust:
Toward the end of the stroke, the piston exposes the intake port, allowing the
compressed fuel/air mixture in the crankcase to escape around the piston into the
main cylinder. This expels the exhaust gasses out the exhaust port, usually located
on the opposite side of the cylinder. Unfortunately, some of the fresh fuel mixture
is usually expelled as well.
Advantages:
 High power produced
 Less complicated
 Ports used
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Dis-advantages:
 More fuel consumption
 Noisy
 Smoky
 Expensive to repair
 Oil changing
Uses:
 Engines
 Vehicles
 Chain saw etc.
What is Four Stroke Engine?
 It completes a power cycle with Four strokes (up and down movements) of
the piston during two crankshaft revolutions
Working:
Intake:
The fuel/air mixture is first drawn into the crankcase by the vacuum that is created
during the upward stroke of the piston. Inlet valve used in it to drive the fuel/air
mixture.
Compression:
During the upward stroke, the inlet valve is forced closed by the increased cylinder
pressure. Flywheel momentum drives the piston upward compressing the fuel air
mixture. The fuel mixture is then compressed in the crankcase at its high ratio.
Power:
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At the top of the stroke, the spark plug ignites the fuel mixture. The burning fuel
expands, driving the piston downward, to complete the cycle. And a power stroke
completes.
Exhaust:
At the bottom of the power stroke the exhaust valve is opened by the cam
mechanism. The upward stroke of the piston drives the exhausted fuel out of the
cylinder.
1-Intake 2-Compression 3-Power 4-Exahust
Advantages:
 High fuel efficiency
 Less noise
 Easy to mantinance
Dis-advantages:
 Low power
 Complicated desgin
 Valves used
Uses:
 Petrol engines
 Diesel engiens
 Cars,bikes,genertors etc.
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What is Six Stroke Engine?
 Type of I.C engine based on the four stroke engine but with the additional
complexity intended to make it more efficient and reduce emission.
 Two types -1 Single piston -2 Opposed piston
Single Piston:
 Steam or Air as working fluid
 Piston goes up and down Three Times for each injection of fuel
 Otto cycle & Diesel cycle
Opposedpiston:
 Uses second opposedpistonin each cylinder
 Moves half the cyclical rate of main piston
 Giving six piston movements
 2nd replaces the valve mechanism
What is Ignition System?
 Burning of fuel & air in the combustion cylinder
 Burning of matter instantly at high power
Spark Ignition Engine:
 Combustion take place in the cylinder by the help of spark
 Or spark is required for burn the fuel/air mixture
 Spark plug used generally
 Less compressionratio (12 to 16)
 Petrol engine
Compression Ignition Engine:
 Combustion take place in the cylinder by the internal compressionpressure
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 High compressionratio (18 to 22)
 Burns the fuel/air mixture
 In the winters glow plug may required
 Diesel engine
What is Cycle in Thermodynamics?
 Perform a whole procedurecame backto its initial point is called cycle in
thermodynamics it is consist on Heat accepted and rejected, Volume, Pressure &
Absorption
 Like ; In an engine intake to exhaust and came back again at intake completes a
cycle
Diesel Cycle:
Process 1-2: Isentropic Compression
 Piston moves from BDC to TDC
 Pressure increased P1 to P2
 Volume decrease V1 to V2
 Entropy S2=S3
Process 2-3: Constant pressure Heat addition
 Heat add constantpressure from external source
 Volume increases V2 to V3
 Temperature increases T2 to T3
 Entropy increases S2 to S3
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 Qin = mCp(T3-T2)kJ
Process 3-4: Isentropic Expansion
 Compressed and heated air expanded
 Piston moves from TDC to BDC
 Pressure of air decreases P3 to P4
 Temperature decreases T3 to T4
 Volume increases V3 to V4
 Entropy stay constant(S3=S4)
Process 4-1: Constant Volume Heat Rejection
 Heat rejected at constant volume (V4=V1)
 Pressure decreases (P4 to P1)
 Temperature decreases (T4 to T1)
 Entropy decreases (S4 to S3)
 Qout =mCv (T4-T1)
Otto cycle:
Process1-2 Adiabatic Process:
Alihaider 12-MT-21
45
 Piston moves from BDC to TDC
 Compressionof air
Process 2-3 Constant Volume Heat:
 Volume and heat transfer while piston at TDC
Process 3-4 adiabatic (isentropic):
 It is expansion power stroke
Process 4-1:
 Complete cycle at constant volume process
 Heat rejected from air while piston at BDC
Wankel engine:
 Rotator is used as piston
Intake:
 Fuel/air mixture came inside the cylinder by inlet valve
Compression:
 Air and fuel being compressed in there
Alihaider 12-MT-21
46
Power:
 This power produced after combustion of fuel/air mixture
Exhaust:
 All burn gases exit from outlet valve
Uses & Advantages:
 For more power
 High speed
 Mazda cars
 Monsters trucks
 Engines for power generation
References: (Wikipedia,
Mechman)
Alihaider 12-MT-21
47
Alihaider 12-MT-21
48
 Assignment on PumpsErection
 Assignments on Gearbox
 LPG Plant Dismantling
 Dispersers’ Drawings (AutoCAD)
 Assignment on Coupling
 Assignment on Steam trap
 Line diagrams of SPP as per process
 Line Diagram of B.M-7 according to process continue
 Line Diagram of Fans & Blowers in B.M-7
 Bearing Mounting/Dismounting
Alihaider 12-MT-21
49
 Pumps Assembly
 Machining operations
 Gascutting
 Condition Monitoring (Stroboscope , Stethoscope & Temperature gun)
 Balancing
 Laser Alignment
 Machine Shop
 Material Consumption Reports
 Filtration Sheet (Vacuum Pumps)
 I would like to conclude thatby this training, we have learned a lot of knowledge which we
cannot obtain in the books.
Alihaider 12-MT-21
50
 The company provides us with the real working environment.
 Not only learning also the practical, we also have got the opportunities to implement the work
scope with our own strength and abilities during the internship.
 The staff andworkers over here are very friendly. They help me a lot during my industrial
practical here.
 The experience in the industry during this internship is valuable for us.
 The company allow trainees to work with anemployee to help aid in the work.
 The conclusion I can make is that The Century Paper andBoard Mills is the right place for
students to do their industrial training.

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INDUSTRIAL TRAINING REPORT

  • 1. Alihaider 12-MT-21 0 SUBMITTEDBY:ALIHAIDER ROLLNO:12-MT-21 SUBMITTEDTO:PROF.ZAFARABBAS NFC INSTITUTE OFENGINEERING AND FERTILIZER RESEARCH FSD INDUSTRIAL TRAINING REPORT CENTURY PAPER & BOARD MILLS BSc ENGINEERING AND TECHNOLOGY MECHANICAL
  • 2. Alihaider 12-MT-21 1 INDUSTRIAL TRAINING REPORT First of all I am gratefultothe Allah Almighty the most gracious,most mercifuland most beneficent whoenabledme to complete this Internship. I pray to Allahhoping myjourney is inHis bliss. I offer my thanksto the Holy Prophet (PBUH) whoisthe beaconofenlightenment andthe greatest benefactor,the mankindeverhad. ThenI offer tothe thanksto Engr. Prof. Dr. Syed AmjadAhmad(HeadofDepartment ofMechanicalEngineering inNFCIE &FRFSD) & Engr. MuhammadNaheed Javed[Assistant Professor in MechanicalDepartment inNFCIE& FRFSD) for including the Industrial Training in our Degree andinspiring me for Industrial Training. I also would like tothank herfor showing me and my classmate some example and also techniques about the industrythat relatedtothe industrial training and how we can serve inthe industry. The time I spent inCentury Paper and Board Millsas an internee Engineerfrom (2nd Feb2016to2nd June 2016)was amemorable one for me as it was rich inexperience sharing and helpedme discovermy potential.I have had so many richexperiencesandopportunitiesthat I personally believe willforevershape and influence my professional life while fostering personal growthand development. The industrial training Ihad withCenturyPaper and Board MillsLtd. great chance for learning and professional development. Therefore, I consider myselfas a veryluckyindividualas I was provided withan opportunity tobe a part of it.I am also gratefulfor having a chance tomeet so many wonderful people and professionals who ledme though thisinternshipperiod. Bearing inmind previous I am using thisopportunity toexpress mydeepest gratitude andspecialthanksto the GeneralManager& Mangersand who inspite of being extraordinarily busywithhis duties, tooktime out tohear, guide and keepme on the correct pathand allowing me tocarry out myproject at theiresteemedorganizationand extending during the training. Specialthanksto Mr.Nadeem-Ullah-Sheikh[GeneralManagerofEngineering inCPBM],Mr. NadeemDenial[Managerof mechanical Maintenance inCPBM],Mr. Zahoor Saleem [ManagerofmechanicalinCPBM],Mr. GhulamQadar[Assistant ManagerofmechanicalMaintenance in CPBM],Mr. Waqas Wakeel [SeniormechanicalEngineerinCPBM]& Mr. TariqYaseen [MechanicalEngineerinCPBM] fortaking part in useful Acknowledgement
  • 3. Alihaider 12-MT-21 2 decision, giving necessaryadvices,guidance and valuable suggestionsand affectionate supervision. I choose this moment toacknowledge hiscontributiongratefully. CPBM Introduction:  CenturyPaper & Board MillsLimited(CPBM) ispart ofLakson Group of Companies Pakistan. The Lakson Groupof Companies is one the leading groupsof the countrywith diversifiedinterestsin industriessuch as Paper &Paperboard, Printing & Packaging,Soaps &Detergents,Instant Fruit Drinks, Fast Food Restaurant , Textiles,SurgicalGoods, Information Technology,Insurance, Travel& Tours, Print & Electronic media,Investments and Software Development.  Lakson Group of Companies has built up Strategic BusinessRelationshipsand Business AllianceswithMulti-NationalCorporations which includesTetleyTea,Colgate-Palmolive, McDonalds and Kraft Foods. Profile:  CenturyPaper & Board MillsLimited(CPBM),establishedin1984.The Company started commercialproduction in1990 and establishedits name as major producerof quality Packaging boards in the country.It has attaineda positionof Market LeaderinPackaging Boards in particular.  The plant iscapable to caterlarge continuousorders for different typesof boxestoserve multifarious sectorsincluding Soaps &Detergents,Home Appliances, DairyProducts, Ice Cream, Food and Beverages,CigarettesandTobaccoand Lubricants etc. The plant comprising of SevenPaper Machines(PMs),a Complete CorrugatedCartons Manufacturing Plant, IntegratedPulpMills(MajorInputs Wheat Straw), inhouse Engineering Workshop, Captive Power GenerationPlant, and ChemicalHouse etc.is situatedon162 Acres close tomajor business city (Lahore) of the country. CONTENTS 1. CPBM Introduction  Profile  Vision & Mission  Core Values 2. Century Policies  Environmental  Quality  Safety 3. Mile Stone 4. Board of Directors 5. Pow er Generation 6. Paper Production 7. Products 8. Financial 9. Technical Wing  Mechanical  Electrical  Instrumentation  Condition Monitor 10. Assignments 11. Practical’s 12. Conclusion
  • 4. Alihaider 12-MT-21 3 Vision:  To be the market leaderand an enduring force in the paper, board and packaging industry,positivelyinfluencing and providing value to our stakeholders, societyandour nation. Mission:  To strive for excellence  Teamwork environment  Customer focusedstrategy Core Values:
  • 5. Alihaider 12-MT-21 4 Century Policies: 1. EnvironmentalPolicies:  Ensure environment friendly operations, products and services.  Mitigate environmentalimpactsthrougheffective implementationofISO14001:2004inorder to achieving conformance toapplicable laws and regulations.  Promote environmentalawareness to allemployeesand the community.
  • 6. Alihaider 12-MT-21 5 2. Quality Policies:  Century, a customerfocusedCompany, is always ready toaccept challengesforachieving itsmission.  Century’squalityobjectivesare designedforenhancing customersatisfaction and operational efficiencies.  Century,with itsprofessional and dedicatedteam,ensures continualimprovement inqualityand productivitythrougheffective implementationof QualityManagement System(QMS) ISO9001:2008; 3. SafetyPolicies:  Improve OccupationalHealthand Safety(OHS) performance continuously inall areas of operations.  Promote OHSpracticesthroughtraining of employeesforhealthyand safe work environment.  Communicate SafetyPolicyto allstakeholdersand reviewit periodicallyfor ensuring adequacyand compliance withOHSAS 18001:2007 standards. Milestone: Productioncapacity  1990Commencedcommercialproductionwiththree machineshaving capacityof30,000Metric Tonsperannum.
  • 7. Alihaider 12-MT-21 6  1996Started12.3MW Captive PowerGenerationPlant as CenturyPower GenerationLimited(aformer subsidiary Company).  1997 Enhancedproductioncapacityto50,000Metric Tonsthroughaddition of a three layersBoard Machine (PM-4).  2003Enhancedproductioncapacityto80,000Metric Tonsperannum after installationof twin layerBoard Machine (PM-5).  2006Enhancedproductioncapacityto110,000Metric Tonsperannum after installationof Paper Machine (PM-6).  2008 EnhancedCaptive PowerGenerationcapacityto30MW asnew18 MW CogenerationPlant startedcommercialoperations.  2009Enhancedproductioncapacityto240,000Metric Tonsperannum as CoatedBoard DuplexPlant (PM-7) starteditscommercial operations.  2011EnhancedBoxMaking capacityto30,000Metric Tonsperannum after aNewBoxMachine isadded with capacityof8,000Metric Tons per annum.  2012InstallednewCoal/BiomassFired Boilerwithcapacityof30ton perhour of steam.  2014Inkedanagreement forinstallationof 18 MW CoalBased Co-GenerationPowerPlant. Board of Directors:
  • 8. Alihaider 12-MT-21 7 Power Generation: CoGen-1  Establishedin 1995  3dieselgenerator  Manufacture by “WATSILA”  Production Capacity12.3 MW CoGen-2  Establishedin 2007  4Dual-fuel GasTurbines  Manufacture by “KAWASAKI”  Production Capacity22MW  Power along with54tons of Steam/hr. CoGen-3  The company on anInvestment of Rupees3.2 billion18 Megawatt CoalBased Co-Generation PowerPlant.
  • 9. Alihaider 12-MT-21 8 Paper Production: RawMaterials  MW (MixedWaste)  ONP(OldNewspaper)  SOP (Sortedoffice paper)  BKP(BleachKraft Pulp)  Wheat Straw Paper Machine (PM) SPP:
  • 10. Alihaider 12-MT-21 9  Raw material  Pulper  Hole screen  Slot screen  H.D press  Pre Heating screw  Disperser/Disparager  Storage tank B.M:  Wire part/sheet  Head Box  Press part/Felt  Press 1  Press 2  Shoe press  Smooth press  Dry part  Calendaring (Hard)  Coating (pre, Top &Middle)  IR Heater  Calendaring (Soft)
  • 11. Alihaider 12-MT-21 10  Tunnel Dryer  Rewinder  Finishing House  Cutting  Counting  Packing Products: Category Description Substance Range (g/m2)
  • 12. Alihaider 12-MT-21 11 Packaging Boards One Side Clay Coated Boards with 100% virgin Fibers 205 - 350 One Side Clay Coated Boards with recycled fiber in middle ply 230 – 400 Un-Coated Multi-layer Boards 125 – 350 Papers Machine Finished Writing Printing Papers 55 – 150 Machine Glazed Papers 22 – 70 Financial:  Sales 14,667,669  Cost of sales 12,646,230  Gross profit before taxation/other charges 2,021,439  (Loss)/profit of year 629,849 Profit and Loss in 2015  Sales 13,186,182  Cost of sales 12,308,379  Gross profit before taxation/other charges 877,803  (Loss)/profit of year 205,398
  • 14. Alihaider 12-MT-21 13 Pumps:  Pumps  Typesof Pump & itsapplication  Centrifugalpump  Positive Displacement pump  Rotary pump  Gearpumps  Screwpumps  Reciprocating pump  Piston pumps  Diaphragm pumps  VacuumPump  Pump Assembly
  • 15. Alihaider 12-MT-21 14  Pedestal: Bearingsonshaft  Stuffing Box: sleeve,glandpacking andpusher, sealing water,gas kit  Casing: Impeller, eye,vanes, wearring Coupling:  Coupling  Types& Application Rigid(ForAlignedshaft)  Flange coupling  Split muff coupling Flexible (ForNon-alignedshaft)  Gearcoupling  Gridcoupling  Jaw coupling  Universal coupling Bearings: Types& Application: 1. FrictionalBearing  BallBearing  DeepGroove bearing  Self-Aligning bearing  Thrust ballbearing
  • 16. Alihaider 12-MT-21 15  RollerBearing  CylindricalRoller bearings  SphericalRollerbearings  TaperedRoller bearing 2. Non-FrictionalBearing  BushBearing Bearing Number Define: Bearing Mounting / Dismounting:  Hot  Cold Bearing Failure Reasons:
  • 17. Alihaider 12-MT-21 16  Improper Bearing Lubrication  Contamination  Improper Mounting  Bearing Misalignment  HighTemperatures  ForeignMatter  Corrosion Power Transmission: Typesof Belts:  Flat belts  Vbelts  Ribbedbelts  Timing belts TypesofChain:  Rollerchain  Silent Chain  Timing chain Types of Gears:
  • 18. Alihaider 12-MT-21 17  Types& Application  Spur gear  Helicalgear  Rackand pinion  Externaland Internal gear  Bevelgear MCC (MotorControlCenter):
  • 19. Alihaider 12-MT-21 18 Motors: DC Motors: AC Motors:  Single Phase  Three Phase
  • 20. Alihaider 12-MT-21 19 PLC (Program Logic Control): DCS (Distribution Control System): • Instrumentation • Instrument air • Pneumatic /Hydraulic cylinder
  • 21. Alihaider 12-MT-21 20 ControlLoops (Flow, Temperature, Consistency& Level):
  • 23. Alihaider 12-MT-21 22 What is Maintenance? • Purpose of Maintenance TypesofMaintenance • BreakDown Maintenance • Preventive Maintenance • Predictive Maintenance • Pro-active Maintenance • RCM (ReliabilityCenterMaintenance) Condition monitoring: • History • Techniques • Vibrationanalyze • Thermography • Stroboscope • Stethoscope
  • 25. Alihaider 12-MT-21 24 Heat Exchanger:  Heat exchanger is a device used to transfer heat between one or more fluids  The fluids may be separated by a solid wall to prevent mixing or they may be in direct contact Uses: 1. Spaceheating
  • 26. Alihaider 12-MT-21 25 2. Refrigeration 3. Air conditioning 4. Power stations 5. Chemical plants 6. Petrochemical plants  Internal combustion engine in which a circulating fluid known as engine coolant flows through Radiatorcoils and air flows past the coils Induction Heater Working Principle:  An induction heater can be compared to a transformer using the principle of a primary coil with a large number of windings, and a secondarycoil with a few windings, on a mutual iron core. The input/output voltage ratio is equal to the ratio of the windings, while the energy remains the same  The secondary coil will provide a low voltage at high amperage  The bearing is a short circuited  Secondarycoil through which a low A.C. voltage flows at high amperage, thus generating high heat
  • 27. Alihaider 12-MT-21 26 What is Shaft coupling?  A coupling is a device used to connect two shafts together at their ends for the purpose of transmitting power  The primary purpose of couplings is to join two pieces of rotating equipment while permitting some degree of misalignment or end movement or both Shaft coupling types: 1. Jaws coupling:  A jaw coupling is a type of general purpose power transmission that also can be used in motion control applications  Consiston jaws and spiderwhich is used for more friction and power transmission purpose
  • 28. Alihaider 12-MT-21 27 2. Gear coupling:  A gear coupling is a mechanical device for transmitting torque between two shafts that are not collinear.  It consists of a flexible joint fixed to each shaft. The two joints are connected by a third shaft, called the spindle 3.Rigid coupling:  Rigid couplings come in two parts and fit together around the shafts to form a sleeve.  They offer more flexibility than sleeved models, and can be used on shafts that are fixed in place.  They generally are large enough so that screws can pass all the way through the coupling and into the second half to ensure a secure hold
  • 29. Alihaider 12-MT-21 28 Difference between Tapping & Threading? 1.Tapping:  Is drilled by hand or drill machine  It consiston three drill method  1-Bottoming -2- Plug -3- Tapper 2. Threading:  Can be done easily on the lathe machine  Die and Tap are used for threading  There are -1- Internal threading -2- External threading  Mechanical Tool File: A file is a metalworking, wood working and plastic working tool used to cut fine amounts of material from a work piece. Types of Files: Mill Files:  Mill files are the most common shape  They are rectangular in cross section and taper  Slightly in both width and thickness from tang to end.  They are all single-cut
  • 30. Alihaider 12-MT-21 29 Hand or Flat File:  Hand files are parallel in width and tapered in thickness  They are used for general work. Half Round Ring Files:  Half round ring files taper in width and thickness  Used for filing inside of rings Barrette File:
  • 31. Alihaider 12-MT-21 30  Barrette files are tapered in width and thickness  Only the flat side is cut, and the other sides are all safe  For doing flat work. Round File:  It has circular cross section  Used to file inside of holes Bearing?  Is a machine element which is used for Support the rolling elements  For easily Rotation  Overcome the friction Bearing parts: 1. Outer race 2. Inner race 3. Rolling elements 4. Cage Types of bearings: 1. Anti-frictional Bearing 2. Frictional Bearing Anti-frictional Bearing:
  • 32. Alihaider 12-MT-21 31  Ball bearing  Cylindrical bearing  Spherical bearing  Tapper bearing 1-Ball bearing:  A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation between the bearing races  The purposeof a ball bearing is to reduce rotational friction and support radial and axial loads 2-Cylinderical roller bearing:  Common roller bearings use cylinders of slightly greater length than diameter  Line contactis more than ball rollers  Can bear more axial load  If the inner and outer races are misaligned, the bearing capacity often drops quickly compared to either a ball bearing or a spherical roller bearing 3-Spherical roller bearing:
  • 33. Alihaider 12-MT-21 32  Spherical roller bearings have an outer ring with an internal spherical shape  The rollers are thicker in the middle and thinner at the ends  Spherical roller bearings can thus accommodate both static and dynamic misalignment  However, spherical rollers are difficult to produceand thus expensive, and the bearings have higher friction than an ideal cylindrical or tapered roller bearing since there will be a certain amount of sliding between rolling elements and rings 4-Tapper roller bearing:  Tapered roller bearings use conical rollers that run on conical races  Most roller bearings only take radial or axial loads, but tapered roller bearings supportboth radial and axial loads  Generally can carry higher loads than ball bearings due to greater contact area Mechanical tool Screw driver: A screw driver is a tool used to turn a screw. It is a feature that allows the screw driver to apply a torque on screw
  • 34. Alihaider 12-MT-21 33 Types of Screw Driver: External Types:  Square  Hex  Pentagon Hex:  A hex screw drive uses six-sided fastener heads  The fastener is known as a hex head cap screw.  The hex drive is better than square drive for locations where surrounding obstacles Pentagonal:  A pentagon screw drive uses five-sided fastener heads  The fastener is known as a penta screw.  They require a special five-point socket in order to be turned.  A pentagon screw drive uses five-sided fastener heads.  The fastener is known as a penta screw. They require a special five-point socketin order to be turned.
  • 35. Alihaider 12-MT-21 34 Circumference Types: Phillips:  A screwdriver having a cross-shaped tip rather than the rectangular tip of a standard screw driver  Useful on automated production lines that use powered screwdrivers. Frierson:  The Friersonscrew drive, also known as the Reedand Prince screw drive  Similar to a Phillips but the Frierson has a sharp tip and larger angle in the V shape  sharp cross, allowing for higher applied torque  Unlike the rounded, tapered Phillips head Flat:  Used to drive flat heads  It is commonly used screw drives  Designed to turn slotted screws
  • 37. Alihaider 12-MT-21 36 Filtration: Filtration is commonly the mechanical or physical operation which is used for the separation of solids from fluids (liquids or gases) by interposing a medium through which only the fluid can pass. SAMPLING: Take subject to be filter Like (Vacuum Pump Storage Tank Water) e.g. PROCEDURE: Shake well before subject to proceed further so contamination which is present in bottom mix up properly with H2O Take some quantity of water in the beaker (1000ml) Now take a filter paper which is already dried (remove moisture) in oven at 135c0 temperature and weighted (1.002g) e.g. Now wet the both sides of filter paper with water Fix the filter paper at the top of the Sucker which is called Funnel Now turn on the (vacuum pressure or negative pressure) valve After that start pouring the subject in to the funnel through filter paper until subject quantity is finished Remove the filter and take it to the oven (for 10-15 min) so it can be dry In the end note weight of filter paper [with contamination-like (1.04g)] and get your values by applying following formulas
  • 38. Alihaider 12-MT-21 37 FORMULAS: For weight: - Dry contaminated filter paper - Dry filter paper weight (1.04-1.002=Ans) e.g. For %age:- Dry contaminated filter paper / Wet contaminated filter paper *100 PRECAUTIONS: All the apparatus must be well cleaned They are accurate or work properly Shake the subject 5 to 6 times for better results Don’t fill the funnel pan full with subject pour it slowly slowly Take weight of filter papers quickly after dry in oven because of moisture contents What is Engine?  Is a device whichconverts the energy one form to another form  Is a device converts the Chemicalenergy into Mechanicalenergy What is I.C Engines & E.C Engines? I.C Engines:  Stands for INTERNALCOMBUSTION Engines  Combustion procedure occurs inside the cylinder  Examples: 1- Diesel -2 Petrol -3 Gas Engines  1860-1920  Generally using cycles 1- Otto cycle -2 Diesel cycle E.C Engines:  Stands for EXTERNALCOMBUSTION Engines  Combustion procedureoccurs outside the cylinder  Example: Steam Engine  3rd century on wards  Generally using cycles 1- Organic rankine cycle -2 Carnot cycle Classification of I.C Engine?  Reciprocating
  • 39. Alihaider 12-MT-21 38  Rotary Reciprocating: By number of strokes: 1. Two-stroke Engine 2. Four-stroke Engine 3. Six-stroke Engine (over view) By type of ignition: 1. Spark ignition 2. Compressionignition Generally used cycles: 1. Otto Cycle 2. Diesel Cycle Rotary:  Wankel Engine What is Stroke?  Piston covers a distance from TDC to BDC  Top dead center(TDC)  Bottom dead center(BDC) What is Two- Stroke Engine?  It completes a power cycle with Two strokes (up and down movements) of the piston during only one crankshaft revolution  It is also consist on Diesel& Petrol Engines Working: Intake: The fuel/air mixture is first drawn into the crankcase by the vacuum that is created during the upward stroke of the piston. The illustrated engine features a poppet intake valve which is drawn open by the vacuum produced bythe intake stroke.
  • 40. Alihaider 12-MT-21 39 Compression: During the downward stroke, the poppetvalve is forced closed by the increased crankcase pressure. The fuel mixture is then compressed in the crankcase during the remainder of the stroke. Power: At the top of the stroke, the spark plug ignites the fuel mixture. The burning fuel expands, driving the piston downward, to complete the cycle. (At the same time, another crankcase compressionstroke is happening beneath the piston.) Transfer/Exhaust: Toward the end of the stroke, the piston exposes the intake port, allowing the compressed fuel/air mixture in the crankcase to escape around the piston into the main cylinder. This expels the exhaust gasses out the exhaust port, usually located on the opposite side of the cylinder. Unfortunately, some of the fresh fuel mixture is usually expelled as well. Advantages:  High power produced  Less complicated  Ports used
  • 41. Alihaider 12-MT-21 40 Dis-advantages:  More fuel consumption  Noisy  Smoky  Expensive to repair  Oil changing Uses:  Engines  Vehicles  Chain saw etc. What is Four Stroke Engine?  It completes a power cycle with Four strokes (up and down movements) of the piston during two crankshaft revolutions Working: Intake: The fuel/air mixture is first drawn into the crankcase by the vacuum that is created during the upward stroke of the piston. Inlet valve used in it to drive the fuel/air mixture. Compression: During the upward stroke, the inlet valve is forced closed by the increased cylinder pressure. Flywheel momentum drives the piston upward compressing the fuel air mixture. The fuel mixture is then compressed in the crankcase at its high ratio. Power:
  • 42. Alihaider 12-MT-21 41 At the top of the stroke, the spark plug ignites the fuel mixture. The burning fuel expands, driving the piston downward, to complete the cycle. And a power stroke completes. Exhaust: At the bottom of the power stroke the exhaust valve is opened by the cam mechanism. The upward stroke of the piston drives the exhausted fuel out of the cylinder. 1-Intake 2-Compression 3-Power 4-Exahust Advantages:  High fuel efficiency  Less noise  Easy to mantinance Dis-advantages:  Low power  Complicated desgin  Valves used Uses:  Petrol engines  Diesel engiens  Cars,bikes,genertors etc.
  • 43. Alihaider 12-MT-21 42 What is Six Stroke Engine?  Type of I.C engine based on the four stroke engine but with the additional complexity intended to make it more efficient and reduce emission.  Two types -1 Single piston -2 Opposed piston Single Piston:  Steam or Air as working fluid  Piston goes up and down Three Times for each injection of fuel  Otto cycle & Diesel cycle Opposedpiston:  Uses second opposedpistonin each cylinder  Moves half the cyclical rate of main piston  Giving six piston movements  2nd replaces the valve mechanism What is Ignition System?  Burning of fuel & air in the combustion cylinder  Burning of matter instantly at high power Spark Ignition Engine:  Combustion take place in the cylinder by the help of spark  Or spark is required for burn the fuel/air mixture  Spark plug used generally  Less compressionratio (12 to 16)  Petrol engine Compression Ignition Engine:  Combustion take place in the cylinder by the internal compressionpressure
  • 44. Alihaider 12-MT-21 43  High compressionratio (18 to 22)  Burns the fuel/air mixture  In the winters glow plug may required  Diesel engine What is Cycle in Thermodynamics?  Perform a whole procedurecame backto its initial point is called cycle in thermodynamics it is consist on Heat accepted and rejected, Volume, Pressure & Absorption  Like ; In an engine intake to exhaust and came back again at intake completes a cycle Diesel Cycle: Process 1-2: Isentropic Compression  Piston moves from BDC to TDC  Pressure increased P1 to P2  Volume decrease V1 to V2  Entropy S2=S3 Process 2-3: Constant pressure Heat addition  Heat add constantpressure from external source  Volume increases V2 to V3  Temperature increases T2 to T3  Entropy increases S2 to S3
  • 45. Alihaider 12-MT-21 44  Qin = mCp(T3-T2)kJ Process 3-4: Isentropic Expansion  Compressed and heated air expanded  Piston moves from TDC to BDC  Pressure of air decreases P3 to P4  Temperature decreases T3 to T4  Volume increases V3 to V4  Entropy stay constant(S3=S4) Process 4-1: Constant Volume Heat Rejection  Heat rejected at constant volume (V4=V1)  Pressure decreases (P4 to P1)  Temperature decreases (T4 to T1)  Entropy decreases (S4 to S3)  Qout =mCv (T4-T1) Otto cycle: Process1-2 Adiabatic Process:
  • 46. Alihaider 12-MT-21 45  Piston moves from BDC to TDC  Compressionof air Process 2-3 Constant Volume Heat:  Volume and heat transfer while piston at TDC Process 3-4 adiabatic (isentropic):  It is expansion power stroke Process 4-1:  Complete cycle at constant volume process  Heat rejected from air while piston at BDC Wankel engine:  Rotator is used as piston Intake:  Fuel/air mixture came inside the cylinder by inlet valve Compression:  Air and fuel being compressed in there
  • 47. Alihaider 12-MT-21 46 Power:  This power produced after combustion of fuel/air mixture Exhaust:  All burn gases exit from outlet valve Uses & Advantages:  For more power  High speed  Mazda cars  Monsters trucks  Engines for power generation References: (Wikipedia, Mechman)
  • 49. Alihaider 12-MT-21 48  Assignment on PumpsErection  Assignments on Gearbox  LPG Plant Dismantling  Dispersers’ Drawings (AutoCAD)  Assignment on Coupling  Assignment on Steam trap  Line diagrams of SPP as per process  Line Diagram of B.M-7 according to process continue  Line Diagram of Fans & Blowers in B.M-7  Bearing Mounting/Dismounting
  • 50. Alihaider 12-MT-21 49  Pumps Assembly  Machining operations  Gascutting  Condition Monitoring (Stroboscope , Stethoscope & Temperature gun)  Balancing  Laser Alignment  Machine Shop  Material Consumption Reports  Filtration Sheet (Vacuum Pumps)  I would like to conclude thatby this training, we have learned a lot of knowledge which we cannot obtain in the books.
  • 51. Alihaider 12-MT-21 50  The company provides us with the real working environment.  Not only learning also the practical, we also have got the opportunities to implement the work scope with our own strength and abilities during the internship.  The staff andworkers over here are very friendly. They help me a lot during my industrial practical here.  The experience in the industry during this internship is valuable for us.  The company allow trainees to work with anemployee to help aid in the work.  The conclusion I can make is that The Century Paper andBoard Mills is the right place for students to do their industrial training.