This industrial training report summarizes Alihaider's internship at Century Paper & Board Mills from February to June 2016. It provides an overview of CPBM, including its profile, vision, mission, policies and milestones. It also describes the technical areas Alihaider learned about and worked in during the internship, such as power generation, paper production, mechanical systems including pumps, bearings, power transmission and maintenance. Alihaider expresses gratitude to those at CPBM who supported and guided him during the training period.
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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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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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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:
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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
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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)
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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
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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.
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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.