In my 6th semester vacation my college MACET allowed me for a 1 month vocational training...during that i made this project..

1. A Project Report
On
General Overview of Mechanical Engineering Department
In
Submitted in Partial Fulfillments of the Requirements
for the Award of the Degree of
B.TECH IN MECHANICAL ENGINEERING
Prepared by
Momin Mohd. Azhruddin A.
Presidency College of Engineering
Project Duration: 14/07/2011 to 11/08/2011
1

2. ACKNOWLEDGEMENT
I AM GLAD TO SAY THAT I GOT A GOLDEN
OPPORTUNITY TO GET TRAINING AT
GUJARAT ALKALIES & CHEMICALS
LIMITED (G.A.C.L) ABOUT 30 DAYS. I
GOT THE TRAINING AT MECHANICAL
DEPARTMENT OF COMPANY AS IT IS
RELATED TO MY BRANCH. I AM GRATEFUL
FOR SUPPORT & GUIDANCE OF
MR.AMIT.PATEL.
MR.M.B.OZA.
MR.JAYESH.PATEL.
MR.DILIP.PATEL.
MR.S.B.PATEL.
MR.PANKAJ BHAI.
MR.J.V.PATEL.
MR.BRIJESH.SHAH.
MR.SAAVAN.ACHARYA.
FOR THEIR ENCOURAGEMENT AND HELP
DURING OUR TRAINING PERIOD DUE TO
WHOM I PURSUED MY TRAINING SESSION.
2

3. WHAT DOES THE NEW
LOGO OF GACL SAY?
Taking into the
Considerations the aspects
of the global warming and
the need to address to the
cleaner and greener
environment,
The logo of the company Gujarat Alkalies and
Chemicals Limited, Vadodara has been
conceived to represent a responsible
corporate. Keeping the Importance of the rising
issue of the pertinent to the environment,
GACL have designed a logo that would reflect
the company's mission to keep earth green.
The “Green Attitude” of company addressing
the aspects of global warming.
The colours Blue and Yellow reflect the rising
temperatures can adversely affect some
regions with excessive rainfall while some
others with heat waves and drought.
3

4. INDEX
1 History
2 Company Profile
3 Board of Directors
4 Awards Received by G.A.C.L.
5 Corporate profile
6 Organization Structure
7 Products of G.A.C.L.
8 Milestone of G.A.C.L.
9 Manpower Strength
10Policies
11Overview of CLM Plant
12Pump
13Compressor
4

5. 14Vales
15Blowers
16Boilers
17Cooling towers
5

6. HISTORY OF GACL
Gujarat Alkalies and Chemicals Limited (GACL)
was incorporated on 29th March, 1973 in the
State of Gujarat by Gujarat Industrial Investment
Corporation Limited (GIIC), a wholly owned
company of Govt. of Gujarat, as a Core Promoter.
GACL has two units located at Vadodara and
Dahej, both in the State of Gujarat. It has
integrated manufacturing facilities for Caustic
Soda, Chlorine, Hydrogen Gas, Hydrochloric
Acid, Chloromethane, Hydrogen Peroxide,
Phosphoric Acid, Potassium Hydroxide,
Potassium Carbonate, Sodium Cyanide,
Sodium Ferro cyanide. The Dahej unit also has
90 MW Captive Power Plant (CPP) for regular
and economical power supply.
The Company commenced its operations in
1976 with 37,425 Metric Tons Per Annum
(MTPA) Caustic Soda Plant based on the then,
state-of-the-art Mercury Cell process at its
Plant which is situated 16 km North of
Vadodara near Village Ranoli on the main
Railway track route between Ahmadabad and
Mumbai.
Right from the inception, GACL has been
following the strategy of continuous capacity
expansion in core areas. The first stage
expansion of the Caustic Soda Plant raising the
capacity to 70,425 MTPA was undertaken in
October, 1981 followed by a diversification
program to produce 2000 MTPA of Sodium
Cyanide in December, 1982.
6

7. In 1984, the second stage expansion to
increase the capacity of Caustic Soda Plant to
103,425 MTPA was undertaken.
Simultaneously, the Company undertook the
diversification project for manufacture of
10,560 MTPA of Chloromethane using
Chlorine, a co-product of the Company and in
1991, the capacity of Chloromethane
production was doubled.
As power is the major input for production of
Caustic Soda and constitutes about 65% - 70%
of the cost of production, the Company along
with other Corporations like, M/s. GSFC,
Petrochemicals Co-operative Ltd. and Gujarat
Electricity Board promoted a gas based power
unit in Vadodara under the name of Gujarat
Industrial Power Company Ltd. (GIPCL) during
the year 1985. As a promoter of GIPCL, the
Company gets low cost power, as the plant is
gas based and is depreciated.
Since production of Caustic Soda is highly
power intensive, in order to reduce power cost
and to eliminate mercury pollution, the
Company during the year 1989 converted one
of its Cell Houses producing Caustic Soda
from Mercury Cell Technology to environment
friendly Membrane Cell Technology, thereby
eliminating the use of mercury. The Capacity
of Caustic Soda was also increased to 132000
MTA.
The conversion of second Mercury Cell to
Membrane Cell was carried out during March,
1994, thereby eliminating the total use of
mercury from the Complex for production of
Caustic Soda and increasing the capacity of
7

8. plant along with this conversion to 170000
MTA including Potassium Hydroxide facility.
As part of this Membrane Cell Conversion
Project, a new facility for manufacture of
16500 MTA of Potassium Hydroxide Lye based
on Membrane Cell was also set up. The
Company has further set up facility for
converting part of this Caustic Potash Lye into
Potassium Carbonate with a capacity of 13200
MTA. In order to add further value to its
products, the company had set up
manufacturing facility for production of
11000 MTA Hydrogen Peroxide (100%) at
Vadodara Complex during the year 1996 to
utilize Hydrogen gas, which is a co-product
from Caustic Soda Process.
In 1995, as a part of diversification program
and to meet the growing demand of its
products in the State of Gujarat and nearby
areas, the Company had set up a plant for
manufacture of Technical Grade Phosphoric
Acid with capacity of 26400 MTA (85%
Phosphoric Acid) at a new location at Dahej,
District Bharuch. The Company also set up
Membrane Cell based grass root Caustic-
Chlorine Unit with a capacity of 100000 MTA
at Dahej. Along with this, a captive 90 MW co-
generation Power Plant was set up so as to
ensure uninterrupted and low cost power for
its captive operations.
8

9. COMPANY PROFILE
 Name of the Company
GUJARAT ALKALIES AND CHEMICALS LIMITED (GACL)
 Registered Office / Vadodara Complex
P.O. Petrochemicals-391 346
Dist. Vadodara, Gujarat, India.
Phone-+91-265-2232681-2
Fax-+91-265-2232130
 Dahej Complex
P.O. Dahej-392 130
Taluka- Vagra, Dist. Bharuch, Gujarat, India.
Phone-+91-2641-256315-6-7
Fax-+91-2641-256220
 URL
www.gacl.com
www.gujaratalkalies.com
 Size of the Organization
Large Organization
 Solicitors
Messer’s Amarchand & Mangaldas
& Suresh A. Shroff & Co. Mumbai.
 Cost Auditors
Messer’s Diwanji & Associate
Cost Accountants Vadodara.
9

10. BOARDS OF DIRECTORS:
Shri. A.K.JOTI (I.A.S)…………… Chairman
Shri. G.C.Murmu (I.A.S)
Shri. M.M.Srivastava (I.A.S)
Shri. D J Pandian (I.A.S)
Shri. G.M.Yadwadkar
Dr. Sukh Dev
Shri. J N Godbole
Shri. Guruprasad Mohapatra
(I.A.S.)……………. Managing Director
10

11. AWARDS & RECOGNITION
The Company is a proud recipient of the
following recognitions and awards:
Sr. Name of the Award Purpose of the Award Name of the Date of receiving
No. Organization the Award
Year 2009-10
1) Excellent achiever Award. For valuable contribution in Gujarat Chemicals February, 2010
chemical industry Association,
Ahmadabad
2) Award for Excellence – 2009. Certificate of Merit Federation of Gujarat May, 2010.
in the field of Export Promotion Industries, Vadodara
3) NSCI safety Award -2009. Appreciation letter by National National Safety Council October, 2010.
Safety Council established by Ministry
of Labour &
Rehabilitation,
Government of India
4) Excellence Certificate for ‘Securing Participation Position in Baroda Productivity For the year 2009-
Good House Keeping Contest Council, Vadodara 10.
2009-10’.
5) CHEMEXCIL Award For Outstanding Export Export Promotion For the year 2008-
Performance Council, Government 09 & 2009-10.
of India
Year 2008
1) Amity Corporate Excellence For one of the best and the most Amity International 20th February, 2008
Award, 2008 admired business organizations Business School
for its unparallel performance.
Year 2007
rd
1) 3 National Award for Excellence For efficient management in cost Institute of Cost & 2nd July, 2007.
in Cost Management - 2006 for the works of the manufacturing unit. Works Accountants of
manufacturing unit in the Public India (ICWAI).
sector.
2) National Energy Conservation For consistent performance on Bureau of Energy 14 December 2007
Award - 2007 : Second Prize in the energy conservation. Efficiency (BEE),Min.
Chlor-Alkali Sector of Power, Govt. of
India
11

12. Year 2006
2.) AIOE Industrial Relations Award Corporate initiative in the field of All India Organization 05 January 2007
2005-2006 industrial relations, social security of Employers
and promoting Bi-partism
3.) Safety Innovation Award -2006 In the field of Safety Excellence Institute of Engineers, 06 September 2006
New Delhi
4.) Indian Society for Training & For Innovative Training Practices: Indian Society for 01 July 2006
Development (ISTD) Certificate of 2005-06 National Level Training &
merit 2005-06 Development (ISTD),
New Delhi
5.) SCOPE Meritorious Award 2004-05 In the field of Good Corporate Standing Conference 26 June 2006
Governance of Public Enterprises
(SCOPE), Delhi
6.) TERI's Certificate of Appreciation For case study of Recovery of TERI - The Energy & 26 June 2006
for Environmental Excellence Calcium Chloride project at Dahej Resources Institute,
award – 2005 which uses the waste effluent to New Delhi
make useful product reducing
pollution in sea.
12
7.) Greentech Safety Silver Award Safety Excellence at Dahej Greentech. 08 April 2006
2006 Complex Foundation, New Delhi

13. 8.) Greentech Safety Gold Award 2006 Safety Excellence at Vadodara Greentech. 08 April 2006
Complex Foundation, New Delhi
9.) FGI (Federation of Gujarat) award For Environment Preservation & FGI (Federation of 03 April 2006
for Excellence in Environment – Pollution Control at Dahej Gujarat), Vadodara
2005 (Dahej) Complex
10.) IMC Ramakrishna Bajaj National For Quality Management Systems Indian Merchants' 06 March 2006
Quality Certificate of Merit 2005 adopted at GACL (as per quality Chamber, Mumbai
Award in Manufacturing Category criteria of management systems of
at National level Malcolm Bald ridge, (USA)
11.) Appreciation Prize for the case For "Economics of Quality" for the Quality Council of 03 March 2006
study on "Economics of Quality" systems at GACL India, Ministry of
Commerce & Industry,
Govt. of India
12.) Jamnalal Bajaj Uchit Vyavahar For Fair & Ethical Business Council for Fair 24 February 2006
Puraskar 2005 Practices Business Practices
(CFBP), Mumbai
13.) Recognition by ICSI (Institute of For National Excellence in Institute of Company 13 January 2006
Company Secretaries of India) compliance of law, ethics and best Secretaries of India
considering GACL in the list of Top management practices in the field (ICSI), New Delhi
25 Companies for the year 2005 of Corporate Governance
Year 2005
14.) First Prize Winner In Category - C House Keeping Baroda Productivity 28 December 2005
for Chemical Process Industries for Council, Vadodara
" House Keeping "
15.) Certificates of Appreciation & Safety Performance Gujarat Safety Council 16 December 2005
Honor for Safety Performance & Factory
(Vadodara) & Certificate of Honor Inspectorate, Govt. of
(Dahej) Gujarat
16.) National Energy Conservation Energy Conservation at Vadodara Bureau of Energy 14 December 2005
Award 2005: National Level (Chlor- Complex Efficiency (BEE),Min. by His Excellency
Alkali Sector) 1st prize (Vadodara of Power, Govt. of the President of
Complex) & Merit Certificate India India.
(Dahej Complex)
17.) IMEA-2005 Award India Excellence in Housekeeping & Frost & Sullivan, 09 December 2005
Manufacturing Excellence Award Effective Deployment of QMS Mumbai,(USA based
for Housekeeping & Effective organization)
Deployment of QMS
18.) Green Tech Environment Environment Excellence at Greentech Foundation, 22 October 2005
13
Excellence Award - 2004-05 (Silver) Vadodara Complex New Delhi
19.) Green Tech Environment Environment Excellence at Dahej Greentech Foundation, 22 October 2005

14. Excellence Award - 2004-05 (Gold) Complex New Delhi
20.) AMA-Metro chem. Outstanding Outstanding Manager of the Year AMA (Ahmadabad 17 July 2005
Manager of the Year Award 2005 Management)
(Declared for MD, GACL) Association)- Metro
chem., Ahmadabad
21.) Greentech Safety Excellence Safety Excellence at Dahej Greentech Foundation, 12 May 2005
(Silver) Complex New Delhi
22.) Greentech Safety Excellence Safety Excellence at Vadodara Greentech Foundation, 12 May 2005
(Gold) Complex New Delhi
23.) Merit Award for ICWAI (Vadodara) National Merit Award for Institute of Cost & 12 March 2005
Excellence in Cost Management - Works Accountants of
2004 India (ICWAI)
24.) Certificate of Appreciation for Safety Performance at Vadodara Gujarat Safety Council 18 January 2005
Safety Performance Complex & Factory
Inspectorate, Govt. of
Gujarat
25.) Certificate of Honor for Safety Safety Performance at Dahej Gujarat Safety Council 18 January 2005
Performance Complex & Factory
Inspectorate, Govt. of
Gujarat
Year 2004
26.) National Energy Conservation Energy Conservation at Dahej Bureau of Energy 14 December 2004
Award 2004 1st prize (Chlor-Alkali Complex Efficiency (BEE),Min. awarded by
Sector) of Power, Govt. of Hon'ble Prime
India Minister of India
14

15. 27.) Greentech Environment Excellence Environment Excellence at Greentech Foundation, 04 November 2004
(Silver) Vadodara Complex New Delhi
28.) Greentech Environment Excellence Environment Excellence at Dahej Greentech Foundation, 04 November 2004
(Gold) Complex New Delhi
29.) Greentech Safety Excellence Safety Excellence at Dahej Greentech Foundation, 21 June 2004
Award (Silver) Complex New Delhi
30.) Dr. H.C. Srivastava Memorial Developing Eco-Friendly cold ATIRA: Ahmadabad 26 February 2004 at
Award 2003 bleaching process using Hydrogen National
Peroxide of GACL for Hand Conference of
Processing Sector of Textile Textile Research
industry Association,
Mumbai
15

16. CORPORATE PROFILE
GACL is a forward-looking company, set up in the year 1973.
30 years is a long time. Long enough to test the character of
any organization. Be it recession, inflation, increased
competition or changing governments, we've lived it all. And
for sure, all the turbulences have made GACL a stronger and a
progressive company. Our stern resolve to manufacture
quality chemicals and trek customer satisfaction to a new
height has yielded unbelievable results.
From an initial capacity of 37,425 TPA Caustic Soda, GACL
have grown to be the largest producer in India, with a
capacity of 3, 58,760 TPA. Spread over 2 complexes at
Vadodara and Dahej.
Knowing that the time ahead may prop-up newer hurdles,
GACL has already started to diversify and expand its existing
infrastructure to consolidate its supremacy in Chlor-Alkali
and other integrated downstream products.
World Class Technology:
Technology moulds generations. GACL’s endeavor to
continually upgrade technology has allowed GACL to
optimize resources, thus bringing down the cost of
production and increasing revenues. Acquired through the
best and prestigious collaborations means that they meet
international specifications for our products. Besides,
GACL’s manufacturing plants are eco-friendly, which ensure
that the environment is well looked after.
The location of both the plants 'Vadodara' and 'Dahej' has
16

17. dual advantage of proximity to the raw material suppliers
and the end users.
While the capacity utilization is about 70% in the Caustic
Soda Industry, GACL's plants are working at almost 100%
capacity.... thereby utilizing the assets to the fullest extent.
Self-Reliance:
 Various factors that influence the success of any
corporation, the self-sufficiency ranks the
foremost. We at GACL understand this all too well.
Power, being a major input to the electrolytic
Caustic Soda process, we promoted a joint captive
power plant, Gujarat Industries Power Company
Limited to meet our energy requirements for
Vadodara Complex. Our complex at Dahej is also
integrated with a captive co-generation plant of
capacity of 90 MW.
 Cost effective natural gas was substituted as fuel in
place of Naphtha for Captive Power Plant. The plant
load factor has increased and surplus power is
supplied to State grid. This has helped achieve
economies of operations.
Green all the way:
Nature bestows human race with umpteen benefits.
Clean air, Lush green trees, GACL's commitment
towards the environment is undying. Safe and
17

18. unadulterated nature is high on our list of priorities;
we are an organization with Green Attitude.
A dedicated senior executive heads a Safety and
Environment Department to maintain high standards of
safety and a harmonious relationship between
environment and technology. The company has planted
more than 1, 00,000 plants and it keeps maintaining the
same. With tree plantation being a regular feature, it
plants 1000 sapling every year.
As a matter of strategy, the company has placed sensors
at strategic locations in and around the complex to
monitor ambient air quality.
For disposal of solid waste, GACL has secured dedicated
landfill site conforming to the hazardous Waste
Management Act. Being a member of Effluent Channel
Project, it releases its liquid effluent in this channel and
adheres to the necessary parameters of the Gujarat
Pollution Control Board before discharging it into the
channel.
People: Our Valued Assets:
World-class technology and self-reliance are baseless
without brains that work ardently to produce high
quality chemicals. People are our real assets, whom we
nurture and harness to get the very best out of them.
Our conviction is:
People make the organization.
A sense of belonging is a must for dedication and
loyalty.
Employees give their best when the company cares for
18

19. them.
Excellent labour relationship helped the company in
achieving very high manpower production turnover per
employee per annum. This is also a result of a thin and
lean workforce, which is lead by the professional
management.
Spreading Our Wings:
The unshakeable desire to deliver quality products to our
customers means that our products are well accepted,
both in India and the world over. Domestic customers
are assured of prompt delivery of quality products at
their doorsteps through our well-established network of
dealers and consignment stockiest. Overseas customers
are serviced directly or through agents.
Caustic-Chlorine being its prime product, the company
has diversified into value added products like Sodium
Cyanide, Chloromethane, Hydrogen Peroxide, Potassium
Carbonate, Phosphoric Acid, etc. These value added
products provide dual benefit to the organization by
hedging against cyclical fluctuations in the Chlor-Alkali
Industry. GACL sells 26 products today, maintaining its
leadership in Caustic-Chlorine industry with 18% market
share and has emerged as a major player in the segment
of value added products.
19

20. VISION, MISSION & GROWTH
STRATEGY
VISION
To continue to be identified & recognized as dynamic, modem
& ecofriendly chemicals company with enduring ethics &
values.
MISSION
To manage our business responsibility & sensitivity in
order to address the needs of our customers & stakeholders.
To strive for continuous improvement performance,
measuring results precisely & ensuring GACL's growth &
profitability through innovations.
To demand from ourselves & others the highest ethical
standards and to ensure products & processes to be of the
highest quality.
GROWTH STRATEGY
 To remain the largest producer.
 To maintain highest quality & be the first choice of
customer.
 To have downstream value added products & product mix
for better margins.
 To ultimate good to remain leader in the Chlor alkalis.
20

21. DEPARTMENTS AT GACL
1) Technical Department:
Development Department
Production Department
Engineering Department
Quality Control Department
Safety & Environmental Department
2) Non- Technical Department:
Marketing Department
Purchase Department
Export Department
Dispatch Department
Finance Department
HR Department
Personnel Department
Security Department
Administration Department
Time Keeping Department
Secretary Department
MS Department (Management System)
21

22. ORGANISATION STRUCTURE
MD
Mm
Sr. ED GM CS&GM GM CFO Sr. ED
(Tech.) (HR&A) (Legal) (MM)&CIO (Commercial)
ED ED ED DGM CM
(MM) (MS) CGM &CMO
(Dahej) (Ranoli) (CPP)
CM GM GM CM GM
Addnl. GM
(Engg. (Operati (Engg. (Security & (Operations)
(Mktg.)
Service) ons) Service) Vigilance)
22

23. PRODUCTS OF GACL
As per the classification and the differentiation of the
products, the products are classified in to SEVEN (7)
different Groups.
The Groups are Listed and described as below.
1) Caustic Soda Group
Caustic Soda Flakes (NaOH)
Caustic Soda Lye
Caustic Soda Pills
Sodium hypo chloride (NaOCl)
Liquid Chlorine (Cl2)
Compressed hydrogen Gas (H2)
Hydrochloric Acid (HCl)
2) Caustic Potash Group
Caustic Potash Flakes (KOH)
Caustic Potash Lye
Potassium Carbonate
3) Chloromethane Group
Methyl Chloride (CH3Cl)
Methylene Chloride (CH2Cl2)
Carbon Tetrachloride (CCl3)
Chloroform (CHCl3)
23

24. 4) Sodium Group
Sodium Cyanide (NaCN)
Sodium Ferro cyanide [Na4Fe(CN)6 :10H2O]
5) Phosphoric Acid Group
Phosphoric Acid (H3PO4)
Calcium Chloride Flakes (CaCl2)
Calcium Chloride Powder
6) Hydrogen Peroxide Group
Hydrogen Peroxide (H2O2)
Bleach win
7) Other products
Dilute Sulphuric Acid (H2SO4)
Scale win (Water treatment chemical)
Aluminum Chloride Anhydrous (AlCl3)
Poly Aluminum Chloride (The New Product)
24

25. MILESTONES OF GACL
Government of Gujarat promoted GACL in 1973. It's first
Caustic Soda, Liquid Chlorine and Hydrochloric
Acid Plants went on stream in 1976.
Year Achievements
1982 Commissioned Sodium Cyanide plant with a capacity of 2000 TPA.
GACL went in for a diversification project to manufacture
1986
Chloromethane.
1987 Commissioned Caustic Soda Flaking unit with a capacity of 26400 TPA
First revamp to energy efficient and environment friendly Membrane Cell
1989
technology.
Commissioned Sodium Ferro cyanide plant (100 TPA) based on in-house
1992
Research & Development.
Converted balance manufacturing facilities to Membrane Cell &
expanded its Caustic Soda capacity to 153500 TPA.
Expanded caustic flaking unit to 53000 TPA.
1994
Commissioned caustic potash plant with a capacity of 16500 TPA.
First certification IS/ISO 9002:1994.
1995
Phosphoric Acid Plant started production at Dahej.
Hydrogen Peroxide plant commissioned.
1996
Commissioning of 300 TPD of Caustic Soda & 90 MW power plants at
1998
Dahej.
Commissioning of Caustic Potash/Flakes, Vadodara.
2000
Increase in H2O2 Capacity to 12540 MTA.
25
2001

26. Up gradation of ISO Certificate from 9002:1994 to 9001:2000.
2003
ISO 14001:1996 Certificate for Vadodara Complex and Dahej Complex.
2004 Commissioning of Calcium Chloride plant at Dahej.
2005 ISO 18001:2000 Certificate for Vadodara Complex and Dahej Complex.
2006 Commissioning of Poly Aluminum Chloride Plant at Dahej Complex
Commissioning of Poly Aluminum Chloride at Vadodra with same
capacity.
Commissioning of Hydrogen Peroxide at Dahej with capacity of 12540
2007
TPA.
Commissioning of Anhydrous Aluminum chloride with capacity of 16500
TPA.
Commissioning of wind power project at Moti Sindhodi, Kutch with 23.75
2008
MW (1.25MW*19Nos.) rs 122.02 crores.
Commissioning of second phase wind mill project of 39 MW at
Gandhidham started on 12.01.2009. In the month of February 2009 all
WTG have been commissioned.
RA-10 commissioned in the month of October in MC-2 2009
2009
Dr. M filter commissioned on 20.11.2009.
G-5B electrolysers(E-1,2,8 and partly 7) are commissioned on 15.12.2009
One more electrolysers commissioned for 50 TPD production of CSL
stated at Dahej CSL plant.
2010 21 MW wind mill project commissioned on 22.03.2010.
25 TPD CaCL2 plant at sodium Cyanide complex of Baroda has been
2011
commissioned on 20.01.2011.
25 TPD stable Bleaching powder plant at Dahej is commissioned on 2nd
2011
march 2011.
42 TPD Hydrogen Peroxide plant (phase-2) is commissioned.
2011
At Dahej on 27.06.2011
26

27. MANPOWER STRENGTH
Manpower is the real strength of any organization & that is
so in GACL also. The total manpower strength at GACL
includes both management & Non- Management Category.
As on 31/5/2011 details Ranoli Dahej Total
Management 424 218 831
Non Management 366 465 831
Trainee Management 7 2 9
Trainee Non Management 21 10 31
Contractual Management 6 2 8
Contractual Non Management 44 34 78
Apprentice Management 10 11 21
Apprentice Non Management 56 41 97
Total 934 783 1717
Thus, the total manpower strength at GACL has
1717 employees
27

28. POLICIES AT GACL
28

29. 29

30. 30

31. 31

32. 32

33. 33

34. 34

35. OVERVIEW OF CLM PLANT
SECTION 100
(THERMAL CHLORINATION)
Thermal chlorination of methane is carried out in four
cylindrical reactors simultaneously.
Gases like methane, chlorine, nitrogen, recycle gases are
passed in these cylinders.
There are basic four reactions involved in production of
chloromethane by thermal chlorination of methane gas.
CH4+CL2 = CH3CL+HCL
CH3CL+CL2=CH2CL2+HCL
CH2CL2+CL2=CHCL3+HCL
CHCL3+CL2=CCL4+HCL
35

36. SECTION 300-400
(HCL ABSORPTION AND DEHUMIDIFICATION)
The product mixture coming from section 100 contains HCL along
with product which must be removed as it is highly corrosive in nature, so
if there is HCL along with product it would be difficult to handle the
process fluid. This product mixture enters in to six columns & where in
HCL is removed by the process of absorption, there after another
processes are carried out in these columns like de-acidification,
neutralization, dehumidification & drying is carried out. Dehumidification &
Drying columns are provided to get moisture level in the product gas
mixture below 50 ppm.
SECTION 500
(COMPRESSION AND LIQUIFICATION)
The process gas from last column is taken to section 500 where
the gas is being compressed & cooled so that the product will liquefy
under these conditions.
36

37. SECTION 800
(DISTILLATION)
In this section the liquefied & pressurized mixture is taken for
distillation to get pure product. There are total ten columns
provided to separate four products from impurities. First two are
provided for Cl separation, then two for C2, three for C3 & last
three for C4 separation from low boilers & other impurities.
Cl-Methyl Chloride
C2 - Methylene Chloride
C3 - Chloroform
C4 - Carbon Tetra Chloride
SECTION 200
(PHOTOCHLORINATION)
This section is provided to raise the higher derivatives of
methane as a product keeping market demand in mind, feed for
photo chlorination can be adjusted in such a way that either
production of C29 C3 & C4 can be optimized as per market
requirement.
37

38. SECTION 700
(CRUDE PRODUCTION HANDLING)
Crude product from almost each section is dumped in
TK-701 tank plus HCL formed in liquid phase is also dumped in
this tank. Product after purification in this section is taken to 800
sections for distillation.
SECTION 900
(PRODUCT HANDLING AND STORAGE)
Product handling & storage is the last section of CLM
plant. As all four products have their properties differing from
each other so their storage conditions are also different.
38

39. CLASSIFICATION OF PUMPS
Pumps are classified o n the basis of the
principle by which the energy is added to the fluid
and their design feature.
PUMPS
(1) Dynamic Pressure (2) Positive Displacement
Pumps Pumps
a) Centrifugal pump (a) Reciprocating pump
b) Turbine pump (b) Rotary pump
c) Propeller pump
CENTRIFUGAL PUMP
(PRINCIPLE OF OPERATION)
The centrifugal pump works on the principle of
forced vortex flow which means the certain mass of
liquid rotated by an external torque. The rise in
pressure head of the rotating liquid takes place.
39

40. MAIN COMPONENTS OF C.P.
The main components of C.P. are shown in figure,
The main components are....
(1) Casing
(2) Impeller
(3) Wear-Ring
(4) Shaft
(5) Shaft-sleeve
(6) Bearing
(7) Bearing Frame
(8) Breather
(9) Cir-Clip
(10) Seals etc....
40

41. Wear Rings Pump Case Shaft Sealing Shaft Bearing Bracket
Front and back renewable The pump case is of rigid design SCP pumps can be fitted with The heavy duty console with
wear rings arc furnished in with a generous wall thickness, most scaling arrangements; incorporated assure silent and
order to achieve the best giving good protection against - Soft packing reliable operation
pump performance and ease erosion and corrosion
the maintenance
Front and back renewable fully Ample dimensioned single and The shaft is protected by a
endorsed. Single-piece casting double row ball bearings improve replaceable shaft sleeve
gives reliability, long trouble- the stiffness and infinite shaft stainless sled
free operation and high deflection
efficiency
For high temperature applications (90-160
STCP C) an arrangement foot hot water is pro-
vided. This modification includes a cooling
chamber for introduction of the cooling
medium
■ Vertical arrangement is mainly used
VSCP in systems for water-supply, miming, civil
engineering, waste water applications,
irrigation systems etc.
CENTRIFUGAL PUMP PARTS
41

42. (1)CASING
The basic function of casing is to provide support to the
components. The casing has to contain the impeller attached to
the shaft and allow them to rotate smoothly inside thus activating
the process. The casing is usually made of C.I. because it has
excellent cast ability coupled with machine ability and low cost.
The following three types of casing are used for general
purpose:-
Volute casing
Vortex casing,
Casing with guide blades.
(2)IMPELLER
The impeller is rotating device in the pump that draws
and delivers out the fluid in a specified direction under pressure.
There are two types of impellers.
Linear Axial Impeller
Francis Impeller
42

43. (3)WEAR RINGS
Wear rings are attachment given to soft areas to prevent
erosion and wear. These are made of hard and wear resistant
materials. Wear rings provide an easy and economically
replaceable leakage proof Joint between impeller and casing.
(4)SHAFT
The basic function of shaft is to transmit the torque
or power.
(5)THE SHAFT SLEEVE
The shaft sleeve covers the shaft tightly and protects it
from corrosion erosion and wear, it must have a close tolerance
in order to have a close running fit. It should have the same
thermal expansion similar to the shaft material have. A sleeve
material used in G.A.C.L. is S
43

44. SFA LS AND STUFFING B
The seal blocks the fluid that is being circulated through
casing from escaping to rear Part of the pump through the
contact between shaft and casing. There are two types of seal:-
Mechanical Type Seal.
Packing Type Seal.
BEARINGS
The main function of the bearing is to support the
rotating assembly by taking load and guide the shaft in order to
avoid the vibrations. The most common bearing is ball bearing.
Bearings are usually made of A1SI -52100 STEEL.
BEARING FRAME
The bearing frame is usually made of steel. For absolute
corrosion resistance and good appearance stainless steel
housing or frame can be used.
44

45. CIR CLIP & STAR LOCK WASHER
Cir clip & Star lock Washer is provided for locking the Bearing.
PREATHER
To provide inlet & outlet of air for bearing frame.
VARIOUS TERMS DEFINITIONS USED
FOR C.P.
SUCTION HEAD
It is the vertical height of the centerline of the c.p. above the
liquid surface in the tank of pump from which the liquid is to be
lifted.
45

46. The vertical distance between the centre line of the pump and
the liquid surface of the tank to which liquid is to be delivered is
known is delivery head.
STATIC HEAD
It is the sum of suction head and delivery head
MANOMATRIC HEAD
The manomatric head is defined against which a C.P. has to
work.
PRIMING
Priming of a c.p. is defined as the operation in which the
suction pipe casing of the pump and a portion of delivery pipe
46

47. up to delivery valve is completely filled up from out-side source
with the liquid to be raised by the pump before starting a pump.
By this way the air from those parts of pump will be removed
and these parts are filled with the liquid to be pumped.
CAVITATION
Cavitation is defined as the phenomena of formation of vapour
bubbles of flowing liquid in a region where the pressure of liquid
falls below its vapour pressure and sudden collapsing of these
vapour bubbles in a region of higher pressure.
The metallic surface above which these vapour bubbles
collapse is subjected to the high pressure which cause pitting
thus cavities is formed on the metallic surface and also
considerable noise and vibration is produced due to the
cavitation, the efficiency of C.P. is decreased.
47

48. PREAUTIONS FOR
CAVITATION
The following precautions should be taken against cavitation….
The pressure of the flowing liquid in any part of the
hydraulic system should not allow falling below its vapour
pressure.
The special materials or coatings such as
Aluminum-bronze and stainless steel which are cavitation
resistant should be used
CAVITATION IN C.P.
In C.P. the cavitation may occur at the inlet of the Impeller of
the Pump or at the suction of the Pump where the pressure is
considerably reduced.
The cavitation in a pump can be noted by a sudden drop of
efficiency and head.
48

49. 49

50. NET POSITIVE SUCTION HEAD
The term NPSH is very commonly used in the pump
Industry. Actually the minimum suction conditions are more
frequently specified in terms of NPSH.
NPSH means the total head required to make the liquid
flow through the suction pipe to the pump impeller.
USES OF THIS TYPE OF PUMPS
IN GACL
For handling alkaline fluids,
For anti corrosive application,
For handling HCL
RECIPROCATING PUMP
In reciprocating pump liquid is drawn through an
Inlet check valve into the cylinder by the withdrawal
of piston & forced out of discharge check valve on
the return stroke. They are also called piston pumps,
50

51. plunger pumps & diaphragm pump.
MAIN PARTS
Piston
Piston rod
Bearing frame
Mechanical seal
Grand inlet
Coupling
Outlet valve
Connecting rod
Crankshaft
51

52. -
Most of piston pumps are double acting. Two or more cylinders are
used in parallel with common Suction & discharge headers adjusted
to minimize the fluctuation in discharge rate.
It is independent of the speed with normal operating limits &
decreases slightly with increase in discharge pressure because of
added friction & leakage.
52

53. USES OF THIS TYPE OF PUMP
For brine separation,
For chemical dosing in boiler feed pump.
COMPRESSORS
RECIPROCATING COMPRESSOR
CENTRIFUGAL COMPRESSOR
SCREW COMPRESSOR
RECIPROCATING COMPRESSOR
There are 14 reciprocating compressors
of different kinds in C.L.M plant of G.A.C.L.
There are 8 RG compressors, 4 Instrument air
compressors and 2 Nitrogen compressors we
find in C.L.M plant.
53

54. Main parts used in reciprocating
compressor are piston, piston rod, cross head,
crank shaft, connecting rod, cylinders, flywheel,
Intercooler, after cooler, pulley, motor, suction
valve, discharge valve, etc.
In reciprocating air compressor, air is
compressed by the movement of the piston in the
cylinder. Piston is reciprocated by flywheel and crank
shaft. The rotary motion of flywheel and crank shaft
is transferred to reciprocating motion of piston by
crosshead. Piston rod moves the piston in the
cylinder and compresses the air in the cylinder.
54

55. In G.A.CL the reciprocating compressors are two
stage compressors. In two stage compressors two
cylinders are used. L.P. cylinders are larger in
volume than H.P. Cylinders. In two stage
compressors the gases first compressed into L.P.
Cylinder and after that it is cooled in intercooler.
Intercooler cools the gases to the temperature
which is equivalent to the temperature desired at the
suction side of the H.P. cylinder. If the gases are not
cooled than in the second stage the temperature of
the gases will so high that it can damage the
compressor. After the gases cooled in intercooler, it
is entered in H.P. cylinder and it compressed to
desired pressure.
Reciprocating Compressors are also of two types:
Lubricating and Non-lubricating compressors.
In non-lubricating compressors the parts are
lubricated accept piston and piston ring. In non-
lubricating compressor the Non lubricating parts are
made of Carbon Filled Teflon (CFT). Non
Lubricating parts are used to avoid contamination of
lubricating oil with Process Gas.
55

56. V-TYPE COMPRESSOR
V-type compressor is special type of reciprocating
compressor. Its L.P. and H.P. cylinders which form
V shape. In v- type compressor the compression of
nature gas take place, it is a two stage double
acting and non lubricating compressor. In v type
compressor at the suction side of L.P. cylinder
natural gas enters and compressed and its
temperature and pressure increases, after that the
compressed natural gas enters intercooler and its
temperature is reduced.
Then low temperature compressed natural gas
enters into the H.P. cylinder and is compressed to
desired pressure. Then highly compressed natural
gas enters into the after cooler and cools down and
fed to the process.
56

57. CENTRIFUGAL COMPRESSOR
In centrifugal compressor, centrifugal force is
exerted over the fluid. Here energy is transferred by
dynamic means from the rotating impeller.
When the impeller rotates at high speed, suction is
created at the impeller eye and air is drawn from the
accelerating nozzle. Due to this the velocity of air is
increased and the pressure, temperature is
decreased.
Housing
Air out Air
Thrown at
rim of
impeller
Air enters
Impeller
in a center
CENTRIFUGAL COMPRESSOR
57

58. The diffuser is provided with impeller.
Diffuser converts velocity of air into pressure and
the air is compressed, Impeller is used to increase
the energy of the fluid by whirling it outwards and
increasing the angular momentum of the fluid.
In G.A.C.L. these compressors are used at
Hydrogen Peroxide unit. In H202 plant, two stage
Centrifugal compressors are used to compress the
air.
In this inter cooling is done by the cooling water
which surrounds the tubes through which
compressed air is passed.
SCREW COMPRESSOR
Screw compressor is positive displacement type
compressor. In screw compressor the compression
is accomplished by the enmeshing two matins
helical grooved rotors which are housed in a
cylinder.
58

59. FIG: SCREW COMPRESSOR
The male rotor is usually a driving
element with series of grooves along the length of
the rotor. Male rotor grooves mesh with similarly
formed helical flutes on the female rotor which is
usually driven element.
The entrapped gas is compressed as it
passes through the two rotors. Here a narrowing
59

60. Passage is formed as the gas will pass through the
gap of two rotors. The gas is passed due to rotating
motion of the two rotors. The gases will be passed
due to rotating motion of rotors and will be
discharged at outlet. Gas will come from the bottom
of the screw compressor and it will get compressed
between the two rotors.
 VALVES
At G.A.C.L various plants contain thousands of
valves of different size and shapes with variety of
designs. Basically all valves serve a common
purpose to slow down or to stop the flow of the fluid.
Other types of valves are designed to throttle or to
reduce the pressure and the flow rate of the fluid.
They will permit flow In One direction only under
certain condition of temperature and pressure. This
is done by placing an obstruction that can be moved
along inside with little or no leakage of the fluid.
60

61. Various types of valves used in G.A.C.L are....
Sate valve
Ball valve
Butterfly valve
Globe valve
Check valve
N.R.V valve
Gate valve
Needle valve
61

62.  BLOWERS
Various types of blowers used in GACL are
Centrifugal blower
Lobe blower.
 BOILERS
In G.A.C.L. mainly gas fired boilers are used for the
purpose of steam production. This steam is used in
various plants of G.A.C.L. in CLM plant it is used in
distillation tower.
 COOLING TOWERS
In G.A.C.L. there are 5 cooling towers, all are induced
draft cross flow and having different cooling
capacities. There are baffles provided for better
contact between cold air & hot water. Cold water is
collected in tank at the base of tower & from there it is
sent to cooling systems through pump.
62

63. 63