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S internship eight semester prersentation
- 1. Gujrat Technical university LaxmiInstute of Technology Sarigam Valsad Prepared By Vipendra Kumar 220863119015
- 2. CONTENTS • Internship Details •Objectives • Introduction • • Brief About Aarti Industry • Production Range • Utility Maintenance • Water treatment plant • Outcomes • Conclusions
- 3. Objectives Technical Objectives : 1.Gain improvement in SAP system. 2 . Learn industry-based standard practices like kaizen and 5S" activity. Soft Skill Objectives: 1 . Improving communication and presentation skills. 2. Learn problem solving and thunking abilities. Personal Growth Objectives : 1 . Contribute to the compnay and its goals. 2 . Gain valuable industry experience and build a professional work. 3 . Gain Knowledge industry working culture and gain experience equipments.
- 4. Internship Details • CompanyName - Aarti Industries LTD Vapi • External Guide - Sudhir Gupta • Internal Guide - Hemant Patel • Department - Utility Maintenance / Engg. Department • Role : intern/ Trainee • Location: Vapi • From : 19/03/2025 to 19/04/2025 • Working Hour : 09:00 AM To 17:30 PM
- 5. Chapter 1 :Introduction
- 6. Introduction Acid Division AppleDevision Fertilizer Organic Devi sion Necent Division Amine De vis ion
- 7. Different Chemical UnderAarti Industry SULFURIC ACID LIQUID SO3 DI-METHYLE SULPHATE PNCB CSA OLEUM DCB GYPSUM DCP NITRO BENZENE HYDROCHLORIC ACID NITRIC ACID
- 8. Chapter 2 :Utility Maintenance (Chilling Plant)
- 9. Introduction of Chillingplant Chiiling Plant Cappicity : 60 TR Refrigrerant Name : 134A COMPRESSOR TYPE : Dual srew compressor Condensor Type : Water shell and tube type Condensor Evoporator Type : Shell and Tube type Hot and Cold Well : 30 M2 Area Insulation type : Nitraile type cold insulation ( thick ness - 50 mm) Insulation Density : 60 mm Chilling water outlet Temp. : 7 deree celcius Chilling water inlet Temp. : 12 degree celceus Cooling tower cappicity : 100 TR Primary circulation pump : 35 m3/hr Secondary circulation pump : 35 m3/hr
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- 11. Chiiling plant working Chillerplant works by using a refrigeration cycle to transfer heat from a sou rce (like chilled water) to a heat sink (like cooling tower or air). This proc ess involves a refrigerant that undergoes phase changes (liquid to vapor and back), absorbing and releasing heat along the way. Chilling plant Main Four Components are bellow ; 1. Evaporation: Liquid refrigerant enters the evaporator (a heat exchanger). Heat is extracted from the chilled water, causing the refrigerant to evapor ate (turn into a vapor). The refrigerant, now a cool, low-pressure vapor, absorbs heat from the c hilled water, cooling it down. This cooled water is then circulated to various areas for cooling, like air h andling units (AHUs).
- 12. Chilling Plant Working Compression: Compression: Thelow-pressure, low-temperature refrigerant vapor is then drawn into a comp ressor. The compressor increases the pressure and temperature of the refrigerant, tur ning it into a high-pressure, high-temperature Condensation: The hot, high-pressure refrigerant vapor enters the condenser (another heat ex changer). The refrigerant releases its heat into the surrounding environment (air or cooli ng tower water), causing it to condense back into a liquid state. This heat rejection process is where the heat from the building is transferred o ut. Expansion: The high-pressure, high-temperature liquid refrigerant then flows through an e xpansion valve. The expansion valve reduces the pressure and temperature of the refrigerant, p reparing it for the next cycle. The refrigerant then returns to the evaporator to start the process all over agai n.
- 13. Chilling Plant SOP STARTUP PROCESS : Before starting the compressor, the utility operator checks & ensures following : He ensures for the power availability. : He ensures that the cooling tower circulation pump is ON & adequate pressure is sh own on the pump. : He ensures that the cooling tower fan is ON. : He ensures that the chilling primary pump to chiller is ON & adequate pressure is Shown on the pump. : He will ensure that the level of NH3 in NH3 receiver is > 60%. : He ensures that the level of the hot well tank is within limits. : He will ensure that the oil level in the compressor is up to the 70%. : Once all these parameters are checked & ensured, the utility operator starts the chilli ng compressor.
- 14. Howden Blower &STPL Turbine Preventive Maintenance: Prepared by : Vipendra Kumar
- 15. Howden Blower inAcid Plants 15 Importance of Howden Blower :- ●Howden blower is most significant and critical equipment of the acid plant. ●The blower compresses the gas to sufficient pressure to overcome the pressure drop through the plant. ●In a sulphur burning acid plant, the gas handled by the blower is air. In a regeneration or metallurgical acid plant the gas contains SO2 and traces of acid mist. ●The gas must be dried in a Drying Tower before passing through the blower in order to prevent corrosion from acid condensation.
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- 18. Blower Silencer : ●Suction Silencer opened found some dust and cleaned by air as well as manually. ● Suction line flange raise checked found ok. ● wall thickness found ok which is 6mm 18
- 19. Inlet guide vanevalve : ( IGV ) 19
- 20. Inlet guide vanevalve : ( IGV ) 20
- 21. Inlet guide vanevalve : ( IGV ) 21 Inspection and maintenance : ●Manual adjustment with handwheel and spindle and spindle found free. ●Vane Bearing & Guide Roller Lubricant quantity for relubrication: until grease comes out of the lubrication point ●Hydraulic operated cylinder top up with the ISO VG - 32 ( 0.80ml) All over IGV operated very smooth and free ,manually .
- 22. Blower Casing &Impeller : ● Casing window open and check inside casing visually ● welded Backward curved blades checked and there is no wear & corrosion and cr ac k. ● Rotor is Dynamically balanced as per the visually inspection as well as not any rust or particle found. 22
- 23. Bearing Housing : ●horizontally split casing checked, split housing inside found o k ● split housing inside chamber Cleaned by air & cloth, surface of split.there is no scoring or marking where insert bearing. ● Oil filling vent & ventilation filter cleaned by air. 23
- 24. Blower Bearing Clearance: ● Bearig clearance - 0.03 mm(radially)the re is no play or inner & outer race & Ball found ok 24
- 25. Bearing Play : 1.CylindricalRoller Bearing NU 1026 M ● Grooved ball bearing Bearing 6222.C3 SKF 2. .Bearing clearance - < 0.05 mm there is no play or inner & outer race & Ball found ok 25
- 26. Shaft : ● ShaftCondition no wear and Corrosion. ● Shaft checked there is no scoring and overheating or not found any heating spot. 26
- 27. Shaft Hub AndBearing Condition. ● The blower is provided with Double ball bearing housing and roller bearing inserts. ● Lubrication by oil bath.Oil grade ISO VG 32. ● Hub condition and bearing condition found ok, as well as there is no play found. 27
- 28. Blower Coupling : ●Flexible couplings between driver and blower. ● torsionally elastic and bending elastic claw coupling checked , Periphery cleaned by air or cloth & no damage or crack on spider. 28
- 29. Clutch SSS : TheSSS clutch is fitted between a driving device and its associated driven machinery ( Motor & Gearbox) ●Empty the existing oil from the clutch by removing the oil fill hole to bottom dead centre. ●Top up oil to top dead centre & fill the clutch with oil until it flow from the oil level.. ●Quantity of oil = 0.85lit. 29
- 30. Turbine Gearbox : ●Turbine gear condition found ok visually and gear teeth has no wear or corrosion. 30
- 31. Turbine Gearbox Gear: ● Turbine gearbox Axial play checked and it is - 0.015 31
- 32. Gearbox Backlash - 00 GearboxBacklash - 0.018mm Backlash : 32
- 33. Radially Play 00 mm RadiallyPlay 0.03 mm Gearbox Radially : 33
- 34. Gearbox Housing : ●horizontally split casing checked visually , no wear or corrosion and there is scoring or marking on split where bearing insert found ok. 34
- 35. JOURNAL BEARINGS : ●Journal Bearing HS Side (Dri ve end)Journal Bearings LS Side (DriveEnd) Drive end and non drive end both bearing found ok there is no marking found . ● Bearing clearance is radially 0.02 mm 35
- 36. Overspeed trip knob Servo motor valve TurbineController: 36
- 37. Oil Filter : ●Cleaned the oil filter by taking out and rinsing the insert gasoline used for Cleaning. ● New Oil filter replace d 37
- 38. Turbine Shaft : ●Turbine shaft is visually checked and found ok and runout is ok Runout of shaft - 0.02 mm 38
- 39. Gear Pump (Oil circulation) ● Pump body surface is cleaned. housing clearance ( 0.1mm) ● gear clearance is ok ( < 0.06mm) 39
- 40. Condensate Pump :CEP ● Pump shaft replaced cleaned casing, impeller) Coupling & spider replaced. ● Water pump strainner cleaned by air and water 40
- 41. Oil Cooler : ●Condenser tube checked and clean by SS wire brush as well as by water jet. ● Hydraulic taken there is no leakages in tube or shell. 41
- 42. Oil Tank &Supply Unit : ● Oil tank condition checked and found ok ● Oil top up , ISO VG 46 ● Oil supply unit and pipe are checked , pipe fitted and leakage connector replaced with the new. 42
- 43. Heat Rejection Equipment Topic:Cooling Towers Prepared by : Vipendra Kumar
- 44. Cooling Towers • Introduction •Types of cooling towers Assessment of cooling towers Energy efficiency opportunities
- 45. Introduction • Main Featuresof Cooling Towers
- 46. Introduction • Components ofa cooling tower • Frame and casing: support exterior enclosures • Fill: facilitate heat transfer by maximizing water / air contact • Splash fill • Film fill • Cold water basin: receives water at bottom of tower
- 47. Introduction • Components ofa cooling tower • Drift eliminators: capture droplets in air stream • Air inlet: entry point of air • Louvers: equalize air flow into the fill and retain water within tower • Nozzles: spray water to wet the fill • Fans: deliver air flow in the tower
- 48. Types of CoolingTowers • Natural Draft Cooling Towers • Hot air moves through tower • Fresh cool air is drawn into the tower from bottom • No fan required • Concrete tower <200 m • Used for large heat duties
- 49. Types of CoolingTowers • Natural Draft Cooling Tower
- 50. Types of CoolingTowers • Mechanical Draft Cooling Towers Large fans to force air through circulated water. Water falls over fill surfaces: maximum heat transfer. Cooling rates depend on many parameters Can be grouped, e.g. 8-cell tower
- 51. Types of CoolingTowers • Mechanical Draft Cooling Towers Three types Forced draft Induced draft cross flow Induced draft counter flow
- 52. Types of CoolingTowers • Forced Draft Cooling Towers Air blown through tower by centrifugal fan at air inlet Advantages: suited for high air resistance & fans are relatively quiet Disadvantages: recirculation due to high air-entry and low air-exit velocities
- 53. Types of CoolingTowers • Induced Draft Cooling Towers Two types Cross flow Counter flow Advantage: less recirculation than forced draft towers Disadvantage: fans and motor drive mechanism require weather-proofinh
- 54. Types of CoolingTowers Induced Draft Counter Flow CT •Hot water enters at the top •Air enters at bottom and exits at top •Uses forced and induced draft fans
- 55. Types of CoolingTowers • Water enters top and passes over fill • Air enters on one side or opposite sides • Induced draft fan draws air across fill Induced Draft Cross Flow CT
- 56. Assessment of CoolingTowers Measured Parameters •Wet bulb temperature of air •Dry bulb temperature of air •Cooling tower inlet water temperature •Cooling tower outlet water temperature •Exhaust air temperature •Electrical readings of pump and fan motors •Water flow rate •Air flow rate
- 57. Assessment of CoolingTowers Performance Parameters 1. Range 1.Approach 2.Effectiveness 3.Cooling capacity 4.Evaporation loss 5.Cycles of concentration 6.Blow down losses •Liquid / Gas ratio
- 58. Assessment of CoolingTowers 1. Range Range (°C) = CW inlet temp – CW outlet temp High range = good performance
- 59. Assessment of CoolingTowers • 2. Approach • Difference between cooling tower outlet cold water temperature and ambient wet bulb temperature: Approach (°C) = CW outlet temp – Wet bulb temp
- 60. Assessment of CoolingTowers 4. Cooling Capacity Heat rejected in kCal/hr or tons of refrigeration (TR) = mass flow rate of water X specific heat X temperature difference High cooling capacity = good performance
- 61. Assessment of CoolingTowers 5. Evaporation Loss Water quantity (m3/hr) evaporated for cooling duty = theoretically, 1.8 m3 for every 10,000,000 kCal heat rejected = 0.00085 x 1.8 x circulation rate (m3/hr) x (T1-T2) T1-T2 = Temp. difference between inlet and outlet water
- 62. Assessment of CoolingTowers Cycles of concentration (C.O.C.) Depend on cycles of concentration and the evaporation losses Blow Down = Evaporation Loss / (C.O.C. – 1)
- 63. Assessment of CoolingTowers Liquid Gas (L/G) Ratio Ratio between water and air mass flow rates Heat removed from the water must be equal to the heat absorbed by the surrounding air L(T1 – T2) = G(h2 – h1) L/G = (h2 – h1) / (T1 – T2) T1 = hot water temp (oC) T2 = cold water temp (oC) Enthalpy of air water vapor mixture at inlet wet bulb temp (h1) and outlet wet bulb temp (h2)
- 64. Energy Efficiency Opportunities 1.Selecting a cooling tower 2. Fills 3. Pumps and water distribution 4. Fans and motors
- 65. Energy Efficiency Opportunities 1.Selecting a cooling tower Range Range Range determined by process, not by system Approach Closer to the wet bulb temperature Bigger size cooling tower More expensive
- 66. CT NAME DESCRIPTIO N 6MW CT2.35 MW CT SO3 OT-1 Model No. ------ PFC -25516 ------ PFC - 24414 ------- Make ----- CANARA BlueChip Canara Canara Type of Flow Cross / Counter CROSS Counter Counter Cross Design I/L T Deg C 42 37 37 37 O/L T Deg C 32 32 32 32 WBT Deg C 28 28 28 28 Capacity Flow M3/HR 1500 200 700 400 Capacity TR 4960 331 1157 661
- 67. Chapter 3 :Water Treatment Plant (Zero Lequid Dischrge)
- 68. Zero Liquid Dischrge :Zero liquid discharge (ZLD) refers to a treatment process in which the plant discharges no liquid effluent into surface waters, in effect completely eliminating the environmental pollution associated with treatment. : In Aarti Industry zld system are given bellow, : MEE Plant ( Multi effect evoporative plant) : ATFD ( Agitator thin filter dryer ) : ETP ( Effuilent treatment plant)
- 69. Zld section • MEEplant Cappicity : 80 KLD • Process : Waste water treatment Plant • Feed water parameter : 25000 TDS , PH - 7 ppm • Condenstate water parameter : 800 TDS , PH - 7 ppm • Consentrate water paremeter : 100000 TDS • Steam inlet pressure : 2 kg/cm2 • Vacuum required : 710 mmhg before and after steam supply 680 mmhg
- 70. ATFD • After MEEPlant waste water feed in ATFD for slurries waste water convert to dry powder form by steam and rotataing equipment. • Key Components of ATFD • Feed System: Introduces the liquid, slurry, or paste to the dryi ng process. • Rotating Shaft with Blades or Wipers: Agitates the material, e nsuring it forms a thin, even film on the heated surface. • Heated Surface (Jacketed Cylinder): Provides the necessary h eat for evaporation. • Vapor Outlet: Removes the evaporated moisture or solvent. • Discharge System: Collects the dried product.
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- 72. Outcomes • Through my90 day internship , I have learnt how to handle with real work time conditions. • Also how maintaining relations with your seniors and batchmates help you grow into your job.They can guide you whenever you are stuck at situations. • It helped me gain insights on to day to day oprations and maintenance. • I got traditional working culture and eniornment. • My guide helped me how to apply theoretical knowledge to pratical knowledge.
- 73. CONCLUSION • The SummerInternship was more than learning experience for me. I got learnt about real work time conditions and learnt them. Learnt about how to handle pressure and how maintaining relations with collegues and seniors is important in your job. • The overall experience was fun and learing in many ways.
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