The document provides details about the author's internship at Jubilant Life Sciences. It discusses: 1) The author's responsibilities in controlling machines like pumps, boilers, and compressors to regulate mass flow rates, temperatures, and pressures. 2) A challenging situation where boiler furnace temperature increased drastically due to high coal mass flow, which was solved by shutting down some nozzles. 3) Maintenance tasks performed on equipment like testing and maintaining a heat exchanger, setting up a new refrigeration system, and replacing compressor parts.

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INTERNSHIP REPORT
ON
CONTROL AND MAINTENANCE OF MECHANICAL SYSTEMS
AT
JUBILANT LIFE SCIENCES
BY
MAYANK BHARDWAJ (13BME1097)
Mayank.bhardwaj2013@vit.ac.in
Mobile-9176858960
School of Mechanical and Building Sciences
SEPTEMBER, 2015

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CERTIFICATE

3. iii
CERTIFICATE BY FIRE AND SAFETY DIVISION

4. iv
ABSTRACT
The author joined the company as a control and maintenance engineer during his one
month training. In this report, the author has highlighted the challenges that he
encountered and the actions taken or solutions to problems during his training in
jubilant life sciences limited. As a control engineer author was assigned the task to
control various machines like pump, boiler and compressor and also control the
amount of mass flow rate of various fluids entering in them along with the temperature
and pressure generated using software and pneumatic control unit. The challenging
situation that came in front of the author when the temperature of boiler furnace
started increasing drastically this problem came due to the high mass flow rate of coal
which is supplied to the furnace through the nozzle the problem was solved by
shutting down few nozzles so as to get the limited mass flow rate.

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ACKNOWLEDGEMENTS
“Gratitude is not a thing of expression; it is more matter of feeling.”
There is always a sense of gratitude which one express towards others for their help and supervision
in achieving the goals. This formal piece of acknowledgement is an attempt to express the feeling of
gratitude towards people who helped me in successfully completing my training.
I would like to express my deep gratitude to the program manager and the other faculty members of
SMBS for encouraging me to undergo the internship at jubilant life sciences.
I do extend my heartfelt thanks to Mr Jawaharlal gupta for providing me the opportunity to be a part
of this esteemed organisation. I am also thankful to all the respondents and group members whose
responses and coordination were of utmost importance.
Above all no words can express my feelings to my parents, friends and all those who supported me
during my internship.

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TABLE OF CONTENTS
Unit No.
1. Introduction……………………………………………………………………..1
1.1.About the industry………………………………………………………….2-6
2. Parts of industrial training
2.1. Fire and safety section……………………………………………………. 6-7
2.2. Steps followed before buying new chemical……………………………......7
2.3. Control and maintenance of boilers…………………………………….......8-10
2.4. Control and maintenance of compressor………………………………….10-13
2.5. Control and maintenance of heat exchanger……………………………...13-15
2.6. Refrigeration system………………………………………………………15-16
3. Contribution at the industry
3.1.Testing and maintenance of shell and tube type heat exchanger…………16-18
3.2.Setting up of new refrigeration system……………………………………18-19
3.3.Replacement of piston along with suction and discharge valve…………..19-20
4. Conclusion…………………………………………………………….21
References……………………………………………………………………...21

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1. INTRODUCTION
This report describes the learning experiences gained during the training period along
with the assigned tasks and the responsibilities that were given to the author and how
they are handled in the intelligent way and finally the achievements and results are
discussed. This report also provides a brief introduction about the industry and along
with the details of various machines like various types of compressors, boilers, fire
extinguisher and along with various refrigeration systems like ammonia and lithium
bromide refrigeration system. Along with the theoretical description this report
describes the individual contribution of the author along with the problem statements
that are given by the company. This report also provides the brief description of the
industry culture and also how innovation takes place inside the company.

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1.1. ABOUT THE INDUSTRY
Jubilant life sciences is a chemical manufacturing company which includes various
chemicals such as alcohol, acetaldehyde, acetic anhydride etc.
VISION
To acquire and maintain global leadership position in chosen areas of
businesses
To continuously create new opportunities for growth in our strategic businesses
To be among the top 10 most admired companies to work for
To continuously achieve a return on invested capital of at least 10 points higher
than the cost of the capital
VALUES
To carefully select, train and develop people to be creative and empower them to take
decisions, so that they respond to all stakeholders with agility, confidence and
teamwork.

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Stretch to be cost effective and efficient in all aspects of our operations and focus on
flawless delivery to create and provide the best value to our stakeholders.
By sharing knowledge and learning from each other and from the markets we serve,
we will continue to surprise our stakeholders with innovative solutions.
With utmost care for the environment and safety, excel in the quality of our processes,
our products and our services.
OUR PROMISE
Caring, Sharing, Growing
With utmost care for the environment and society, continue to enhance value for the
customers by providing innovative products and economically efficient solutions; and
for our stakeholders through growth, cost effectiveness and wise investment of
resources.

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Jubilant Life Sciences Limited is an integrated global pharmaceutical and life sciences
company engaged in manufacture and supply of APIs, Solid Dosage Formulations,
Radiopharmaceuticals, Allergy Therapy Products and Life Science Ingredients. It also
provides services in Contract Manufacturing of Sterile Injectable and Drug Discovery
Solutions. The Company‟s strength lies in its unique offerings of Pharmaceutical and
Life Sciences products and services across the value chain.
The company‟s success is an outcome of strategic focus on the pharmaceuticals and
life sciences industry, moving up the pharmaceutical value chain for products and
services across geographies, constantly investing in various growth platforms and
promoting a culture of innovation.
It is engaged in continuous improvement of products and processes to enhance the
quality of production and cost competitiveness in order to build value for our
customers. Jubilant Life Sciences serves its customers globally with sales in over 100
countries and ground presence in India, North America, Europe and China. It is well
recognised as a „Partner of Choice‟ by leading life sciences companies worldwide.
Jubilant has relationship with 19 of Top 20 pharmaceutical companies and 6 amongst
top 10 agrochemical companies across the globe.
Over the years, Jubilant Life Sciences has extended its footprint beyond India in the
USA, Canada, Europe, and other countries across the globe. It has also expanded the
business by building capabilities internally, through strategic expansions and
acquisitions ,this resulted in a network of 7 world class manufacturing facilities in
India and 3 in North America and a team of around 6100 multicultural people across
the globe with ~ 1300 in North America and ~1000 in Research and development.

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Its multi-location presence helps in getting closer to customers and serving them better
with the best in class products developed most efficiently, economically with speed to
market.
Jubilant Life Sciences' progress in diverse businesses has been made possible through
the contribution of Research and development; for quality, non-infringing process for
product development and cost reduction through process innovation. Innovation at
Jubilant is backed by strong chemistry, bio science expertise and the knowledge bank
created over the years. We have harnessed our strengths – a strong Research and
development team, modern Research and development facilities, command over cheap
technologies and economies of scale into a synergistic organic entity, continuously
creating and nurturing high quality products and technologies.
In line with Jubilant Life Sciences continued focus on sustainability of business, its
aim is to improve stakeholder value through improved eco efficient use of capital and
natural resources. Jubilant approach to sustainable development focuses on the triple
bottom line of Economics, Environment and Social performance. The company is
committed and working on various areas for energy conservation and climate change
mitigation. Its sustainability efforts have been reported through a Corporate
Sustainability Report since 2003 and this report has been receiving GRI G3.1 A+ level
and GRI Check, since 2007 from Global Reporting Initiative (GRI). This reflects
Jubilant Life Sciences commitment towards sustainable development and continued
efforts directed towards protecting the environment wherever it operate.
Corporate Social Responsibility is an integral part of how Jubilant Life Sciences
conducts business and how the efforts are directed towards community development
through focus on primary education, basic healthcare service, and livelihood
generation programs focused on improving the employability of women and local
youth.
The company has been recognised with several awards and recognitions, which bear
testimony to our commitment towards operational excellence, innovation, corporate

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governance and social responsibility. Jubilant Life Sciences is committed to leverage
innovation and scale of operations at every step of the pharmaceutical value chain to
deliver value to our stakeholders.
2. PARTS OF INDUSTRIAL TRAINING
2.1 Fire and safety section
The internship starts from the fire and safety section as jubilant life sciences is a
chemical company so always there is a risk of fire so they taught us various
methods to escape in the case of emergency caused by fire or in case of any
chemical or gas leakage inside the industry.
Topics which are covered by them are as follows-
2.1.1 Brief introduction about Fire, Safety and Environment department and its
functions.
2.1.2 Plant round and familiarization of work inside the industry.
2.1.3 Study of Onsite Emergency Plan and Offsite Emergency Plan.
2.1.4 Study of safety manual
2.1.5 Knowledge of fire protection inside the plant which are
2.1.5.1 Hydrant system
Fig 1 showing hydrant system
A fire hydrant is an active fire protection measure, and a
connection point by which fire-fighters can tap into a water supply.

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2.1.5.2 Fire extinguishers
It is a portable device that discharges a jet of water, foam, gas, or
other material to extinguish a fire. They taught us how to hold it
and how to use it which is shown in the image below
Fig 2 showing how to extinguish fire in different situations
2.1.6 Knowledge of environmental systems in the plant
2.1.6.1 Zero discharge
In all the processes which are practised inside the industry they are
following the zero discharge policy which means that no waste and
harmful chemicals are going to the outside environment.
2.1.6.2 Zero emission
This refers to no emissions of poisonous gases to the environment
along with the odour control.
Electrostatic precipitator is a simple device they are using to
remove the particulate matter like dust and smoke.
2.1.7 A mock of fire safety was also carried out.

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2.2 Steps followed before buying any new chemical
2.2.1 First and foremost before buying any chemical they make sure whether
they have all the equipment required in case of fire or explosion caused
by that chemical.
2.2.2 They make sure whether they have all the machines available with them
which may be compressor, various refrigeration systems may be
ammonia refrigeration systems or lithium bromide refrigeration system.
2.2.3 What are the reactants or catalysts required for its production.
2.2.4 Design of the storage tank which is to be used for that specific chemical.
2.2.5 Ensuring all these four steps finally they buy the chemical.
2.2.6 Then they perform various tests on the chemical and design the process
so that they can decide how to use it and where to use it.
2.3 Control and maintenance of boilers
2.3.1 Description of a boiler and its components
A boiler is a closed vessel in which water or other fluid is heated. It
consists of various parts which are-
2.3.1.1 Furnace
2.3.1.2 Nozzle
2.3.1.3 Fan
2.3.1.4 Pneumatic system
2.3.1.5 Tube system
Fig 3 shows a boiler in operation

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Boilers function on rankine cycle, the main part of the boiler is furnace in
which bed combustion takes place. In the bed nozzles are fixed and the air is
passed through these nozzles and the discharge of air comes from the
blower. Coal is used as the fuel with the particle size of 0-6mm.Due to the
increased velocity of air by the nozzle the fine coal particles are also carried
by the air coming from the nozzle and by proper ignition combustion inside
the furnace starts. Tubes are passes through the walls of the furnace which
absorb heat from the furnace and the water gets heated up.
2.3.2 Control of boiler functioning
As the boilers produce very high temperature so it is not possible for the
workers to control it manually. In jubilant they are using electronic
control unit and pneumatics to control the functioning of boilers. They are
controlling boilers from the control room. In the control room various
parts of the boiler are displayed on the computer screen and they are
controlling the various parameters of the boiler like the working of the
nozzle, flow rate of air by using electronic control unit and pneumatics. If
they want to change the parameter of any part they just click on that part
and change it. If any unusual thing happens like excess increase of
temperature inside the boiler or malfunction any part they can even turn
off that part by just clicking on it and when the part is turned off it will be
displayed with red colour. The whole system is very user friendly when
anything goes wrong a siren starts beeping showing that something is
wrong and need to correct immediately.
2.3.3 Maintenance of boilers
In the industry there are three boilers and after specified time they need
maintenance so they are following a particular cycle which is two boilers
are kept at working mode and the third boiler is handled to the
maintenance department with the problem statement mentioning what
problems occurred during its functioning. According to the problem
statement the action will be taken by the maintenance department suppose

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in the problem statement it is mentioned that nozzle 3 and nozzle 4 is not
working properly so we need to change them or if it is mentioned that
very high temperature is developed inside the so we need to decrease the
frequency of the nozzles in the furnace bed.
2.4 Control and maintenance of compressors
2.4.1 Description of compressors
2.4.1.1 Reciprocating compressor
The reciprocating type compressor consists of a piston which is
enclosed within the cylinder & equipped with suction & discharge
valves. The piston receives power from main shaft through
crankshaft and connecting rod. A flywheel/belt wheel is fitted on
the crankshaft which is driven by electric motor or diesel engine. It
supplies uniform motion throughout the cycle of operations.
The compression of air is done by first drawing a volume of air
into its cylinder through suction valves during suction stroke by the
piston and then compressing and discharging it on the return stroke
of the piston through delivery valves. This simple working is used
in every Reciprocating Air Compressor.
2.4.1.1.1 Single stage
In single stage reciprocating air compressor the entire
compression is carried out in a single cylinder. If the
compression is affected in one end of the piston and cylinder
then it is known as single acting and if the compression is
affected in both ends of piston and cylinder then it is known as
double acting reciprocating air compressor.
The opening & closing of simple check valve (plate or spring
valve) is depend upon difference in pressure, if mechanically
operated valves are used for suction & discharge then their
functioning is controlled by cams.
The weight of air in the cylinder will be zero when the piston is
at top dead centre, if we neglect clearance volume. When piston

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starts moving downwards, the pressure inside the cylinder falls
below atmospheric pressure and suction valve/inlet valve opens.
The air is drawn into the cylinder through suction filter element.
This operation is known as suction stroke.
When piston moves upwards, compresses the air in cylinder and
inlet valve closes when pressure reaches to atmospheric
pressure. Further compression follows as the piston moves
towards the top of its stroke until, when the pressure in the
cylinder exceeds that in the receiver. This is compression stroke
of compressor. At the end of this stroke discharge/delivery
valve opens and air is delivered to receiver.
When it is double acting reciprocating air compressor, suction
stroke is in process at one end of piston while at same time
discharge stroke is in process at other end of piston. In simple
word we can say that suction and compression took place on
both end of piston and cylinder in double acting reciprocating
air compressor.
2.4.1.1.2 Multi stage
In three stage air compressor, fresh air from atmosphere enters
in first stage which is low pressure cylinder through suction
filter. This air is compressed by piston up to 4 kg/centimetre
square and then delivered to second stage which is middle
pressure cylinder through inter cooler for further compression.
In this stage suction and compression took place on both side of
piston. In second stage cylinder low pressure air is compressed
up to 14 kg/centimetre square and discharge to third stage
which is high pressure cylinder through second inter cooler to
achieve air pressure up to desired delivery pressure. In this stage
suction and compression took place on one side of piston.

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2.4.1.2 Screw compressor
A rotary screw compressor is a type of gas compressor which uses
a rotary type positive displacement mechanism. They are
commonly used to replace piston compressors where large volumes
of high pressure air are needed, either for large industrial
applications or to operate high-power air tools.
Fig 4 shows screws used in screw compressor
Fig 5 shows fixing of screws

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In screw compressor there are two screws which are in mesh with each other
and as they rotate the gap between them keeps on decreasing and as a result air
is compressed to high pressure and then finally discharged from the discharge
valve.
2.4.2 Control of compressors
In case of reciprocating compressors once they are turned on they will
keep on developing pressure and the pressure will keep on increasing and
if they are not turned off by some person the high pressure container may
burst and may lead to a disaster so reciprocating compressors require
manual control while in screw compressors once they are turned on they
will develop pressure up to a specified limited and will automatically get
turned off without causing any hazard.
2.4.3 Maintenance of compressors
In reciprocating compressors oil change is important after 30 days of
operation as oil is important for lubrication of cylinder and piston. In
reciprocating compressors change of piston is required after every three
months as wear in the pistons takes place due to the relative motion
between the piston and cylinder. Air need to be cleaned and replaced if
required. Screw compressors require maintenance once in five years in
which old screws are replaced by new ones.
2.5 Control and maintenance of Heat exchanger
2.5.1 Description and design of heat exchangers
There are two types of heat exchangers
2.5.1.1 Shell and tube type heat exchanger

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Fig 6 shows outer part of heat exchanger
A heat exchanger consisting of outer shell and inside this shell there are long tubes in
which fluid at a specified temperature flows and another fluid flows inside the shell of
the heat exchanger and as a result heat transfer takes place.
2.5.1.2 Plate type heat exchanger
This consists of thin plates and between them gaps are present
different fluids flows through these gaps as a result heat transfer
takes place. This type of heat exchanger is used in most
applications as it occupies very less space.
Fig 7 plate type heat exchanger
2.5.2 Control
It is just connected to the required place no need to control it separately.

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2.5.3 Maintenance
If any malfunctioning happens it is either due the blockage in the gaps
present between the plates or in the inlet and exit pipes and this problem
can be solved either by using high pressure water jet or by opening the
heat exchanger and then cleaning it.
2.6 Refrigeration systems
2.6.1 Ammonia refrigeration system
Fig 8 working of ammonia refrigeration system
The solubility of ammonia in water at low temperatures and pressures is higher than it
is at higher temperatures and pressures .The ammonia vapour leaving the evaporator is
readily absorbed in the low temperature solution in the absorber. This process is
accompanied by rejection of heat .The strong solution which is pumped from the
absorber to the generator must be heated and the weak solution from the generator to
the absorber must be cooled – accomplished by a heat exchanger.
Due to reduced solubility of ammonia in water at higher pressure and temperature, the
vapour is removed from the solution in the generator .The vapour then passes to the

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condenser through rectifier and the weakened ammonia in water solution is returned to
the absorber .Rectifier is a water cooled heat exchanger which condenses water vapour
and some ammonia and sends back to the generator. Final reduction or elimination of
the % of water vapour takes place in a rectifier.
2.6.2 Vapour absorption heat pump- lithium bromide based
Vacuum is created inside the chamber using vacuum pump as a result
water which is used as a refrigerant here starts boiling at a very low
temperature for example 3.7degree Celsius for 6 mm Hg pressure this
boiling water will extract heat from the water sent from the inlet and
reduces its temperature to 6-10 degree Celsius. This chilled water is sent
to various parts of plant using motor
3. CONTRIBUTION AT THE INDUSTRY
3.1 Testing and maintenance of shell and tube type heat exchanger
3.1.1 Maintenance of internal tubes
Fig 9 shows fixing of projectiles inside plate holes of heat exchanger

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Fig 10 shows pressurized jet and projectile coming out of heat exchanger at safe speed
Problem statement 1
The mass flow rate of water in the heat exchanger is decreased which lead to
the decrease in the overall efficiency of the heat exchanger.
Solution to the above problem
Projectile method was used in which small bullet like geometry is inserted
inside the inlet of the heat exchanger as shown in first figure and using high
pressure water it is made to pass through the tube cleaning the tube and finally
the projectile comes out from the outlet of the heat exchanger along with the
pressurized water at a safe speed.
3.1.2 Testing of internal cracks and correcting it
Problem statement 2
There is leakage in the heat exchanger present in the ammonia
refrigeration system.
Solution
The leakage problem in the heat exchanger is due to crack inside
any part of the heat exchanger. Ultrasound is used to detect the
crack and it was found that there was a crack in one of the tubes.

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That tube is replaced after opening the heat exchanger. An
infrared camera can also be used in such a case.
3.1.3 Maintenance of tube sheet
Problem statement 3
The holes present in the tube sheet are of less diameter but the
diameter of the holes need to be increased so as to fit this heat
exchanger in some other application
Solution
Problem is solved by preparing new sheet using drilling operation
as shown in the figures below
Fig 11 shows the making of holes in the plate for heat exchanger
3.2 Setting up of new refrigeration system
Problem statement
A refrigeration system needs to be set up which produce chilled water with
temperature ranging from 5-6 degree Celsius.

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Solution
After appropriate discussion lithium bromide refrigeration system is
finalized as chilled water of this temperature can be easily produced by this
system. During discussion one idea was that to use ammonia based
refrigeration system but it produces sub-zero temperatures so lithium
bromide is chosen.
3.3 Replacement of piston along with suction and discharge valve
Fig 12 shows weared out piston due to excessive friction

26. 20
Fig 13 shows the suction and discharge valves used in reciprocating compressor
In reciprocating compressors need to be replaced after every 90 days as they wear
out and spring system of suction and delivery valve is replaced.

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4 CONCLUSION
This internship has been an excellent and rewarding experience. A lot of practical
experience is gained during this internship and along with that a small introduction
to the industry culture. Industry exposure also gave a proper insight of how
creative ideas are applied practically and how innovation takes place. Industry is
giving equal opportunities to its employees and their valuable suggestions related
to any matter. Various skills such as teamwork, time management skills and along
with that decision ability are developed during this internship.
REFERENCES
1. Fluid power with applications by Anthony Esposito
2. Engineering thermodynamics by PK Nag
3. Wikipedia