Internship Report: ICI Soda Ash Khewra Saram Ali
Internship Report: ICI Soda Ash Khewra Saram Ali
Internship Report: ICI Soda Ash Khewra Saram Ali
Saram Ali
[ INTERNSHIP REPORT ]
ACKNOWLEDGEMENT
All praise is to Almighty Allah, the Beneficent, and the Merciful. He showered His great
blessings upon us in the form of Holy Prophet, Hazrat Muhammad (P.B.U.H).
With much effort and time spent, we thank God for being able to complete the internship in
Imperial Chemical Industries (ICI) Pakistan, Khewra.
We wish to take this space and opportunity to express our thanks to all employees for
providing us with helpful information and exchanging thoughts, family members for their
financial support and ICI Pakistan for supporting us in doing our intern.
Thank you.
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ABSTRACT
This report encompasses all the technical experience that we went through, the
configuration and detailed maintenance process of the machinery; overhauling of the
equipment, the operating parts and working mechanism of the Boilers, Gas turbines and
Steam Turbines. The detailed surveys are performed over the time of four weeks of the
complete plant. This internship proves to be very helpful in understanding how products are
mass manufactured in industries. We give special thanks to all the Engineers, supervisors
and workers for providing the necessary guideline and helping us in our time of need.
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TABLE OF CONTENTS
1. Introduction…………………………………………………………………………………….……………………………………………………………. 4
2. Safety Precautions………………………………………………………………………………………………………………………………………. 5
3. Technical leaning during internship duration…………………………………………………………………………………………….....6
3.1 Different types of valves………………………………………………………………………………………………………………………...6
3.1.1 Ball Valve .………………………………………………………………………………………………………………………………...7
3.1.2 Gate Valve.………………………………………………………………………………………………………………………………...7
3.1.3 Butterfly Valve.………………………………………………………………………………………………………………………….7
3.1.4 Safety Valve.………………………………………………………………………………………………………………………………7
3.1.5 Relief Valve.……………………………………………………………………………………………………………………………….7
3.1.6 Plug Valve…………………………………………………………………………………………………………………………………..8
3.1.7 Non-Returnable Valve………………………………………………………………………………………………………………..9
3.2 Star type Epicyclic Speed Reduction Gear……………………………………………………………………………………………..10
3.2.1 Assembly of all parts…………………………………………………………………………………………………………………11
3.2.2 Role of all parts ………………………………………………………………………………………………………………………12
3.2.3 Lubrication………………………………………………………………………………………………………………………………13
3.3 Steam Trap....................................................................................................................................................…... 12
3.3.1 Thermodynamic Steam Trap…………………………………………………………………………………………………….12
3.4 Centrifugal Pumps………………………………………………………………………………………………………………………………..14
3.5 Steam Boiler…………………………………………………………………………………………………………………………………………..16
3.5.1 Parts of boiler…………………………………………………………………………………………………………………………..18
3.6 Y-Strainer…………………………………………………………………………………………………………………………………………….18
3.7 Screw Compressor………………………………………………………………………………………………………………………………19
4. References………………………………………………………………………………………………………………………………………………... 23
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1. Introduction:
It would be hard to go anywhere in today‟s world without being close
to a product produced without containing Soda Ash. Reading the newspaper,
sipping on a glass of orange juice, biting into a hot croissant, or simply wearing
freshly laundered clothes, you experience the use of Soda Ash every day. Without
Soda Ash, the manufacturing of necessary commodities such as glass, paper and
detergents would not be possible. The closest you get to this versatile chemical
compound that is the baking soda tin in your kitchen, used as a baking ingredient.
ICI Pakistan, Khewra is the largest Soda Ash producer in the
country. Soda Ash Plant in Khewra was established in the 1940s, even before the
creation of Pakistan starting with a capacity of 18,000 tons per annum (figures
taken from the ICI Pakistan's official Site).
ICI Pakistan made huge investments in growing this business and
the current annual capacity of 350,000 tons per annum provides assurance to its
customers that ICI Soda Ash can be relied upon as a trusted and reliable supplier
for high quality of Soda Ash. The substantial foreign exchange savings are ensured
through import substitution by utilizing indigenous raw materials.
Apart from manufacturer of Soda Ash, ICI Pakistan is also a chief
producer of a wide range of industrial and consumer products. These products
include:
Polyester Staple Fibers
POY Chips
Light and Dense Soda Ash
Sodium Bicarbonate
Specialty Chemicals
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Polyurethanes
Adhesives
Pharmaceutical
Animal Health products manufactured
Agricultural Products including Field Crop Seeds and Vegetable Seeds
2. Safety Precautions:
House keeping
Horse play
PPE‟s
Working at the height
Working in the noise area
Working in the toxic gas
Working in the dust
The basic thing that you should every time in the factory:
Wear helmet
Wear glasses
Wear ear plug
Wear the safety shoes
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3. Technical Learning during Internship Duration:
During the internship duration we were appointed to the
maintenance department where we were first given the theoretical overview of
the mechanism and then we were taken out for the visual overview of the working
mechanism of the machinery. All the mechanisms of the machinery covered
during the theoretical demonstrations and plant surveys are as follows:
Figure 1a: Closed Ball Valve Figure 1b: Open Ball Valve
3.1.3
Figure 2b: Closed Gate Valve Figure 2c: Open Gate Valve
Butterfly Valve:
Butterfly valves are quarter-turn rotary motion valves used as
throttling valves to control flow through a system. They can be used with many
different media. Butterfly valves offer several advantages including quarter-turn,
openness for less plugging, and good control capabilities.
They may be used in a wide variety of chemical services, are available
with small dimensions allowing for use in areas where space is limited, and allow
a high coefficient of flow. The disadvantages include difficulty cleaning internal
parts; therefore they should be avoided in situations that call for sterile, medical
or food processing applications.
Figure 3a: Butterfly Valve Figure 3b : Closed Butterfly Valve Figure 3c : Open Butterfly Valve
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3.1.4 Safety Valve:
Safety Valve is a one type of valve that automatically actuates when
the pressure of inlet side of the valve increases to a predetermined pressure, to
open the valve disc and discharge the fluid ( steam or gas ) ; and when the
pressure decreases to the prescribed value, to close the valve disc again. Safety
valve is so-called a final safety device which controls the pressure and
discharges certain amount of fluid by itself without any electric power supply.
Safety Valve is mainly installed in a chemical plant, electric power boiler, gas
storage tank, preventing the pressure vessels from exploding or damaging.
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fluid can enter or leave. The plug in this kind of valve has one passageway going
through it. The ports are typically at opposite ends of the body; therefore, the plug
is rotated a fourth of a full turn to change from open to shut positions. This makes
this kind of plug valve a quarter-turn valve.
Figure 6a : Plug Valve Figure 6b: Plug Valve Cross section View
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loops in heating and cooling systems to ensure proper operation, and with
domestic water systems to prevent backflow.
A central Sunwheel
Annulus or internally toothed gear ring
Star wheels mounted on the Fixed star carrier (Wheels revolve along the sun wheel
and engage with the annulus at the same time)
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3.2.2 Role of the main parts:
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3.3.1 Thermodynamic Steam Trap:
Thermodynamic disc steam traps have an intermittent, cyclical
operating characteristic. The valve mechanism — comprised of a disc and seat
rings — opens to discharge condensate for a few seconds; and then closes for a
generally longer period until a new discharge cycle begins.
The opening and closing action of thermodynamic disc traps is
caused by the difference in the forces acting on the bottom and top sides of the
valve disc. These forces are essentially based on variations in kinetic and
pressure energy of the typical fluids involved: air, condensate, and steam.
At start-up, incoming fluids consisting of air, and/or
condensate (and even sometimes steam) at line pressure exert an Opening Force
(Lifting Force) on the bottom of the valve disc; thereby causing it to rise and open.
This Opening Force elevates the disc off the seat to allow condensate flow. The
next section explains how the disc mechanism closes after it is opened.
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Situation 1: From the Open to the Closed Position (Thermodynamic
Explanation)
When in the open position, there are two main forces that act on the disc valve:
steam in the pressure chamber on top of the disc, and steam racing across the
underside of the disc. This steam acting to open and close the valve is known as
Control Steam.
Control Steam within the pressure chamber exerts a downward force on the top
of the valve disc as a result of its Pressure x Area. Control steam on the
underside of the disc causes a pressure drop under the disc because of its high
velocity (as long as the disc is in the open position).
The valve is designed to close on flashing condensate near-to-steam temperature,
which occurs once the accumulated condensate is discharged. When the Closing
Force is big enough to overcome the Opening (Lifting) Force, the valve closes.
Oil rings
Bearings
Casting
Seal
Shaft
Volute
Impeller
Suction Nozzle
Discharge Nozzle
Oil Unit
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O-type boilers(generation tubes are shaped in form of o)
D-type boilers(generation tubes are shaped in form of D)
Economizer
Steam Drum
Generation Tubes
Mud Drum
Combustion Chamber
Super heater
3.5.1.1 Economizer: An economizer uses the waste heat from the boiler
exhaust that would otherwise be lost to atmosphere to (in most cases) preheat
the feed water into the boiler.This improves the boiler efficiency and reduces
fuel costs
3.5.1.3 Generation Tubes: Many tubes link the steam drum to the water
drum and to the header. The tubes that lead from the water drum to the steam
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drum are the generation tubes. They are arranged in the furnace so the gases
and the heat of combustion can flow around them. The generation tubes are
made of steel that is strong enough to withstand the high pressures and
temperatures within the boiler. In most boilers these tubes are usually 1 to 2
inches in diameter but some may be 3 inches in diameter as well.
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3.5.2 Controlling the Excess Temperature in the Boiler (Temperator):
The Temperator in the mud drum is used to control the excess temperature
of the steam after flowing through the super heater.
For example in case the temperature exceeds from 385oc (desired
temperature) sensed via temperature sensor then the steam will be directed
towards the tubular portion through a three way valve inside the Mud drum
where estimated temperature is 250oc so the temperature drop does occur
there and the temperature drops to 350oc which is the controlled one.
In case after passing through the Superheater the
temperature is below the sensor activation range i.e. 375oc (in our case) then
steam will flow through the three way valve towards the desired delivery
section.
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3.6 Y-Strainer:
The strainers and filtrations are designed for the efficient removal
and retention of solid/foreign material from flowing liquids and gases. It provides
the ultimate in protection to vital process equipment, both in simple and in the
very increasing sophistication of process plant systems. Their operational areas
are to protect:
pumps and compressors
flow meters
valves and regulator
heat exchangers and refrigerating sets
steam traps
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Screw Compressors:
The rotary screw compressor uses two rotors (helical screws)
to compress the air. There is a „female rotor‟ and a „male rotor‟. The rotors are of
different shape, but fit each other exactly.
Mechanism:
When the rotors start turning, air will get sucked in on one side
and gets „trapped‟ between the rotors. Since the rotors are continuously turning,
the air gets pushed to the other end of the rotors (the „pressure side‟) and new
fresh air gets sucked in.
Operation:
The working of a screw compressor is a continuous process, this
kind of compressor doesn‟t make a lot of noise; it runs quiet and smooth. Hence,
they do not require spring suspension. Many rotary screw compressors are,
however, mounted using rubber vibration isolating mounts to absorb high-
frequency vibrations, especially in rotary screw compressors that operate at high
rotational speeds.
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3.7.1 Types of Screw Compressors:
The rotary screw compressors are available in two basic types depending upon the
usage of oil:
Oil free Screw Compressors
Oil Injected Screw Compressors
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4. References:
http://www.tlv.com/global/TI/steam-theory/how-disc-traps-work.html
https://www.c-a-m.com/products-and-services/valves/valve-academy/how-does-it-work-
check-valves
http://www.learnengineering.org/2014/01/centrifugal-hydraulic-pumps.html
http://www.rpi.edu/dept/chem-eng/Biotech-
Environ/Environmental/was2en/BoilerOperation2.html
http://summith.blogspot.com/2011/08/boiler-accessories-super-heater-working.html
http://www.tecmara.com/en/products/strainer/design-and-function.html
http://www.air-compressor-guide.com/wp-content/uploads/2014/05/rotary-screw-element3-
300x223.jpg
http://www.air-compressor-guide.com/learn/compressor-types/rotary-screw-compressor/
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