Internship Training

Report

Submitted to :-

The HRD

Submitted by:-

Vijayashree
(Trainee)
B-Tech 2rd Year
RTU Kota (Raj.)
PROCESS
VISCOSE PREPARATION:

 STEEPING: In this section wood pulp is steeped with Caustic Soda

in the Steeping press. This is initial step taken to obtain Alpha
Cellulose from the wood pulp.

 SHREDDING: The steeped wood pulp is then sent in Shredder

Section. Here it is broken in to small pieces. This increases its total
surface area for exposure. There are 5 Shredders.

 AGEING: This section involves an activity called depolymerizing of

Alkali Cellulose there are 54 containers in which the Alkali Cellulose
is kept. This process is basically to decrease the DP of the Cellulose.

 XANTHATION: The process carried in baratte is called xanthation

due to reaction with xanthate solution Alkali Cellulose gets converted
to xanthate cellulose.

 DISSOLVING: This xanthation cellulose is next passed to dissolver

section there are eight dissolvers. It involves dissolver of xanthate
cellulose in dilute caustic soda finally produced.

 VISCOSE RIPENING ROOM (VRR): Finally the viscose produced

has to be filtered ripened to produce yarn thus. There is one blender, 4
A-Tanks, 11 A-Filters, 18 C-Tanks, 9 C-Filters. The viscose is filtered
in this section and passed on to spinning.
 SPINBATH: The chemicals required for treatment to yarn in
spinning are prepared in this section supplying or chemicals and
taking them back in to section is a cycle process.

 SPINNING: The viscose is made to pass through a spinneret of 1100

holes. This produced rayon of 1100 filaments then this yarn is washed
and passed through chemical to give finish. Due to its smooth texture
and shinning rayon was called artificial Silk. This yarn is them
collected on the bobbins and sent to Textile.

 TEXTILE: The yarn is empties from bobbins and recollected as the

specification given by the customer.

Generally there are three kinds of customer:

1. Customer for Yarn
2. Customer for Grey Fabric
3. Customer for Dipped Fabric

GODOWN & MOVEMENT:

Once the product is packed. It is sent to the Go-down for storage

and finally to be sent for shipment. Marketing Department sends
sale notes as well as dispatch advice to Shriram Rayons, Kota, in
Kota there are Go-down Department is monitoring and conducting
the dispatch to domestics and foreign buyers to dispatch are being
made on daily basis as customer’s requirement.
NATURE OF PACKAGE:

DOMESTIC BUYERS:
The yarn and cord is packed in the boxes and fabric is packed in
the form of roll. The Anhydrous Sodium Sulphate is packed in the
bags with uniform weight of 50 Kg. The goods are dispatch as per
advised received from the Marketing through the nominated
transport.

FOREIGN BUYER:
The yarn, cord is packed in the form of Pallets and Fabric in the
form of Roll. The goods are normally dispatched in 20 and 40 Ft.
containers.
Viscose Department converts pulp sheets in to viscose. The whole
process for making viscose can be classified in to 6 steps. These steps are:
 Steeping
 Shredding
 Ageing
 Xanthation
 Dissolving
 Viscose Ripening

STEEPING:

Caustic conc. = 230 gpl

Pressure = 2500 psi
Pulp sheet Length x Width = 52 x 67 Cm.
No. of steeping press = 5
Time duration = 50 ± 10 minutes
Temp. = 20 ± 3°C
No. of limit switches = 6

In this section pulp is dissolved in Caustic for 50 minutes

and compressed in steeping press steadily for 10 minutes.
After pressing the pulp and draining out the NaOH solution,
Alkali Cellulose is put in to Shredder.
SHREDDING

No. of m/cs. = 5
Time = 50 ± 10 min.
Temp. = 29 ± 2°C
Capacity of motor = 50 HP

It is for shredding of Alkali Cellulose, the shredder has 2

sigma blades which cut the Alkali Cellulose in pieces.
Shredder can tilt up to 120°C to transfer shredded cellulose
to ageing section.

AGEING:

Batch weight of Alkali Cellulose = 860 ± 10 Kg.

Ageing time = 12 – 24 Hrs.
Wet Bulb temp. = 70 ± 15°F
Dry Bulb temp. = 78 ± 15°F
Tilting trolleys = 2 Nos.

Alkali Cellulose is given age before further processing for

more uniformity as well as depolymerization. Alkali
Cellulose is kept in Ageing cans before further processing.
The humidity is maintained in Ageing Room. By the auto
oxidation, break the chain of cellulose.
XANTHATION:

No. of barattes = 8 Nos.

Xanthation time = 110 ± 10 min.
Xanthation temp. = 30 ± 3°C
Initial vacuum = 500 ± 100 mmHg
CS2 dose = 83.5 Ltr.

Alkali cellulose is treated with CS2 to form Sodium

Cellulose xanthate. The reaction is carried out in baratte. At
first, vacuum is applied to 400 mmHg then CS2 is added by
a spray pipe in vessel. Temp. is maintained by circulation of
cooling water.

DISSOLVING:

No. of dissolvers = 8 Nos.

Dissolving time = 110 ± 10 min.
Dissolving temp. = 13.5 ± 0.5°C

Xanthate is put in dissolver by dumping conveyor belt drive

driven by pneumatic motor. Triplex solution is added in
dissolver which has Soft Water + Caustic + Modifier. By this
process orange colour liquid is obtain which is known as
viscose.
V.R.R. (Viscose Ripening Room)

No. of Tanks Blender = 1

A Tank = 6
A Series Filters = 12
C Tank = 20
C Series filter press = 10
Blending Temp. 15 ± 2°C
Deaeration time 17 Hrs min. & 28 Hrs max.
Vacuum 680 – 720 mmHg
Filter cut off pressure 8 Kg/Cm2 max.
2 Kg/Cm2 min.

When cut off pressure is >8 Kg then filter is cut off and put again
for dressing.

To filter deaerate & allow ripening of viscose before supply to

Spinning Department.

Transfer of viscose batches from blender to ‘A’

Vacuum is taken in ‘A’ Tank to the level of 600 mmHg and then
viscose batches are transferred one at a time from blender then
viscose filtered by ‘A’ Series filter press.
TRANSFER VISCOSE BATCH FROM ‘A’ TANK TO ‘C’
TANK:

When one ‘C’ Tank gets empty vacuum to the level of 650 mmHg
and then viscose from ‘A’ tank is pumped to ‘C’ Tank through ‘A’
Series filters. Air pro to the level of 2 Kg/Cm 2 is applied on ‘A’
Tank and ‘A’ Tank give positive pro in the suction of ‘A’ series
filter pumps. Then viscose is filtered by ‘C’ Series press.

Supply of viscose batch from ‘C’ Tank to Spinning Department:

As per viscose consumption by spinning machines level in a ‘C’

Tank reduces when viscose level comes 1000 to 1500 Ltr. Operator
starts viscose feedings slowly just to check for exact tank. When
viscose level drops to about 600 Ltr., air starts coming-out from
bleeding line. At this point Operator first opens the viscose supply
valve from the ‘C’ Tank and then closes the viscose supply valve of
the on line ‘C’ Tank. About 30 min. before the approx. tank change
time, Operator breaks vacuum of the next ‘C’ Tank and applied air
pro of 2 Kg/Cm2.
Spin bath Department maintains concentrations of different solutions
used in spinning to convert viscose to yarn. These solutions are classified
in to 5 solutions. These solutions are:
 Spinbath solution
 Hot Stretch solution
 Regeneration Solution
 Purification Solution
 Finish Solution

SPINBATH SYSTEM WITH ACID RECOVERY

Spinbath is supplied to the spinning machines having following

characteristics:

H2SO4 = Depend on RI
ZnSO4 = 65.0 gpl
Spgr. = 1.258
Noigen G-200 = 200-250 ppm)
Na2SO4 = 200.0 gpl
Temp. = 63°C
H2S = <15 ppm

Spinbath returns from the machine having following average analysis:

H2SO4 = 96.0
ZnSO4 = 610
Spgr. = 1.253
The return bath from the Spinning machines flows by gravity into Bath
addition tank. In this tank all the concentrated solution i.e. conc.
Sulphuric Acid, conc. Zn.Soln. Filtrate soln. are added for makeup of the
loss and consumption on the spinning machine. Apart from these spin
aids like Noigen G-200, Defoamer etc. are also added.

From addition tank return bath flows by gravity to 7 Nos. gravity sand
filters operating in parallel. Here all the suspended matters contaminated
on the spinning machines are filtered out by gravity through a bed of
sand. Filtered bath flows by gravity to filtered bath tank in basement.
From the filtered bath tank, bath is pumped through filtered bath pumps
to spinbath evaporator.

Three filtered bath transfer pumps each of 900 GPM capacity are in lower
basement near filtered bath tank.Out of the three pumps, two are running
at a time and one is standby.

From filtered bath transfer pumps, bath is partly pumped to the spinbath
evaporator and partly is bypassed to the spinbath head tanks and partly
goes to the degassifier. Part of the bath going to the degassifier is mixed
with air sucked in due to fall to remove the dissolved H2S gas. H2S is
vented out from the top of the tower along with air. From the bottom of
the tower bath flows to the transfer pump which pumps it back to
spinbath head tank No.4 or Evaporator Seal Tank.

In Spinbath evaporator bath is boiled under a vacuum of 25” of Hg to

remove water added to bath on spinning M/c. The vacuum in the
evaporator is maintained through barometric condenser followed by the
two stage steam ejectors. From evaporator the bath comes to seal tank or
spinbath head tank No.3 by gravity, constant level is maintained in the
seal tank and other head tanks by maintaining small amount of overflow
from overflow box back to filteredbath tank.

From seal tank spinbath flows to spinbath supply head tanks (6 in Nos.).
These head tanks are always kept full to have constant gravity head for
feeding to spinning machines. From spinbath head tanks spinbath flows
by gravity through spinbath heaters to spinning machines. There are six
heaters operating in parallel. At a time normally four heaters are kept on
line and two will be in spare.

Thus spinbath is continuously kept under circulation from spinbath head

tank to spinning machines and back through addition tank, filters, filtered
bath tank, evaporator and degassifier to head tanks. Between the head
tanks and heaters a continuous sampling point is provided where spinbath
gravity is continuously measured and Acid concentration is analyzed
every ½ hr.
ACID RECOVERY AND GALUBER SALT CRYSTALLIZATION:

On first floor from seal tank a 4” tapping is taken and connected to (2

Nos.) crystallizer feed pumps of 220 gpm capacity. These pumps supply
spinbath feed to crystallizer in batches. Spinbath is fed to crystallizer feed
tanks (3 Nos.) on second floor, having total capacity of 42 M3. The
spinbath is pumped from the feed pump to crystallizer feed tank through a
shell and tube type heat exchanger known as crystalliser feed cooler. Here
the bath is cooled by exchanging heat with the cold filtrate solution. After
measuring the fixed volume of spinbath in these tanks, bath is fed to the
crystallizer.

The whole mass of bath is crystallizer is cooled by pulling high vacuum

(735 mm). The high vacuum is pulled-up by means of steam booster,
barometric condenser and two stage steam ejector system. After the bath
is cooled to 3°C it is dumped in the magma tank. The mixture of glauber
salt crystals and the solution is known as magma. The average
composition of magma is as under:

Glauber Salt Cryst. (Na2SO4, 10H2O) 15.0%

H2SO4 11.3% Approximately
Na2SO4 13.0 %
ZnSO4 7.2%

From the magma tank, magma is pumped to Rotary vacuum filter where
glauber salt crystals are removed and are dissolved back in the dissolving
trough into the circulation hot glauber salt soln. The glauber salt solution
is pumped to Anhydrous Sodium Sulphate Recovery Plant for further
processing. The glauber salt solution has the following composition:

Spgr. 1.278 ± 0.003

Zinc 0.25 gpl
Na2SO4 360 – 370 gpl
Temp.39 – 41 °C

The mother liquor filtered out from the rotary vacuum filter flows by
gravity through vacuum receiver to filtrate pit tank in the basement. A
vacuum of 5” of Hg. is maintained on rotary vacuum filer.

From filtrate pit tank the solution is pumped to filtrate head tank from
where filtrate solution is added back into spinbath through crystallizer
feed cooler at desired rate into bath addition tank.
HOT STRETCH SOLUTION

From hot stretch heater hot soft water is supplied to spinning machines at
a temperature of 87-88°C where it is heated further up to 92°C with steam
purged in the trough, is called hot stretch solution. Flow on spinning
machine is at the rate of 32 lts/min/machine. The heating of soft water is
carried out partly in hot stretch heat recovery system and partly in hot
stretch head tank and balance e.g. up to 88°C in hot stretch heater, all
installed at 1 floor. In heat recovery system, heat of dezincified water
(effluent after recovery of zinc from return hot stretch soln. in Zinc
Recovery Plant) is utilized to heat up the cold soft water up to about 54°C
with the help of plate heat exchangers. Hot soft water from heat recovery
system then flows to hot stretch head tank where it is further heated by
purging steam directly in to it up to temperature 70-75°C. Purging of
steam (50 psig) is distributed uniformally with the help of a multi arm
distributor pipe fitted in the center of the tank. Level in the head tank is
maintained constant with the help of an automatic pneumatic level
controller. Soft water supply piping arrangement is such that if needed,
heat recovery system can be bypassed and controller can directly feed the
head tank. Also cold soft water can directly be fed to the hot stretch
heater to carry out complete heating there. Hot soft water from hot stretch
head tank flows to spinning machines by gravity through the hot stretch
heater used for further heating up to 88°C. Heater is a shell & tube type
heat exchanger with automatic temperature controller fitted in steam
supply line (50 psig). Temperature sensing element is fitted in the header
going to spinning machines. Hot stretch from spinning machines retuns to
hot stretch pit tank in basement by gravity where from it is pumped by a
500 gpm. Capacity pump to the zinc Recovery plant for recovery of Zinc.
REGENERATION SOLUTION SYSTEM

Regeneratin solution containing 44± 1 gpl H2SO4 is supplied to spinning

machines at a rate of 8 lpm per machine (2 spinning sides) at 73-75°C
from regeneration solution. Head tanks placed on 1st floor. It is heated
further to 92°C on spinning machines regeneration troughs and returns
back to regeneration pit tank in basement by gravity duly filtered.
Filtration takes place in gravity sand filters (3 Nos.) placed above the pit
tank in basement. Filters are lead lined M.S. rectangular tanks filled with
acid resistant silica gravels and sand as filter media. The thickness of bed
(gravels & sand layers) is same as that in spinbath gravity sand filters.
Return regeneration solution is fed at the top of filter media bed and
filtered solution flows out from bottom to the pit tank by gravity. These
filters are back washed one by one in shift day with about 15M3 of
filtered water. Regeneration pit tanks are acid proof brick lined R.C.C.
tank of capacity about 10M3. Return solution received here is of low
temperature and concentration but with increased zinc build-up. For
make-up of acid conc. H2SO4 (94.5%) is added to it through a rotameter
along with addition of measured flow rate (through rotameter) of soft
water. Then the solution is pumped to regeneratin solution head tank with
the help of alloy (R-55) pumps. Apart of this solution (around 20-24 lpm)
is put to spinbath system through a in-line rotameter to keep the zinc
build-up reasonably low to <8 gpl in regeneration solution. Solution is
heated to 73-75°C is being pumped to head tanks through steam heater
(two in Nos.) Heaters used are shell & tube type heat exchangers with
steam as heating media on shell side and regeneration solution flowing
through the karbate tubes. Temperature is controlled with the help of an
automatic pneumatic controller fitted in steam supply line. Head tanks are
always kept overflowing to maintain constant level there and overflow
returning to pit tank. Head tanks are made of M.S. lined with lead
whereas pipelines used are made of antimonial lead.

PURIFICATION SOLUTION SYSTEM

Purification solution is dilute solution of sodium carbonate of
concentration 0.58 ± 0.03 gpl and is used on spinning machines to
neutralize the acid carryover of the yarn. Flow from head tanks to
spinning machines is by gravity and rate is about 32 lts/min/machine (2
sides). The soft water (from tower) is heated up to 75°C with the help of a
steam heater called purification heater (2 Nos.). Heater is a shell & tube
type heat exchanger using steam (50 psig) on the shell side to heat up the
cold soft water which is inside the heater tubes. Apart of the hot soft
water flows to purification head tanks through a flow meter and a level
control valve. Conc. carbonate solution is added to it in a definite
proportion through a metering pump to maintain the required
concentration of Na2CO3 in purification solution

Conc. carbonate solution (Na2CO3 :110 – 120 gpl) is prepared by adding

a calculated amount of soda ash to the measured volume of hot soft water
(about 2 M3) taken in preparation tank and is uniformly mixed in the
preparation tank with the help of a circulation pump. It takes about 3-4
hrs for uniform mixing and then the same pump is used to transfer the
conc. Na2CO3 solution to the supply tank. From supply tank the solution
is continuously purged in to the hot soft water line feeding purification
head tanks with the help of the carbonate metering pump. The level in
purification head tanks is maintained constant with the help of a
pneumatic level controller. A pneumatic ratio controller is also installed
there which helps in maintaining the required concentration of Na2CO3
in purification solution by adjusting the discharge of carbonate metering
pump to the varied flow of water running to head tanks. Flow rate of
concentrate carbonate solution as well as that of hot soft water flowing to
purification head tanks can be observed at the rotameter provided in the
discharge line of carbonate metering pump and hot soft water line going
to purification head tanks respectively. Any change in the water flow rate
followng a change in the level in the purification head tanks activates the
ratio controller which in turn controls the stroke length of the metering
pump through air motor and thus a required flow of conc. carbonate
solution is passed to the water coming to purification head tanks. Failure
of carbonate metering pump is immediately indicated by an alarm
connected to the system.
All tanks, pumps and pipe lines used in the system are of S.S.

FINISH SOLUTION SYSTEM

Finish solution are used on spinning machines to impart softness and

good grip to the yarn surface and also to act an lubricant during Textile
processing of yarn.
Return solution from spinning machines is received, then the
concentrations of their constituents and temp. is made up and fed back to
the respective spinning machines.

Finish solution is natural milky white colour.

Finish solution is dilute solutions of finish oils (Sapco 2169M, Sopalcol
12R) & chemicals such as Kalestrene and T.E.A. (Triethanol amine)
mixed together & diluted with hot soft water. Concentration of above
ingradients in finish ‘solution is normally maintained in the following
rage:
Finish Oil : 6 – 12 gpl
Kalestrene : 0.3 – 0.6 gpl and
 T.E.A. : 1.5 – 2.5 gpl

Return finish solution (returning from spinning machines) is received in

finish pit tank in basement. Finish pit tank is a cylindrical S.S tank. Tank
is provided with one circulation pump (capacity : 225 lpm) for in-tank
circulation of the mixture of conc. finish solution & return finish solution
and two transfer pumps (one standby, capacity : 400 lpm) for transfer of
solution to finish head tank at 1st floor.

Concentration of above ingradients in return finish solution are usually

low and are made up by adding concentrated finish solution with them.
Concentrated finish solution is prepared & stored in a separate tank called
oil preparation tank (capacity 400 ltrs.). The normal composition of
concentration finish solution is as follows:
Finish oil : 200 – 300 gpl
Kalex : 10 – 15 gpl and
T.E.A. : 40 – 60 GPL.

A plungers type metering pump (capacity : 60 lp.hr.) fitted in the outlet of

the Finish solution preparation tank is used to add concentrated finish
solution. It is added to both of the finish solution in pit tank. Manual
addition is also possible.

For manual addition, bucket is filled with desired volume of

concentration finish solution (drawn from oil preparation tank directly)
and then dumped in the pit tank. Manual additions are normally done in
case of metering pump failure or while preparing fresh finish solution in
large volume. Fresh solution is prepared when level in pit tank is low.
Normally 100 – 150 Cm. level is maintained in the pit tank. Addition by
metering pump is done in the suction of circulation pump, which run
continuously for proper mixing of concentration solution with return
solution.

Finish solutions from pit tank are then transferred to finish head tank at 1 st
floor with the help of finish transfer pump. During transfer, solutions are
filtered by in-line cloth wrapped wire mesh filters (2 Nos.) fitted in
transfer pump’s discharge lines near pit tank. Finish head tank is always
kept overflowing to maintain a constant head for uniform supply to
Spinning machines, overflow returns pit tank.

In finish head tank, temp. of solutions is maintained at 50-51°C (50°C on

spinning machines) by means of steam heating. Steam coil has been laid
in the individual chamber of head tank which is connected with automatic
pneumatic temp. controller and recorder for proper control.

Solutions flow from head tank spinning machines metering boxes, by

gravity through separate S.S. pipe lines. Flow rate on spinning machines
is about 5 lpm/machine approx.

Finish solution carried away with the yarn (while having passed through
finish trough on spinning machines) is also recovered to some extent with
the help of vacuum strippers. Finish vacuum strippers are under the
vacuum of about 100 mmHg. Vacuum is developed by strippers vacuum
pumps (3 Nos., capacity 800 Cfm. At 280 mmHg) in basement and
passed on to vacuum strippers through vacuum receivers installed in the
basement. Vacuum receivers are cylindrical S.S. Tanks connected to
vacuum strippers through a 2” dia S.S. pipeline and to the suction header
of vacuum pump by a 3” dia sub header.
Finish solution thus accumulated in vacuum receiver is transferred to
finish pit tank with the help of a automatic drain pump called vacuum
receiver drain pump.

Thus, finish solutions keep on circulating continuously from pit tank to

head tank to spinning machines and then back to pit tank from spinning
machines as used solution for make-up etc.
Spinning Department converts viscose to Rayon Yarn. The whole process
for making yarn is done on a spinning machine.
Spinning is done on two types of machines:

 Conventional machines.
 Parma (Tube spinning)

SPINNING (CONVENTIONAL MACHINES):

There are 31 conventional machines installed for spinning. These

spinning machines are single motor driven continuous machines
having two sides and both the side are identical. Each side is an
independent unit in itself with 54 spindles having a production
capacity of 640 Kgs per day. The spinning can be classified into 8
steps. These steps are:
 Reaction of viscose with spinbath
 Stretching
 Regeneration
 Washing
 Finish Application
 Drying
 Winding
 Visual Inspection

Reaction of viscose with spin bath

At the required pressure, viscose is fed to each machine side

through a common header through isolating valves.
Viscose is pumped to spinnerets through candle filters and goose
necks at constant rate. The goosenecks are dipped in spinbath and
the pumps are engaged to the rotating shaft. Viscose comes out
through 1100 holes (50 micron each) spinneret in 1100 streams and
gets coagulated, regenerated and in the process comes-up.
Spinning machines when spinbath comes in contact with viscose
following actions take place:

SPINBATH + VISCOSE = Na2SO4 + Cellulose+ H2O +

(H2SO4) + (NaOH ) H2S + CS2
(Alkali cellulose xanthate))

Viscose Metering Pump

Viscose Metering Pump is a Gear Type pump which is used in
Spinning Machine for the uniform (Constant) flow of viscose. As the
constant flow of viscose is required to fulfill the product quality.

Details of viscose VMP used in Spinning Machine.

Capacity Actual Discharge Sides

S.No. Make Category
(per rev.) ( in cc at 75 Rev.) Running
1 ZENITH I 1.752 129.5 TO 131.5 7
ZENITH
(with new
centre
plate &
2 gear) I 1.752 129.5 TO 131.5 12
ZENITH
3 (Thick) I 1.752 129.5 TO 131.5 NIL
4 ZENITH II 1.752 128.5 TO 129 NIL
5 SPPL I 2.92 217 to 220 1
6 TELMEC I 2.92 217 to 220 4

These Pumps according to there Discharge range are further

divided in different category which is following

For ZENITH

Category Discharge Range

I 129.5 to 131.5
II 128.5 to 129
III Below 128 rejected
For SPPL & TELMEC

Category Discharge Range

I 217 to 220

Stretching
When yarn appears on the spinbath surface, it is wrapped on lower
godet and then taken to upper godet through hot stretch and in the
process, yarn is stretched.

Regeneration
The yarn is then taken to regeneration trough where the extra
chemicals dissolve in regeneration solution.

Washing
From regeneration yarn is washed with sodium carbonate solution
where the acid in yarn gets neutralize.
Finish Application
After washing the yarn is passed through finish oil. The finish oil is
lubricating oil which works as an antistatic agent. It helps to
eliminate the static charges produced in the further process in
textile.
Drying
After finish oil trough the yarn is winded on booster roller and then
to drier can. Drier can are maintained at 105°C where drying of
yarn takes place.
Winding
After drier can through guides and traveler yarn is winded on to an
aluminium bobbin. After getting required length of yarn, the
bobbin is changed and sent to Textile Department.
PIRNA MACHINES (TUBE SPINNING):

There are total 10 Pirna machines installed. The machine has 36

spinning positions with the viscose supply and filtration to
individual positions identical to the conventional process. Each
machine has the production capacity of 380 Kgs per day. However,
in the tube spinning, viscose from gooseneck is spun into
individual positions having a tube dipped in the spinbath trough.
The viscose coagulates, regenerates in ;the tube and is drawn out
on to the lower godet via two guiding rollers and from there, it is
guided in to the hot stretch trough and taken on to the upper godet.
During this phase, the yarn is subjected to stretch and further
wound on to a pair of wash rollers where wash water is sprayed.
The yarn further is guided into the finish trough and then on to the
drier cans for drying.

The yarn is finally guided by the reversing rollers and taken on

paper tubes through a traverse movement winding mechanism.
After winding for specified time, the material is doffed and fresh
paper tubes are fixed to continue the yarn winding process.

Material is inspected for export, domestic and substandard quality

and sent to Textile Department.
 TEXTILE: The yarn is emptied from bobbins and recollected as the
specification given by the customer.

Generally there are three kinds of customer:

1. Customer for Yarn
2. Customer for Grey Fabric
3. Customer for Dipped Fabric

NATURE OF PACKAGE:

DOMESTIC BUYERS:
The yarn and cord is packed in the boxes and fabric is packed in
the form of roll.

FOREIGN BUYER:
The yarn, cord is packed in the form of Pallets and Fabric in the
form of Roll. The goods are normally dispatched in 20 and 40 Ft.
containers.

In Textile, two main activities are carried out:

1. Manufacturing of rayon yarn, cord and fabric, both grey and dipped.
2. Conversion of nylon yarn in chafer fabric.
MANUFACTURING OF RAYON YARN, CORD AND FABRIC,
BOTH GREY AND DIPPED:

Rayon yarn is received from Spinning Department and is processed

as below:

 Coning: Superior! grade yarn is coned on paper cone. Export

grade yarn after inspection is packed for export and domestic
grade yarn is packed for domestic customers. Balance yarn is
sent for processing on redraw.

 Redraw: Left-over yarn after packing is taken back on bobbins

on redraw machines from cones. They are sent for further
processing on ply cabler machines.

 Ply cabler (PC): Balance yarn from spinning department and

redraw machine is sent to ply cabler machine to make cord for
further processing on loom. We can manufacture 2- ply and 3-
ply cord as per the customers specifications.
 

 Tyrecord loom: Cord from ply cabler (PC) are woven on

looms. Part of fabric is packed as grey and balance is sent for
dipping. Grey fabric is sent to packing for domestic as well as
export.

Elements of Weaving:

Weaving is carried out on a machine traditionally known as a loom.

Fig. illustrates the layout of a weaving loom in the form of a simple
schematic diagram.

The sheet of warp yarns, which consists of a number of ends is carried

upon the weavers beam A. The warp ends from the beam are then drawn
through the healds B1 and B2, threaded through the splits of the reed C
and at the point D they become interlaced with the weft supplied by the
shuttle E. The cloth is formed at the fell of the cloth, marked F and is
wound upon the cloth roller marked G situated at the front of the loom.

There are three types of motions identified on a loom.

PRIMARY MOTIONS:

Every loom requires three primary motions to produce woven fabrics.

1. Shedding
2. Weft Insertion
3. Beating up

Shedding:
It is the name given to the motion which moves the heald frames up and
down in order to separate the warp sheet into two layers and create a
triangle in front of the reed (referred to as the shed) through which the
weft can be passed.

Weft Insertion (Picking):

It is the means by which the weft is projected through the shed. This was
traditionally by shuttle, but more recently it is done by projectile, airjet or
water jet.
Beating up:

It is where the reed pushes the weft into the fell of he cloth to form fabric.
This requires considerable force. Hence the term, beating up.

SECONDARY MOTIONS:
There are three secondary motions in weaving : let off; take up

Let off motion - It ensures that the warp ends are controlled at the
optimum tension for the fabric that is being woven.

Take up motion - It withdraws cloth from the fell and stores it at the
front of the loom.

 Dipping: The main purpose of dipping is to adhere the textile

fabric to the rubber inside the tyre. Grey fabric from loom is
dipped in dip solution and dried. The dip solution used is RFL
i.e. Resorcinol, Formaldehyde, Latex. This process is carried
 out on fabric dipping units. Dipped rolls are sent to packing for
domestic customers as well as export.

 Yarn/twine dipping: Yarn and twines are also dipped to cater

the requirement of hose and V belt manufacturers. This is done
on Kiddie Dipping Unit.

CONVERSIN OF NYLON YARN CHAFER FABRIC:

Nylon yarn is received in party’s account for conversion in to nylon

chafer fabric. The processing starts from redraw twister machine
through warper to loom for weaving.

In general, weaving involves the interlacing of two sets of threads at right

angles to each other: the warp and the weft. The warp are held taut and in
parallel order. The warp threads run lengthways of the piece of cloth, and
the weft runs across from side to side.
Ends per inch

Ends per inch (or e.p.i.) are the number of warp threads per inch of
woven fabric. In general, the higher the ends per inch, the finer the fabric
is.

The number of ends per inch varies on the pattern to be woven and the
thickness of the thread.

Picks per inch

Picks per inch (or p.p.i.) is the number of weft threads per inch of woven
fabric. A pick is a single weft thread, hence the term. In general, the
higher the picks per inch, the finer the fabric is.
Tex

Tex is a unit of measure for the linear mass density of fibers and is
defined as the mass in grams per 1000 meters. Tex is more likely to be
used in Canada and Continental Europe, while denier remains more
common in the United States and United Kingdom. The unit code is
"tex". The most commonly used unit is actually the decitex, abbreviated
dtex, which is the mass in grams per 10,000 meters.

Denier

Denier is a unit of measure for the linear mass density of fibers. It is

defined as the mass in grams per 9,000 meters. In the International
System of Units the tex is used instead. As with all metric system units,
the denier has its standard based in nature. The term denier is a literal
combination of the words linear and density.

Physical lab
The quality parameters are governed by in-house Physical Test Lab. The
following parameters are taken care of:
1840/1 Dtex Rayon tyre yarn :

PROPERTIES UNIT VALUE RANGE

S.N
O
1 Dtex 1855 85
Linear Density @11% Denier 1670
75
MR
2 No. of filaments - 1100 -
3 Twist ‘Z’ Turns/Metre 65 5
4 Avg. Elongation at break % 9.0 1.0
(Oven dry)
5 Avg. Breaking strength KG 9.5 Min. 9.0
(Oven dry)
6 Finish % 0.5 0.1
7 Thickness (gauge) MM 0.71 0.02

Testing Machine : INSTRON

Lab. testing conditions : Temperature =24C
Relative Humidity = 55%
1840/2 Dtex Rayon tyre yarn :

PROPERTIES UNIT VALUE RANGE

S.N
O
1 Dtex 4225 165
Linear Density @11% Denier 3820
150
MR
2 Twist ‘Z’ 472 15
Cable ‘S’ Turns/Metre 472
15
3 Avg. Elongation at break % 14.5 1.0
(Oven dry)
4 Avg. Breaking strength KG 16.4 Min.15.6
(Oven dry)
5 Thickness (gauge) MM 0.71 0.02

Testing Machine : INSTRON

Lab. testing conditions : Temperature =24C
Relative Humidity = 55%

1650/3 Dtex Rayon tyre yarn :

PROPERTIES UNIT VALUE RANGE

S.N
O
1 Dtex 6550 330
Linear Density @11% Denier 5900
300
MR
2 Twist ‘Z’ 395 15
Cable ‘S’ Turns/Metre 395
15
3 Avg. Elongation at break % 17.5 1.5
(Oven dry)
4 Avg. Breaking strength KG 3.5 1
(Oven dry)
5 Thickness (gauge) MM 0.9 -

Testing Machine : INSTRON

Lab. testing conditions : Temperature =24C
 Relative Humidity = 55%

8 PLY DIPPED RAYON TYCORD :

PROPERTIES UNIT VALUE RANGE

S.N
O
1 Dtex 13880 200
Linear Density @11% Denier 12490
MR
2 Twist Z/Z/S 1.7/4.5/2.0 0.2/0.2/0.2
Turns/Inches
3 Avg. Elongation at break % 11.0 1.0
(Oven dry)
4 Avg. Breaking strength KG 65 Min.60
(Oven dry)
5 Thickness (gauge) Inches 0.055 0.002

Testing Machine : INSTRON 1122

Lab. testing conditions : Temperature =24C
Relative Humidity = 55%

9 PLY DIPPED RAYON TYCORD :

PROPERTIES UNIT VALUE RANGE

S.N
O
1 Dtex 15460 200
Linear Density @11% Denier 13920
MR
2 Twist Z/Z/S 1.7/3.2/2.0 0.2/0.2/0.2
Turns/Inches
3 Avg. Elongation at break % 11.0 1.0
(Oven dry)
4 Avg. Breaking strength KG 75 Min.70
(Oven dry)
5 Thickness (gauge) Inches 0.056 0.002

Testing Machine : INSTRON 1122

Lab. testing conditions : Temperature =24C
Relative Humidity = 55%

12 PLY DIPPED RAYON TYCORD :

 PROPERTIES UNIT VALUE RANGE
S.N
O
1 Dtex 20730 200
Linear Density @11% Denier 18660
MR
2 Twist Z/Z/S 1.7/3.2/2.0 0.2/0.2/0.2
Turns/Inches
3 Avg. Elongation at break % 12 1.0
(Oven dry)
4 Avg. Breaking strength KG 100 Min.90
(Oven dry)
5 Thickness (gauge) Inches 0.056 0.002

Testing Machine : INSTRON 1122

Lab. testing conditions : Temperature =24C
Relative Humidity = 55%
CS2 PLANT:

CS2 is produced by reacting Sulphur with charcoal at suitable

temperature in the furnace. A part of CS2 produced is used in
Viscose Department for xanthation and part of it is sold.

Main steps involved in CS2 manufacturing are:

 Melting of Sulphur in melter at 120 – 149°C and charging it to
furnace.
 Calcination of charcoal and charging it in to furnace.
 Maintaining reaction conditions in furnace.
 Separation of unreacted sulphur and charcoal particles from the
product gases.
 Condensation of CS2 vapours and transferring it to storage
tanks.
 Recovery of CS2 from uncondensed gases.
 Disposal of waste gases.

Properties of CS2:

 Specific gravity = 1.26 at 20°C

 Self ignition temperature = 90°C
 Flash point = 30°C
 Boiling point = 246.4°C
 Melting point = 242°C
 Non-corrosive gas but when it has H2S vapours and is mixed
with water, it becomes corrosive.
 It is a neutral gas.
CALCINATION:

 There are two calciners for calcinations of charcoal.

 One batch of charcoal has around 14 bags of charcoal, each
weighing around 40 Kgs.
 450 Kg of charcoal is fired at a time.
 Flame is introduced in the calciner and within one hour entire
charcoal becomes red hot.
 With the help of charging vessel, it is transferred to rotary
screen and dumped in the furnace.
 For every M.T. of CS2, 0.45 MT of charcoal is used.
 Charcoal has 70% carbon so preferred over coal.

CS2 Furnace:

Sulphur and charcoal react at temperature of 800 – 1000°C to form

CS2 and H2S is formed as byproduct. As the reaction between
carbon and sulphur is endothermic, a constant source of heating is
required, which is supplied by electric arc.

Ash of charcoal gets deposited inside the furnace and therefore

furnace requires deashing after 60days.
Furnace starting:

 Insert loose brick in the opening of ash hole, seal it with earthen
mud.
 Flush the sulphur separator with fresh sulphur.
 Safety diaphragms are locked.
 Sulphur feeding nozzles are poked and rubber tube connections
with the manometer is fixed.
 Steam to sulphur doser and distributor is opened.
 Current is maintained between 2100 – 2500 A. Current is
adjusted by charging the tapping of transformer.
 Furnace pressure should not exceed 350 mm water.
 Distance between electrodes = 2.45 M.
 Consumption of Sulphur = 4.5 TPD.

Check parameters:

1. Furnace temperature.
2. Time
3. Electrical energy
4. Voltage, current, energy meter
5. Transformer oil temperature
6. Steam pressure.
Process:

Charcoal and molten sulphur are fed to the furnace. Gases are
taken out through pipe to separator where molten sulphur is stored.
Any Sulphur and Carbon particles present in CS2 gas are removed
there. Then the gas is passed through primary condenser. Here full
gas is not condensed, uncondensed gases contains H2S.

Now the gas is passed through secondary condenser where some

more gas is condensed. The condensed gas is passed through
stainer which is a sort of filter and where sulphur and any other big
particles are blocked. Crude gas then passes through metering
vessel and then sent to storage tanks.

On the top of furnace, there is a safety line given which is

diaphragm blocked. When pressure increases beyond limit, then
this diaphragm burst and gases are released. Molten sulphur first
comes to decantor first where impurities settle and sulphur
overflows to float. Here a float is provided to maintain level of
sulphur. This sulphur then passes through doser which controls the
flow rate of molten sulphur to 12 distribution seals which
distributes sulphur in furnace.
Separation of unreacted sulphur:

CS2 gas coming out from the furnace contains charcoal particles
and sulphur which are to be removed. To remove sulphur, the gases
are passed through sulphur separator which contains molten
sulphur. Sulphur present in the gas is condensed in the sulphur
separator. After separator, gas passes through primary condenser in
which water is flown in tubes. In secondary condenser, gas pass
through tubes with water around:
 Chilled water inlet temperature (secondary) = 6 °C
 Chilled water outlet temperature (secondary) = 12°C
 Cooling water inlet temperature (primary) = 26°C
 Cooling water outlet temperature (primary) = 29°C

Recovery from uncondensed gases:

Oil scrubbing system is used for separation CS2 is fed from bottom
to oil tower (4 Nos.) and oil from top through pumps. CS2 gets
absorbed in the oil and H2S does not H2S is taken to scrubber
where NaOH solution (NaOH H2O = 2.3) is sprayed to form Na2S.

CS2 recovered is sent to crude tank. The temperature inside oil

heater is not allowed to exceed 80°C.
Disposal of waste gases:

Na2S system NaOH mixed with water in the ratio 20:80 is sprayed
to form Na2S in scrubber which is transferred to drier and after
drying, it is sold. There are 3 scrubbers out of which one is
working. Concentration of NaOH is kept 15% Na2S when
examined was found of concentration 150 – 170 gpl and free alkali
0 – 20 gpl.

Refining of Crude CS2:

CS2 produced from furnace contains H2S and sulphur as impurities

which are refined by simple distillation. The Crude CS2 is taken
still column # 1 which is heated by steam coils. Because of heating,
liquid CS2 along with H2S gets vaporized and moves towards
condenser # 1 and 3. These condensers have chilled water tubes. A
taping from condenser # 3 is taken to still column # 2 which is also
coil heated and the vapours are sent to condenser # 2. CS2 gets
liquefied but H2S does not from still column (2) outlet passes
through sulphur separator to separate any sulphur present and
vapours from separator is taken to condenser # 4 which again
venting to still column # 2 product line from condenser # 2 is taken
to Refined CS2 tank.
 H2S left in Refined CS2 = 0.5 ppm (0.27%)
 Residue left in Refined CS2 = 100 ppm
 CS2 consumption in plant = 6 M.T. (Daily)
WATER TREATMENT PLANT:

Raw Water coming to Water Treatment Plant is first treated with

chlorine. We add 4 ppm of it, 20 ppm of alum added then through
the flash mixer, water is sent to clarifier here, alum forms flocks of
impurities which settle down. The scrapper scraps the flocks
towards bottom. At the bottom there is desludging pump which
continuously removes flocks.

From the clarifier, water is sent to sand filters where it is filtered.

These sand filters are back washed from time to time to open up its
choked pores. From sand filters, water reaches in underground
filtered water collection tank. From filter water tank, pumps pump
the water to overhead storage tanks. The overflow comes back to
show that water flow to the tank is constant.

One pump transfers filtered water to activated carbon filter where

chlorine is removed along with coloring agents. Then water is sent
to softener. Softener has a bed of Zeolite resin which exchanges the
reactions of hardness causing salts with Na ions. The soft water is
pumped to underground tank from where it is pumped to overhead
storage tank. Overhead tank has two partitions, one stores soft
water of capacity 80000 gallons and other contains filtered water of
capacity 120000 gallons.
EFFLUENT TREATMENT PLANT (E.T.P.)

Here effluent is treated before being disposed so as to eliminate

any hazardous element present which can cause problems to living
bodies and pollute the environment.

There are two lime slurry tanks equipped with agitator for mixing
of lime. This slurry is continuously mixed with effluent water.
There are 5 lime dumping pit where dry lime is stored from where
it is discharged for slurry preparation. Apart from water from
Spinbath/Spinning/Textile/CS2/Power House, there is a line from
Water Treatment Plant also. This is partially mixed and rest is used
to make lime slurry.

Lime is added in the effluent. The zinc and acid reacts with lime to
form sludge. This water opens in the bottom of clarifier. The outlet
is sent to gate # 3 where its pH is checked and then is released.
Sludge which is settled and bottom of clarifier, is removed by
desludging pump.
POWER HOUSE

 Coal based thermal power plant Total 9.2MW

 SR has 4 boilers and 3 turbines.

 Capacity of each boiler has 30MT/hr.

 Capacity of Turbines are:

1. 4MW:Double Extraction Turbine

2. 2MW:Straight condensing Turbine

Following are the main section of the SR Power House :

 Coal handling Section

 Boiler House

 Turbine

 Boiler Feed water treatment

COAL HANDLING PLANT:

o No. of coal bunkers = 4

o Capacity of each bunker = 150 M.T.
o Consumption per day = 200 M.T.
o Minimum size of coal = ½” to ¼”
o Cost of coal = Rs.4000/MT approx
o Coal for Boilers comes from North Chiri Miri Hills, Bijoori,
Rajnagar,Bishrampura Rake etc.

Description

Coal is first dumped in hopper by means of truck. Now, through a

belt (24”), coal is put in vibrator which separates fine coal from big
pieces. The coal is then dumped in crusher where coal is crushed.
Through a belt (24”), coal is taken up. The coal is then transferred
to horizontal belt (26”) and then finally to bunkers. There is an
 interlocking between belts and crusher. The crusher will start only
when horizontal and slant belts are running.

BOILER

A boiler is a closed vessel in which water or other fluid is heated. The

heated or vaporized fluid exits the boiler for use in various processes or
heating applications.

Boilers can be classified into the following configurations:

 "Pot boiler" or "Haycock boiler": a primitive "kettle" where a fire

heats a partially-filled water container from below. 18th century
Haycock boilers generally produced and stored large volumes of
very low-pressure steam, often hardly above that of the
atmosphere. These could burn wood or most often, coal. Efficiency
was very low.

Fire-tube boiler. Here, water partially fills a boiler barrel with a small
volume left above to accommodate the steam (steam space). This is the
type of boiler used in nearly all steam locomotives. The heat source is
inside a furnace or firebox that has to be kept permanently surrounded by
the water in order to maintain the temperature of the heating surface just
below boiling point. The furnace can be situated at one end of a fire-tube
which lengthens the path of the hot gases, thus augmenting the heating
surface which can be further increased by making the gases reverse
direction through a second parallel tube or a bundle of multiple tubes
(two-pass or return flue boiler); alternatively the gases may be taken
along the sides and then beneath the boiler through flues (3-pass boiler).
In the case of a locomotive-type boiler, a boiler barrel extends from the
firebox and the hot gases pass through a bundle of fire tubes inside the
barrel which greatly increase the heating surface compared to a single
tube and further improve heat transfer. Fire-tube boilers usually have a
comparatively low rate of steam production, but high steam storage
capacity. Fire-tube boilers mostly burn solid fuels, but are readily
adaptable to those of the liquid or gas variety.
 Water-tube boiler. In this type,the water tubes are arranged inside a
furnace in a number of possible configurations: often the water
tubes connect large drums, the lower ones containing water and the
upper ones, steam and water; in other cases, such as a monotube
boiler, water is circulated by a pump through a succession of coils.
This type generally gives high steam production rates, but less
 storage capacity than the above. Water tube boilers can be designed
to exploit any heat source and are generally preferred in high
pressure applications since the high pressure water/steam is
contained within small diameter pipes which can withstand the
pressure with a thinner wall.

 Flash boiler. A specialized type of water-tube boiler.

 Fire-tube boiler with Water-tube firebox. Sometimes the two above
types have been combined in the following manner: the firebox
contains an assembly of water tubes, called thermic syphons. The
gases then pass through a conventional firetube boiler. Water-tube
fireboxes were installed in many Hungarian locomotives, but have
met with little success in other countries.
 Sectional boiler. In a cast iron sectional boiler, sometimes called a
"pork chop boiler" the water is contained inside cast iron sections.
These sections are assembled on site to create the finished boiler

FUNTION: To generate the steam.

WATER

COAL - Steam

AIR

Boiler 4 Specifications

 Type AFBC
 Make Thermax Limited

 Capacity 30TPH

 Steam Pressure 43kg/cm2

 Steam Temperature 460 oC

  Fuel 80% indian coal

20%Musturd Husk

 Planum Chamber area 19.7m2

Heating Surface Area of Boiler 4

 Water wall panels 198.1 m2

 Boiler Bank Zone 519.4 m2

 Primary SH 332 m2

 Secondary SH 100 m2

 Economizer 358 m2

 Inbed Coil 155.4 m2

 Total 1662.9 m2

BOILER NO 1, 2 & 3
S NO PERAMETER UNIT SPECIFICATIONS
1 Type Travo Grate
Babcock and
2 Make Wilcox
3 design pressure psig 525
4 Capacity lb\ hr 65000
5 Steam temperature F 805
Feed water inlet o
C
6 temperature 104
7 heating surface Sq. feet 12243
8 Grate surface Sq. feet 195
9 Chimney height feet 112
BOILER
NO 4
1 Type AFBC
2 Make Thermax Limited
3 design pressure Kg/cm2 43
 4 Capacity TPH 30
o
5 Steam temperature C 460
Feed water inlet o
C
6 temperature 104
7 heating surface M2 1662.9
8 Planum chamber area M3 19.762
9 Chimney height Meter 41

BOILER # 4- AVG OPERATING PARAMETERS

RUNNING DESIGN
S.NO. DESCRIPTION UNIT
PARAMETERS PARAMETERS
1 STEAM PRESSURE KG/CM2 40 43
0
2 STEAM TEMPERATURE C 440 460+ or - 5
3 STEAM FLOW TPH 30 30
4 WINBOX PR(1/2/3) MMWC 560 600/600
0
5 BED TEMP 1 COMP C 840/835 875/875
0
6 BED TEMP 2 COMP C 838/820 875/875
0
7 BED TEMP 3 COMP C 836/846 875/875
0
8 FURNACE TEMP C 720 850 - 895
9 FURNACE DRAUGHT MMWC -2.5 -5
0
10 F.W ECO I/L TEMP C 118 125
0
11 F.W ECO O/L TEMP C 157 175 - 195
0
12 D.SUP I/L TEMP C 360 406
0
13 D.SUP O/L TEMP C 353 330
14 F.D FLOW TPH 35.5 47.7
0
15 AIR TEMP AFTER APH C 125 150
0
16 FLUE GAS TEMP AT ECO I/L C 300 365
FLUE GAS TEMP AT ECO
0
17 0/L C 195 245
0
18 FLUE GAS TEMP AT ESP I/L C 128 155
%
19 UNBURNT IN BED ASH 0.5 0.3
%
20 UNBURNT IN BB ASH 15.13 6-7
%
21 UNBURNT IN APH ASH 26.06 8
%
22 UNBURNT IN ESP FLY ASH 23.8 10
%
23 BLOW DOWN 8 1 TO 3
24 PA PRESSURE MMWC 1200 1250
25 O2 % 5 4

Boiler 1,2,3 Operating Perameters

RUNNING DESIGN
S.NO. DESCRIPTION UNIT
PARAMETERS PARAMETERS
 1 Boiler feed water pressure Kg/Cm2 36 35
2 Boiler drum Pressure Kg/Cm2 35 35
3 SH outlet pressure Kg/Cm2 32.5 33
4 Main steam header Kg/Cm2 31.6 31.6
5 steam temperature °C 405 415
6 furnance temperature °C 700 Max 900
7 Water inlet temerature °C 104 104
8 Economiser water outlet °C 155
9 Feed water flow MT/hr 25 30
10 steam flow MT/hr 23 30
CM of
11 FD fan pressure H2O 6
CM of
12 Sec. air prussure H2O 46
CM of
13 Economiser water vac H2O 1
CM of
14 ID vac H2O -7.2
CM of
15 Furnance draft H2O -0.5 0.15
16 CO2 in gas outlet % 11 11.5
17 Flue gas inlet °C 287
18 Flue gas outlet °C 157 157

Steam Turbine: A steam turbine is a mechanical device that extracts thermal

energy from pressurized steam, and converts it into rotary motion.

DOUBLE EXTRACTION TURBINE/GENERATOR TECH. DATA SHEET AND CHRONIC PROBLEMS

4 MW TURBINE TECHNICAL DATA SHEET

1 MAKE WORTHINGTON
2 SHOP ORDER UE-13566
3 SERIAL NO 23982
4 FRAME T4B4B1V2X4
5 TYPE DOUBLE EXTRACTION CUM CONDENSING
6 RATING KW 4000 at 3000 rpm
7 NO OF STAGE 16
8 INLET STEAM PRESSURE psig 425
9 INLET STEAM TEMPERATURE Deg F 750
10 STEAM EXHAUST PRESSURE inch of Hg 4
11 CONDENSING CAPACITY Lbs/HR 30000
12 HP EXTRACTION. NO. OF VALVES 4
13 LP EXTRACTION. NO. OF VALVES 4
14 SPEED RPM 3000
15 EMERGENCY TRIP SETTING RPM 3300
16 TYPE/MODEL OF GOVERNOR MAKE-WOODWAR MODEL-UG 32

BOILER FEED WATER TREATMENT PLANT:

The water which is fed to Boiler is first treated in BFWT. The
complete flow of water through different stages can be understood
as:

The water from drain condensate booster pump is fed through heat
exchanger where it gets heat from blow down water from Boiler. This
water is fed to settling tank (# 1) in which following chemicals are
added – Lime, Soda Ash, Calcium Magnesite, Steam (150 psig). The
water is then passed through filters (3 Nos.). Anthracite bed is there
as filter media. The water is stored in filtered water storage tank (# 1).
Through the booster pumps, the water is then passed through softener.
FROM softener, the water is passed to deaerator in which steam (150
psig), Phosphate and Hydrazine is added. Through the feed pumps the
water is passed through economizer and finally to Boiler Drum.

Blow down:
Since water is evaporating constantly, TDS (Total Dissolved
Solvents) in Boiler increases with time. To reduce this TDS, small
quantity of water is continuously taken out. This is called blow
down.

2p-m test:

There are three kinds of alkalinity found in water-hydroxide (OH),

normal Carbonate (CO3) and bicarbonate (HCO3). To distinguish
between the alkalinities present in a sample and to determine the
quantities of each, a titration is made with the standard acid and using
phenolphthalein and methyl orange respectively.

Phenolphthalein gives pink colour in presence of OH or CO3 but OH

and HCO3 can not be present in the same sample. If a sample is
alkaline to phenolphthalein, it is due to the presence of either
hydroxide or normal carbonate or both. If a sample is alkaline to
 methyl orange, it is due to any of three alkalinities of OH & CO3
together or CO3 and HCO3 together.

2Na2CO3 + H2SO4  2NaHCO3 + Na2SO4

2NaHCO3 + H2SO4  Na2SO4 + 2CO2 + 2H2O

Methyl orange gives indication of H2SO4 used for titrations of OH-

ions i.e. complet3e reaction. If we subtract reading of H2SO4 used
from NaHCO3 (indicated by methyl orange), we will get alkalinity
due to only OH- ions.

Boiler emergencies sequence (steam load shedding):

1. BFWT steam
2. CS2 furnace
3. Non essential electric loads suiting LP extraction.
4. Change-over BFW (Boiler Feed Water) pump, CW (Chilled
Water) pump and CT (Cooling Tower) fans to RSEB.
5. CS2 STEAM
6. Crystallizer steam
7. ASSR steam
8. Evaporator LP steam
9. Reduce steam load of ACVR
10.Minimum spinning machines
11. In delay of 5 & 6, reduce LP pressure to 30 psig.
12.If inlet pressure falls below 18 Kg/Cm2, trip the Turbine.

Equipment stoppage priority:

S. No. Equipment Running load (KW) Cumulative load (KW)

1 One CS2 Furnace 200 200
2 One main exhaust fan 85 285
3 Second CW pump 40 325
4 Change-over of feed pump 110 435
5 Second CS2 furnace 200 635
6 Third CS2 furnace 200 835
7 Textile fresh air fan # 3 50 885
8 Spinning fresh air fan # 3 50 935
9 Second main exhaust fan 85 1020
10 PC machines (20 Nos.) 60 1080
ELECTROSTATIC PRECIPITATOR (ESP):
ESP here is provided by Flake India Ltd. It is dry collection type. It
has been installed to reduce the existing emission level to 150 mg/M 3.

Principle:

DC voltage is imparted through electrode creating an electrical field

around it dust particles are changed and collected on electrodes. Dust
is removed by rapping.

Following events take place in ESP.

1. Corona formation or ionization.

2. Charging of particles
3. Migration and precipitation of particles.
4. Removal of deposited dust.
5. Gas flow = 66000 M3/Hr.

o Gas temperature = 180°C

o Pressure drop across ESP = 20 mm WG
o Treatment time = 8 second
o Collecting efficiency of design flow = 97.5%
o No. of hours an ESP can run at specified gas flow and dust
loading without emptying hopper = 16 hrs.

Performance of ESP is influenced by following parameters:

 Temperature of gas
 Gas volume
 Moisture content
 Gas velocity within ESP
 Inlet dust concentration
 Dust particle size distribution
 Dust resistivity
 Dust composition.
INTRODUCTION:

ACV&R stands for Air Conditioning, Ventilation & Refrigeration.

In order to manufacture rayon tyre yarn it is desirable that supply of

UTILITIES should be as per requirement to achieve the quality
product.

The basic objective of the ACVR Dept. Is to looks after the utility
i.e.
Air conditioning, ventilation & refrigeration, cooling water, plant
air, instrument air & Vacuum as per requirement to achieve the
quality product.

Key parameters

 Chilled water
 Cooling water
 Vacuum
 Air conditioning/refrigeration for process
 Compressed Air ( Plant air and instrument air)
 Fresh Air system
 Ventilation system

REFRIGERATION

For Refrigeration there are two types of chiller

1) VAPOUR ABSORPTION MACHINE
 2) VAPOUR COMPRESSION CYCLE

In ACVR three Vapor Absorption M/c

a. Vapour Abs M/c # 2
MAKE : BROAD

CAPACITY : 300 TR at 5 °c

b. Vapour Abs M/c # 3

MAKE : THERMAX

CAPACITY : 360 TR at 4.5 °c

c. Vapour Abs M/c # 5

MAKE : THERMAX

CAPACITY : 255 TR at 4.5 °c

VAPOUR ABSORPTION MACHINE:

Single effect VAM consist of 2 sections in one shell. The lower

section houses the evaporator and absorber. The upper section
houses generator and condenser. The pressure in lower section is 6
mmHg while in upper section is 70 mmHg. In this

Refrigerant : Water
Absorbent : Li.-Br Solution

1. Evaporator – Refrigerant (water) is sprayed over evaporator

tube bundle. Water to be chilled gets cooled as refrigerant
 evaporates because of extremely low pressure in evaporator
shell.

2. Absorber – The refrigerant vapour goes to the absorber through

a mist eliminator. Concentrated Li.-Br solution is sprayed over
absorber tube bundle. The refrigerant vapour is absorbed by
strong Li.-Br solution being sprayed and heat of absorption is
removed by cooling water passing through the absorber tubes.
The weak solution from the absorber is sent by absorbent pump
to generator.

3. Generator – Weak solution from absorber is heated in the

generator with the help of low pressure steam (10 psig). The
refrigerant water vapour is evaporated and goes to the
condenser. The strong solution is sent down to the absorber for
further absorption of water vapour.

4. Heat exchanger – To recover the heat energy from the strong

solution returning from generator to absorber, a heat exchanger
is used. The cold weak solution being pumped from the
absorber picks up excess heat from the strong solution. This
improves cycle efficiency.

5. Condenser – The water vapour evaporated in the generator at

higher temperature and pressure is condensed to liquid form in
the condenser where the heat of condensation is picked up by
the cooling water from the absorber inlet circulating in the
condenser tubes. The condensed refrigerant water is returned to
the evaporator.
VAPOUR COMPRESSION CYCLE:

There are two types of Vapour Compressor Chiller K/as CS2

Chiller No # 3, 4
In this cycle, the refrigerant used is Freon-22.
Four parts
a. Compressor (Reciprocating type)
b. Condensor (Shell & Tube type Heat exchanger)
c. Expansion valve
d. Evaoprator (Shell & Tube type Heat exchanger)

First, the Freon is compressed in the compressor. In this, it converts

in high pressure gas. Then this gas is passed through condenser
where high pressure gas is condensed to high pressure liquid. This
high pressure liquid is then allowed to expand in Expansion valve .
By doing this, it gets cooled. This cooled refrigerant is then passed
in evaporator where it takes heat from the liquid to be cooled and it
self is converted in to low pressure gas. This gas is then sucked in
compressor and the whole cycle is repeated.

AIR WASHER:

For supplying fresh air in Spinning, Textile, there are several air
washers. There are Seven Air washers for supplying Fresh air to
Spinning and Seven Air washers for supplying Fresh air. Generally,
two motors are required for each washer, one for fan and one for
pump. Capacity of fan motor is around 30 HP and that of pump
motor is 20 HP.
 General details of air washer is like this.

Fresh air is sucked from the atmosphere and is first passed through
air filter. This air filter contains ferules in which fly ash or dust is
accumulated. The air then passed through a wet zone in which
water is sprayed from several nozzles. By passing through this, air
gets cooled. Then the air passes through eliminator which are
nothing but zigzag plates. Any water droplet present in air is
removed here. Then finally through a big fan the air is passed in
duct and is distributed to required area with the help of several
small ducts.
For maintaining RH water is sprayed through pump.

VENTILATION

Ventilation is required for the process requirement and also to

provide a healthy working atmosphere.
For this flue gases (CS2 gas, H2S gas etc) are exhaust out through
Exhaust Fan & Fresh air is supplied through Air washer.

Exhaust Fan

A. Main Exhaust fan # 1,2,3

FUNCTION : TO EXHAUST THE OUT GASES FROM SPINNING WET
END SIDE AND S/BATH BASEMENT AREA.

Capacity : 200000 cfm

 Motor : 150 hp
RPM : 670
B. S/Bath Exhaust fan # 1,2,3,4( 2nd floor), 5( Basement)
FUNCTION : TO EXHAUST THE OUT GASES FROM S/BATH AREA.
Capacity : 21000 cfm
Motor : 15 hp
RPM : 380
RPM : 670
C. Baratte Exhaust fan # 1,2

FUNCTION : TO EXHAUST THE OUT GASES FROM S/BATH AREA.

Capacity : 15000 cfm
Motor : 15 hp
RPM : 1440

AIR WASHER

FUNCTION : To supply Fresh Air.

a) Spinning Air Washer # 1,2,3,4,5,6,7
b) Textile Air Washer # 1,2,3,4,5,6,7
c) VRR Air Handling Unit # 1,2,3
d) Ageing Air Handling Unit # 1,2
e) Chemical Lab Air Handling Unit

f) Physical Lab Air Handling Unit

g) Packing Air Handling Unit
AIR COMPRESSERS:

We have six compressors reciprocating type to produce compressed

air for process requirement. Two types of Compressed Air is used
1) Plant air : 80 – 95 psi pressure
2) Instrumentation air : 25 to 35 psi.

a. Air Compressor # 1 & 2

Capacity : 600 cfm at 100 psig
Motor : 135 HP
RPM : 1440 rpm
b. Air Compressor # 1,2,3,4
Capacity : 200 cfm at 100 psig
Motor : 50 HP
RPM : 1440 rpm

Required: 600 cfm

VACUUM SYSTEM

Vacuum is required for Viscous Ripening at Viscous Ripening

room. This Vacuum is generated by Vacuum pump or by Steam
Ejector.
For maintaining vacuum there are two ejector
a. Ejector at 3.5 Kg/cm² steam Pressure.
b. Ejector at 1 Kg/cm² steam Pressure.