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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

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CERTIFICATE BY FIRE AND SAFETY DIVISION

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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

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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