IN THE PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD OF THE DEGREE OF Mechanical Engineering B.Tech (Batch !

"#"$

%i& M'nth( In)*(trial Training at Ne(tl+ In)ia Lt)., M'ga

PREFA-E

I have endeavored in this training report to explain basic principles can be applied in

TABLE OF -ONTENT% Declarati'n Pre.ace Ac0n'1le)ge2ent ! / 3

-HAPTER #4 INTRODU-TION TO -OMPAN56 Company Profile10 A Word About Nestle- he Nestl! Nestle philosophy Nestle #istory Nestle $ission %tatement Nestle 'ogo Nestle oday Nestle )actories In India ,perations In India Nestle $oga
INTRODU-TION TO PRODU-T%1.-""
3

11-1"

1& 1(

1*-1+ 1+ 1-

/everages Chocolates and Confectionary Nestle 0ishes and coo1ing 2hee Products Aids $oga )actory %alient )eatures of Nestle $oga )actory 3arious 0epartments in the Nestle $oga )actory he )actory Consists of )our Production Plant "&-"* "&

MIL7 OPERATION%"*-&1

$il1 ,peration )resh $il1 4eception 2hee Plant 5grons Po6der )illing Plant Cereals 7tility %ervice 0epartment /oiler #ouse 5ffluent reatment Plant Culinary
-HAPTER !4 %AFET5/!

Why %afety Accident $ain 4easons of Accidents&& 4eason of Careful Wor1 Accident se8uence&(
4

7nsafe Acts 7nsafe Condition Accident Prevention Near $iss Important Note&9-&+
-HAPTER /4 UTILIT5 %ER8I-E DEPARTMENT&--&.

&*

4efrigeration and Air Conditioning 4efrigeration Plant Principle of 4efrigeration Plant(0 Component of 4efrigeration %ystem A ypical 3apour Compression Cycle 0escription of 3apour Compression Cycle(1 4efrigerant 7sed ,il %eparation Cooling o6ers Introduction ypes of Cooling o6ers Natural 0raft Cooling o6er $echanical 0raft Cooling o6er )orced 0raft Cooling o6er Induced 0raft Counter )lo6 Cooling o6er Induced 0raft Cross )lo6 Cooling o6er )actors Affecting Cooling of Water in a Cooling o6er #eat 5xchangers ypes of #eat 5xchangers Plate #eat 5xchanger %hell and ube #eat 5xchanger
5

(" (& ((

(*

(9 (+ (--(.

*0

*1

%election of the ube $aterial #eat 5xchanger in Industry Air #anding 7nit Air #anding Components #eating and Cooling 5lements )ilters #umidifiers $ixing Chamber #eat 4ecovery 0evice Controls 3ibration Analysis
-HAPTER 34 PRO9E-T BA%ED ON BOILER HOU%E91

*"-*& *(-*.

90

/oiler #ouse /oiler /asic %hell /oiler Pac1age /oiler Water ube /oiler
%UGGE%TION FOR IMPRO8EMENT9+ REFEREN-E%9-

9"-9& 9( 9*-99

-HAPTER # INTRODU-TION TO -OMPAN5

(HENRI NE%TLE$

-OMPAN5 PROFILE A WORD ABOUT NE%TL: 4 THE NE%T

Nestle India is a multinational company 6ith its 6orld6ide operations in over +0 countries : he founder of Nestle 6as #enry Nestle 6ho from a modest beginning founded the company in 1-99 at %6it;erland for manufacturing mil1 po6ders for babies: At that time %6it;erland faced one of the highest infant mortality rates and the mil1 formula saved the lives of many infants 6hose mothers 6ere unable to breast feed successfully: At present Nestle is the 6orld<s largest food company 6ith its international head8uarters at 3evey= %6it;erland= 6ith almost *00 factories 6orld 6ide it employs almost " &0=000 people: Nestle is often 8uoted by most as >multinational of multinationals:? here is a good reason= as less than "@ of the turnover comes from the domestic mar1et in %6it;erland: Nestle is much decentrali;ed in its operations and most of the mar1ets are given considerable autonomy in its operation: It is more of a people and products oriented company rather than systems oriented company there are >un6ritten guidelines? 6hich are to be follo6ed= based on common senses and a strong set of moral principals emphasi;ing a lot of respect for fello6 beings:
8

Nestle has al6ays adapted to the local conditions and at the same time integrates its %6iss heritage: It has al6ays ta1en a long-term vie6 in the countries in 6hich it operates: here is a great emphasis placed on training by the company: It believes in re6arding and promoting people from 6ithin: he Company<s transparent business practices= pioneering environment policy and respect for the fundamental values of different cultures have earned it an enviable place in the countries it operates in: Nestl!<s activities contribute to and nurture the sustainable economic development of people= communities and nations: oday its product brand name ANestl!< is associated 6ith A8uality products< in 6orld6ide consumer mar1et:Above all= Nestl! is dedicated to bringing the Boy of A G'')F''), G'') Li.e; to people throughout their lives= throughout the 6orld:

NE%TLE PHILO%OPH5
When #enry Nestle introduced the first commercial infant formula in 1-9+= he also created a symbol of the /ird<s nest= graphic translation of his name= 6hich personifies the company<s business: he symbol= 6hich is universally understood= evo1es security= motherhood and oday it is the central element of affection= nature and nourishment= family and tradition:

Nestle corporate identity and closely parallels the company<s corporate values and culture:

NE%TLEHI%TOR5
he Nestl! Company 6as #enri Nestl!Cs search for a healthy= economical alternative to breastfeeding for mothers 6ho could not feed their infants at the breast: he Company formed by the 1.0* merger 6as called the Nestl! and Anglo- %6iss $il1 Company: he close of World War II mar1ed the beginning of the most dynamic phase of Nestl!Cs history: In 1.(+= Nestl! merged 6ith Alimentana %:A:= the manufacturer of $aggi seasonings and soups= becoming Nestl! Alimentana Company: After the agreement 6ith '<,real in 1.+(= Nestl!Cs overall position changed rapidly:

 /et6een 1.+* and 1.++= the price of coffee beans 8uadrupled= and the price of cocoa tripled: Nestl! approached the 1.-0s 6ith a rene6ed flexibility and determination to evolve: hus= bet6een 1.-0 and 1.-(= the Company divested a number of non-strategic or unprofitable businesses: Nestl! managed to put an end to a serious controversy over its mar1eting of infant formula: Nestl! opened the "0th century by merging 6ith the Anglo-%6iss Condensed $il1 Company to broaden its product range and 6iden its geographical scope: In the ne6 millennium= Nestl! is the undisputed leader in the food industry= 6ith more than (+0 factories around the 6orld: Nestl!Cs existing products 6ill gro6 through innovation and renovation:

10

%.N' # ! / 3 = > ? @ 6 #" ## #!

5ear 1-99 1.0* 1.". 1.(+ 1.+1 1.-* 1.-1.-1.." 1..* 1..+ 1..-

Achie<e2ent( CompanyCs foundation $erger bet6een Nestl! and Anglo-%6iss Condensed $il1 Company $erger 6ith Peter-Cailler-Dohler Chocolates %uisses %:A: $erger 6ith Alimentana %:A: E$aggiF $erger 6ith 7rsina-)ranc1 E%6it;erlandF Ac8uisition of Carnation E7%AF Ac8uisition of /uitoni-Perugina EItalyF Ac8uisition of 4o6ntree E2/F Ac8uisition of Perrier E)ranceF Nestl! ac8uires 3ictor %chmidt G %Hhne= AustriaCs oldest producer of confectionery= including the famous C$o;art1ugelnC: Nestl!= through the Perrier 3ittel 2roup= expands its mineral 6ater activities 6ith the outright ac8uisition of %an Pellegrino: Nestl! ac8uires %pillers Pet foods of the 7D and strengthens position in the pet food business 6hich began in 1.-* 6ith the ac8uisition of the Carnation )ris1ies brand: 0ivestiture of )indus brand Eexcept in %6it;erland and ItalyF and parts of Nestl!Cs fro;en food business in 5urope: 0ivestiture of #ills /ros= $I/ and Chase G %anborn roast and ground coffee brands E7%AF: Ac8uisition of Po6er /ar: Nestl! ac8uires 4alston Purina - Nestl! Purina Pet Care Company established: Perrier 3ittel 2roup re-named as Nestl! Waters: Pantnagar plant starts manufacturing noodles: Cup noodle starts at $oga plant

#/ #3 #= #> #? #@ #6

1... 1... "000 "001 "00" "009 "00-

NE%TLE MI%%ION %TATEMENT

At Nestle= 6e believe that research can help us ma1e better food so that people live a better life: 2ood )ood is the primary source of 2ood #ealth throughout life: We strive to bring consumers foods that are safe= of high 8uality and provide optimal nutrition to meet physiological needs: In addition to nutrition= health and 6ellness= Nestle products bring consumers the vital ingredients of taste and pleasure:
11

As consumers continue to ma1e choices regarding foods and beverages they consume= Nestle helps provide selections for all individual taste and lifestyle preferences: 4esearch is a 1ey part of our heritage at Nestl! and an essential element our future: We 1no6 there is still much to discover about health= 6ellness and the role of food in our lives= and 6e continue to search for ans6ers to bring consumers 2ood )ood for 2ood 'ife:

NE%TLE LOGO
he Nestl! logo 6as launched by #enri Nestl! in 1-9- on the basis of the meaning of his name in 2erman= i:e: little nest= and of his family emblem Ethat you can see hereF:

#enri obtained company:

1*-year

)rench

patent

for

his

logo in

1-9-:

After he retired= it 6as registered in 3evey in 1-+* by the ne6 o6ners of his

In 1.&-= the traditional nest design 6as combined 6ith the JNestl!J name to form 6hat is called the combined mar1:

In 1.99 the design 6as simplified:

In 1.--= the 6orm in the mother birdCs bea1 6as removed and the fledglings became t6o instead of three: It is said that it 6as meant to better illustrate the activities of the company= no longer active only in utrition= and to reflect the average modern family of t6o children:

12

he logo 6e 1no6 no6 has Bust been simplified:

NE%TL: 4TODA5 %ome names seem to belong to legend and Nestl! no6 synonymous 6ith a prestigious trademar1 and 6orld<s foremost food group originally consisted of t6o companies #enry Nestle of 3evey %6it;erland G Anglo %6iss Condensed $il1 Company in Cham: /oth companies competed vigorously from 1-99- 1.0*: hese groups merged in 1.0* and become the starting point of the recent food group: Nestl! is no6 the No: 1 )ood Company: It is present on all five continents has an annual turnover of nearly -.:" /illion %6iss )rancs is present on all five continents: At present there are around *0- factories spread over -0 countries 6ith around "90 operating companies ,ne basic research center and 1+ technological development groups and has in excess of "=&0=000 employees: Ne(tl+ 'Aerati'n( 1'rl)1i)e are )i<i)e( int' / B'ne(C4 DONE EUR C E*r'Ae DONE AOA C A(ia an) Oceanic DONE AM% C A2erica(

India comes under ;one A,A 6hich includes %outh- 5ast Asian trading giants of the li1es of hailand= Indonesia= $alaysia= %ingapore= China etc: besides Australia: Mr. Nan)* Nan)0i(h'recurrently heads DONE AOA: Currently Mr. Peter BraEec0 heads the Nestle group 6orld6ide and Mr. Pa*l B*lc0e is -OE 28% NE%TLE %.A.
$% Pharmaceuticals 27% "#% Chocolate Con ectioner! Biscuits Milk Products Nutrition Ice Cream Beverages

25% Cooking Aids Prepared dishes Pet Care

13

Ne(tle In)ia ha<e @ Fact'rie( in O*r -'*ntrFC

MOGA Fact'rFC4 $oga factory started production
in1.9": oday= $oga contributing almost +*@ of Nestle India<s total production volume and manufacturing 10.9+1 tons of food products: It employs around 1900 people: 0airy creamers= I$)= %C$= Cereals= 3ending $ixes= Noodles= Detchups= /ouillon are manufactured in$oga

-h'la)i Fact'rFC4
he factory ion Choladi started production in 1.9+= %ituated in %outh Asia= about "+* 1ilometers from /angalore: he factory today has around -0 employees: It processes about +"* tons of soluble tea= 6hich is all exported:

NanGang*) Fact'rF C4 Production

in NanBangud )actory started in 1.-. 6ith the manufacturing of Nescafe and %unrise $ilo manufacture at NanBangud begun in 1..9: It situated 190 1ilometers south of /angaloreK the factory has around "(* employees: It manufactures 1**00 tons of Nescafe
14

mixes= $ilo:

Bich'li2 Fact'rFL-A satellite factory of

Ponda at /icholim for manufacturing of Noodles and Cold %auces= It started their operational activity in 1..+:

P'n)a Fact'rFC4Ponds )actory started

production of DitDat in 1..*: It is located (0 1ilometers from PanBi Athe capital of 2oa<: It manufactures Chocolates: Ponda currently employed around "*0 people:

%a2al0ha
%amal1ha )actory started

.act'rFC4

production in 1..& situated +0 1ilometers from 0elhi:

It has "90 employees and manufactures about &*000 tons of food products

Pant Nagar Fact'rFC4 his is the one of the

ne6ly situated and the +th factory of the Nestle in the India: Pantnagar )actory began production of Noodles in "009

15

Tahli1al Fact'rFC4 he -th )actory 6as set up at

ahli6al= #imachal Pradesh= in "01": It 6ill

manufacture confectionery and chocolates:

OPERATION% IN INDIAC
Nestl! set up its operations in India= as a trading company in 1.1" and began manufacturing at the $oga factory in 1.9": he production started 6ith the manufacture of $il1maid and other product 6as gradually brought into the fold: Nestl! India 'imited 6as formally incorporated in 1.+- prior to 6hich the manufacturing license 6as issued in the name of the )ood %pecialties 'imited: he corporate office is located at 2urgaon and the registered office at $-*A= Connaught Circus= and Ne6 0elhi At present Nestl! have + manufacturing units country6ide 6hich are successfully engaged in meeting the domestic as 6ell as the exports demand: In addition there are several co pac1ing units:

Ne(tl+M'ga

16

$,2A P'AN In the $al6a region of PunBab %tate= there is a small to6n= 6hich is popularly 1no6n among the famous grain mar1ets of the 6orld: #o6ever the credit of bringing this to6n on the industrial map of the 6orld goes to Nestle M a %6iss $ultinational company engaged in the largest food processing operation in the 6orld: When in 1.*. Nestl! too1 decision to establish a mil1 processing factory= a very little could the people of $oga to6n and the farmers in the surrounding villages reali;e that the company no6 as Nestl! India 'td 6ould play such an important role in economic G social development of the area:Company started mil1 collection in$oga area on 1* Nov 1.91 and on the first day *10 1g of mil1 6as collected from four villages: he total procurement in 1.9" 6as "=0*( million 1g from (=990 mil1 suppliers of 99 villages and in 1.9" fresh mil1 reception are 10"= && $illion 1g from (9=&0- farmers delivering mil1 at 9*0 collection centers in *+( villages and 10 mil1 chilling centers: /y 1..- the mil1 chilling centers had increased from 10 to 1-9:

INTRODU-TION TO PRODU-T%C4
Be<erage(C
17

NE%-AFE -LA%%I- is a 100@ pure coffee and is made from carefully selected coffee beans pic1ed from the finest plantations= blended and roasted to perfection to create the uni8ue rich and smooth N5%CA)5 taste:

NE%-AFE %UNRI%E is an Instant Coffee-Chicory blend= popular for its robust body and a flavor a1in to fresh roast-and-ground coffee: he secret lies in the right blend of flavorful coffee and roasted chicory to give you an incomparable experience:

NE%TEA Tea Bag( are made from the finest blend of Assam eas= 6hich give a refreshing cup of bright= colour tea of fair strength and superior taste: hey are available both in individually enveloped and non-enveloped formats:

he improved ne6 NE%TLH MILO gives children the energy they need to enBoy their active lifestyle: Pac1ed 6ith Actigen - 5= a uni8ue mix of /vitamins and other 1ey micro nutrients 6hich help optimi;e energy release effectively: In addition its extra cocoa and rich malt ma1es it so chocolaty and irresistible that they 6ill al6ays be as1ing for more: A 6ide range of premixes for the vending machines: he bas1et of products include N5%CA)N Classic= N5%CA)N )rappe= ea Premix EPlain= CardamomF= #ot Chocolate= Iced ea E'emon= Peach= AppleF= and /adam EAlmondF $il1 vending mixes.

We manufacture high 8uality H't I -'l) Water %'l*Ele Blac0 an) Green Tea P'1)er( at our state-of-the-art factory in Choladi= located in the midst of tea
18

plantations 6hich ensure availability of fresh green leaves

-h'c'late( an) -'n.ecti'narFC4

NE%TL: 7IT 7AT is delicious crisp 6afer fingers covered 6ith ChocO layer: ,ur special tropical ;ed recipe ensures that N5% 'P DI DA is preserved even in 6armer climates:

NE%TL: MIL75 BAR is a delicious mil1y treat 6hich 1ids love: With its Calcium 4ich recipe= N5% 'P $I'DQ /A4 is a favorite 6ith parents to treat their 1ids 6ith: 5xtremely popular in India= NE%TL: MUN-H is 6afer layer covered 6ith delicious ChocO layer: A crispy light irresistible snac1R

NE%TL: Mil0 -h'c'late is a mil1 chocolate 6ith a delicious taste for you to savors:

NE%TL: BAR4ONE is a luscious nougat and caramel core covered 6ith a delicious ChocO layer:

N5% 'P offers a bou8uet of three exciting !clair variantsL N5% 'P Pclairs are rich mil1y caramel Pclairs 6ith a soft center: N5% 'P Chocolate Pclairs are a delicious delight 6ith luscious creamy chocolate inside:

NE%TL: MIL75 BAR, :clair( are delightful Pclairs 6ith a creamy mil1y chocolate center:
19

POLO is a mint roll popularly described as A he $int 6ith the hole<: No6 also in the ne6 extra strong singles format as P,', Po6er mint:

Ne(tle Di(he( I -''0ing Ai)(C4

MAGGI !4MINUTE N'')le( is one of the most popular brand of instant noodles in India: Available for export in * authentic Indian flavors Espicy $asala= tangy Chatpata= Chic1en= omato and CurryF= it is a delicious anytime snac1 that<s ready in Bust " minutes:

MAGGI 8egetaEle Atta N'')le( is a uni8ue innovative product 6ith the goodness of 6hole 6heat and real vegetables: Available in the popular $asala flavor:

MAGGI -hine(e N'')le( ma1es it so simple to prepare delicious AIndian %tyle< Chinese Noodles at home in a BiffyR ,ffered in t6o exciting flavors= 3eg Cho6mein and 'emon Chic1en: hese pac1s are for export

In addition to the nutrition from 6hole 6heat= MAGGI Dal Atta N'')le( offers the goodness of 0al ElentilsF in the deliciously ethnic %amber astema1er:

20

MAGGI offers a 6ide range of specialty Indian %auces 6hich are relished for their uni8ue taste: Available in the follo6ing delightful variantsL T'2at' 7etch*A, T'2at' %a*ce, T'2at' -hillF, Ma(ala -hillF, -hillF Garlic, Ta2arina, T'2at' -hatAata, T'2at' P*)ina and the all-time-favorite MAGGI H't I %1eet %a*ce:

MAGGI JTa(te '. In)ia; Pa(te( are a delicate blend of traditional spices and freshly ground pastes= offering the convenience of preparing authentic Indian recipes at home= in no time at allR he range includes /iryani Paste= Curry Paste= Dorma Paste= andoori Paste and i11a $asala Paste:

Ne6 MAGGI HealthF %'*A( are even more delicious= 8uic1 to prepare= convenient and healthy: hey contain real vegetables= are lo6 fat and cholesterol free: hey also do not have added $%2= preservatives or artificial colours:

21

GHEE PRODU-T%
N5% 'P 5354Q0AQ 2hee is 100@ pure Clarified /utter hygienically pac1ed to preserve its rich aroma and granular texture: As a coo1ing medium= N5% 'P 5354Q0AQ 2hee helps you add that authentic ethnic aroma and flavor to Indian preparations every time= everyday:

A Partly %1immed %6eetened Condensed $il1= N5% 'P $I'D$AI0 is a versatile product and excellent as a dessert ingredient: With $I'D$AI0= you can 6hip up lip-smac1ing desserts for your family the shortest possible time: N5% 'P 5354Q0AQ 0airy Whitener is a creamy 0airy Whitener specially made to add a rich= smooth taste to your tea: 5very time= every day:

MOGA FA-TOR5 %ALIENT FEATURE OF NE%TLE MOGA FA-TOR5 In the $al6a region of PunBab %tate= there is a small to6n= 6hich is popularly 1no6n among the famous grain mar1ets of the 6orld: #o6ever the credit of bringing this to6n on the industrial map of the 6orld goes to Nestle M a %6iss $ultinational company engaged in the largest food no6

22

M'ga Fact'rF
Processing operation in the 6orld: When in 1.*.= Nestle too1 decision to stablish a mil1 processing factory= a very little could the people of $oga to6n and the farmers in the surrounding villages reali;e that the company no6 as Ne(tl+ In)ia Lt). 6ould play such an important role in economic and social development of the area: he company is not only an industrial and a commercial house but has ma1e sustained efforts to improve economic and social environment of the people in the area of its operation M be it farmers or residents of $oga: In the initial stages company faced many problems including procurements of mil1 sales of 6hich 6as considered a sin at that time: /ut the team that surveyed that area found that it is 8uite suitable for development of mil1 and it has been proved to be right decision:

23

he company started its operation in 1.9" 6ith a capacity of (0=000 Dgs of mil1 per day 1ept on expanding on regular intervals and at present handling capacity of 11=00=000 Dg of mil1 per day: $any more products are being developed: Company started mil1 collection in $oga area on 1* Nov= 1.91 and on first day *10 Dgs of mil1 6as collected from four villages: )rom that day on6ards company is collecting mil1 continuously both morning and evening 6ithout brea1: he total procurement in 1.9" 6as to "0*( million Dgs from (9&0- farmers delivering mil1 at 9*0 collection centers in *+( villages and 10 mil1 chilling centers: In 1..- the mil1 chilling centers have increased from 10 to 1-9: Nestle India 'td: $oga factory is the oldest factory in India 6ith the layout spread *+ Acres and have & plants 6ithin the factory and it is also largest factory in India

8ari'*( )eAart2ent( in the Ne(tle M'ga .act'rF %upply Chain NSAC IPE Industrial performanceF )$4 Cereals P)P Culinary SA 5ngineering
24

 )$P00 #4

The .act'rF c'n(i(t( '. .'*r Ar')*cti'n Alant(C

MIL7 OPERATION% -EREAL% -ULINAR5 POWDER FILLING AND PA-7AGING

MIL7 OPERATION%
his plant as the name suggests is engaged in the processing of mil1 and all the related activities that ta1e place in $oga )actory: his plant can be categori;ed

into a number of sub- plants= 6hich are discussed belo6 in briefL

MILK RE$EPTION AND PRO$ESSING
MILK-TANKER Packo-cooler
#RES% MILK RE$EPTION

TEMP. "!$ - &!c Milk -churn Temp. ! - "!!c

LP
MILK EGRON P#P C545A'% EVAPORATOR MILK SILO -STD TEMP. "!$

#7$AN 45%,74C5 05P

: = $,2A )AC ,4Q

Mil0 ReceAti'n his plant as name suggested is engaged in the processing of mil1 and all related activities that ta1e place in $oga factory: his plant can be categori;ed in to number of subplantsL

25

Fre(h Mil0 ReceAti'n

he fresh mil1= 6hich is fundamental constituent of various products= 6hich are manufactured in this factory= is received in this area in tan1ers and churns: he fresh mil1 is received in t6o 6ays namely churn mil1 and tan1er mil1: here are t6o reception lines both for churn and tan1er mil1: here are 1100 agencies= 6hich supply fresh mil1 in churns: he fresh mil1 is supplied by various chilling centers: Nestle has four o6n mil1 chilling centers: esting of fresh mil1 is done in fresh mil1 lab churn is tested for flat and %N) only: he supplier are paid only for fat according to @age: In buffalo and co6 mil1 fat varies from (:*@ to *:*@ and upto (@ respectively: While a number of tests are performed on tan1er mil1: If any one of the test is found to be positive then the tan1er is reBected: he received mil1 is received in silos after passing through P#5s: he pasteuri;ed mil1 is stored in 9 namely A= /= C= 0= 5 G ): he pasteuri;ed mil1 is pac1ed in 1*=000 polypac1s per day: he fat and %N) in it is (:9@ and -:9@: he mil1 stores in silos used in production of various products in 2hee plant and 'i8uid plant:

Ghee Plant
he mil1 stored in silo 0= 5 G ) is used for manufacturing 2hee= 6hich is mar1ed under the brand name 5veryday: In this plant mil1 is passed through t6o separators: A phase inversion from (0-*0@ cream in the first and +0--0@ fat in the second is obtained: he final concentration become .+@ crude fat:

LIQUID PLANT

26

his plant is engaged in the processing of mil1 in the li8uid form= prior to the drying operations done in the 5gron that converts it into mil1 po6der: #o6ever various products such as %C$ G 0esert $ixes are produced in the plant= besides the base li8uid for drying in 5grons he general process-ta1ing place in the plant can be summari;ed as follo6sL he fresh mil1 received from the silos is first standardi;ed: I:e: the ingredients are added on the basis of the report send by )$ lab and the product they are going to manufacture: his is needed= as there are al6ays variations in the

conditions at each different batch of mil1: After this the mil1 is boiled 6ith steam under vacuum in evaporators in order to manufacture %C$: No other industry has been able to ma1e this product in all over India: A part of the mil1 is sent to 5grons in order to get the mil1 po6der: his mil1 po6der is

then blended 6ith certain ingredients in order to manufacture the recently launched products namely dessert mixes:

EGRON%
5gron is a spray drier used to dry the mil1= coffee li8uid into po6der form by using hot air: While drying= the s1immed mil1 at lesspressureand the hot air at the higher pressure are passed to the cone through the no;;les: he high pressure hot air brea1s the mil1 into the very tiny particles: /ecause of the vertical length of the cone these particles gets converted into the dry mil1: he dry mil1 falls over the sha1er 6hich does not allo6 the hot particles to collaborate 6ith each other again:
27

After this the dry mil1 is collected in the tote bins in the bin room:

he bins

are then tilted over the hopers and from 6hich they are subse8uently sent to po6der filling and pac1ing machines: )or all this= there are four 5grons in $oga factory 5grons "= &= (= are used for drying mil1 po6der and No:1 is used for drying coffee 6hich is closed right no6:

POWDER FILLING PLANT

he filling and the pac1ing of mil1 li1e 5veryday= 'actogen and Nestogen is done in this plant: here are four filling and pac1ing lines for this purpose: 6o of

these are used in filling of tins G the other t6o are used for filling polypac1s or bagn-boxes re8uired by the production program:

-EREAL%
his plant is engaged in the production of cereal-based baby foods and infant formula: he production process consists of the addition of various 5n;ymes= here are t6o filling and

3itamins= $inerals G fruit extracts to the cereal base:

pac1ing lines in the cereal plant: ,ne is for filling of (00 gm: sachets and other for filling of (00gm tins: No6 a *gm every day creamer filling line machinery is also installed in the filling section: shift operation: he he manufacturing of products is a continuous three-

in filling line is generally run for the export pac1ing and he maBor product of the Cereal plant is

accounts for the manufactured products: Cerelac: EWheat= Apple= ,rangeF

28

UTILIT5 %ER8I-E% DEPARTMENT BOILER HOU%E

/oiler #ouse provides the %team to 6hole factory: And it also loo1s after 6ater generation= de-al1ani;ation of 6ater to feed to boiler= soft 6ater generation= po6er generators and air heaters:

EFFLUENT TREATEMNT PLANTC

his department loo1s after the 6aste 6ater treatemnt before draining out of plant: In this plant= the polluted 6ater from the factory is passed through the sieves and collected in the aerator tan1: In this tan1 the fan 6hich is having the four blades at right angle to the 6ater is allo6ed to rotate : he rotation of the vertical blades or vanes

splashes the effulent: his process of splashing continous until the 6ater gets oxidised: > /asically the effluent 6ater lac1s in the oxygen so it is aerated in the open air and again gets oxidised in the open air:? /y this stirring operation the sludge comes to6rds the corners of the aerator 6ater tan1 and gets collected by the sludge collector and gets collected in the sludge tan1 through the pipes: his sludge is allo6ed to dry in the sludge bath in the open air and 6hich is further used as the manure after the drying: he submersible pumps are used to maintain the level of the aerator tan1: After this the 6ater is passed to the clarifier 6here the further clarification of the 6ater is done by moving the pan containing the sieves:And after this the 6ater is passed to the mixing tan1= from this tan1 the 6ater is pumped to the chimney: he chimney is provided to maintain the

29

head: he 6ater from this chimney is used for gardening in the factory and the rest of the 6ater is dumped in to the $C pipe:

-ULINAR5
his plant is engaged in the production of Noodles= aste mar1ers= %oups sauces G the li1e: he plant is divided into three sectionsL N,,0'5% %5A%,NIN2 C,'0 %A7C5% The OAerati'n '. the (ea('ning i( inter4 relate) 1ith E'th the n'')le an) c'l) (a*ce (ecti'n a( the (Aice 2i& Ea(e .'r E'th i( 2an*.act*re) in the (ea('ning (ecti'n.

30

-HAPTER ! %AFET5
%a.etF i( the .ree)'2 .r'2 ri(0 '. inG*rie( 'r the Are<enti'n '. the acci)ent(. %a.etF i( a th'*ght 1hich 2a0e( *( Ar'acti<e an) helA( *( t' Are<ent the acci)ent(.

WhF (a.etF
It is a basic human need Concerns all of us %afety has to be on our mind al6ays At home= at 6or1 and in our community Accidents happen 6hen 6e don<t pay attention

Acci)ent
It is a sudden and unforeseen occurrence 6hich results in damage to material=building=environment and above all to human beings: %tatus of accidents: 7nsafe actions ----------------@ 7nsafe conditions------------10@

31

 Natural calamities-----------0"@

98%acci)ent( are ca*(e) EF h*2an err'r(.

I.E. *n(a.e act( 'r c'n)iti'n(.

2%acci)ent( are EeF'n) h*2an;( c'ntr'l.

I.E. EarthK*a0e etc.

Main rea('n( '. the acci)ent(C

I did not see: I did not as1: I did not listen:

Rea('n( t' Ee care.*l at the 1'r0

4esponsibility to ourself: 4esponsibility to co-6or1er G company: 0o not 6or1 at time if you are not feel good: If any unsafe placed you are seen than as1 your supervisor:
32

Acci)ent (eK*ence
'ac1 of 1no6ledge= s1ill= mental condition )ault of person 7nsafe actTcondition Accident InBury

Un(a.e act(
,perating 6ithout authority: ,perating at unsafe speed: $a1ing safety devices inoperative: 7nsafe position or posture: 0istracting=teasing=abusing G startling:

33

Un(a.e c'n)iti'n
0efective condition=rough=%harp=slippery=crac1ed=corroded etc: 7nsafe illumination=ventilation=dress: 7nsafe method=process planning etc: #a;ardous arrangement= process layout:

Acci)ent Are<enti'n
Illuminate the ha;ard Control the ha;ard rain personnel

Prescribe personnel protective e8uipments: $otivate people and safety participations: /ehavioral safety 5nforcement of safety rules:

34

Near 2i((C
When any miss happening occurs suddenly to a person and does not get any inBury due to that miss occurrence is called as the near miss:

While handling the chemicals= the follo6ing PP5 must be usedL

1: Apron ": )ace shield or safety goggles &: 4ubber gloves (: %afety 2um /oot *: Nose mas1

I2A'rtant n'teC
Al6ays use safety belt 6hile 6or1ing at height above 1:-m height: Also use the helmet tight 6ith chin strip 6hile 6or1ing at the height: Al6ays 6ear the helmet if any 6or1 in progress above your 6or1ing place or at construction sight: Al6ays use the nose mas1 6here the danger of the chemicals fumes=toxic gases is present: It avoids the inhalation of these toxic and harmful fumes:
35

 Al6ays 6ear the goggles G gloves 6hile cutting=grinding=drilling= hammering and chiseling: Al6ays 6ear the safety shoes 6hile 6or1ing in the factory premises: Al6ays use the rubber gloves 6hile handling the chemicals: Al6ays use the leather gloves 6hile handling the glass: Al6ays use the both side handrailing 6hile moving over the stairs: In case of the lea1age of the harmful gases in the plant al6ays follo6 the opposite direction of the 6ind soc1s and move across the direction of 6ind: Al6ays 6ear the ear plug or ear muff 6here the noise level above -*d/ EAF: Never use the mobile phone 6hile 6or1ing in factory premises: Al6ays 6al1 in a 6al1 6ay: Al6ays 6ear high reflective apron 6hile driving: $ove the hand lift in proper body posture not play horse riding:

36

Per('nal Ar'tecti<e eK*iA2ent(

ABOUT %AFET5

-HAPTER /
37

UtilitF %er<ice( DeAart2ent

1: 4efrigeration and air-conditioning ": 5ffluent reatment plant &: /oiler house (: Compressor room

Re.rigerati'n an) air4c'n)iti'ning

Thi( )eAart2ent l''0( a.ter the -hiller Water Plant( 1hich (*AAlF the chille) 1ater t' .act'rF an) the AHU;( '. .act'rF, Air -'n)iti'ner( '. .act'rF an) the Air -'2Are(('r '. the .act'rF.

Re.rigerati'n Alant
A 4efrigeration plant uses gas=li8uid and mechanical energy to move heat from one place to another:A li8uid=such as ammonia=6hich has a lo6 boiling temperature= is allo6ed to pass into a space via tubing:As the pressure in the ammonia drops=the li8uid begins to boil and enter a phase change from li8uid to gas:In doing so= there is a great absorption of heat energy by the li8uid in the tubing to create this phase change:

38

REFRIGERATION PLANT

he heat energy is absorber from the space and as the li8uid boils off=it forms a gas: he gas is pulled through the tubing in the space into a suction header outside the space to the suction of a compressor: he compressor depressuri;es the gas and discharge the li8uid through cold 6ater heat exchanges or cooling fans=exhausting the heat exchangers or cooling fans= exhausting the heat absorbed from the space=into the outside atmosphere:/y pressuri;ing and cooling the gas=the gas returns to a li8uid stage=6here it is stored and reintroduced to the space to be cooled:

39

PrinciAle '. re.rigerati'n (F(te2

It is based on vapor compression refrigeration cycle: he vapor-compression uses a circulating li8uid refrigerant as the medium 6hich absorbs and removes heat from the space to be cooled and subse8uently reBects that heat else6here:)iguredepicts a typical=single-stage vapor-compression system:

-'2A'nent( '. a re.rigerati'n %F(te2

1: Compressor ": Condenser &: 5xpansion valve (: 5vaporator

A TFAical <aA'*r c'2Are((i'n cFcle

%INGLE %TAGE 8APOUR -OMP. -5-LE

40

De(criAti'n '. <aA'*r c'2Are((i'n cFcle

he vapor-compression uses a circulating li8uid refrigerant as the medium 6hich absorbs and removes heat from the space to be cooled and subse8uently reBects that heat else6here:0epicts a typical=single-stage vapour-compression system: All such systems have four componentsLA compressor=a condenser=a thermal expansion valve Ealso called a throttle valveF= and an evaporator :Circulating refrigerant enters the compressor in the thermodynamic state 1no6n as a saturated vapour and is compressed to a higher pressure=resulting in a higher temperature as 6ell: he hot=compressed vapor and it is at a temperature and pressure at 6hich it can be condensed 6ith typically available cooling 6ater or cooling air: hat hot vapor is routed through a condenser 6here it is cooled and condensed into a li8uid by flo6ing through a coil or tubes 6ith cool 6ater or cool air flo6ing across the coil or tubes:this is 6here the circulating refrigerant reBects heat from the system and the reBected heat is carried a6ay by either the 6ater or the airE6hichever may be the caseF: he condensed li8uid refrigerant= in the thermodynamics state 1no6n as a saturated li8uid= is next routed through an expansion valve 6here it undergoes an abrupt reduction in pressure: hat pressure reduction results in the adiabatic flash evaporation of a part of the li8uid refrigerant: he auto refrigerant of the li8uid and vapor refrigerant mixture to 6here it is colder than the temperature of the enclosed space to be refrigerated: he cold mixture is then routed through the coil or tubes in the evaporator: A fan circulates the 6arm air in the enclosed space across the coil or tubes carrying the cold refrigerant li8uid and vapor mixture: hat 6arm air evaporates the li8uid part of the cold refrigerant mixture: At the same time= the

41

circulating air is cooled and thus lo6ers the temperature of the enclosed space to the desired temperature: heevaporator is 6here the circulating refrigerant absorbs and removes heat 6hich is subse8uently reBected in the condenser and transferred else6here by the 6ater or air used in the condenser: o complete the refrigeration cycle= the refrigerant vapor from the evaporator is again a saturated vapor and is routed bac1 into the compressor:

Re.rigerant *(e)C A22'niais the main refrigerant used in the refrigeration cycle:
AmmoniaEN#&F is the most 6idely used refrigerant :It is a chemical compound of Nitrogen and #ydrogen: Pr'Aertie( '. A22'nia Re.rigerant Na2e N'. M'lec*lar %Aeci.ic 8aA'*r B'iling 2a(( gra<itF )en(itF A'int at FreeBing A'int at A*t' igniti'n

at2'(Aheric at2'(Aheric A'int 4-+1+ Ammonia 1+:0" :91 0:9 Are((*re -&&:&o C Are((*re -+9:9 o C 9*0 oC

TABLE/.# PROPERTIE% OF AMMONIA

42

A)<antage( '. *(ing A22'nia (NH/$

1: Po6er consumption is less than C)C: ": 'ess operational problem of oil return: &: /etter heat transfer: (: 0ue to lo6 po6er consumption high heat transfer capacity: *: N#& has no effect on ,;one layer:

Oil %eAarati'n
4efrigeration compressors are lubricated by refrigeration oil that circulates from the compressor cran1case or housing: As refrigerant gas is discharged by the compressor= it 6ill leave 6ith a fine oil mist that 6ill be circulated throughout the entire system: %mall amounts of oil circulating through the system 6ill not affect the system performance: oo much refrigeration oil circulating in the system 6ill have adverse effects on the components in the system: Circulating oil reduces the ability of the system to effectively remove the heat:Condensers=evaporators and other heat exchangers loose the efficiency 6hen coated internally 6ith an oil film:4efrigeration oil not returning to the compressor causes improper lubrication and eventual compressor failure:At lo6 temperature

application=refrigeration oil thic1ness becomes difficult to move=causing oil to be trapped in the system:

43

4efrigerant gas leaving the compressor through the discharge lines contains refrigeration oil in a vapourousmist: As this mixture enters the oil separator=the velocity is reduced to allo6 oil separation to begin: his refrigerant gas and oil mixture enters the oil separator and passes through an inlet screen=causing the fine particles to combine: 'arger oil particles are formed and drop to the bottom of the oil separator: he refrigerant gas then passes through an outlet screen to remove residual oil particles: he oil gathers in the bottom of the oil separator until a float operated needle valve opens to allo6 the return of the oil to the compressor:,il returns 8uic1ly to the compressor=because of the higher pressure in the oil separator than in the compressor cran1case:When the oil level has lo6ered=the needle valve closes to prevent refrigerant gas from returning bac1 to the compressor: he refrigerant gas leaves through the outlet of the oil separator and goes to the condenser

-''ling T'1er(
In the plants=the hot 6ater from the condenser is cooled in the cooling to6er= so that it can be reused in the condenser for the condensation of the steam:In a cooling to6er 6ater is made to tric1le do6n drop by drop so that it comes in contact 6ith air moving in the opposite direction:As a result of this some 6ater is evaporated and is ta1en a6ay 6ith air:In evaporation=the heat is ta1en a6ay from bul1 of 6ater=6hich is thus cooled:

Intr')*cti'n

44

A cooling to6er is e8uipment used to reduce the temperature of a 6ater stream by extracting heat from 6ater and emitting it to the atmosphere:

-''ling t'1er(

TFAe( '. c''ling t'1er(C

1: Natural draft ": $echanical draft

FORCED DRAFT

INDUCED DRAFT COUNTER FLOW

INDUCED DRAFT CROSS FLOW

Nat*ral Dra.t c''ling t'1er

45

he natural draft or hyperbolic cooling to6er ma1es use of the difference in temperature bet6een the ambient air and hotter air inside the to6er:it 6or1s as follo6s

#ot air moves up6ards through the to6erEbecause hot air risesF: Fre(h c''l air i( )ra1n int' the t'1er thr'*gh an air inlet at the E'tt'2.

-OOLING TOWER

46

Mechanical )ra.t c''ling t'1er

$echanical draft to6ers have large fan to force or dra6 air through circulated 6ater: he 6ater falls do6n6ords over fill surfaces:

Cooling rates of mechanical draft to6ers depend upon various parameters such as fan diameter and speed of operation=fills for system resistance etc:

F'rce) )ra.t c''ling t'1erC

Air is blo6n through to6er by centrifugal fan at air inlet

F'rce) )ra.t c''ling t'1er A)<antage(C (*ite) .'r high air re(i(tance I .an( are relati<elF K*iet
47

Di(a)<antage(C recirc*lati'n )*e t' high air entrF an) l'1 air e&it <el'citie(.

In)*ce) )ra.t c'*nter .l'1 c''ling t'1erC

In a counter flo6 design the air flo6 is directly opposite to the 6ater flo6: Air flo6 first enters an open area beneath the fill media and is then dra6n up vertically: he 6ater is

sprayed through pressuri;ed no;;les and flo6s do6n6ard through the fill= opposite to the air flo6:

48

In)*ce) )ra.t c'*nter .l'1 c''ling t'1er

In)*ce) )ra.t cr'(( .l'1 c''ling t'1erC

Cross flo6 is a design in 6hich the air flo6 is directed to perpendicular to the 6ater flo6: Air flo6 enters one or more vertical faces of the cooling to6er to meet the fill material: Water flo6s Eperpendicular to the airF through the fill by gravity: he air continuous through the fill and thus past the 6ater flo6 into an open plenum area: A distribution or hot 6ater basin

49

consisting of a deep pan 6ith holes or no;;les in the bottom is utili;ed in a cross flo6 to6er: 2ravity distributes the 6ater through the no;;les uniformly across the fill material:

In)*ce) )ra.t cr'(( .l'1 c''ling t'1er

Fact'r( a..ecting c''ling '. 1ater 'n a c''ling t'1er areC

1: emperature of air

": #umidity of air: &: emperature of hot air

(: %i;e and height of to6er *: 3elocity of air entering to6er 9: 0egree of uniformity in descending 6aterArrangement of plants in to6er

50

Heat e&changer(
A heat exchanger is a device built for efficient heat transfer from one medium to another=6hether the media are separated by a solid 6all so that they never mix=or the media are in direct contact: hey are 6idely used in space heating=refrigeration=air

conditioning=po6er plants=chemical plants=electrochemical plants=petroleum refineries and natural gas processing:,ne common example of a heat exchanger is the radiator in the car=in 6hich a hot engine-cooling fluid=li1e antifree;etransfers heat to air flo6ing through the radiator:

TFAe( '. heat e&changer(C

Acc. T' .l'1 arrange2ent the heat e&changer( 2aF Ee cla((i.ie) int' three tFAe(. 1: -r'((4.l'1 In a cross-flo6 heat exchanger=the fluids travel roughly perpendicular to one another through exchanger: ": -'*nter4.l'1 In a counter flo6 heat exchangers the fluids enter the exchanger from the opposite end: he counter current design is most efficient=in that it can transfer the most heat: &: Parallel4.l'1 In parallel-flo6 heat exchangers= the t6o fluids enter the exchanger at the same end=and travel in parallel to one another to the other side:

51

Plate heat e&changer

A plate heat exchanger is a type of heat exchanger that uses metal plate to transfer heat bet6een t6o fluids: his has a maBor advantage over a conventional heat exchanger in that the fluids are exposed to a much large surface area because the fluids spread out over the plates: his facilities the transfer of heat= and greatly increases the speed of the temperature change: he concept behind a heat exchanger is the use of pipes or other containment vessels to heat or cool one fluid by transferring heat bet6een it and another fluid: In most cases= the exchanger consists of a coiled pipe containing one fluid that passes through a chamber containing another fluid: he 6alls of the pipe are usually made of metal or another substance 6ith a high thermal conductivity= to facilitate the interchange= 6hereas the outer casing of the large chamber is made of a plastic or coated 6iththermal insulation= to discourage heat from escaping from the exchanger:

Plate tFAe heat e&changer

52

%HELL AND TUBE HEAT EL-HANGER

A shell and tube that heat exchanger is a class of heat exchanger designs: It is the most common type of heat exchanger in oil refineries and other large chemical process= and is suited for higher-pressure applications: As its name implies= this type of heat exchanger consists of a shell Ea large pressure vesselF 6ith a bundle of tubes insides it: ,ne fluid runs though the tubes= and another fluid flo6s over the tubes Ethrough the shellF to transfer heat bet6een the t6o fluids: he set of tubes is called a tube bundle= and may be composed by several types of tubesLplain= longitudinally finned= etc:

%hell an) t*Ee heat e&changer

%electi'n '. the t*Ee 2aterialC

o be able to transfer heat 6ell= the tube material should have good thermal conductivity: /ecause heat from a hot to a cold side through the tubes= there is atemperature difference through the 6idth of the tubes:/ecause of the tendency of the

53

tube material to thermal expand differently at various temperatures= thermal stresses occur during operation: his is in addition to any stress from high pressure from the fluids themselves: he tube material also should be compatible 6ith both the shell and tube side fluids for long periods under the operating conditions Etemperature= pressure= p#= etc:F to minimi;e deterioration such as corrosion: All of these re8uirements call for careful selection of strong= thermally-conductive= corrosionresistant= high 8uality tube materials= typically metals= including copper alloy= stainless steel= and carbsteel: Non-ferrous copper alloy= inconel= nic1el= hastelloy and titanium::Poor choice of tube material could result in a lea1 through a tube bet6een the shell and tube sides causing fluid cross-contamination and loss of pressure:

HEAT EL-HANGER IN INDU%TR5

#eat exchangers are 6idely used in industry both for cooling and heating large scale industrial processes: he type and si;e of heat exchanger used can be tailored to suit a process depending on type of fluid= its phase= temperature= density= viscosity= pressures= chemical composition and various other thermodynamic properties: In much industrial process there is 6aste of energy or a heat stream that is being exhausted= heat exchangers can be used to recover this heat and put it to use by heating a different stream in the process: his practice saves a lot of money in

industry as the heat supplied to other streams from the heat exchangers 6ould other6ise come from an external source 6hich is more expensive and more harmful to the environment: Heat e&changer( are *(e) in 2anF in)*(trie(, ('2e '. 1hich incl*)eC Waste 6ater treatment

54

4efrigeration systems Wine bravery industry Petroleum industry

In this 6aste 6ater treatment industry= heat exchangers play a vital role in maintaining optimal temperature 6ithin anaerobic digesters so as to promote the gro6th of microbes 6hich remove pollutants from the 6aste 6ater: he common types of heat exchangers used in these applications are the double pipe heat exchangers as 6ell as the plate and frame heat exchanger:

E..l*ent treat2ent Alant

AIR HANDLING UNIT

Air handling unit Eoften abbreviated to A#7F= is a device used to condition and circulate air part of a heating= ventilating= and air-conditioning E#3ACF system: An air handler is usually a large metal box containing a bo6ler= heating or cooling elements= filter rac1s or chambers= sounds attenuators= and dampers: Air handlers usually connect to duc1 6or1 that distributes the conditioned air through the building and returns it to the A#7: %ometimes A#7s

55

discharge EsupplyF and admit EreturnF air directly to and from the space served 6ithout duc1 6or1:

%'2e AHU c'2A'nent( (h'1n areC

1F %upply duc1 "F )an compartment &F 3ibration isolator EAflex Boint< (F #eating andTor cooling coil *F )ilter compartment 9F $ixed Erecalculated U outsideF air duct

AHU %5%TEM
56

Air han)ling c'2A'nent(C

Air handlers typically employ a large s8uirrel cage blo6er divan by an AC induction electric motor to move the air: he blo6er may operate at a single speed= offer a variety of set speeds= or be driven by a 3ariable fre8uency drive to allo6 a 6ide range of air flo6 rates: )lo6 rate may also be controlled by inlet vanes or outlet dam person on the fan: %ome residential air handlers Ecentral Afurnaces< or Aair conditioners<F use a brushless 0C electric motor that has variable speed capabilities: $ultiple blo6ers may be ore sent in large commercial air handling units= typically placed at the end of the A#7 and the beginning of the supply duct6or1 Etherefore also called >supply fans?F: hey are often augmented by fans in the return air duct E>return fans?F pushing the air into the A#7:

Heating an)M'r c''ling ele2ent(

Air handlers may need to provide heating= cooling= or both to change the supply air temperature depending on the location and the application: %maller air handlers may contain a fuel-burning heater or a refrigerationevaporator= placed directly in the air stream: 5lectric resistance and heat pumps can be used as 6ell: 5vaporative cooling is possible in dry climates: 'arge commercial air handling units contain coils that circulate hot 6ater or steam for heating= and chilled 6ater for cooling: Coils are typically manufactured from copper for the tubes= 6ith copper or aluminum fins to aid heat transfer: Cooling coils 6ill also employ delimiters plates to remove and drain condensate: he hot 6ater or stream is provided by a central boiler= and the chilled 6ater is provided by a central chiller: 0o6nstream temperature

57

sensors are typically used to monitor and control Aoff coil< temperatures= in conBunction 6ith an appropriate motori;ed control valve prior to the coil:

Filter(
Air filtration is almost al6ays present in order to provide clean dust-free air to the building occupants: It may be via simple lo6-$543 pleated media= #5PA= electrostatics= or a combination of techni8ues: 2as-phase and ultraviolet air treatments may be employed as 6ell: It is typically placed first in the A#7 in order to 1eep all its components clean: 0epending upon the grade of filtration re8uired= typically filters 6ill be arranged in t6o Eor moreF ban1s 6ith a coarse-grade panel filter provided in front of a fine-grade bag filter= or other Afinal< filtration medium: he panel filter is cheaper to replace and maintain= and thus protects the more expensive bag filters: he life of a filter may be assessed by monitoring the pressure drop through the filter medium at design air volume flo6 rate: his may be done by means of a visual display= using a

pressuregauge= or by a pressure s6itch lin1ed to an alarm point on the building control system: )ailure to replace a filter may overcome its inherent strength= resulting in collapse and thus contamination of the air handler and do6nstream duct6or1:

H*2i)i.ier

58

#umidification is often necessary in colder climates 6here continuous heating 6ill ma1e the air drier= resulting in uncomfortable air 8uality and increased static electricity: 3arious types of humidification may be usedL 5vaporativeL dry air blo6n over a reservoir 6ill evaporative some of the 6ater: he rate of evaporation can be increased by spraying the 6ater onto baffles in the air stream: 3apori;erL scream or vapor from a boiler is blo6n directly into the air stream: %pray mistL 6ater is diffused either by a no;;le or other mechanical means into fine droplets and carried by the air: 7ltrasonicL A tray of fresh 6ater in the airstream is excited by an ultrasonic device forming a fog or 6ater mist: Wetted mediumL A fine fibrous medium in the airstream is 1ept moist 6ith fresh 6ater from a header pipe 6ith a series of small outlets: As the air passes through the medium it entrains the 6ater in fine droplets: his type of humidifier can 8uic1ly clog if the primary air filtration is not maintained in good order:

Mi&ing cha2Eer
In order to maintain indoor air 8uality= air handlers commonly have provisions to allo6 the introduction of outside air into= and the exhausting of air from the building: In temperature climates= mixing the right amount of cooler outside air 6ith 6armer return air can be used to approach the desired supply air temperature: A mixing chamber is therefore used 6hich has damperscontrolling the ratio bet6een the return= outside= and exhaust air:

59

Heat rec'<erF )e<ice

#eat recovery device heat exchangers of many types= may be fitted to the air handler bet6een supply and extract airstreams for energy savings and increasing capacity: hese types more commonly include forL 4ecuperate= or plate heat exchangerL A sand6ich of plastic or metal plates 6ith interlaced air paths: #eat is transferred bet6een airstreams from one side of the plate to the other: he plates are typically spaced at ( to 9mm apart: Can also be used to recover colt: #eat recovery efficiency up to +0@: hermal Wheel or 4otary heat exchangersL A slo6ly rotating matrix of finely corrugated motel= operating in both opposing airstreams: When the air handling unit is in heating mode= heat is absorbed as air passes through the matrix in the exhaust airstream= during one half rotations= and released during the second half rotation into the supply airstream in a continuous process: When the air handling units is in cooling mode= heat is released as air passes through the matrix in the exhaust airstream= during one half rotations= and absorbed during the second half rotation into the supply airstream: #eat recovery efficiency up to -*@: Wheels are also available 6ith a hydroscope coating to provide latent heat transfer and also the drying or humidification of airstream: 4un around coilL 6o airs to li8uid heat coils= in opposing airstream= piped together 6ith a circulating pump and using 6ater or a brine as the heat transfer medium: his device= although not very efficient= allo6s heat recovery bet6een remote and sometimes multiple supply and exhaust airstream: #eat recovery efficient up to *0@:

60

#eat pipeL ,perating in both opposing air paths= using a confined refrigerant as a heat transfer medium: he Apipe< is multiple sealed pipes mounted in a coil configuration 6ith fins to increase heat transfer: #eat is absorbed on one side of pipe= by evaporation of the refrigerant= and released flo6s by gravity to the first side of the pipe to repeat the process: #eat recovery efficiency up to 9*@:

-'ntr'l(
Controls are necessary to regulate every aspect of an air handler= such asL flo6 rate of air= supply air temperature= mixed air temperature= humidity=air 8uality: hey may be as simple as an offTon thermostat or as complex as a building automatic system using /ACnet or 'onWor1s=for examples:

8iErati'n i('lat'r(
he blo6ers in air handlers can create substances vibration and the large area of the duct system 6ould transmit this noise and vibration to the occupants of the building: o avoid this= vibration isolators Eflexible sectionsF are normally inserted into the duct immediately before and after the air handler and often also bet6een the fan compartment and the rest of the A#7: he rubberi;ed canvas-li1e material of these sections allo6s the air handler to

vibrate 6ithout transmitting much vibration to the attached ducts:

61

-HAPTER 3 M5 PRO9E-T BA%ED ON BOILER HOU%E BOILER HOU%E

B'iler H'*(e Ar'<i)e( the (tea2 t' 1h'le .act'rF. An) it al(' l''0( a.ter 1ater generati'n, )e4al0aliBati'n '. 1ater t' .ee) t' E'iler, ('.t 1ater generati'n, A'1er generat'r( an) air heater(. There are .'*r E'iler( in the Ne(tle M'ga .act'rF. The t1' are c'al .ire) an) the t1' are the 'il .ire) E'iler(. BOILER BA%I/oilers are the most important part of the steam circuit= after all=this is 6here the steam is initially created: A boiler can be definedas a vessel in 6hich the heat energy from a fuel is transferred toa li8uid: In the case of saturated steam= the boiler also provides heat energy to produce a phase change from li8uid to vapour: #istorically= steam boiler plant has al6ays re8uired a high level of

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manual supervision toprovide the necessary degree of plant safety: Contemporary thin1ing demands such plant to be run efficiently= and this may often be attempted by matching supply to demand as muchaspossible: his can mean boilers running continuously in some instances= or being shutdo6n for long or short intervals in others: 5ither 6ay= modern technology enables the plant engineerto confidently choose the boiler regime to best suit his application= 6ith control systems able to provide the re8uired degree of efficiency= integrity and safety: A boiler is often the largest piece of e8uipment to be found in a steam circuit: hey can range In si;e depending upon the application on 6hich they are used: ,ften several boilers may beusedon a large site= 6here varying steam loads exist:

A TFAical Diagra2 '. E'iler

%hell E'iler(
%hell boilers operate by passing heat through tubes in the boiler= 6hich in turn transfer heat to the surrounding boiler 6ater: here are several different combinations of tube layout for

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shell boilers= involving the number of CpassesC the heat from the boiler furnace 6ill usefully ma1ebefore being discharged: A typical arrangement can be seen in )igure A 6hich sho6s a t6o pass boiler configuration: )igure A and )igure / also sho6s the t6o methods 6here the heat from the furnace is reversed to flo6 along the second pass: )igure A sho6s a dry bac1 boiler 6here the heat flo6 is reversed by a refractory lined chamber on the outer plating of the boiler: A more efficient method of reversing the heat flo6 is through a 6et bac1 boiler configuration as sho6n in )igure /: he reversal chamber is contained entirely 6ithin the boiler 6hich allo6s for a greater heat transfer area= as 6ell as allo6ing the boiler 6ater to be heated at the point 6here the heat from the furnace 6ill be hottest - on the end of the chamber 6all: It is important to note that the combustion gases should be cooled to at least ("0NC for plain steel boilers and (+0NC for alloy steel boilers before the reversal chamber: emperatures in excess of this 6ill cause overheating and crac1ing of the tube end plates: hese limitations 6ill be observed by the boiler manufacturer 6ithin his design criteria: here are several different types of shell boilers that have been developed= 6hich 6ill no6 be loo1ed at in more detail:

EaF 0ry /ac1 /oiler

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EbF Wet /ac1 /oiler

Pac0age E'ilerC
he improvement of materials and manufacturing processes meant that more tubes could be accommodated 6ithin the boiler: 5arly in its development the basic boiler 6as long and re8uired a large boiler house area: /y forcing the hot gases to go bac16ards and for6ards through a series of tubes= the boilers 6ere designed to be shorter= and heat transfer rates 6ere improved: he modern multi-tubular pac1aged boiler is the present state of this evolutionary process: he pac1aged boiler is so called because it comes as a complete pac1age: ,nce 0eliveredto site it re8uires only the steam= 6ater and blo6do6n pipe6or1= fuel supply and electrical connectionsto be made for it to become operational: hese boilers are classified by the number of passes - the number of times the hot combustion gases pass through the boiler: he combustion chamber is ta1en as the first pass: he most common boiler is a three pass unit as sho6n in )igure 9 6ith t6o sets of fire-tubes and the exhaust gases exiting from the bac1 end of the boiler:

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Packag !"#$ %

A ypical Pac1age /oiler

Water T*Ee B'ilerC

Water tube boilers differ from shell type boilers in that the 6ater iscirculated inside the tubes 6ith the heat source surroundingthem: his means that much higher pressures can be used because the tube diameter is significantly smaller than the shellon the fire tube boiler= and therefore the circumferential stress isalso significantly less:Water tube boilers tend to be considered for large steam outputs=for high pressure= or for superheated steam: )or most industrialand commercial applications= a multi-tubular shell boiler is oftenappropriate: ,nly if the re8uirement is for an individual outputabove "+ 000 1gTh or at pressures above "+ bar= or steamtemperatures above &(0NC is it necessary to use a 6ater tubeboiler: he reason for this is that 6ater tube boilers cost more tobuild for a given output than multi-tubular shell boilers: #o6ever= throughout the 6orld= 6ater tube boilers compete6ith shell boilers si;e for si;e belo6 "+0 bar g: o give anidea of the diversity of 6ater tube boilers on land= units start from about " 000 1gTh and rise to po6er station si;ed unitsrated at & *00 000 1gTh and above:

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he smaller si;ed units can be manufactured and then deliveredto the site in one piece: he larger si;ed units are generallymanufactured in sections= to be transported to site for final assembly:Water tube boilers operate on the principle of 6ater circulation: his is a subBect 6hich is 6orth covering before loo1ing at thedifferent types of 6ater tube boilers 6hich are available: 7se ofthe follo6ing diagram best helps to explain this theory:

Ri(er D'1n c'2er c'n.ig*rati'n '. 1ater t*Ee E'iler Cold feed6ater is introduced into the steam drum 6here it falls inthe do6ncomer to the lo6er or mud drum= due to it having agreater density than that of hot 6ater: Its density decreases as itpasses up the riser= 6here it is heated= eventually creating steambubbles: he hot 6ater and steam bubbles pass into the steamdrum once again= 6here the steam naturally separates from the6ater= and is then ta1en off:#o6ever= 6hen the pressure in the 6ater tube boiler is increased=the difference bet6een the density of the 6ater and saturatedsteam reduces= therefore less circulation occurs: o 1eep thesame level of steam output as design pressure increases= thedistance bet6een the lo6er drum and the steam drum must beincreased:

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%UGGE%TION% FOR IMPRO8EMENT %afety is very important for all those 6ho 6or1s in the industry even all those 6ho 6or1s outside the industry: /ecause= accident happens only 6hen the human being not ta1e interest to perform the Bob: %ome of employees follo6 the safety rules and regulations but most of employees not follo6: %ome of 6or1ers use the personal protective e8uipment: /ut most of 6or1ers not used: hey fill the behavior based safety sheets only for formalities G only for completing the targets: $y proBect report is based on boilers: %o= I should give suggestion about to improvement of boiler: Water tube boiler give higher efficiency than the fire tube boiler or shell tube boiler: %o= my suggestion is that most of time use 6ater tube boiler than fire tube boiler: he 6ater from soft 6ater plant or 4, plant used by boiler is only "*@ and reBect by boiler is +*@: %o such type of these 6astage of 6ater 6ill have to be stopped by reusedthis 6ater in boiler:

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REFEREN-E%

1:

2uidance from $r: %achidananda %6ainE$anager ,f %afetyF and $r: #arpal %ingh $a11ar E%r: 5xecutiveF:

":

$anuals of 5very Plant:

3& WWW:N5% '5:IN

(: Actual Captured %naps at site: *: 2oogle search engine:

6& httpLTT666:bluegrass1esco:comT/oiler@"0%ystem:html 7& httpLTTen:6i1ipedia:orgT6i1iTPac1ageVboiler

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