STUDY AND IMPROVEMENT IN

OPERATIONS OF CHEMICAL PLANT

ANJOOM NAIK
SIDDESH NAIK

(111102040)
(111102044)

PRATIK PARSEKAR
(111102050)
MOHIT KESARKAR
(111102061)

Guide: Shri. Mahesh Dhawalikar

Department of Mechanical Engineering

Goa College of Engineering

ABSTRACT
In chemical industry, the reactors are the vital equipment which ensures the achieving of desired
product. Reactors ensure that the reaction proceeds with the highest efficiency towards the
desired output product, producing the highest yield of product while requiring the least amount
of resource to operate. Reactor operating expenses include energy input, energy removal, raw
material costs, labor, etc. Energy changes can come in the form of heating or cooling, pumping to
increase pressure, agitation, etc. The use of batch reactors is most suitable when switching from
one process or product to another.
The various processes like Hydrogenation, Halogenation, Grignard Reactions, Crystallization,
Distillation etc., are carried in contained operation. The chemical reaction involves high degree
of risks posing to operator, process & environment. Here arises the need for automation of the
Reactor. The aim of the project is to suggest ways to automate the reactor in terms of safety
measures. The labour cost incurred in monitoring reactor can be reduced by automating the
reactor.
We have also studied and suggested the ways to improve the boiler efficiency. In this we have
calculated the boiler efficiency and have found the ways to improve the boiler efficiency. We
have presented a boiler maintenance program. Suggestions for the implementation of 5s and 5s
implementation program is also presented.

INTRODUCTION
In our project we have tried to improve the efficiency of thermax boiler using
the following ways discussed below. We also have suggested a way to
automate the reactor. Firstly we have carried out a detailed study of the
plant and prepared a detailed flow diagram of material in the chemical plant.
A complete study of boiler and reactor was done. To improve the boiler
efficiency we first have calculated the efficiency by direct method and also
studied the factors affecting boiler efficiency. The ways suggested were
reduce excess air, install an economizer, determination of economic
thickness, use of solar power to heat the feed water, automatic TDS
blowdown. For each of these ways we have calculated the payback period.
Boiler is an integral part of the industry which is used to produce steam. Any
damage to the boiler may lead to serious damage. Therefore we have
presented a boiler preventive maintenance program.
A complete layout of the automated reactor with all the components and
their description is provided. Various types of sensors are also mentioned
below. Supervisory control and data acquisition system can be used to
automate the reactor .the various utilities connected to the reactor are
boiler, chiller, cooling towers, screw feeder, vacuum generator etc. .Presently
the reactors are manually operated ball valves. During the operation of the
reactor continuous monitoring by the operator is required. solution for this
problem is automation of the reactor.
Rectors can be remotely controlled and the safety of the operator can be
enhanced.

The working condition of the plant can be improved therefore we have

suggested 5s

implementation.

This implementation plan will

include

installation of safety pathways and standardization.

Company Profile
Esteem industries which is leading producer of chemical products is located at Pissurlem Valpoi
Goa. It was establish on 7th July 1987. Total area covered by company is100, 000 Square Mtrs.
The major promoters are Mr. Zubin K. Gandhi, Dr. Amol A. Walke. The Vice president Tech.
Mktg.: Dr.Nitin B. Nevrekar.
There are more than 800 employees .Total production capacity of the company is Approx. 50,000
MT per annum. Company has an assortment of S.S., Glass Lined and Lead Bonded Reaction
vessels of various capacities ranging from 5 Kgs. To 10,000 Kgs. As of date, more than 50
reaction vessels are in operation. In addition, company has support equipments like Spray Dryer,
Flakers, Nitrogen Plants, etc.
Company also has excellent and versatile Pilot Plant facilities.
Main

products

manufactured

Ethoxylates,Propoxylates,EO/PO

in

the

Block

Esteem

Industries

Co-Polymers,EO/PO

are

as

Capped

follows
Co-

Polymers,Carbamates,Emulsifiers,Low Foam Emulsifiers,Phosphate Esters ,Leather Chemicals

& Auxiliaries,Paper Chemicals & Auxiliaries,Intermediates for Disperse Dyes,Plastic
Additives,Cosmetic Chemicals,Other Miscellaneous Chemicals.These manufactured products are
exported to global market.

Ethoxylates are surfactants found in products such as laundry

detergents, surface cleaners, cosmetics and for use in agriculture, textiles and paint. Emulsifiers
are the compound used whenever you want to mix two components and keep them from
separating. Emulsifiers are used where one part is oil based and the other is water based. Some
Emulsifiers are Silicon Oil Emulsifier, Amino Oil Emulsifier etc.

Flow of Material
The flow of raw material is shown below. The diagram shown below shows the various stages
through which material passes as it is converted from raw material to finished product.

Figure 1 Flow of raw material

Firstly the raw material is brought and kept in the raw material store. These raw materials are in
two forms solid and liquid. These raw materials are transported via trucks to raw material stores

from the outside world. The raw material is transported via fork trucks to lift or the screw feeder
from the raw material stores.
If the raw material is in solid form it is added to reactor in two ways using
a)

Screw feeder: - If large amount of material is to be added together at the same time then

screw feeder is used.

b) Manually: - If small amount of material is to be added to the reactor then worker adds it
directly in the reactor.
If the raw material is in liquid form then it is added to the reactor using pipes.
After adding raw material other inputs to reactor are
1. Steam from Boiler.
2. Cooling water from Cooling towers
3. Nitrogen from Nitrogen plant.
The steam from the Boiler is used to increase the temperature of the material inside the Reactor.
The steam is passed through the tubes which resides on the outer wall the reactor. These tubes
are shown in the figure below. The Reactor is heated to a specific temperature for the proper
mixing of the raw material. Cooling water from the cooling towers is used to cool the reactor.
Both cooling water and steam are passed through the same tubes. Entry and exit of the steam in
the tube is controlled by operating the valves. These valves are operated by the operator. If large
drop of temperature is required in the Reactor then chilling water is used.
In a cooling tower, cooling of the main mass of water is obtained by the evaporation of a small
proportion into the airstream. Cooled water leaving the tower will be 3-8 K cooler than the
incoming water. The capacity of the cooling towers at the Esteem Industries is 200 Ton.
After completion of process output is taken from reactor, it is generally in liquid form but if
customer wants the output in solid form then liquids passed through flaker machine which
converts the output in solid form.

Raw Material Stores

Figure 2 Raw material stores

Cooling Towers

Figure 3 Cooling towers

REACTOR

Reactors are generally vessels in which chemical reactions are performed. A chemical reactor
needs to be able to carry out at least three functions provide the necessary residence time for the
reactants to complete the chemical reaction, allow the heat exchange necessary, place the phases
into intimate contact to facilitate the reaction.
The chemical reaction involves high degree of risks posing to operator, process & environment.
Here arises the need for automation of the Reactor. The aim of the project is to suggest ways to
automate the reactor in terms of safety measures. The labour cost incurred in monitoring reactor
can be reduced by automating the reactor.
We are trying to automate safety (Pressure relief) valve and cooling water inlet valve.

Types of Reactor
Reactors are classified as:1. Batch Reactor
All reactants are added at the commencement the product withdrawn at the completion of the
reaction. They are conducted in tanks attached with impellers,
Gas bubbles or pumps.
2. Continuous Stirred Tank Reactor (CSTR)
One or more fluid reagents are introduced into a tank reactor equipped with an impeller while the
reactor effluent is recovered. A stepped up concentration gradient exists.
3. Plug Flow Reactor (PFR)
One or more fluid reagents are pumped through a pipe or tube. These are characterized by
continuous gradients of concentration the direction of flow.
4. Stirred Tank Reactor
The stirred tank reactor can be considered the basic chemical reactor; modeling on a large scales
the conventional laboratory flask. Tank sizes range from a few liters to several thousand liters.
They are used for homogeneous and heterogeneous liquid-liquid and liquid-gas reactions and for

reactions that involve freely suspended solids, which are held in suspension by the agitation. As
the degree of agitation is under the designers control, stirred tank reactors are particularly
suitable for reactions where good mass transfer or heat transfer is required.
When operated as a continuous process the composition in the reactor is constant and the same as
the product stream and except for very rapid reactions, this will limit the conversion that can be
obtained in one stage. The power requirements for agitation will depend on the degree of
agitation required and will range from about 0.2kW/m3 for moderate mixing to 2kW/m3 for
intense mixing.
5. Tubular Reactors
Tubular reactors are generally used for gaseous reactions, but are also suitable for some liquid
phase reactions. If high heat transfer rates are required small diameter tubes are used to increase
the surface area to volume ratio. Several tubes may be arranged in parallel, connected to a
manifold or fitted into a tube sheet in a similar arrangement to a shell and tube heat exchangers.
For high temperature reactions the tubes may be arranged in a furnace.

6. Packed bed Reactor

There are two basic types of packed bed reactor; those in which the solid is a reactant and those
in which the solid is a catalyst. In chemical process industries, the emphasize is mainly on the
designing of catalytic reactors. Industrial packed bed catalytic reactors range in size from small
tubes, a few centimeters diameter to large diameter packed beds. Packed bed reactors are used
for gas and gas-liquid reactions. Heat-transfer rates in large diameter packed beds are poor
therefore, where high heat-transfer rates are required, fluidized beds should be considered.
6. Fluidized bed Reactor
A fluidized-bed reactor is a combination of the two most common, packedbed and stirred tank,
continuous flow reactors. It is very important to chemical engineering because of its excellent
heat and mass transfer characteristics. The essential features of a fluidised bed reactor are that the
solids are held in suspension by the upward flow of the reacting fluid. This promotes high mass

and heat transfer rates and good mixing. Heat-transfer coefficients in the order of 200 W/m2 0C
to jackets and internal coils are typically obtained. The solids may be a catalyst, a reactant in
fluidized combustion processes or an inert powder, added to promote heat transfer. Though the
principal advantage of a fluidised bed over a fixed bed is the higher heat transfer rate, fluidised
beds are also useful where it is necessary to transport large quantities of solids as part of the
reaction processes, such as where catalysts are transferred to another vessel for Regeneration.
Fluidisation can only be used with relatively small sized particles, which is less than 300 m. This
is the limitation of the process.

REACTORS AT ESTEEM INDUSTRY

Esteem Industries uses two types of reactors- Glass coat and Stainless steel Reactor
Available in sizes: - 900Lit, 6 Ton, 9 Ton.
Reactor operating pressure: - 3-4 K Pa.
Reactor operating temperature: - 170 C to 180 C.

GLASSCOAT REACTOR :Glass coat reactor has inner lining of glass. This type of reactor is used is when products involve
H2SO4. H2SO4 reacts with S.S therefore reactor with inner glass lining is used.

STAINLESS STEEL REACTOR:The inner lining of this reactor is made up of stainless steel. This type of reactors are used when
product do not involve H2SO4. H2SO4 degrades the inner lining and affect the chemical reaction.

COMPONENTS OF REACTOR
Reactor is an integral part of chemical industry and the components are explained below.
Agitator: - Impeller anchor type agitators are offered with standard reactor. Agitator is used for
constantly stirring the mixture. The agitator is connected to the driving motor.
Thermowell:-Straight thermowell for anchor agitators, Bat or Finger type baffles with propellers
agitators.
Bottom outlet valve:-Flush bottom valve, Diaphragm valve, pneumatically operated flash
bottom valve. The reactor is connected to barrel via bottom outlet valve. Output material is
stored in this barrel. Bottom outlet valve can be used to interrupt the flow output material into the
barrel.
Manway cover:-spring loaded man way cover for convenient and safe operation Helical Gear.
Manway cover is used to feed input raw material into the reactor. Once the raw material is added
the manway cover is closed.
Motor
TEFC, Flang/Foot-mounted, flameproof motor, 1440 RPM
Voltage
: 415+ 10%
Frequency
: 50 Hz + 5%
Insulation
: Class F
Temp Class
: T3/T4
Degree of Protection : IP-55
1. Bearing housing
Self-aligned double ball bearing close to sealing diameters minimizes runout of agitators and
ensures remarkably longer life of gland packing/mechanical seals.
2. Shaft sealing
Shaft sealing is used to seal agitator shaft and the reactor interface so as to prevent pressure
loss. Types of shaft sealing used are as follows
Gland packing
Single mechanical seal
Double mechanical seal
3. Muff coupling

Specially designed two piece muff coupling facilities easy alignment of the gear output
shaft and agitators shaft and also provide rigidity. Muff coupling is used to connect driving shaft
connected to motor and driven shaft connected to the agitator. Muff coupling is used to
compensate the slight misalignment in the shafts
4. Hanger bolt
Hanger bolt specifically designed for the axial location of agitator. Hanger bolt is used to
hold bearing housing.

Reactor

Figure 4 Reactor

Figure 5 Reactor

Heating and cooling tubes on the outside surface

Figure 6 Cooling and Heating pipes for reactor

Reactor Valves

Figure 7 Reactor valves

Colour Codes For Pipelines

The following are the colour codes used in esteem industry. The purpose of colour codes is to
differentiate between various utilities connected to reactor. The colour codes are shown in above
diagram.
Green- Cooling water in and out.
Blue - Vaccum.
Orange - Nitrogen.
Red Fire water.
Yellow - Vent and Safety Regulatory valve

BOILER
INTRODUCTION
A boiler is an enclosed vessel that provides a means for combustion heat to be transferred to
water until it becomes heated water or steam. The hot water or steam under pressure is then
usable for transferring the heat to a process.

The boiler system comprises of: a feed water

system, steam system and fuel system. The feed water system provides water to the boiler and
regulates it automatically to meet the steam demand. Various valves provide access for
maintenance and repair. The steam system collects and controls the steam produced in the boiler.
Steam is directed through a piping system to the point of use. Throughout the system, steam
pressure is regulated using valves and checked with steam pressure gauges. The fuel system
includes all equipment used to provide fuel to generate the necessary heat. The equipment
required in the fuel system depends on the type of fuel used in the system.
The purpose of studying the Boiler the is to understand Boiler operation and calculate the Boiler
efficiency study the various factors affecting the Boiler efficiency and suggest ways to improve
the Boiler efficiency. If the efficiency of the Boiler is increased than proper utilization of the fuel
will take place and this will lead to saving of the fuel.

GENERAL BOILER ARRANGEMENT First the feed water is treated to remove hardness this is done in softeners using brine (mixture of
salt & water). The treated water is then fed to the boiler using valves by a pump. For optimum
operation of boiler VSDs (variable speed drives) are used which regulates feed water supplied to
the boiler as per requirement. After this fuel is burned in the burner and the combustion gases
produced converts feed water into steam in the combustion chamber. The steam is then supplied
to the required process. Boiler is provided with Blow down separator to control the increase in
pressure inside the boiler. Flue gases are passed through economizer to raise the temperature feed
water. Flue gases are then treated to remove dirt and ash content in ash collector after which
gases are passed through the chimney.

Figure 8 ideal boiler layout

TYPES OF BOILER
Various types of boilers are mentioned below.

1. Fire Tube Boiler

In a fire tube boiler, hot gases pass through the tubes and boiler feed water in the shell side is
converted into steam. Fire tube boilers are generally used for relatively small steam capacities
and low to medium steam pressures. As a guideline, fire tube boilers are competitive for steam
rates up to 12,000 kg/hour and pressures up to 18 kg/cm2. Fire tube boilers are available for
operation with oil, gas or solid fuels. For economic reasons, most fire tube boilers are of
packaged construction (i.e. manufacturer erected) for all fuels.

2.Water Tube Boiler

In a water tube boiler, boiler feed water flows through the tubes and enters the boiler drum. The
circulated water is heated by the combustion gases and converted into steam at the vapour space
in the drum. These boilers are selected when the steam demand as well as steam pressure
requirements are high as in the case of process cum power boiler / power boilers.
Most modern water boiler tube designs are within the capacity range 4,500 120,000 kg/hour of
steam, at very high pressures.

3.Packaged Boiler
The packaged boiler is so called because it comes as a complete package. Once delivered to a
site, it requires only the steam, water pipe work, fuel supply and electrical connections to be
made to become operational. Package boilers are generally of a shell type with a fire tube design
so as to achieve high heat transfer rates by both radiation and convection.

4. Fluidized Bed Combustion Boiler

Fluidized bed combustion (FBC) has emerged as a viable alternative and has significant
advantages over a conventional firing system and offers multiple benefits compact boiler
design, fuel flexibility, higher combustion efficiency and reduced emission of noxious pollutants

such as SOx and NOx. The fuels burnt in these boilers include coal, washery rejects, rice husk,
bagasse other agricultural wastes. The fluidized bed boilers have a wide capacity range- 0.5 T/hr.
to over 100 T/hr

BOILER EFFICIENCY
Calculation of boiler efficiency
Boiler efficiency=

Heat output
Heat input

Observed Parameters:Ms-steam per hour in kg=1000kg

Mf-fuel consumption per hour=225kg
C.V. - Calorific value of briquette
= (3500*4.184) =14644 KJ/kg

M s ( h ghf )100
M f G .C . V .

From steam tables:hf- Enthalpy of fluid=716.3 KJ/kg

hg- Enthalpy of steam=2766.4 KJ/kg

Substituting values in equation:-

Efficiency =

1000( 2766.4716.3)
22514644

=62.22%
Calculated efficiency of boiler at esteem industry=62.22 %

Factors affecting Boiler Efficiency

The different parameters affecting boiler efficiency is shown using ISHIKAWA diagram. As
shown the major factors affecting are Environment, Human condition, Amount of Air and
Impurities in feed water.

Figure 9 Fish bone

The main problem is reduction in Boiler efficiency, for which we have drawn the ishikawa
diagram. The various factors identified were environment, human, air, impuruities in water. Once
the factors were identified the subfactors controlling the main factors were also identified. Health
and experience of the operator would affect the Boiler efficiency. Experienced operator would
operate boiler more fluently. The second factor was environment the subfactors identified were
humidity, temperature and purity. Increase in humidity will result efficiency to reduce and
increase in temperature will result in increase in efficiency. Oxygen content in air affects the
combustion process. Impurities in water lead to decrease in boiler efficiency.

WAYS TO IMPROVE BOILER EFFICINCY

Various ways to improve the boiler efficiency are mentioned below. Implementing which boiler
efficiency can be improved.

1. Reduce Excess Air

Boilers are usually fired with more air than ideal stoichiometric fuel to air ratio in order to ensure
complete combustion of fuel to reduce carbon monoxide in the exhaust gasses, however energy

is wasted in cases where too much excess air is used, as the energy that can be transferred to the
steam is instead used to heat the air. Usually 15 % excess air (3% excess oxygen) is sufficient for
optimum operation of Boiler. This is the trial an error method in which inlet air is controlled
based on the flame.

2. Install an Economizer
Economizers transfer energy from the boiler exhaust gas to the boiler feed water in the form of
sensible heat. This sensible heat increases the temperature of feed water. On average, adding
standard economizer increases boiler system efficiency by 3 percent to 5 percent. Every
20degree Celsius decrease in flue gas temperature will give fuel saving of around %.

Figure 10 Economiser

Economiser Operation
Economizer is made up of large number of coils which carry feed water. Flue gases before
treatment are made to pass through economizer coils. The high temperature flue gases transfers
some amount of heat to feed water which raises temperature of feed water, hence energy required
to produce steam is reduced.
Profit from Economiser

Cost of briquette fuel per Kg = Rs 5.5

Fuel required per hour =225 per Kg
Fuel cost per day = 5.5*225*24
= Rs 29700/Since for 20 C rise in feed water temp. 1% fuel cost is saved total fuel cost saved
for 1 day is Rs. 297/Implementation cost of economizer is Rs. 90000/Cost of implementing economiser is cleared in one year Total profit in 4years
=fuel cost saved in 1 day*Number of days- Intial cost of economizer
=4*365*297-90000=343000/-

3. USE OF SOLAR ENERGY TO HEAT BOILER FEED WATER

India has very good conditions for the development of solar systems due mainly to the high mean
daily radiation and the high number of sunny days in most parts of the country. One of the best
features of rooftop solar systems is that they can be permitted and installed faster than other
types of renewable plants. They are clean, quiet, and visually unobtrusive. Users wont even
know that the rooftop plants are working there. Keeping in view the impending shortfalls in
conventional power generating sources and growing demand of energy, it is important to go for
non-conventional sources. Advantage of solar systems is that it has a long life upto 20 years.
Disadvantage of the solar system is that it requires high initial investment and it works only
during the day time.
Solar water heater can be used to heat the water upto 80 degree Celsius. Using heated water as
feed water for the boiler, the efficiency of the boiler can be increased. If we are able to increase
water temperature by 8 degree Celsius then about 1 percent of fuel cost is saved.
Presently the feed water temperature to the boiler is 40-45 degree Celsius. Our aim is to increase
the feed water temperature to 60 degree Celsius. Therefore fuel cost saved during solar hours
will be 2%.

Calculations:Cost of briquette fuel per Kg = Rs 5.5

Fuel required per hour = 225 per Kg
Total fuel cost per hour is Rs. 1237
Total fresh water required per day = 21KL
Formula used
Q = m*cp*dT
Q = 21000*4.19*(60-45)
= 1319850/(24*3600)
= 15.27 Kg/sec
= 15.27 KW
Cost for the installation of solar plant = 0.73$per Watt
Cost for the installation of solar plant = 15.27*1000*0.73*60
= Rs 668826
For 10 hour cost of fuel = Rs12370
Considering 2% of fuel cost saved.
Total amount saved per day= Rs 247.4
Period required to overcome the cost of solar plant= 7.4 years
The life of the solar plant will be 20 years and it will be requiring very less maintenance during
the operation period. Therefore for 12.6 years less amount of fuel will be required.

4 TDS Based Automatic Boiler Blow down System

Total dissolved solid (TDS) is the amount of solids dissolved in the water present in the Boiler.
Major sources of TDS are the salts present in feed water. Dissolved solids settle down and
accumulate as more feed water is fed. TDS can cause scaling of oiler inner lining and also
decrease heat transfer surface area and hence blowdown is necessary. Blowdown is the force
removal of water from the boiler. Boiler TDS varies with:

1) Feed water TDS:

If the feed water TDS increases then the Boiler TDS increases quickly for the same steam load.
2)

Steam Load:

If the steam load increases then the Boiler TDS increases quickly for the same feed water TDS.

To maintain the level of Total Dissolve Solids (TDS) inside the boiler within the permissible
limit, boiler water is drained periodically from the boiler. Following are the two methods used
for the same.

Manual Blow down

TDS Based Automatic Blow down

In manual blow down, the blow down pattern is fixed irrelevant of the change in feed water TDS
or Steam Load on boiler.
Hence sometimes there is excess blow down from the boiler & sometimes lesser Blow Down.
Both of the excess or lesser Blow down is not Advisable.
Excess Blow down will Cause:

Increase in Fuel Consumption as Loss of energy in the form of hot

water from boiler

Increase in water consumption

Increase in makeup water cost & its chemical treatment cost

Lesser Blow down will Cause:

High TDS level inside Boiler

Foaming on water level inside boiler which may mislead the Mobrey level control & lead
to accident

Foaming also results in moisture carryover

TDS Based Automatic Boiler Blow Down System

The system comprises a sensor chamber with conductivity sensor and temperature sensor,
mounted in bypass to the Manual Blow down Valve. The sensor is connected to the controller
that constantly monitors and displays the TDS level & takes the control action whenever
necessary.

AUTOMATIC BLOWDOWN SYSTEM

BLOW DOWN MODE

VALVE CLOSED

WORKING OF THE SYSTEM

The system works by periodically opening the sampling valve in order to purge the pipe
work and set up a flow of boiler water past the sensor. To avoid wasteful blowdown especially
whilst a boiler is on standby or low load, the period between each purge is automatically related
to the steam load by monitoring the time the boiler is firing. The controller measures the level of
TDS (total dissolved solids) of the boiler water. The measured value and the set point in the
controller are compared. If it is lower than the set point the blow down valve closes at the end of
the purge time (typically 10sec) and remains closed. If it is higher than the set point the
controller continues the blow down cycle until the measured value drops below the set point.
Light on the facial panel indicate when the TDS is normal or when the blowdown cycle is
Operating. The system is easy to calibrate and commission and the set point can be quickly
adjusted.

THE CONTROLLER
The Unique Controller incorporates state of the art features to optimize your blowdown cycle,
protect your steam system and save your money. With microprocessor based electronics a 4 Digit
LED continuous display of TDS and system status and simple Push Button interface for easy
commissioning, calibration and operation.
Other features include high TDS alarm relay output for remote indication , an advance probe
Conditioning circuit that automatically descales the conductivity probe and Automatic
Temperature compensation.

5 Economic Thickness of Insulation

Economic thickness of insulation is the thickness upto which heat loss increases and is maximum
at this value and decreases with further increase in the thickness. Insulation of any system means
capital expenditure. Hence the most important factor in any insulation system is to analyse the
thermal insulation with respect to cost. The effectiveness of insulation follows the law of
decreasing returns. Hence, there is a definite economic limit to the amount of insulation, which is

justified. An increased thickness is uneconomical and cannot be recovered through small heat
savings. This limiting value is termed as economic thickness of insulation.
Area of application:Boilers are an integral part of any industry. Esteem industry has 24 hour steam requirement and
thus large steam requirement. High temperature steam is transferred through steel pipes which
lead to large amount of heat loss through convection. Thus the need for implementation of proper
thickness of insulation.

Method used:The simplest method of analyse economic thickness of insulation is by comparing the cost of
energy saved and cost of insulating the pipe for 1 inch,2inch and 3 inch thickness. Each industry
has different fuel cost and boiler efficiency. These values can be used for calculating economic
thickness of insulation aim is to determine the thickness which will save the maximum.
Parameters to be calculated:The determination of economic thickness requires the attention to the following factors.
Cost of fuel = 5 Rs/Kg

ii. Annual hours of operation = 8000hrs

iii. Heat content of fuel = 14644 KJ/Kg

iv. Boiler efficiency = 62.22%

v. Operating surface temperature = 120 C

vi. Pipe diameter/thickness of surface = 152.4 mm

vii. Ambient still air temperature = 30 C

COST SAVINGS
I.

Heat energy = calorific value of fuel*mass of fuel per second*hours of operation

annually
= 14644*225/3600*8000
= 7322000KWh/year

II.

Fuel cost annually = fuel cost /Kg*fuel fed/hour * annual hours operation
= 5*225*8000
= 9000000Rs/year

III.

Heat energy cost = 9000000/7322000

=1.23Rs/KWh

1. Savings with 1 inch thickness =1.23*188632

=232017.36 Rs/year
Implementation cost =50*265
= Rs. 13250
Total savings = 232017.36-13250
=218767Rs/year
2. Savings with 2 inch thickness =1.23*189264
=232794.72/year
Implementation cost = 50*370
= Rs.18500
Total savings = 232794.72-18500
=214294.72 Rs/year
3. Savings with 3 inch thickness= 1.23*189952

= 233640.96Rs/year
Implementation cost=50*500
= Rs. 25000
Total savings = 233640.96-25000
= 208640.96Rs/year

IV.
V.

The data above shows that 1 inch thickness gives maximum cost savings and hence is the
economic thickness of insulation.
Thus we can conclude that implementation of 1 inch thickness will reduce heat loss.

Preventive maintenance operation for Boiler

Boiler is an integral part of an industry. Boiler is also an expensive equipment. As boiler are
operated under high pressures failure of any part of boiler can result in severe injuries to the
operator and nearby personnels. Hence preventive maintenance is essential for any boiler. Below
are some of thhe ways to carry out preventinve maintenance for the boiler.

1. Installing meters on makeup water lines to monitor flow.

If the system is closed-loop, installing meters in the system helps detect leaks.
Closed loop systems are one in which steam condensate is reused in the boiler.

Installing flow meters can help detect source of the leaks.

Blowing down routinely without overdoing it. Excessive blow-down wastes water,
chemicals and energy.

2. Blowing down routinely without overdoing it. Excessive blow-down

wastes water, chemicals and energy.

Blowdown is the forced removal of boiler water along with salts settled in the bottom.

Blowdown is necessary as the salts from feed water will keep on increasing and lead to
scaling and decrease in heat transfer area.

TDS stands for total dissolved salts, TDS meters are available for checking TDS value,
regular TDS checking is necessary

3. Checking insulation on piping and storage tanks.

Monthly visual inspection is required.

Insulation pipes need to be checked as any pipe surface without insulation will lead to
high energy loss as high temperatures are encountered.

Insulation thickness needs to be of correct value.

4. Cleaning and inspecting water and fire tubes regularly to reduce

scaling.

Water and fire tubes are to be cleaned whenever possible as any scales will lead to heat

loss.
This process increases as the heat gets absorbed and makes the system more efficient. It

also helps maintain proper emissions.

The most common maintenance issues include steam-side or waterside deposits retarding

heat transfer, flow obstructions, corrosion, fatigue, and erosion.

PM techniques include visually inspect tubing to detect discoloration, distortion, swelling
or surface damage.

5. Checking safeties, including primary and auxiliary low-water cutoffs,

gauge glass, pressure controls, scanners, and pressure switches.

Inspect water column gauges, blow down the gauge to keep it clean and easily readable.

Inspect valves visually to ensure that there is no rust buildup impeding its operation.

If there are any leaks have the valve replaced.

Keep the valve wide open for at least 10 seconds to blow dirt and scale clean from the
seat. Close the valve by suddenly releasing the lever.

6. Tuning boilers regularly to optimize performance.

Excessive soothing results from incomplete combustion. If technicians notice it while

cleaning, it might indicate they need to fine-tune the fuel-to-air mixture.

Optimal boiler performance correlates strongly with reduced wear on components.

7. Inspecting steam traps and steam lines routinely for leaks.

Visual inspection depends on a release valve situated downstream of certain traps. valve
needs to be opened and checked if the trap is discharging condensate or steam.

Acoustic techniques can be used to listen

and detect steam trap operations and

malfunction. Types of listening devices are stethoscopes, screwdrivers, mechanical

stethoscopes and ultrasonic detection instruments.

Thermal inspection relies on upstream/downstream temperature variations in a trap. It

includes infrared, heat bands (wrapped around a trap, they change color as temperature
increases), and heat sticks (which melt at various temperatures).

REACTOR AUTOMATION

INTRODUCTION
In chemical/pharmaceutical industry, the reactors are the vital equipment which ensures the
achieving of desired product. Reactors ensure that the reaction proceeds with the highest
efficiency towards the desired output product, producing the highest yield of product while
requiring the least amount of resource to operate. Reactor operating expenses include energy
input, energy removal, raw material costs, labor, etc. Energy changes can come in the form of
heating or cooling, pumping to increase pressure, agitation, etc. The use of batch reactors is most
suitable when switching from one process or product to another. The various processes like
Hydrogenation, Halogenation, Grignard Reactions, Crystallization, Distillation etc., are carried
in contained operation. The chemical reaction involves high degree of risks posing to operator,
process & environment.

NEED OF AUTOMATION
Chemical reactions are the critical process in the pharmaceutical industry in this process, various

levels of risks are involved in the process demanding the process and parameters monitoring/
controlling. The aim of automation is handle the required operations in effective manner to
achieve

High productivity

Less Operational Cost

In focus to Personnel Safety & Plant Safety

Adherence to Regulatory Needs

Guidance of Quality Systems

The efficient system needs stringent process monitoring & controlling involves Temperature,
Utility, Pressure, Agitator,

Scada control system

CONTROL SYSTEM (SCADA SYSTEM).

A control system with Open architecture design provides complete flexibility, high performance
& ease of operation to the end user. The high-performance processor is considered which is
capable of multi-tasking, best memory management & high reliable. Remote I/O modules for
far spread blocks. HMI at various production blocks for ease of operation. Remote process
monitoring is performed by SCADA and various management information reports. The system
uses advanced software tools and components to build the necessary logic for better process

controlling and process. The software includes features like Graphics, Trending, History and
reports on customized formats.
Open architecture is a type of computer architecture or software architecture that is designed to
make adding, upgrading and swapping components easy. For example, the IBM PC and Apple
Iie have an open architecture supporting plug-in cards, whereas the Apple IIc and Amiga 500
computers have a closed architecture. In a closed architecture, the hardware manufacturer
chooses the components, and they are not generally intended to be upgraded by the end-user.
Data acquisition (DAQ) is the process of measuring an electrical or physical phenomenon such
as voltage, current, temperature, pressure, or sound with a computer. A DAQ system consists of
sensors, DAQ measurement hardware, and a computer with programmable software. Advantech
is a global leader in remote IO module, offering complete stand-alone data acquisition modules
which are broadly used in ItT or other industrial applications, such as facility monitoring,
environment monitoring, and industrial process control. Advantech distributed remote IO
modules are categorized into two families,

Ethernet IO (ADAM-6000 series)

RS-485 IO (ADAM-4000 series)

which are subdivided into Analog IO and Digital IO modules. Some of them support Modbus
RTU communication protocol. the main difference between ADAM 4000 and ADAM 6000 is the
communication interface ADAM 6000 modules leverage ethernet while ADAM4000 modules
adap RS-485 and latter one less in cost compared to former.

A SCADA system usually consists of the following subsystems:

Remote terminal units (RTUs) connect to sensors in the process and convert sensor signals to
digital data. They have telemetry hardware capable of sending digital data to the supervisory
system, as well as receiving digital commands from the supervisory system. RTUs often have
embedded control capabilities such as ladder logic in order to accomplish Boolean logic
operations.
Programmable logic controller (PLCs) connect to sensors in the process and convert sensor
signals to digital data. PLCs have more sophisticated embedded control capabilities (typically
one or more IEC 61131-3 programming languages) than RTUs. PLCs do not have telemetry
hardware, although this functionality is typically installed alongside them. PLCs are sometimes
used in place of RTUs as field devices because they are more economical, versatile, flexible, and
configurable their cost is above Rs 3000/A telemetry system is typically used to connect PLCs and RTUs with control centers, data
warehouses, and the enterprise. Examples of wired telemetry media used in SCADA systems
include leased telephone lines and WAN circuits. Examples of wireless telemetry media used in
SCADA systems include satellite (VSAT), licensed and unlicensed radio, cellular and
microwave.
A humanmachine interface or HMI is the apparatus or device which presents processed data
to a human operator, and through this, the human operator monitors and interacts with the
process. The HMI is a client that requests data from a data acquisition server.
A Historian is a software service which accumulates time-stamped data, Boolean events, and
Boolean alarms in a database which can be queried or used to populate graphic trends in the
HMI. The historian is a client that requests data from a data acquisition server.
A supervisory (computer) system, gathering (acquiring) data on the process and sending
commands (control) to the SCADA system. Communication infrastructure connecting the
supervisory system to the remote terminal units.

How SCADA Works

A SCADA system, at the machine level, consists of a central station for gathering data and
managing the overall operation. It also has sensors (these could be RTUs, or PLCs) placed near
to where the action is. The RTU or the PLC collects the information locally and then passes it on
to the central station. This can be located several miles away.
RTUs and PLCs today are capable of controlling the actions within their range of vision through
closed loop feedback systems. The central station oversees the overall performance of the one or
more RTUs/ PLCs under its control. SCADA systems also allow staff or supervisors to change
the settings as appropriate at the level of the RTU or the central station. Alarming conditions like
high temperature can then be stored and displayed.

1. SENSORS
In the industrial automation section, sensors play a very important role to make the products
intelligent and highly automatic. These allow one to detect, analyze, measure and process various
changes like change in position, length, height, appearance and displacement that occurs in the
production sites. These sensors also play an important role in predicting and preventing many
future events, thus, catering to the needs of many sensing applications. The following are the
various types of sensors used in industrial automation: Proximity sensors, Vision sensors,
Ultrasonic sensors, Position sensors, photoelectric sensors, Temperature sensors, Inclination
sensors, etc. in our case important factors are TEMPERATURE and PRESSURE.

TEMPERATURE SENSORS
A device that gathers information related to temperature from a source and then converts it into a
form that can be easily understood by an observer or any other device. These are the most
commonly used sensors in the present world, a very good example being a thermometer. These
sensors are used to measure the temperature of a medium so that they can be controlled. There
are two types of temperature sensors- Contact sensors and Non-contact sensors.

Contact Sensors:
As the name suggests, this sensor measures the temperature of the object to which the sensor is
in contact with. However, it has a limitation, that is both the sensor and the object should be in
thermal equilibrium that is there should not be any flow of heat between them.

Non-Contact Sensors:
On contrary to the contact sensors, these measure the heat radiations from the environments
within a given area. These do not need to be in actual contact with the object. Many non-contact
sensors now a days are being used to control temperature as well as humidity of an area and to
make the area comfortable for us.

CONTACT TYPE TEMPERATURE SENSORS

1. RTD

Resistance thermometers, also called resistance temperature detectors (RTDs), are sensors used
to measure temperature by correlating the resistance of the RTD element with temperature. Most
RTD elements consist of a length of fine coiled wire wrapped around a ceramic or glass core.

The element is usually quite fragile, so it is often placed inside a sheathed probe to protect it. The
RTD element is made from a pure material, typically platinum, nickel or copper. The material
has a predictable change in resistance as the temperature changes and it is this predictable change
that is used to determine temperature. They are slowly replacing the use of thermocouples in
many industrial applications below 600 C, due to higher accuracy and repeatability. Common
RTD sensing elements constructed of platinum, copper or nickel. COST RANGES FROM 100010000/Advantages and limitations
The advantages of platinum resistance thermometers include:

High accuracy

Low drift

Wide operating range

Suitability for precision applications.

Limitations: RTDs in industrial applications are rarely used above 660 C. At temperatures above
660 C it becomes increasingly difficult to prevent the platinum from becoming contaminated by
impurities from the metal sheath of the thermometer. This is why laboratory standard
thermometers replace the metal sheath with a glass construction. At very low temperatures, say
below -270 C (or 3 K), because there are very few phonons, the resistance of an RTD is mainly
determined by impurities and boundary scattering and thus basically independent of temperature.
As a result, the sensitivity of the RTD is essentially zero and therefore not useful.[citation needed
Compared to thermistors, platinum RTDs are less sensitive to small temperature changes and
have a slower response time. However, thermistors have a smaller temperature range and
stability.

2.THERMOCOPLE

Overview of thermocouple connection

A thermocouple is a temperature-measuring device consisting of two dissimilar conductors that
contact each other at one or more spots, where a temperature differential is experienced by the
different conductors (or semiconductors). It produces a voltage when the temperature of one of
the spots differs from the reference temperature at other parts of the circuit. Thermocouples are a
widely used type of temperature sensor for measurement and control and can also convert a
temperature

gradient

into

electricity.

Commercial

thermocouples

are

inexpensive,

interchangeable, are supplied with standard connectors, and can measure a wide range of
temperatures. In contrast to most other methods of temperature measurement, thermocouples are
self-powered and require no external form of excitation. The main limitation with thermocouples
is accuracy; system errors of less than one degree Celsius (C) can be difficult to achieve.
Any junction of dissimilar metals will produce an electric potential related to temperature.
Thermocouples for practical measurement of temperature are junctions of specific alloys which
have a predictable and repeatable relationship between temperature and voltage. Different alloys
are used for different temperature ranges. Properties such as resistance to corrosion may also be
important when choosing a type of thermocouple. Where the measurement point is far from the
measuring instrument, the intermediate connection can be made by extension wires which are

less costly than the materials used to make the sensor.

Thermocouples are widely used in science and industry; applications include temperature
measurement for kilns, gas turbine exhaust, diesel engines, and other industrial processes.
Thermocouples are also used in homes, offices and businesses as the temperature sensors in
thermostats, and also as flame sensors in safety devices for gas-powered major appliances.

NON-CONTACT THERMOCOPLES
INFRARED THERMOMETER
Infrared thermometer is a thermometer which infers temperature from a portion of the thermal
radiation sometimes called blackbody radiation emitted by the object being measured. They are
sometimes called laser thermometers if a laser is used to help aim the thermometer, or noncontact thermometers or temperature guns, to describe the device's ability to measure
temperature from a distance. By knowing the amount of infrared energy emitted by the object
and its emissivity, the object's temperature can often be determined. Infrared thermometers are a
subset of devices known as "thermal radiation thermometers.The most basic design consists of a
lens to focus the infrared thermal radiation on to a detector, which converts the radiant power to
an electrical signal that can be displayed in units of temperature after being compensated for
ambient temperature. This configuration facilitates temperature measurement from a distance
without contact with the object to be measured. These are used

in applications where

conventional sensors cannot be employed .Specifically, in cases dealing with moving objects
(i.e .rollers ,moving machinery, or a conveyer belt), or where non-contact measurements are
required because of contamination or hazardous reasons (such as high voltage), where distances
are too great, or where the temperatures to be measured are too high for thermocouples or other
contact sensors .there cost- is around- is Rs 2000-20000/-

Types of infrared thermometers

The most common infrared thermometers are the:

Spot Infrared Thermometer or Infrared Pyrometer.

Infrared Scanning Systems.

Infrared Thermal Imaging Cameras

1. Spot Infrared Thermometer or Infrared Pyrometer

Spot Infrared Thermometer or Infrared Pyrometer, which measures the temperature at a spot
on a surface (actually a relatively small area determined by the D:S ratio)The distance-to-spot
ratio (D:S) is the ratio of the distance to the object and the diameter of the temperature
measurement area. For instance if the D:S ratio is 12:1, measurement of an object 12 inches (30
cm) away will average the temperature over a 1-inch-diameter (25 mm) diameter spot.

2. Infrared Scanning Systems

Infrared Scanning Systems scan a larger area, typically by using what is essentially a spot
thermometer pointed at a rotating mirror. These devices are widely used in manufacturing

involving conveyors or "web" processes, such as large sheets of glass or metal exiting an oven,
fabric and paper, or continuous piles of material along a conveyor belt.

3. Infrared Thermal Imaging Cameras

Infrared Thermal Imaging Cameras or Infrared Cameras are essentially infrared radiation
thermometers that measure the temperature at many points over a relatively large area to
generate a two-dimensional image, called a thermogram, with each pixel representing a
temperature. This technology is more processor- and software-intensive than spot or scanning
thermometers, and is used for monitoring large areas. Typical applications include perimeter
monitoring used by military or security personnel, inspection / process quality monitoring of
manufacturing processes, and equipment or enclosed space hot or cold spot monitoring for safety
and efficiency maintenance purposes.

LIMITATIONS
Sometimes, especially near ambient temperatures, false readings will be obtained indicating
incorrect temperature. This is most often due to other thermal radiation reflected from the object
being measured, but having its source elsewhere, like a hotter wall or other object nearby - even
the person holding the thermometer can be an error source in some cases. It can also be due to an
incorrect emissivity on the emissivity control or a combination of the two possibilities.

PRESSURE SENSORS
Pressure must be considered when designing many chemical processes. Pressure is defined as
force per unit area and is measured in English units of psi and SI units of Pa.

1. Elastic Sensors

Most fluid pressure sensors are of the elastic type, where the fluid is enclosed in a small
compartment with at least one elastic wall. The pressure reading is thereby determined by
measuring the deflection of this elastic wall, resulting in either a direct readout through suitable
linkages, or a transduced electrical signal. Elastic pressure sensors are sensitive; they are
commonly fragile and susceptible to vibration, however. In addition, they tend to be much more
expensive than manometers, and are therefore preferentially used for transmitting measured data
and measuring pressure differences. A wide variety of flexible elements could conceivably be
used for elastic pressure sensors; the majority of devices use some form of a Bourdon tube,
bellows, or diaphragm.

2. Electric Sensors

Sensors today are not necessarily only connected to a gauge meter needle pointer to indicate
pressure, but may also serve to convert the process pressure into an electrical or pneumatic
signal, which can be transmitted to a control room from which the pressure reading is
determined. Electric sensors take the given mechanics of an elastic sensor and incorporate an
electrical component, thus heightening the sensitivity and increasing the amount of instances in
which you could utilize the sensor. The types of pressure transducers are capacitive, inductive,
reluctive, piezoelectric, strain gauge, vibrating element, and potentiometric.

2. RTU

A remote terminal unit (RTU) is a microprocessor-controlled electronic device that interfaces

objects in the physical world to a SCADA (supervisory control and data acquisition) system by
transmitting telemetry data to a master system, and by using messages from the master
supervisory system to control connected objects Another term that may be used for RTU is
remote telecontrol unit or Remote terminal units (RTUs) connect to sensors in the process
and convert sensor signals to digital data. They have telemetry hardware capable of sending
digital data to the supervisory system, as well as receiving digital commands from the
supervisory system. RTUs often have embedded control capabilities such as ladder logic in order
to accomplish boolean logic operations

3. HMI

Supervisory Control and Data Acquisition (SCADA) systems require a Human Machine
Interface (HMI). This interface presents data collected from Remote Telemetry Units (RTUs) and
Intelligent Electronic Devices (IEDs). It also allows an operator to control the RTUs / IEDs or
connected equipment. The SCADA HMI is a core component of a Remote Monitoring and
Controlling System.
A SCADA HMI, can provide a number of helpful extensions for network alarm management.
RTU data can be filtered, analyzed and monitored against operational standards. Out-of-range

data can generate alerts to operators or maintenance personnel as required.

The HMI is a critical component of a network monitoring system. Without an HMI installed
within the SCADA network, operators would be unable to see or act upon the data gathered by
RTUs and individual sensors. An HMI program not only allows operators to understand this data,
but can also provide operators extensive reports related to network alarms.

SCADA
SCADA (supervisory control and data acquisition) is a system operating with coded signals over
communication channels so as to provide control of remote equipment (using typically one
communication channel per remote station). The control system may be combined with a data
acquisition system by adding the use of coded signals over communication channels to acquire
information about the status of the remote equipment for display or for recording functions. It is
a type of industrial control system (ICS). Industrial control systems are computer-based systems
that monitor and control industrial processes that exist in the physical world. SCADA systems
historically distinguish themselves from other ICS systems by being large-scale processes that
can include multiple sites, and large distances. These processes include industrial, infrastructure,
and facility-based processes, as described below

Some of the significant features of a modern SCADA system are as follows:

User-friendly (windows/graphics) interface.

Automatic control.

Off-line processing.

Integrated environments.

Extensive Historical data manipulation.

Extensive processing power.

Extremely high data throughput.

Extremely quick response.

On-line complex electrical network analysis.

Real time supply/demand-side economic calculations.

Automatic voltage and power factor correction.

Distributed processing power.

Custom SCADA programming capability.

Software Languages used in SCADA Programming

Most SCADA systems are now programmed using standard interfaces whenever possible. Most
programs are written in C, or a derived programming language. You shouldn't have to dig that
deep unless you are a really advanced user. As a SCADA professional, you are required to
maintain the software programs on your SCADA systems. This includes updating software and
applying bug fixes and enhancements. You won't typically be working with the program code
itself.

IMPLEMENTATION OF 5S
Clean environment around us help to locate the problems easily and also the system appears to
be well maintained. All the multinational companies target a clean working environment for the
optimal working and to produce defect free items. Clean environment around us gives a pleasant
filling and all the workres fill fresh and motivated during the working hours.
One way to achieve clean environment is 5s. the 5s takes into account cleanliness,
standardization, sorting out the important required or equipments. The detailed explanation of the
5s is explained below.

WHY 5S
The 5S concept is easy for everyone to understand because:
It does not require the understanding of difficult terminologies.
It is simple, driven by logic and natural to human behavior.
It is within the reach of all type and size of industry or organisation.
5S is a management tool from Japan, that focuses on establishing a quality environment in the
organization , ensuring adherence to standards and in the process, fosters the spirit of continual
improvement. It focuses on five management techniques that are the
foundation for any organisations competitive initiative. The 5s are defined with examples as
follows.

SORT
To sort and systematically discard items that are not needed in the workplace. Identify what is
necessary.

SET IN ORDER
To arrange necessary items in a neat and systematic manner so that they can be easily retrieved
for use and to return after use. Define what and how to arrange.

SHINE
To clean and inspect the workplace thoroughly so that Identify dirt sources.

Identify root causes.

Take action to eliminate dirt sources and root causes.

STANDARDISE
To maintain a high standard of workplace organisation by keeping everything clean and orderly
at all times.

SUSTAIN
To train people to practice the 5S system continuously so that it becomes habitual and ingrained
in the culture of the organisation. Everyone understands, obeys and practices the rules and
procedures

The benefits are:

Workplace becomes cleaner and better organised.
Shop floor and office operation becomes safer.
Visible results enhance the generation of more and better ideas.
Lead-time reduced.
Changeover time reduced by streamlining operations.
Breakdowns and minor stops eliminated on production lines.
Defects reduced by mistake proofing.
Clear methods and standards are established.
In-process inventory is reduced.
Space usage is improved.
Customer complaints are reduced.

HOWTO INITIATE QE 5s IMPLEMENTATION

PLAN
Preparation:

Provide training and education for everyone.

Form 5S Council.
Set-up 5S Zones.
Determine 5S objectives, goals and implementation phases.
Plan 5S action plan and 5S Launch.

ROADMAP TO 5S IMPLEMENTATION

Figure 11 Roadmap to 5s

STEP 1 : FORMATION OF 5S COUNCIL

Objectives:
To enhance total participation at all levels of employees and develop a continuous improvement
culture and best performance spirit in the teams.
5S Council
5S Council comprises the following:
5S Steering Committee
Managing Director as Advisor
General Manager as Chairman
Head of Departments as Facilitators
5S Training Committee
5S Promotion Committee
The 5S Steering Committee are responsible for developing the implementation plan, and the
selection of team members.
5S implementation responsibilities are to be distributed throughout the organisation. Every
member must know their own 5Sresponsibilities and perform accordingly.
STEP 2 : - SET-UP 5S ZONES
5S Coordinator will demarcate the zones. 5S Facilitators will assign responsibilities and divide
activities into manageable tasks. This involves:
Obtaining the layout of the entire work area and dividing each section into small zones
Assigning one team to each section, determining the number of people per team, and displaying
the names of team members and their areas
Ensuring that at least one person is assigned to each section and there is a leader for every team
Ensuring that section size and team strength are uniform
Defining who is responsible for shared spaces
STEP 3 :- 5S TRAINING
Objectives:
To disseminate 5S methodology and prepare the workforce
for meaningful participation in 5S activities.

This training programme, which is the starting point of 5S:

Step-by-Step Implementation, encourages workers to become
actively involved in the application exercises

STEP 4: -5S DECLARATION / LAUNCH

Objectives:
To announce the promotion plan for the sole purpose of Promoting the establishment of 5S
activities. Guidelines for 5S Launch:
Announcement of 5S Policy, Objectives and Goals
Announcement of 5S Zones

RAW MATERIAL STORES LAYOUT

Proper space utilization is very important, therefore we have presented a new layout which can
increase the storage capacity of the raw material stores. Bit changes and more investment can
increase the storage capacity of the plant. Present layout with calculations is presented and the
revised layout with calculations is also provided. Up to 5 meters of height can be used but
presently only 3.27 meter height is used. Layout with both the heights is provided.
RAW MATERIAL STORES PRESENT LAYOUT

Present layout 1

Dimensions of raw material store

Length = 28 m
Width =23.53 m
Height which can be utilized = 5m
Present height of racks = 3.27m

Area of raw material store = 658.84sq m

Volume of raw material store =3294.2 m3
Calculations for the height of 3.27m
Area of racks = 26.56+26.56*2+23.86*2
=127.4sq m
Volume of racks = 416.598 cubic m
Volume Ratio = 416.598/3294.2
= 0.1264
Calculations for the height of 5m
Volume of racks if 5 m is utilized = 637 cubic m
Ratio volume = 0.19337
% increase in storage w.r.t present = (637-416.598)*100/416.598
=52.9%

RAW MATERIALS STORE REVISED LAYOUT

Revised layout 1

Area of racks= (22.09*1)*2 + (22.09*2)*2+ (13.53*2)

=44.18+88.36+27.06=159.6sq. m
Calculations for the height of 3.27m with revised layout
For height=3.27 m

Volume=521.892 cubic m
Ratio of volume=0.1584
% increase w.r.t present=25.274%

Calculations for the height of 5m with revised layout

For height=5 m
Volume=798 cubic m
Ratio of volume=0.2422
% increase w.r.t present=91.55%
Volume ratio with original layout of raw material store was found to be0.1264. This ratio can be
increased by revising the stack height to 5 m and the volume ratio was found to be 0.19337 in the
present layout. After changing the arrangement of racks the percentage increase was 91.55 %
with respect to present system. If we incorporate the 5m stack height in the new arrangement
maximum achievable volume ratio is 0.2422.

Conclusion
The project study and improvement in the operations of chemical plant was undertaken at
Esteem Industries Valpoi. The company wanted to automate the manual operation of a of a
reactor and also to improve efficiency of their Boiler.
Methods shown to improve efficiency of boiler includes reduce excess air, install an economizer,
TDS Based Automatic Boiler Blow down System, use of solar energy to heat feed water to boiler
and economic thickness of insulation with their associated cost savings. Layout of an automated
reactor is also provided with associated detail. To improve the working conditions of the plant,
ways to implement 5s were suggested.
Working on this project taught us many things about industry works and what are the roles
carried out by a mechanical engineer. Through this project we got an in depth knowledge of the
boiler and reactor and how to reduce losses.

Future scope

Reactor automation concept can also be used to automate other utilities of the plant.
We have only shown how solar power can be used to heat feed water and other methods

of heating feed water can also found.

Application of solar power is only shown to heat feed water to boiler but solar energy can
also be utilized in the plant

Softwares used
1) Corel iGrafx Enterprise v15.0.1.1547
2) Solid works 2013
3) Tex studio 2.8.6
4) Microsoft word 2013
5) Microsoft powerpoint 2013

References:
1) B. Divya and P. Rajani, International journal of innovative research and deelopement, volume
2 issue 7
2) Khurmi R.S.(2003), Refrigeration and Air Conditioning,Eurasia Publishing House(P)
LTD,Ramnagar,New Delhi.
3) Spain David.(2010) Ways to Improve Efciency for Boilers,Nationwide Boiler
Inc.
4) Jinjala Bhavesh and Shukla Rashmikant N, International Journal of Innovative Research in
Science, Engineering and Technology.
5) Filler Bob.(1997),CIBO Energy Efficiency Hand book
6) Nag P.K.: Power Plant Engineering, TMH
7) Souvik Ganguli and Jasvir Singh, International journal of applied Engineering research,
Volume 1, No 2, 2010

ACKNOWLEDGEMENT
The satisfaction and euphoria that accompany the successful completion of any task would be
incomplete without the mentioning of the people whose constant guidance and encouragement
made it possible.
We take pleasure in presenting before you, our project, which is result of studied blend of both
research and knowledge.
We express our earnest gratitude to our internal guide, Professor, Department of BE, our project
guide, for his constant support, encouragement and guidance. We are grateful for his cooperation
and his valuable suggestions.
Finally, we express our gratitude to all other members who are involved either directly or
indirectly for the completion of this project.