IN PLANT TRAINING REPORT

PRAJ HIPURITY SYSTEMS LIMITED

MANUFACTURING UNIT, WADA PLANT

Mentor- Submitted by-

Mr. Deepak Arora, Hrushikesh Patil,
Manager, T.E. Chemical,
Praj HiPurity systems, MGMCET Kamothe,
Wada plant UID- 116CH1321A
 ACKNOWLEDGEMENTS
I’m highly indebted to Mr. Deepak Arora (Manager, Praj HiPurity systems
limited, Wada plant) for allowing me to pursue my Summer Vocational
Training through their Technical Training Cell in this organization.

I’d like to express my sincere and wholehearted thanks to my training guides

and I extend my deep sense of gratitude to all plant members for their valuable
suggestions during the whole training.

I also highly obliged to Dr. N.S. Kolhe, Head of Chemical Engineering

Department, MGMCET. I’m also thankful to departmental Inplant Training
coordinators and all faculty members of chemical engineering department for
their support.
 TABLE OF CONTENTS

1.Acknowledgement
2.Introduction and safety
3.Preparatory overview
4.Heavy shop overview
5.Module shop overview
6.QC overview
7.FAT overview
8. Water treatment plant
Introduction And Safety
▪About Praj
Praj HiPurity Systems is an end-to-end solutions provider to the Bio-pharmaceutical,
Biotech, Cosmetics, Healthcare and F&B sector for Sterile Process Water
Generation, Water for Injection, Storage and Distribution System, CIP/SIP, Systems
for Core Processes, Wastewater Treatment etc. These solutions find application in
the production of wide ranging products right from liquid orals to parentrals to
production of APIs, Ointments/Emulsions, Oncology Formulations etc. Each solution
is backed by technical inputs from Praj Matrix- R & D Center, the biopharma hub.

▪Safety
The safety program in the company works on the EOHS policy which means
Environmental, Occupational, Health and Safety policy. There is a compulsion
for wearing safety gears like safety shoes, helmet, ear plugs, eye glasses.
Various assembly points are created for safe evacuation of workers. The safety
approach mainly contains Human safety, Environment safety, Process safety.
Preparatory Overview
The material of construction used is SS304, SS304L, SS316 and SS316L from sizes 2mm to
50mm. Raw material is ordered as per the P&ID drawing requirement. The drawing shows
the each and every measurement details. Cutting is done by using regular cutter or by
plasma cutter as per the sizes. If the shop is unable to manufacture any part then the
cuttings are sent to the vendor. This material is known as semi-furbished material. The
cuttings of raw material are divided into three parts viz. i) Project material, ii) Off-cut
material, iii) Scrap material.
The project material is sent further to the next department for the construction of heat
exchangers, storage tanks, reactor vessels etc.
Heavy shop overview
Heavy shop mostly performs the fabrication process. The fabrication process mainly consists
of
1. Shell, dished end preparation
2. Shell, nozzle welding
3. Boxup
4. Limpet, jacket, dimple welding.

After fabrication process Insulation and Polishing is done. Process plants are manually
polished while pharma like other plants are polished by using electropolishing process. The
electropolishing process is carried out by using sulfur and potassium solution with current.
This removes crests on the wall which helps to reduce bacterial growth, removes foreign
particles, dust and strains.

Few tests are also done to check the working quality of the project viz.
1. Surface roughness test
2. Molybdenum test
3. Hydrostatic test
4. Spray ball test
5. Drainability test
6. Pneumatic test
Hydrostatic test is the commonly used test for checking leakages , pressure drop etc.
Sometimes pneumatic test is performed by using air flow and soap foam for finding
leakages.

Heat exchanger:
Heavy shop also performs the construction of heat exchangers. A heat exchanger is a piece of
equipment built for efficient heat transfer from one medium to another. The media may be
separated by a solid wall to prevent mixing or they may be in direct contact. They are widely
used in space heating, refrigeration, air conditioning, power plants, chemical plants,
petrochemical plants, petroleum refineries, natural gas processing, and sewage treatment. The
classic example of a heat exchanger is found in an internal combustion engine in which a
circulating fluid known as engine coolant flows through radiator coils and air flows past the
coils, which cools the coolant and heats the incoming air. There are two primary classifications
of heat exchangers according to their flow arrangement. In parallel-flow heat exchangers, the
two fluids enter the exchanger at the same end, and travel in parallel to one another to the other
side. In counter-flow heat exchangers the fluids enter the exchanger from opposite ends. The
counter current design is the most efficient, in that it can transfer the most heat from the heat
medium.
Heat exchangers are widely used in industry both for cooling and heating large scale industrial
processes. In many industrial processes there is waste 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.

Heat Exchanger (source-Google)

Module shop overview
Module shop mainly performs the piping work for the process. The major types of piping
used are process and power piping. The project is done on the basis of P&ID. The various
types of P&ID’s are,
1. Legend P&ID’s
2. Battery limit P&ID’s
3. Interconnecting P&ID’s
4. Process P&ID’s
5. Utility & off side P&ID’s
6. Utility distribution P&ID’s
7. Heat safety P&ID’s

Major process equipments are,

(1) Pumps

A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by

mechanical action. Pumps can be classified into three major groups according to the method
they use to move the fluid: direct lift, displacement, and gravity pumps.

Pumps operate by mechanism typically reciprocating or rotary, and consume energy to

perform mechanical work by moving the fluid. Pumps operate via many energy sources,
including manual operation, electricity, engines, or wind power.

Pumps are used to transport the fluids through the pipelines between different units and
different storage tanks. They are used to supply raw material to the unit as well as to
transport the ready product to the storage tank or further processing unit. In industries
mostly used pump is centrifugal pump. For some processes one can also use positive
displacement pump.

Centrifugal pump (source-Google)

 (2) Control valves

The most common final control element in process control industries is the control valve.
It manipulates a flowing fluid to keep the regulated process variable as close as possible
to the desired set point.

The control valve is designed to ensure accurate proportioning control of flow. It

automatically varies the rate of flow based on signals it receives from sensing devices in a
continuous process. Some valves are designed specifically as control valves. However,
most types of valves can be used as control valves, both linear and rotary motion, by the
addition of power actuators, positioners and other accessories.

The main functions of valves are:

 Stopping and starting flow.

 Reducing or increasing a flow.
 Controlling the direction of flow.
 Regulating a flow or process pressure.
 Relieve a pipe system of a certain pressure

The types of valves are:

Gate valve
Ball valve
Butterfly valve
Needle valve
Diaphragm valve
Check valve
Non-return valve

The other equipments used are pressure gauge, temperature indicator, flow
indicator/ switch, etc.
QC overview
Quality check department works on the P&ID’s and checks the required material as per the
ASME standards. Hydrostatic testing is done by the department when the project is
completed. The processes like passivation and electrolysis are done to test the quality of
the project.

FAT overview
This department works on the factory acceptance by the clients. The control panel designing
and checking is done by the respected person in the FAT department. The proper working of
the project is checked and re-checked in front of the client by this department.
WATER TREATMENT PLANT
Water is treated especially for drinking purpose, domestic use, industrial use and other uses.
Basically water treatment is consist of three main types:
1. Pre-treatment
2. Main treatment
3. Polishing treatment
These three types also contains various treatments.
1. Pre-treatment includes:
i) Clarification- to remove suspended solids
ii) Filtration- to remove suspended impurities
2. Main treatment includes:
iii) Softening- converts hard water to soft water
iv) De-mineralization- removes dissolved solids from water
v) Ultrafiltration- removes colloidal impurities, bacteria, algae etc by
membrane separation process
vi) Reverse osmosis- removes dissolved impurities by membrane
separation process

PW generation system ( source- Google)

Types of filters used are:
1.MGF- Multi grade sand filter
2.DMF- Dual media filter
3.ACF- Activated carbon filter
4.SSF- Side stream filter