A TECHNICAL VISIT REPORT On · Mitsubishi, Fuji, Danfoss, Telemecanique etc. R.C.P.I.T., Shirpur...

A TECHNICAL VISIT REPORT

On “Priyadarshani Sahakari Soot

Girni Ltd. and Water

Filteration Plant, Shirpur”

By

Department of Computer Engineering The Shirpur Education Society’s

R. C. Patel Institute of Technology Shirpur - 425405.

[2017-18]

A TECHNICAL VISIT REPORT

On “Priyadarshani Sahakari Soot

Girni Ltd. and Water Filteration Plant, Shirpur”

In partial fulfillment of requirements for the degree of Bachelor of Engineering

In Computer Engineering

Submitted By:

Department of Computer Engineering The Shirpur Education Society’s

R. C. Patel Institute of Technology Shirpur - 425405. [2017-18]

The Shirpur Education Society’s

R. C. Patel Institute of Technology Shirpur, Dist. Dhule (M.S.)

Department of Computer Engineering

CERTIFICATE

This is to certify that the technical visit report entitled “Priyadarshani

Sahakari Soot Girni Ltd. and Water Filteration Plant, Shirpur” has been carried out

by in partial fulfillment of the requirement

for the degree of Bachelor of Engineering in Computer Engineering of North

Maharashtra University, Jalgaon during the academic year 2017-18 (Sem-I).

Date: /10/2017 Place: Shirpur

IV Co-ordinator H.O.D. Principal Prof. Nitin N. Patil Prof. Dr. J. B. Patil

ACKNOWLEDGEMENT

I take this opportunity to express our heartfelt gratitude towards the

Department of Computer Engineering, RCPIT, Shirpur that gave us an

opportunity for the presentation of my technical visit in their esteemed organization.

It is a privilege for us to have been associated with Prof. R. J. Jaiswal and Prof. M. M. Mahajan, our coordinators during technical visit. I have been greatly

benefited by his valuable suggestion and ideas. It is with great pleasure that I

express my deep sense of gratitude for his valuable guidance, constant

encouragement and patience throughout the work.

I express my gratitude to Prof Nitin N. Patil [H.O.D. of Computer Engineering] for his constant encouragement, co-operation and support and also

thankful to all people who have contributed in their own way in making this visit

successful.

I am also thankful to Principal Prof. Dr. J. B. Patil for giving me the

necessary resources and support to complete my technical visit.

I take this opportunity to thank all our classmates for their company during the

course work and for the useful discussion I had with them.

Under these responsible and talented personalities I am efficiently able to

complete my technical visit in time with success.

i

INDEX

Chapter No.

Topic Page No.

-PRIYADARSHANI SOOT GIRNI-

1 INTRODUCTION 1

2 YARN MANUFACTURING PROCESS 3 2.1 Ginning 6 2.2 Blow Room 6 2.3 UNIMIX 7 2.4 CARD 8 2.5 CONNNECTION DIAGRAM 8 2.6 PERFORMANCE DATA & CAPABILITIES 12 2.7 ENERGY REQUIREMENTS 17

2.7.1 Signaling 17 2.7.2 Speed frame 19

2.8 HUMIDIFICATION 19 2.9 POWER DISTRIBUTION 20

-WATER FILTERATION PLANT-

3 INTRODUCTION 22 3.1 PROCESS OF WATER TREATMENT PLANT 22

4 REFERENCES AND BIBLIOGRAPHY 44

R.C.P.I.T., Shirpur

“A Technical Visit Report” 1

CHAPTER 1 INTRODUCTION

“PRIYADARSHNI SAHAKARI SOOT GIRNI LTD. ” is situated at village

Tande, 10 KM away from Shirpur town. It is established in 1997 – 98. Its

name covered its product. It’s a process industry manufacturing yarn, raw

material is cotton. This raw material is available from local area. The raw

purchasing activity depending upon its quality.

Initially it’s a 38000 spindle mill now a day it’s expansion work is in

progress. After completion of expansion 1, 25,000 spindle mills. Now a day

it’s production is 75000 kg./day means monthly production capacity 7500000

Kg., out of total capacity 90% is exports. Mill exports yarn directly and some

of the exports done through merchants in following area such as Korea, Japan,

German, Colombia, England etc.

Mill having the following department network.

R.C.P.I.T., Shirpur


Sr.

No.

Department Name Departmental Activity

1 Security Department It’s working area is around the mill.

These people taking care of material

in / out also taking care of safety.

2 Time Office These people taking care of

attendance of workers / staff and it’s

payment activity

3 Engg. Department Here electrical people taking care of

machines maintenance and attending

it’s break down.

4 Mechanical

department

These people taking care of machines

maintenance and attending it’s break

down.

5 Production

department

These people giving the line to

achieve final targeted product.

6 Quality Control Dept. These people giving the line to

achieve final product with good

quality as per the norms by taking

certain tests in quality control lab.

R.C.P.I.T., Shirpur


CHAPTER 2

YARN MANUFACTURING PROCESS

RAW MATERIAL

COTTON

GINNING PRESSING GODOWN

COMBER CARDING BLOW ROOM

MIXING ROOM

DRAW FRAME LDO/ 6

DRAW FRAME RSB851

SPEED FRAME

RING FRAME

YARN GODOWN

PACKING YARN CONDITIOINING

WINDING

RAW MATERIAL

AND GINNING

BLOW ROOM

PREPRATION RING FRAME

WINNDING YARN CONDITIONING AND PACKING

GODOWN

R.C.P.I.T., Shirpur


The above block diagram shows the process of manufacturing yarn.

To achieve final yarn with good quality, mill installed machine listed as

Unit – I

Sr.

No.

m/c name Model Make Quantity(No.)

1 Mixing bale opener L.M.W. 4

2 Mono cylinder L.M.W. 4

3 Deduster L.M.W. 4

4 Unimix L.M.W. 2

5 ERM/Flxiclean L.M.W. 4

6 Card LC300/LC300A L.M.W. 29

7 Comber LK250 L.M.W. 18

8 Comber E32 Rieter 5

8 Draw frame LDo/6 L.M.W. 4

9 Draw frame RSB 851 L.M.W.

/Rieter

9

10 Speed frame LF 1465 L.M.W. 12

11 Ring frame LG 5/1 L.M.W. 26

12 Ring Frame LR6 L.M.W. 12

13 Winding AC338 Schlafhorst 10

14 Yarn conditioner Contaxxor Xorella 01

R.C.P.I.T., Shirpur


Unit – II ( Expansion )

Sr.No. m/c name Model Make Quantity(No.)

1 Mixing bale opener L.M.W. 1

2 Mono cylinder L.M.W. 2

3 Deduster L.M.W. 2

4 Unimix L.M.W. 1

5 ERM/Flxiclean L.M.W. 1

6 Card LC300/LC300A L.M.W. 14

7 Comber E32 Rieter 10

8 Draw frame LDo/6 L.M.W. 4

9 Draw frame RSB 851 L.M.W.

/Rieter

4

10 Speed frame LF 1465 L.M.W. 5

11 Ring frame LR6 L.M.W. 6

12 Ring Frame RXI – E K.T.T.M. 12

13 Winding AC338 Schlafhorst 8

All these above listed machine having complete electronics automation.

Automation done with the help of PLCS, Speed controller Inverters,

Electronics circuitry called as IDS. These PLCS, inverters, Electronics

circuitry have the big brand name such as Allen Braddly, Siemens,

Mitsubishi, Fuji, Danfoss, Telemecanique etc.

R.C.P.I.T., Shirpur


2.1 Ginning:

In ginning section removed the seed from raw cotton and given the cotton

in soft form called as lint. This lint form cotton cant stored in go down, as

per as safety concern (i.e., Protection from fire ) and more area required

to store cotton in this form. So cotton lint can stored in the form of bale

each bale having 200 Kg. weights. Cotton bale can form by pressing

cotton lint on hydraulic press.

2.2 Blow Room:

In blow room following listed machine installed for operation

1) Mixing bale opener ( M.B.O. )

2) Mono cylinder

3) Deduster

4) Unimix

5) ERM / FLEXICLEAN

The raw material bale having different quality in goes down.

Depending upon the quality and requirement of yarn different types of

bale removed from go down section and lay in mixing room for

conditioning. After that it comes on MBO m/c. This m/c. removed the

dust as well as quantamination, trash in cotton after removing above

mention material given to next process m/c.

The process can be done in MBO m/c. with the help of some

motorized operated belts called as lattice and feed apron. The sequential

process & auto control of motors in m/c. is done with the help of some

R.C.P.I.T., Shirpur


optical sensors and its control unit, relays, contactors. Optical sensor may

be called photo cell. Photo cell having one transmitter & one receiver.

Transmitter transmit rays & these ray receive by receiver means no

material in particular section or on belts which carry cotton material, so

it’s control unit gives signal pervious line of control for feeding material.

This feeding of material is continues till these material blocks the rays

receive by receiver. In this way material proceeds further for processing

section to section in m/c. Finally the material from MBO transport to the

next m/c UNIMIX through mono cylinder, dedustor m/c to m/c material

transport carried out with the help of fans driven by 3 Ph. Induction

motors.

2.3 UNIMIX:

Unimix received material from MBO & carry the same operation as in

MBO . One more operation carry the Unimix i.e. it store the material

received from MBO up to certain limit & condense the same for further

operation. The limit for storing material depends on pressure switch.

Setting is a electromechanical switch which receives pressure signal from

Unimix chamber & it operates as switch as per mechanical setting, the

switch signal used in control to control the start or stop the material

feeding from previous m/c.

Again the Unimix provide the material to carding m/c for further

processing through mono, deduster, ERM. Here material requirement

given by ERM to Unimix with the help of photocell.

R.C.P.I.T., Shirpur


2.4 CARD:

Card receives material from ERM. & its output is in the form of sliver.

This sliver is totally uniform its weight per meter is fixed & uniform.

This uniformity is done by analog sensors, its amplifying unit, plc, speed

control invertors, all these works in close loop system. Say material

received from previous line, it enters in card m/c. where analog sensors

are fixed & they given the analog input signal to plc. Plc store in

memory & wait for delivery side analog input , compare with reference ,

if it is coarser then reference signal, plc gives analog output so as to

lowering the speed of feeding with the help of inverter & vice versa. This

action is continuously going on so as to maintain the final output of card

sliver weight per meter. During the operation Card m/c elimination of

impurities & overshot fibers, initial opening of the tuff down to the

individual fibers, without detriment to the staple.

2.5 CONNNECTION DIAGRAM:

Connection diagram with factory preset values

1. line choke if required

2. fault relay contact, for remote signaling of the speed controller state

3. plc relay or input – 24 v.

4. + 24 v internal. When using a + 24 v external supply, connect the 0

v to the com terminal, & do not use the + 24 terminal of the speed

controller.

R.C.P.I.T., Shirpur


NOTE :- suppressors should be fitted to all circuits close to the speed

controller or connected on the same circuit( relay, contactors, solenoid

valves, etc) the speed controller must be earthed, in order to comply with

regulations concerning high leakage current (over 3.5 mA)

-Functions which do not required adjustment

Fault relay, resetting.

The fault relay is energized when the speed controller is power up & not

faults. It comprises a C/O contact.

The speed controller is reset after a fault:

- by switching it off until the display & red indicator lamp disappear &

then resetting the speed controller,

-Thermal protection of speed controller

Function:

Protection via a thermistor fixed to the heat sink.

Indirect protection of the speed controller by calculating the I2t.

-Logic & analog input functions which can be configured

Logic input:

LI1:- forward operation, cannot be assigned to other function.

When the direct contact is closed, the frequency set point is applied in the

forward direction.

• L12, L13, L14 : can be assigned to the following functions :

R.C.P.I.T., Shirpur


Reverse direction : r r S assignment

When the contact is closed, the frequency set point is applied in reverse

direction. If L11 is also closed, the first one to have been closed has

priority.

- 2 speeds : P 5 2 assignment

Open contact : reference = L S P + analog reference.

Closed contact : reference = H S P

- 4 speeds : assignment of one input to P S 2 and another to P S 4 (

it is not possible to assign P 5 4 only )

K1 and K2 open : set point = L S P + analog set point.

K1 closed and K2 open: set point = S P 3 (Level 1 adjustment)

K1 open and K2 closed: set point = S P 4 (Level 1 adjustment)

K1 and K2 closed: set point = H S P.

-Logic and analog input functions which can be configured:-

J 0 G: jog operation J O G assignment

If the contact is closed and then operating direction contact

is also closed, the ramp time is 0.1 s irrespective of the A C C

and d E C settings.

If the speed controller is already operating and contact

assigned to J O G is closed, the ramp times are those of A C

C and d E C.

R.C.P.I.T., Shirpur


The minimum time between two J O G operations is 0.5 s.

Note:- 1. During “Jog” operation, automatic DC injection braking

when the motor is stopped is inhibited.

2. Injection braking on the logic input has priority over J O G

operation.

- Fast stop : F S t assignment

Note:- Fast stop command is activated when the contact between the

input and the + 24 V is open. Braked stop, with the d E C ramp time

divided by 4, but limited to the acceptable minimum without locking on

an “excessive braking” fault (self- adaptation if the braking capability is

exceeded).

Note:- During fast stop, braking either by automatic DC injection or on

the logic input is inhibited.

- DC injection braking : d C I assignment

Note: Injection braking command is activated when the

contact between the input and the + 24 V is closed.

The braking current is equal to the speed controller nominal current

during 5 seconds. After 5 seconds braking current is peak limited to a

maximum value of 0.5 I t H motor.

Note:- 1. Automatic injection braking when stopped remains active if

the d C I function is assigned .

R.C.P.I.T., Shirpur


2. Fast stop has priority over injection braking.

-Analog input:-

An extra analog input can be used as:

- Voltage on AI2

- Current on AIC

And can be assigned as:

- A summing input of AI1

- PI regulator feedback.

Summing with AI1: S A I assignment

P I regulator feedback: P I F assignment

This assignment automatically configures AI1 as a reference for the P I

regulator.

Adjustment parameters r P G , r I G and F b S are in level 1

A I C parameter setting: 0 – 20 mA or 4 – 20 mA.

2.6 PERFORMANCE DATA & CAPABILITIES:

Delivery speed ( m/min.) 250,300,350

400,450,500

550, 600, 650

700, 750, 800 (by step pulley)

R.C.P.I.T., Shirpur


Number of delivery :- 1

Doubling :- 6 or 8 fold

Total ratch(mm) :- drafting zone 73 to 180 mm

These m/cs are designed for continuous operation in shifts.

For first and second drawing passage, cotton and manmade fibers,

(Manmade preferably with rectangular staple), staple 25 to 80 mm.

Total feed :- 20 to 50 g/ m ( 20 to 50 ktex )

Delivery :- Nm 0.15 to 0.4 ( 7 up to 2.5 ktex )

Ne 0.09 to 0.24

-Description of the machine and its mode of operation:

The Draw frame LRSB 851 is a one-delivery Draw frame with leveling

system. This model is equipped with 3-over-3 draft system with pressure

bar as well as with cleaning and suction systems.

Overall machine efficiency is enhanced radically by the can change. As

soon as the predetermined sliver length has been coiled into a can, the full

can is pushed out and the next can is pushed into the working position.

The U-shaped movement of cans enables the space requirement for the

changer to be kept very small. Along a roller conveyor the empty cans are

brought into the waiting position counter to the flow of material. They are

R.C.P.I.T., Shirpur


pushed in and out by a rotary pusher. The cans may then be pushed

optionally onto a suitable truck standing in the direction of material flow.

-The Electronic leveling system:

The auto leveler LRSB851 is equipped with an electronic leveling

system. At the feed side of the machine the thickness of the incoming

slivers is permanently scanned by means of a mechanical sensing.

The measured values are converted to electrical signals, which are then

used to control the draft in the main draft zone so that sliver variations are

evened out.

The result is a sliver with very high regularity over short and medium

lengths and equally good count constancy.

The principle of the leveling system is shown in fig. 1.

The feed slivers run through a pair of sensing rollers. One of these is

swiveling and moves according to the sliver variations. These movements

are transformed by a signal converter into voltages (measuring

voltage).

The measuring voltage is fed into an electronic memory. This memory

assures that the draft is changed exactly when the irregular piece of sliver

is in the main draft zone.

The electronic memory transmits the measuring voltage to the set point

stage with a certain delay.

The set point stage uses the measuring voltage and the machine speed to

calculate the number of revolutions needed for the servo-drive.

R.C.P.I.T., Shirpur


The servo-drive transmits this additional speed requirement via a

planetary gear mechanism to the middle roller of the draft system. This

assures that the draft is changed accordingly in the main draft zone.

The speeds of the feed rollers, sensing rollers and break draft rollers are

varied appropriately with the speed of the middle roller. This system

ensures constant delivery speed unaffected by leveling, and hence exactly

calculable production.

-Control Display:

The control display consists of one green and ten red LEDs, five on each

side of the green LED. These LEDs serve to illustrate the volume

variation of the fed in sliver, The green LED represents the average value

i. e. + 0 starting from the green light each red LED signals indicates 5%

deviation from the average value.

-Safety Devices :

Location Trouble Monitoring Device

Power creel Broken sliver Contact roller photo electric

sensor

Feed roller Lap- up Contact pin

Clearer roller Dirty Contact pin

Leveling

device

+ 25 % Sliver weight Electronic trip

Draft system Lap – up Contact pin

R.C.P.I.T., Shirpur


Fleece trumpet Broken sliver Proximity switch

Draw-off

rollers

Lap-up Sliver

jamming

Contact ledge, Contact Pin

Suction filter

sieve

Heavy soiling Differential pressure switch

Cover Open doors or covers Safety proximity switch

Can changer No reserve can Photo sensor

No can truck

Full truck not moved

away

Proximity

switch

Proximity

switch

Optional

Can exit area Unauthorized entry Photo sensor

Main motor

Fan motor

Excess temperature Thermistor trip device

Overload Motor protection circuit breaker

( MPCB)

Emergency OFF switches (mushroom- headed) on the sides of the

machine serve to stop it. Restarting is possible only after releasing the

emergency OFF switcher.

The safety switches ensure the safety of personnel, and their functions

must be checked from time to time.

R.C.P.I.T., Shirpur


When a cover is opened, the proximity switch goes on and switches off

the machine. To observe the running of the machine (belts etc.) with

doors open, the safety switches can be bridged with a key- operated

switch on the rear.

2.7 ENERGY REQUIREMENTS:

Description Power

Ratings(kw)

Voltage Frequency( Hz)

Main motor 7.5/1.3 3 ph, 440 v 50

Suction motor 1.5 3 ph, 440 v 50

Can changer 0.25 3 ph, 440 v 50

Variable speed

motor

1.0 70v/ 1000 rpm V ac

Control power 0.3 50

Total installed

power

10.55

2.7.1 Signaling:

Causes of trouble are signaled on the pillar lamps (see fig.)

Rotary switches used on both side for initiating can changer & resetting

counter.

R.C.P.I.T., Shirpur


Signal color Location of fault Type of fault

Orange

H 90

Continuous

light

Auto leveling

system

In programming mode

Blinking

light

Auto leveling

system

Speed fault of drive

Over loading of drive

Range exceeds +/-25 %

Main or scanning

encoder failure

Red H3 Continuous

Light

Suction filter

sieve

Strong accumulation

Broken sliver

creel

Sliver broken

Silver missing

Feed roller clearer

roller

Strong accumulation of

dust

Orange

H1

Blinking

light

Counter pre

selection value

reached

m/c doffing

Continuous

light

Final value

reached

Red H2 Continuous Drafting Lapping

R.C.P.I.T., Shirpur


light Trumpet Sliver breakage

Drafting hood Open

Draw off disc Lapping

Can gear drive Can overfill

Orange

H50

Continuous

light

Sliver monitor Stop

The set value exceeded

2.7.2 Speed frame:-

Here the auto leveled sliver received from RSB draw frame m/c. &

convert it in to reduction form by means of twisting & drafting. The same

happen with the help of pneumatic system. This reduction form of sliver

is known as roving. Machine operation done with the help of plc’s ,speed

controller invertors, electronic circuitry (IDS) m/c having 120 nos.

spindle ,it require air for controlling pneumatic operation

2.8 HUMIDIFICATION:

As far as cotton industry concern humidification play’s some important

role. As cotton absorbed moisture. & for processing cotton, industry

required different condition at different stages as explain below

R.C.P.I.T., Shirpur


Dept. name RH % Temperature req.

Blow room 65 +/ - 2.5 35 C

Card 55 +/ - 2.5 33 C

Comber 55 +/ - 2.5 35 C

Speed frame 55 +/ - 2.5 35 C

Ring frame 55 +/ - 2.5 37 C

Winding 65 +/ -2.5 30 C

Humidification not only maintains the Rh% & temp. But also collect the

fluffs, micro dust & exhaust from m/cs. & accommodate in one common

room called as filter room. This happens with the help of axial fans .these

fans creates a suction in dept. This suction helps for collecting the above

mention particles. This said particle on rotary filter on which a cotton

mesh overlap & from that it collect by creating suction & called as dust

collector. The air from axial fan may re-circulate for maintaining

temperature in department & for Rh% water spraying in air flow

direction for mixing with air & absorbed the moisture to maintain

required RH% level.

2.9 POWER DISTRIBUTION:

Mill have installed 33 kv substation, 33 kv power is received from

dahivad power substation. It’s a 132 kv power substation. Mill have

installed the 33kv/ 433v power transformer so as to archive 440 v ac. &

R.C.P.I.T., Shirpur


the 440 v ac used for the operation of m/c. initially the power is

distributed in substation ( low tension room) called as feeder. This

individual feeder given the power to distribution board called as PDB’S

& these PDB’S distribute to m/c.

Mill having 5 nos. 33kv /433v transformer each having rating of 1500

KVA. It’s a oil cool type transformer. It has some indication & tripping

points such as temperature indicator & switch for higher temperature

tripping as per setting by us. Also transformer having oil level indication.

R.C.P.I.T., Shirpur


CHAPTER 3 WATER FILTERATION PLANT

3.1 PROCESS OF WATER TREATMENT PLANT

1. Aeration Fountain:-

Initially water is pumped from karvand jack well & by principle of gravitational force in enters to aeration fountain. In aeration fountain water absorbs oxygen due to sunlight. On line turbidity meter is set up in distribution chamber of aeration fountain which shows present turbidity (amount of solid particles present) in water.

From aeration fountain water through distribution chamber flows to the alum chamber. In this chamber proper amount of alum solution according to present turbidity is added and water flows to flash mixer tank where alum is thoroughly mixed with the help of stirrer. After getting thoroughly mixed, water flows towards clarriflocculator.

Specifications:

On line turbidity meter details:-

Sensor !

Manufactured By: Endress and Hauser, Germany

Model: Turbimax WCUS 31

Range: 0.00 to 9999 NTU

Type of temperature sensor: NTC type

Meter !

Manufactured By: Endress and Hauser, Germany

Model: CUM233-TSO115

R.C.P.I.T., Shirpur


Range: 0.00 to 9999 NTU

Scale: -10 to 60°C

Power: 230VAC, 50 Hz

Flash Mixer Tank !

Stirrer motor and gear box details:-

Motor !

Type: Induction motor

Manufactured By: Crompton greaves

Voltage: 3 Phase 440 V , 50 Hz A.C.

Rated current: 7.60 Amp.

KW / HP: 3.7 / 5

Speed: 1440 rpm

Gearbox !

Manufactured By: Shanti gears

Ratio: 12.35

Type: A30YU

2. Clarriflocculator:-

In clarriflocculator there are two big stirrers which again mix the alum & TCL powder thoroughly. Due to the addition of alum all the turbidity in the water get settled down and water overflows into the channel. In this clarifier 50 to 60% of water is filtered. The turbidity

R.C.P.I.T., Shirpur


which is settled at the bottom of the clarriflocculator is removed with the help of drain valve. Bridge is provided in clarifier which is used to collect all the turbidity at the center towards the drain valve.

Specifiactions !

Motor gearbox details (stirrer) :-

Motor !



Voltage: 3 Phase 440 V, 50 Hz A.C.

KW / HP: 0.75 / 1

Speed: 1410 rpm

Gearbox (double reduction) !

Manufactured By: Greaves gears

Serial no: 160503

Ratio: 10/1 LE35

Manufactured By: Greaves gears

Serial no: 160603

Ratio: 40/1 LD24

Bridge motor gearbox details !

Type: Induction motor.


Voltage: 3 Phase 440 V, 50 Hz A.C.

R.C.P.I.T., Shirpur


KW / HP: 0.75 / 1

Speed: 1410 rpm

Clarifier construction details !

Water inlet diameter: 750 mm ID

Inner tank diameter / height: 9.850m / 4.9m

Outer tank diameter / height: 24.100m / 4m

Water storage capacity: 20 lacs litre

RPH of bridge: 2 RPH

Desludge valve details !

Manufactured By: Transpower Equipments Ltd., Pune

Type: MOR1500

Pmax: 10 bar

Valve size: 150 mm

Valve actuator: Type electrical

3. Filter Beds: -

In filter beds water enters through the channel in equal amount. Filter beds are of sand filter type. It is constructed as shown in the figure below.

Backwash of the filter beds depends upon the Differential Pressure (D.P). When the D.P. of the filter bed crosses the SET points it undergoes into back wash mode.

Process description of the backwash operation is as follows,

a. Drain b. Air Scouring

R.C.P.I.T., Shirpur


c. Backwash d. Rinsing.

a) Drain:

In this operation inlet & outlet valves of filter bed are closed and drain valve is kept open. All the water in the filter bed flash out to the drain chamber & filter bed gets empty. Drain valve remain open throughout the backwash operation.

b) Air Scouring:

In this operation blower starts automatically & air is used to flow through the compressor at the bottom of filter bed. Air flows from bottom to top of the filter bed by which all the mud/sticky (raw) material gets free from water.

c) Backwash:

In this operation clear water is used to flow from bottom to the top of filter bed. As the water flows from bottom to top all the mud/sticky material which gets free by air scouring is thrown out to the drain chamber.

d) Rinsing:

In this operation only drain valve is kept open & bed is given sufficient time to settle down.

After these four operations filter bed automatically goes into service mode i.e. inlet & outlet valve gets open.

R.C.P.I.T., Shirpur


Specifications !

Type: Sand filter

Filtration rate: 125 m3/hr

Valve details !

Manufactured By: Transpower Equipments Ltd. Pune

Type: MOR1500

Pmax: 10 bar

Size: 300 mm

Valve actuator !

Manufactured By: Alfalavel, Pune

Type – Electrical

Level meter details !

Level transmitter !

Type: Capacitance

Manufactured By: Techtrol , Pune

Model: CPT

Sensor: Probe

Output: 4 to 20 mA DC

Supply: 24 V DC

Range: 0 to 4000 mm

R.C.P.I.T., Shirpur


Level controller !


Model: TLIC-POWN

Input: 4 to 20 mA DC

Output: 4 to 20 mA DC / Relay

Supply: 24 V DC

Range: 0 to 4000 mm

Blower motor details !

Motor ! Type: Induction motor

Manufactured By: Siemens

Voltage: 3 Phase 440 V, 50 Hz AC

KW / Hp: 18.5 / 27

Rated current: 34 Amp

Speed : 1460 rpm

Blower !

Type: Twin lobe compressor

Manufactured By: Swam pneumatics, Noida

Pressure: 4000 MMWG

Speed: 1900 rpm

Capacity: 960 m3/ Hr

R.C.P.I.T., Shirpur


Differential pressure measurement system details !

D.P. Transmitter !

Manufactured By: ABB Ltd.

Model: 2600T

Range: 0 to 1.5 bar


Supply: 10.50 to 42 V DC

D.P. Meter !

Manufactured By: Masibus

Model: DTC 5002U

Range: 0 to 1000 bar (Programmable )


Output: Relay

Supply: 24 V DC

Motor and pump details !

Motor !



Voltage: 3Phase 440 V, 50 Hz AC

KW: 5.5

Rated current: 10.90 Amp

R.C.P.I.T., Shirpur


Speed: 1455 rpm

Pump!.

Manufactured By: Mather and Platt

Type: Centrifugal

Head: 15 meter

Discharge: 75 m3 / hr.

Speed: 1455 rpm

Wash water tank level control system details !

Level transmitter !

Type: Capacitance


Model: CPT

Sensor: Probe


Supply: 24 V DC

Range: 0 to 2000 mm

Level controller !


Model: TLIC-POZY


Output: Relay / 5A

Supply: 24 V DC

R.C.P.I.T., Shirpur


Range: 0 to 2000 mm

Operating air for control valves

For pneumatic operation air is supplied by air compressor to the control valves. Air compressor maintain the air pressure of tank between 5 to 7 Kg / cm2 Motor !

Type : Induction motor


Voltage: 3 Phase 440 V, 50 Hz

KW: 1.5


Speed: 1420 rpm

Compressor !

Manufactured By : Ingersoll Rand

4. Sump (Storage Tank):

After filtration process water is stored in sump. In sump chlorine gas is added for killing micro-organism & finally water is pumped to ESR (Elevated Stock Reservoir)

Sump construction details !

Storage capacity: 10 lacs lit.

R.C.P.I.T., Shirpur


Total height: 4 meter.

Overflow height: 3 meter.

Diameter: 20.85 meter.

Motor, pump and delivery valve details !

Motor !



Voltage: 3Phase 440 V, 50 Hz AC

KW / HP: 75 / 100

Rated current: 131 Amp

Speed: 1480 rpm

Pump !

Manufactured By: Mather and Platt

Type: Centrifugal

Head: 32.5 meter

Discharge: 490 m3 / hr

Control valve !

Manufactured By: Rotork controls Ltd.

Serial no.: Z3949BA2

Actuator type: K150 F10E

R.C.P.I.T., Shirpur


Output speed: 18 rpm

Max torque: 152 Nm

Supply: 3 Phase 440V AC, 50Hz

Motor KW: 0.52

Water lubricated pump specification !

Motor !

Type: KV30

Manufactured By: Kirloskar

Voltage: 3 Phase 440 V AC, 50 Hz

KW / HP: 2.3 /3

Rated current : 4.7 Amp

Surge vessel equipments details !

Compressor !

Manufactured By: Ingersoll Rand. Ahemdabad

Model: 2340

Serial No: 02083193

Motor !



Voltage: 3Phase 440 V AC, 50 Hz

KW: 1.5


R.C.P.I.T., Shirpur


Speed: 1420 rpm

Level controller !

Manufactured By : Techtrol , Pune

Model : TLC -MP 4 N

Input : NO/NC relay switch

Output : Relay / 5 A

Supply - 230V AC , 50Hz

Ultrasonic flow meter details !


Series: Sono 3000

Code: FDK 085F5005

Supply: 24 V DC / AC

Range: 0 to 1000 m3 / hr

Made in Denmark.

Flow meter in control room details !

This meter is installed in parallel with flow meter for indication of flow rate in control room.

Manufactured By: Masibus, Gandhinagar

Model: 1006

Supply: 24 V DC


R.C.P.I.T., Shirpur


Range: 0 to 1000 m 3 / hr

Level meter details !

Level transmitter !

Type: Capacitance

Manufactured By: Techtrol, Pune

Model: CPT

Sensor: Probe


Supply: 24 V DC

Range: 0 to 4000 mm

Level controller !

Manufactured By: Techtrol, Pune

Model: TLIC-POWN


Output: 4 to 20 mA DC / Relay

Supply: 24 V DC

Range: 0 to 4000 mm

R.C.P.I.T., Shirpur


5. Automation System Design:

Automation is totally based on latest technology i.e. PLC

(Programmable Logic Control) and SCADA system.

SCADA stands for Supervisory Control And Data

Acquisition. As the name indicates, it is not a full control system, but

rather focuses on the supervisory level. As such, it is a purely software

package that is positioned on top of hardware to which it is interfaced, in

general via Programmable Logic Controllers (PLCs), or other

commercial hardware modules.

SCADA systems are used not only in industrial processes:

e.g. steel making, water filtration, power generation (conventional and

nuclear) and distribution, chemistry, but also in some experimental

facilities such as nuclear fusion. The size of such plants range from a few

1000 to several 10 thousands input/output (I/O) channels. However,

SCADA systems evolve rapidly and are now penetrating the market of

plants with a number of I/O channels of several 100 K

It basically consists of 2 parts viz. data acquisition and

supervisory control. First data is acquired from various parts of the

system and then if require it could be controlled to the desired value.

Every engineer knows that in this world, automation plays a

great deal of part in each and every control system. We sometimes need

everything to be controlled accurately, precisely and economically. So to

acquire all these aspects and qualities a system called as SCADA

(Supervisory Control And Data Acquisition) can be employed.

R.C.P.I.T., Shirpur


To the uninitiated, SCADA may seem like just another chunk

of consonants and vowels floating around in the alphabet soup of today’s

culture. But a SCADA system is, in reality, an extremely important

application of computer technology that has created huge gains in

productivity and efficiency in the processing industries. SCADA systems

have made substantial progress over the recent years in terms of

functionality, scalability, performance and openness such that they are an

alternative to in house development even for very demanding and

complex control systems as those of physics experiments.

SCADA system reduces human error and provides best accuracy in

economical way. It can be applied in plants automation for energy saving

and reduction in wastage of material. SCADA refers to the process of

gathering information often in real time from remote locations.

SCADA system shows all the water filtration activity, which is

carried in the plant. If there is any problem in plant then it gives audio

and visual alarm so ultimately using SCADA system troubleshooting is

easy. It also generates report regarding to backwash operation and pump

running hour.

Specifications !

SCADA ! Manufactured By: Rockwell automation.

Software - RS VIEW 32

R.C.P.I.T., Shirpur


PLC !

Manufactured By: Allen Bradley, USA

Model: SLC 5 / 03

I/O Capacity: 4000 digital

Programming software: RS logix 500 STARTER

Input Module: 1746 IB 32

Output Module: 1746 OB 32

6. Chlorination System:

a) Vacuum Regulator

Vacuum regulator is fixed on chlorine cylinder. This regulator allows flowing of the gas if and only if vacuum is created at the output of regulator.

Specifications ! Model: 210 m/s

Capacity: 200 LB / day

Gas supply pressure: 20 to 220 psi

Made in Germany.

b) Chlorinator/Rota meter

This is connected after the chlorine gas regulator. This meter is used to control the flow of chlorine gas (Kg / Hr).

Specifications !

Model: S10 KYNotch

Flow rate:0 to 90 Kg / day (adjustable)

R.C.P.I.T., Shirpur


Max Output: 0 to 3 Kg / Hr

Made in USA

c) Injector

The output gas from rotameter is given to injector and it is mixed with chlorine gas and water. Finally this concentrated chorine water is fed to sump.

d) Booster pump

The Booster pump is used for creating a vacuum in vacuum regulator.

Specifications !

Motor !

Manufactured By: LUBI

Voltage: 3Phase 440 V, 50 Hz

KW: 0.75


Speed : 2850 rpm

e) Online Residual Chlorine Analyzer

It is an online meter to show chlorine contain in filter water. The input (water) for this meter is taken from delivery pipeline. If chlorine in water is high / low from the set value then it gives the indication in control room using alarm.

R.C.P.I.T., Shirpur


Specification !

Model: DEPLOX-3, Germany

Manufactured By: Wallace and Tiernan

Range: 0 to 19.99 ppm

Power: 230 V AC, 50 Hz

Sample flow rate: 580 ml /min

f) Chlorine Gas Leak Detector

Chlorine gas is very hazardous in nature. Small amount of gas leak is detected by this leak detector and it gives a display using alarm in control room.

Specification !

Manufactured By: Pennwalt (I) , Ltd. Mumbai.

Model: Chloratekt -2 Simplex

Range: 0 to 5 ppm

Power: 230 V AC, 50 Hz

g) Gas Tunner

This gas is used to store the chlorine gas and it is filled and supplied by company.

Specifications !

Manufactured By : Anup Engg, Ahemdabad.

Gas weight : 900 Kg

Tare weight : 610 Kg

R.C.P.I.T., Shirpur


Gross weight : 1510 Kg

Test Pressure : 42 Kg / cm 2

Gas pressure : 8 Kg / cm 2

7. Alum Room:

Stirrer Specifications: -

Motor !



Voltage: 3Phase 440 V AC, 50 Hz

KW - 0.75

Speed - 1410 rpm

Gearbox !

Manufactured By: Shanti gears, Coimbatore.

Type: 020 YU

Ratio: 13.26

Level sensor !

Manufactured By: Techtrol, Pune.

Type: Float

Model: FTS J 001

Sensor: M / 8A / 230 AC / 00

Supply: 230 V AC, 50 Hz

R.C.P.I.T., Shirpur


8. Laboratory Equipment Specifications:

1. Turbidity meter !

Manufactured By: Hach, USA.

Model: 2100 P

Range: 0 to 1000 NTU

Accuracy: +/- 2 %

Sample require: 15 Ml

2. Pocket calorimeter !

Manufactured By: Hach, USA.

Model: Pocket calorimeter, TM11

Absorbance Range: 0 to 2.5 Abs

Sample cell: 1cm (10 ml), 25 mm (10 ml)

3. Ph meter !

Manufactured By: YSI INC. U.S.A.

Model: PH 100-4

Range: 0.0 to 14.0 Ph

Accuracy: +/- 0.1

Resolution: 0.1Ph

R.C.P.I.T., Shirpur


9. Distribution Transformer:

Specifications !

Manufactured By - ATLANTA Electrical Ind. Ltd.

KVA / Ph: 200 / 3

Voltage H.V: 11 KV

Voltage L.V: 433 V

AMP H.V: 10.5 A

AMP L.V: 266.7 A

Frequency: 50 Hz

Oil fill: 340 lit

10. Diesel Generator:

Engine !

Manufactured By: Cummins Ind. Ltd. Pune

Alternator !

Manufactured By – Stampford

KVA - 200

Voltage / Ph - 415 V / 3

Amp - 278 A, 50 Hz

R.C.P.I.T., Shirpur


CHAPTER 4

REFERENCES AND BIBLIOGRAPHY

[1]. www.textilea2z.com/priyadarshini-sahakari-soot-girani-ltd.html

[2]. http://www.tradeindia.com/Seller-2854907-Priyadarshini-Sah

Soot-Girni-Ltd-/

A TECHNICAL VISIT REPORT On · Mitsubishi, Fuji, Danfoss, Telemecanique etc. R.C.P.I.T., Shirpur...

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