2015

ICI Soda Ash Khewra

Saram Ali

[ INTERNSHIP REPORT ]
 ACKNOWLEDGEMENT

All praise is to Almighty Allah, the Beneficent, and the Merciful. He showered His great
blessings upon us in the form of Holy Prophet, Hazrat Muhammad (P.B.U.H).

With much effort and time spent, we thank God for being able to complete the internship in
Imperial Chemical Industries (ICI) Pakistan, Khewra.

We wish to take this space and opportunity to express our thanks to all employees for
providing us with helpful information and exchanging thoughts, family members for their
financial support and ICI Pakistan for supporting us in doing our intern.

Thank you.

1
 ABSTRACT

This report encompasses all the technical experience that we went through, the
configuration and detailed maintenance process of the machinery; overhauling of the
equipment, the operating parts and working mechanism of the Boilers, Gas turbines and
Steam Turbines. The detailed surveys are performed over the time of four weeks of the
complete plant. This internship proves to be very helpful in understanding how products are
mass manufactured in industries. We give special thanks to all the Engineers, supervisors
and workers for providing the necessary guideline and helping us in our time of need.

2
 TABLE OF CONTENTS

1. Introduction…………………………………………………………………………………….……………………………………………………………. 4
2. Safety Precautions………………………………………………………………………………………………………………………………………. 5
3. Technical leaning during internship duration…………………………………………………………………………………………….....6
3.1 Different types of valves………………………………………………………………………………………………………………………...6
3.1.1 Ball Valve .………………………………………………………………………………………………………………………………...7
3.1.2 Gate Valve.………………………………………………………………………………………………………………………………...7
3.1.3 Butterfly Valve.………………………………………………………………………………………………………………………….7
3.1.4 Safety Valve.………………………………………………………………………………………………………………………………7
3.1.5 Relief Valve.……………………………………………………………………………………………………………………………….7
3.1.6 Plug Valve…………………………………………………………………………………………………………………………………..8
3.1.7 Non-Returnable Valve………………………………………………………………………………………………………………..9
3.2 Star type Epicyclic Speed Reduction Gear……………………………………………………………………………………………..10
3.2.1 Assembly of all parts…………………………………………………………………………………………………………………11
3.2.2 Role of all parts ………………………………………………………………………………………………………………………12
3.2.3 Lubrication………………………………………………………………………………………………………………………………13
3.3 Steam Trap....................................................................................................................................................…... 12
3.3.1 Thermodynamic Steam Trap…………………………………………………………………………………………………….12
3.4 Centrifugal Pumps………………………………………………………………………………………………………………………………..14
3.5 Steam Boiler…………………………………………………………………………………………………………………………………………..16
3.5.1 Parts of boiler…………………………………………………………………………………………………………………………..18
3.6 Y-Strainer…………………………………………………………………………………………………………………………………………….18
3.7 Screw Compressor………………………………………………………………………………………………………………………………19
4. References………………………………………………………………………………………………………………………………………………... 23

3
 1. Introduction:
It would be hard to go anywhere in today‟s world without being close
to a product produced without containing Soda Ash. Reading the newspaper,
sipping on a glass of orange juice, biting into a hot croissant, or simply wearing
freshly laundered clothes, you experience the use of Soda Ash every day. Without
Soda Ash, the manufacturing of necessary commodities such as glass, paper and
detergents would not be possible. The closest you get to this versatile chemical
compound that is the baking soda tin in your kitchen, used as a baking ingredient.
ICI Pakistan, Khewra is the largest Soda Ash producer in the
country. Soda Ash Plant in Khewra was established in the 1940s, even before the
creation of Pakistan starting with a capacity of 18,000 tons per annum (figures
taken from the ICI Pakistan's official Site).
ICI Pakistan made huge investments in growing this business and
the current annual capacity of 350,000 tons per annum provides assurance to its
customers that ICI Soda Ash can be relied upon as a trusted and reliable supplier
for high quality of Soda Ash. The substantial foreign exchange savings are ensured
through import substitution by utilizing indigenous raw materials.
Apart from manufacturer of Soda Ash, ICI Pakistan is also a chief
producer of a wide range of industrial and consumer products. These products
include:
 Polyester Staple Fibers
 POY Chips
 Light and Dense Soda Ash
 Sodium Bicarbonate
 Specialty Chemicals
4
  Polyurethanes
 Adhesives
 Pharmaceutical
 Animal Health products manufactured
 Agricultural Products including Field Crop Seeds and Vegetable Seeds

2. Safety Precautions:

The Safety of an employee is given the chief importance here at ICI

Pakistan. During the start of the intern we were given all the necessary training
regarding the safety during our stay at the plant.
The multiple sessions were held with Mr. Akbar at “Training
Center” for first two days of internship duration. He told us techniques for not
only saving our own life but also helping out others in their time of need by using
safety precautions. We have the discussion over the following topics:

 House keeping
 Horse play
 PPE‟s
 Working at the height
 Working in the noise area
 Working in the toxic gas
 Working in the dust

The basic thing that you should every time in the factory:
 Wear helmet
 Wear glasses
 Wear ear plug
 Wear the safety shoes

5
 3. Technical Learning during Internship Duration:
During the internship duration we were appointed to the
maintenance department where we were first given the theoretical overview of
the mechanism and then we were taken out for the visual overview of the working
mechanism of the machinery. All the mechanisms of the machinery covered
during the theoretical demonstrations and plant surveys are as follows:

3.1 Different Types of Valves:

During the internship days we were given the demonstration of the
valves used in the network of pipes and their use at that particular positions. The
complete understanding of the different types of valves and their need for using
them at that particular points depending upon the economic and technical basis.
The kind of valves studied are as follows:
 Ball Valve
 Gate Valve
 Butterfly Valve
 Safety Valve
 Relief Valve
 Plug Valve
 Non-returnable Valve
3.1.1 Ball Valve:
Ball valves in stainless steel valve is a valve with a spherical disc, the
part of the valve which controls the flow through it. The sphere has a hole, or port,
through the middle so that when the port is in line with both ends of the valve, flow
will occur. When the valve is closed, the hole is perpendicular to the ends of the
valve, and flow is blocked. The handle or lever will be in line with the port position
letting you "see" the valve's position. The ball valve, along with the butterfly valve
and plug valve, are part of the family of quarter turn valves. Ball valves are
durable and usually work to achieve perfect shutoff even after years of disuse.
6
They are therefore an excellent choice for shutoff applications (and are often
preferred to gate valves for this purpose). They do not offer the fine control that
may be necessary in throttling applications but are sometimes used for this
purpose.

Figure 1a: Closed Ball Valve Figure 1b: Open Ball Valve

3.1.2 Gate Valve:

A gate valve consists of an actuator-such as a lever, a hand wheel
which holds the valve mechanism, and a gate-a rectangular or circular piece of
metal that acts like the gate on a fence. When the gate is raised, liquids or gases
can pass through the gate. When the gate is closed, the flow stops. Most gate
valves are operated by a handle, whether the handle is a lever or a hand wheel,
like the knob on a faucet. If you turn the handle counterclockwise, the gate raises.
If you turn the handle clockwise, the gate drops.
Gate valves are used in many industrial settings and, in such
a setting, the valve may be controlled by an electric motor operated either on
command from a human or computer, or automatically, perhaps by a timer.
Note: Gate valves should not be used to restrict flow; that is, they should not be
partially opened. Using a gate valve to restrict flow puts unnecessary strain on
the gate and the supporting structures, particularly in a high-pressure setting.
This strain will eventually cause the mechanical failure of the valve
7
Figure 2a: Gate Valve

3.1.3

Figure 2b: Closed Gate Valve Figure 2c: Open Gate Valve

Butterfly Valve:
Butterfly valves are quarter-turn rotary motion valves used as
throttling valves to control flow through a system. They can be used with many
different media. Butterfly valves offer several advantages including quarter-turn,
openness for less plugging, and good control capabilities.
They may be used in a wide variety of chemical services, are available
with small dimensions allowing for use in areas where space is limited, and allow
a high coefficient of flow. The disadvantages include difficulty cleaning internal
parts; therefore they should be avoided in situations that call for sterile, medical
or food processing applications.

Figure 3a: Butterfly Valve Figure 3b : Closed Butterfly Valve Figure 3c : Open Butterfly Valve

8
 3.1.4 Safety Valve:
Safety Valve is a one type of valve that automatically actuates when
the pressure of inlet side of the valve increases to a predetermined pressure, to
open the valve disc and discharge the fluid ( steam or gas ) ; and when the
pressure decreases to the prescribed value, to close the valve disc again. Safety
valve is so-called a final safety device which controls the pressure and
discharges certain amount of fluid by itself without any electric power supply.
Safety Valve is mainly installed in a chemical plant, electric power boiler, gas
storage tank, preventing the pressure vessels from exploding or damaging.

Figure 4: Safety Valve

3.1.5 Relief Valve:

At the top is a spring which presses against a piston. The piston (the
green part) seals against its seat keeping the flow of water (blue) through its
normal path. If the pressure become too great. The pressure of the water pushes
the piston upwards against the force of the spring allowing some portion of the
water to flow through the bypass port as indicated by the red arrows. Getting the
pressure just right is done by the screw shown at the very top. Turning that screw
inwards (tightening it) pushes against the spring, compressing it further. The
more the spring is compressed the more force the water needs to push the piston
9
upwards. Adjusting that screw outwards (loosening it) lowers the spring's tension
and the piston can be moved by a lower pressure from the water.
In actual operation the piston will be displaced slightly and a small flow of
water will pass by the piston. It is important to note that these valves do not
maintain a set pressure; they only control the highest pressure which can be
reached

Figure 5: Relief Valve

3.1.6 Plug Valve:

Plug valves are valves with cylindrical or conically tapered "plugs"
which can be rotated inside the valve body to control flow through the valve. The
plugs in plug valves have one or more hollow passageways going sideways
through the plug, so that fluid can flow through the plug when the valve is open.
Plug valves are simple and often economical. The simplest and most common
general type of plug valve is a 2-port valve with two positions: open to allow flow,
and shut (closed) to stop flow. Ports are openings in the valve body through which

10
fluid can enter or leave. The plug in this kind of valve has one passageway going
through it. The ports are typically at opposite ends of the body; therefore, the plug
is rotated a fourth of a full turn to change from open to shut positions. This makes
this kind of plug valve a quarter-turn valve.

Figure 6a : Plug Valve Figure 6b: Plug Valve Cross section View

3.1.7 Non-Returnable Valve:

A non-return valve allows a medium to flow in only one
direction. A non-return valve is fitted to ensure that a medium flows through a
pipe in the right direction, where pressure conditions may otherwise cause
reversed flow.
A non-return valve can be fitted to ensure that a medium flows through a pipe in
the right direction, where pressure conditions may otherwise cause reversed
flow. A non-return valve allows a medium to flow in only one direction. The flow
through the non-return valve causes a relatively large pressure drop, which has
to be taken into account when designing the system.
There are different types of non-return valves, such as spring-loaded,
swing type, and clapper type valves. Non-return valves are e.g. used with mixing

11
loops in heating and cooling systems to ensure proper operation, and with
domestic water systems to prevent backflow.

Figure 7: Non-Returnable Valve

3.2 Star Type Epicyclic Speed Reduction Gear:

Star type Epicyclic gear is
designed to reduce the rpm of the the st4eam turbine
to the optimum rpm for the generator to generate
electricity.
The one installed at power house at ICI
Pakistan, Khewra reduces the speed from 17417 rev/min to
Figure 8: Star Type Epicyclic Gear
1500rev/min.

3.2.1 Assembly of all the parts:

The parts of the Epicyclic gear set is assembled in the following way:

 A central Sunwheel
 Annulus or internally toothed gear ring
 Star wheels mounted on the Fixed star carrier (Wheels revolve along the sun wheel
and engage with the annulus at the same time)

12
 3.2.2 Role of the main parts:

Sunwheel: is not supported by bearings but is free to rotate over star

wheels.
Annulus: ensures perfect load equalization between star wheels and it is
itself free to rotate
Star Wheels: star wheels rotate between annulus and Sunwheel to
distribute the Rotational energy and hence helps in stepping down the speed.
3.2.3 Lubrication:
 Oil passes through the radial holes from the centers of the star wheel
spindles thus lubricating wheel spindle and bearing too.
 Turbine end flexible coupling teeth are lubricated by an external spray pipe.

3.3 Steam Trap:

The removal of condensate from the steam pipes is very necessary to
ensure the supply of condensate free steam throughout the plant where
needed.The steam trap is of the following types:

 Thermodynamic steam trap

 Ball steam trap
 Thermostatic steam trap

13
 3.3.1 Thermodynamic Steam Trap:
Thermodynamic disc steam traps have an intermittent, cyclical
operating characteristic. The valve mechanism — comprised of a disc and seat
rings — opens to discharge condensate for a few seconds; and then closes for a
generally longer period until a new discharge cycle begins.
The opening and closing action of thermodynamic disc traps is
caused by the difference in the forces acting on the bottom and top sides of the
valve disc. These forces are essentially based on variations in kinetic and
pressure energy of the typical fluids involved: air, condensate, and steam.
At start-up, incoming fluids consisting of air, and/or
condensate (and even sometimes steam) at line pressure exert an Opening Force
(Lifting Force) on the bottom of the valve disc; thereby causing it to rise and open.
This Opening Force elevates the disc off the seat to allow condensate flow. The
next section explains how the disc mechanism closes after it is opened.

Figure 9: Closed Disc Valve

14
Situation 1: From the Open to the Closed Position (Thermodynamic
Explanation)
When in the open position, there are two main forces that act on the disc valve:
steam in the pressure chamber on top of the disc, and steam racing across the
underside of the disc. This steam acting to open and close the valve is known as
Control Steam.

Control Steam within the pressure chamber exerts a downward force on the top
of the valve disc as a result of its Pressure x Area. Control steam on the
underside of the disc causes a pressure drop under the disc because of its high
velocity (as long as the disc is in the open position).
The valve is designed to close on flashing condensate near-to-steam temperature,
which occurs once the accumulated condensate is discharged. When the Closing
Force is big enough to overcome the Opening (Lifting) Force, the valve closes.

Situation 2: From the Closed to the Open Position (Thermodynamic

Explanation)
When in the closed position, steam inside the pressure chamber exerts a Closing
Force on the valve disc and seals the pressure chamber shut.
Over time, the pressure chamber loses Closing Force (i.e. pressure) from
conduction losses caused by the inflow of condensate, radiant or convection heat
losses caused by environmental conditions, and by any leakage that occurs
15
through the outer seat ring (such as if worn-out or otherwise compromised).
When the Closing Force becomes weaker than the Opening Force (Lifting Force),
the disc elevates and discharges condensate again.

Figure 10: Open disc Steam Trap

3.4 Centrifugal Pumps:

Centrifugal pumps are the most common type of pump used in

industry, agriculture, municipal (water and wastewater plants), power generation
plants, petroleum and many other industries.
Centrifugal pumps are the primary pump type in the class of pumps called
"kinetic" pumps and are distinctly different than "positive displacement" pumps.
All centrifugal pumps include a shaft-driven impeller that rotates (usually at 1750
or 3500 RPM) inside a casing. Liquid flows into the suction port (inlet) of the
casing and is thrown to the outside of the casing and then exits the discharge
port. The velocity imparted to the liquid by the impeller is converted to pressure
energy or "head".
16
Centrifugal pumps are unique because they can provide very high flowrates and
because their flowrate varies considerably with changes in the Total Dynamic
Head (TDH) of the particular piping system. This allows the flowrate
from centrifugal pumps to be "throttled" considerably with a simple valve placed
into the discharge piping, without causing excessive pressure buildup in the piping
or requiring a pressure relief valve. Therefore, centrifugal pumps can cover a
very wide range of liquid pumping applications.

3.4.2 Parts of the centrifugal pumps:

The centrifugal pumps has the following parts:

 Oil rings
 Bearings
 Casting
 Seal
 Shaft
 Volute
 Impeller
 Suction Nozzle
 Discharge Nozzle
 Oil Unit

3.5 Steam Boiler:

The steam boilers are divided into different types depending upon the
configuration of generation tubes. The two types of boilers here at soda sh plant
khewra are:

17
  O-type boilers(generation tubes are shaped in form of o)
 D-type boilers(generation tubes are shaped in form of D)

3.5.1 Parts of the boiler:

The basic working parts of the boiler are as follows:

 Economizer
 Steam Drum
 Generation Tubes
 Mud Drum
 Combustion Chamber
 Super heater

3.5.1.1 Economizer: An economizer uses the waste heat from the boiler
exhaust that would otherwise be lost to atmosphere to (in most cases) preheat
the feed water into the boiler.This improves the boiler efficiency and reduces
fuel costs

3.5.1.2 Steam Drum:

A steam drum is a standard feature of a water-tube boiler. It is a
reservoir of water/steam at the top end of the water tubes. The drum stores
the steam generated in the water tubes and acts as a phase-separator for
the steam/water mixture.

3.5.1.3 Generation Tubes: Many tubes link the steam drum to the water
drum and to the header. The tubes that lead from the water drum to the steam
18
drum are the generation tubes. They are arranged in the furnace so the gases
and the heat of combustion can flow around them. The generation tubes are
made of steel that is strong enough to withstand the high pressures and
temperatures within the boiler. In most boilers these tubes are usually 1 to 2
inches in diameter but some may be 3 inches in diameter as well.

3.5.1.4 Mud Drum:

The mud drum is a unit located beneath the boiler drum to collect the
solid materials which precipitate out of the boiler feed water due to the high
pressure and temperature conditions of the boiler. The process by which
suspended solids are collected in the boiler is referred to as cycling. This is
done to produce the maximum amount of steam per unit volume of feed water.
On each run through the boiler drum, a portion of the boiler feed water is
vaporized. This results in an increase in the solids concentration in the boiler
drum.
3.5.1.5 Superheater:
It is integral part of boiler and is placed in the path of hot flue gases
from the furnace. The heat recovered from the flue gases is used in
superheating the steam before entering into the turbine (i.e., prime mover).Its
main purpose is to increase the temperature of saturated steam without
raising its pressure.

19
 3.5.2 Controlling the Excess Temperature in the Boiler (Temperator):
The Temperator in the mud drum is used to control the excess temperature
of the steam after flowing through the super heater.
For example in case the temperature exceeds from 385oc (desired
temperature) sensed via temperature sensor then the steam will be directed
towards the tubular portion through a three way valve inside the Mud drum
where estimated temperature is 250oc so the temperature drop does occur
there and the temperature drops to 350oc which is the controlled one.
In case after passing through the Superheater the
temperature is below the sensor activation range i.e. 375oc (in our case) then
steam will flow through the three way valve towards the desired delivery
section.

Figure 11: Excess Temperature Control

20
 3.6 Y-Strainer:
The strainers and filtrations are designed for the efficient removal
and retention of solid/foreign material from flowing liquids and gases. It provides
the ultimate in protection to vital process equipment, both in simple and in the
very increasing sophistication of process plant systems. Their operational areas
are to protect:
 pumps and compressors
 flow meters
 valves and regulator
 heat exchangers and refrigerating sets
 steam traps

21
 Screw Compressors:
The rotary screw compressor uses two rotors (helical screws)
to compress the air. There is a „female rotor‟ and a „male rotor‟. The rotors are of
different shape, but fit each other exactly.
Mechanism:
When the rotors start turning, air will get sucked in on one side
and gets „trapped‟ between the rotors. Since the rotors are continuously turning,
the air gets pushed to the other end of the rotors (the „pressure side‟) and new
fresh air gets sucked in.
Operation:
The working of a screw compressor is a continuous process, this
kind of compressor doesn‟t make a lot of noise; it runs quiet and smooth. Hence,
they do not require spring suspension. Many rotary screw compressors are,
however, mounted using rubber vibration isolating mounts to absorb high-
frequency vibrations, especially in rotary screw compressors that operate at high
rotational speeds.

Figure 12: Screw Compressor

22
3.7.1 Types of Screw Compressors:
The rotary screw compressors are available in two basic types depending upon the
usage of oil:
 Oil free Screw Compressors
 Oil Injected Screw Compressors

Oil free Screw Compressors:

In an oil-free compressor, the air is compressed
entirely through the action of the screws, without the assistance of an oil seal.
They usually have lower maximum discharge pressure capability as a result.
However, multi-stage oil-free compressors, where the air is compressed by
several sets of screws, can achieve pressures of over 150 psig, and output
volume of over 2000 cubic feet (56.634 cubic meters) per minute (measured at
60 °C and atmospheric pressure).
Oil-free compressors are used in applications where
entrained oil carry-over is not acceptable, such as medical research and
semiconductor manufacturing. However, this does not preclude the need for
filtration as hydrocarbons and other contaminants ingested from the ambient air
must also be removed prior to the point-of-use. Subsequently, air treatment
identical to that used for an oil-flooded screw compressor is frequently still
required to ensure a given quality of compressed air.
Oil Injected Screw Compressors:
In an oil-injected rotary screw compressor, oil is
injected into the compression cavities to aid sealing and provide cooling sink for
the gas charge. The oil is separated from the discharge stream, then cooled,
filtered and recycled. The oil captures non-polar particulates from the incoming
23
air, effectively reducing the particle loading of compressed air particulate
filtration. It is usual for some entrained compressor oil to carry over into the
compressed gas stream downstream of the compressor. In many applications,
this is rectified by filter vessels. In other applications, this is rectified by the use
of receiver tanks that reduce the local velocity of compressed air, allowing oil to
condense and drop out of the air stream to be removed from the compressed air
system via condensate management equipment.
Difference between the two types:

24
4. References:

 http://www.tlv.com/global/TI/steam-theory/how-disc-traps-work.html
 https://www.c-a-m.com/products-and-services/valves/valve-academy/how-does-it-work-
check-valves
 http://www.learnengineering.org/2014/01/centrifugal-hydraulic-pumps.html
 http://www.rpi.edu/dept/chem-eng/Biotech-
Environ/Environmental/was2en/BoilerOperation2.html
 http://summith.blogspot.com/2011/08/boiler-accessories-super-heater-working.html
 http://www.tecmara.com/en/products/strainer/design-and-function.html
 http://www.air-compressor-guide.com/wp-content/uploads/2014/05/rotary-screw-element3-
300x223.jpg
 http://www.air-compressor-guide.com/learn/compressor-types/rotary-screw-compressor/

25