Feroze1888 Mills – H-23Winter Internship Program 2016

Syed Salman Haider NaqviMechanical EngineeringNED University of Engineering and Technology

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Disclaimer:This report include material which is property of Feroze1888 Mills. Photos and documents attached are property of Feroze1888 Mills which is supposed to be confidential. Use of information otherwise would invoke copyright law. Feroze1888 Mills reserves right to take actions if found guilty.

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Table of Contents1. Acknowledgement.....................................................................................................................5

2. Company Overview...................................................................................................................5

2.1 Ambition.............................................................................................................................. 5

3. Manufacturing Process..............................................................................................................6

3.1 Spinning...............................................................................................................................7

3.2 Twisting/Doubling...............................................................................................................7

3.3 Warping................................................................................................................................7

3.3.1 Indirect Warping............................................................................................................7

3.3.2 Direct Warping..............................................................................................................8

3.4 Sizing................................................................................................................................... 8

3.5 Weaving............................................................................................................................... 8

3.6 Bleaching............................................................................................................................. 9

3.7 Dyeing................................................................................................................................10

3.7.1 Continuous Dyeing......................................................................................................10

3.7.2 Exhaust dyeing............................................................................................................ 10

3.8 Shearing............................................................................................................................. 10

3.9 Printing...............................................................................................................................11

3.9.1 Engraving.................................................................................................................... 11

3.9.2 Piece Printing...............................................................................................................11

3.9.3 Continuous Printing.....................................................................................................11

3.10 Cutting..............................................................................................................................12

3.11 Stitching........................................................................................................................... 12

3.12 Packaging and Transportation..........................................................................................12

3.13 RnD – Research and Development...................................................................................12

4. Maintenance & Documentation...............................................................................................13

4.1 Preventive Maintenance.....................................................................................................13

4.2 Breakdown Maintenance....................................................................................................13

4.3 Shutdown Maintenance......................................................................................................13

4.4 Preventive Maintenance Procedure at Feroze1888 H-23....................................................14

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5. Power House............................................................................................................................15

5.1 Waste Heat Recovery.........................................................................................................15

5.2 Flow Gases Block Diagram................................................................................................16

5.3 Economizer and Feed Water Tank.....................................................................................16

5.4 Jacket Water Heat Recovery..............................................................................................17

5.5 Air Ventilation System – Power House..............................................................................17

5.6 Cooling Tower Specifications............................................................................................18

5.7 Gas Turbine – GT...............................................................................................................18

5.8 LT and HT Distribution......................................................................................................18

6. Boilers......................................................................................................................................21

6.1 Fire-tube boiler...................................................................................................................21

6.2 Water-tube boiler............................................................................................................... 21

6.3 Flow Diagram for DESCON Boiler...................................................................................22

7. Water Treatment......................................................................................................................24

7.1 Waste Water Treatment Plant Configuration H-23.............................................................25

7.2 Reverse Osmosis – RO.......................................................................................................26

7.3 Process Diagram RO Plant Feroze1888 H-23....................................................................28

8. HVAC – Heating Ventilation & Air Circulation......................................................................29

8.1 HVAC Process Feroze1888 H-23.......................................................................................29

8.2 HVAC – RECO Plant Process Flow...................................................................................30

9. Air Compressor Room.............................................................................................................31

9.1 Positive displacement.........................................................................................................31

9.2 Dynamic Displacement......................................................................................................31

10. Chiller and Application..........................................................................................................32

11. Internship Activities – Feroze1888 H-23...............................................................................33

11.1 Activity #1 – Generator repairing.....................................................................................33

11.2 Activity #2 – Fire Training...............................................................................................33

11.3 Activity #3 – Air Calculations..........................................................................................35

12. Suggestions............................................................................................................................36

13. Conclusion.............................................................................................................................36

14. Life Goals.............................................................................................................................. 36

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1. AcknowledgementFeroze1888 Mills provided a great opportunity to work and learn under their highly-qualified staff. I would like to give my special regards to Ms. Asifa for providing a great learning exposure. Furthermore, I would extend my gratitude to Mr. Nadeem Abbas, as my internship supervisor. He not only facilitates us throughout the program but also guided us throughout the internship plan.I would also pay thanks to Mr. Noor, Mr. Anwer, Mr. Ali Murtaza, Mr. Ahsan, Mr. Kashif, Mr. Rafiq, Mr. Mohsin and to all the technical staff whom I encountered, aiding in my learning experience.

2. Company OverviewFeroze1888 Mills are the leading Manufacturer and Exporter of Specialized Yarn & Textile Terry Products in Pakistan. Starting the journey in early 1970s, Feroze1888 has progressed gradually & today it enjoys an eminent presence among all. As an ISO 9001:2008 certified company they maintain high sets of standards in all areas, ranging from the highest quality products to maximum employee satisfaction. Company has state of the art vertically integrated terry towel manufacturing facility.

Feroze1888 believe in providing a professional work environment with tremendous growth opportunities at all levels. Being partnered with 1888 Mills (USA), they are recognized as a Progressive and Global manufacturer of quality textiles for Home, Hospitality & Healthcare.

2.1 AmbitionTo be a market leader in terry textile manufacturing with their strong commitment to 3 Ps (People – Planet – Prosperity). That is to have care for the workers and the customers, safer and greener environmental operations and working for the wellbeing of Pakistan.

The word “PROSPER”People Development

RespectOwnership and accountability

Success WillProactive

Excellence in workReliability

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3. Manufacturing Process

1Spinning

2Twisting/Doubling(On Demand)

3Warping

4Sizing

5Weaving

6Bleaching

7Shearing(On Demand)

7Dyeing or Printing

8Cutting

9Stitching

10Packaging

11Transportation

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3.1 SpinningSpinning is a major part of the textile industry. It is part of the textile manufacturing process where three types of fibre are converted into yarn, then fabrics, which undergo back processes such as singing, desizing, washing, equalizing bleaching, dying, printing and finishing process to become textiles. The textiles are then fabricated into finished fabrics, garments, home textiles, clothes or other products. There are three industrial processes available to spin yarn, and a handicraft community who use hand spinning techniques. Spinning is the twisting together of drawn out strands of fibres to form yarn, though it is colloquially used to describe the process of drawing out, inserting the twist, and winding onto bobbins. In simple words, spinning is a process in which we convert fibres by passing through certain processes like blow room, carding, drawing, combing, simplex, ring frame and finally winding into yarns. These yarns are then wound onto the cones.In Feroze1888 Spinning is performed in Hub Unit.

3.2 Twisting/DoublingDoubling of yarn where two or more stands or ends of yarn are twisted together. There are many purposes where doubled yarn is used. Sometimes thread is doubled to make warp, and it is invariably used for the manufacture of knitting yarn, crochet yarn and sewing yarn. All these yarns must be smooth and free from knots. In a sewing thread, the treads are doubled in two phases. Two or three strands are twisted together then three of these threads are twisted together, to form a six or nine cord. The spun yarn is wound onto a bobbin using a doubling winding machine, and two or more of these bobbins are placed on doubling frame (doubling winding machine).

In Feroze1888 there are 6 machines for Doubling and Twisting.

3.3 WarpingThe yarn manufacturers, these days, can supply prepared warps but most of the knitting firms prefer to prepare their own warping equipment and warp beams independently. Mostly, they select the standard types of yarns and warp effect yarns in the plant. There are two basic methods of warping that can be used to prepare the warps for the knitting machines- Indirect Warping and Direct Warping

3.3.1 Indirect Warping: The yarns from the yarn packages are wound onto an intermediate cylinder (mill) in many parallel groups with a specified density, and then they are back wound onto the warp beam.

Section Warping is an example of Indirect Warping at Feroze1888 H-23. There is no need for sizing after section Warping. At H-23, Feroze1888 has single Section Warping Machine. Here the Threads on Section Warping machine can be no more than 300.

3.3.2 Direct Warping: The ends of the yarn are wrapped in one operation, from the yarn packages onto the warp beam.

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There are Four Direct Warping or Simple Warping Machines at H-23. Maximum Thread count here is 740. Sizing is required after direct warping.

3.4 SizingSizing of the warp yarn is essential to reduce breakage of the yarn and thus production stops on the weaving machine. On the weaving machine, the warp yarns are subjected to several types of actions i.e. cyclic strain, flexing, abrasion at various loom parts and inter yarn friction.

With sizing, the strength — abrasion resistance — of the yarn will improve and the hairiness of yarn will decrease. The degree of improvement of strength depends on adhesion force between fiber and size, size penetration as well as encapsulation of yarn. Different types of water soluble polymers called textile sizing agents/chemicals such as modified starch, polyvinyl alcohol (PVA), carboxymethyl cellulose (CMC), acrylates are used to protect the yarn. Also wax is added to reduce the abrasiveness of the warp yarns. The type of yarn material (e.g. cotton, polyester, linen), the thickness of the yarn, type of weaving machinery will determine the sizing recipe.

The sizing liquor is applied on warp yarn with a warp sizing machine. After the weaving process the fabric is desized (washed).

3.5 WeavingWeaving is a method of textile production in which two distinct sets of yarns or threads are interlaced at right angles to form a fabric or cloth. Other methods are knitting, felting, and braiding or plaiting. The longitudinal threads are called the warp and the lateral threads are the weft or filling. (Weft or woof is an old English word meaning "that which is woven". The method in which these threads are inter woven affects the characteristics of the cloth. Cloth is usually woven on a loom, a device that holds the warp threads in place while filling threads are woven through them.

The way the warp and filling threads interlace with each other is called the weave. The majority of woven products are created with one of three basic weaves: plain weave, satin weave, or twill. Woven cloth can be plain (in one colour or a simple pattern), or can be woven in decorative or artistic design.

3.6 BleachingBleaching is a process of whitening the weaved cloth for the purpose of Dying or printing process. There are two type of bleaching processes.

Full Bleach Half Bleach

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The material for full bleach is bleached, washed, dried, cut and stitched then ready for export. However, the Half Bleach material is for Dying process. Hence the cloth after being sent to Dying process its dried then cut finally stitched then packed and ready for export.

Bleaching process at Feroze1888 H-23 can be illustrated as follows.

Weaved Rolls are fixed in Bin Piller where they are turned to ropes. The ropes are then sent to J-box where the bleach is added to the ropes. The Ropes are then sent to MCS. The 16 chambers of MCS only hot washes the cloth. After MCS the cloth is sent to pit. The material from pit is afterwards sent to can dryer after which its ready for further

processing.

3.7 DyeingDyeing is the process of adding color to textile products like fibers, yarns, and fabrics. Dyeing is normally done in a special solution containing dyes and particular chemical material. After dyeing, dye molecules have uncut chemical bond with fiber molecules. The temperature and time controlling are two key factors in dyeing.

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There are two main types of dyeing process conducting in Feroze1888 H-23

Continuous Dyeing Exhaust Dyeing

3.7.1 Continuous DyeingIn Continuous dyeing, there are two available methods for dyeing. Pad Steam and Pad Batch. In Pad Steam the rolls are brought through lifters into the dyeing room where they are mounted on pad steam after which the dyeing process begins. The dyeing starts with the addition of Dye then softener chemical. Afterwards its sent into the steamer then the washing procedure starts in the next 5 chambers before the dye cloth is sent to the wetout and then to the loop dryer for finishing process.

In pad batch the dye material is left for 16-20hrs for the color to make its permanent place. After which its sent to the Washing range and then sent to wetout finally loop dryer.

3.7.2 Exhaust dyeingIn Exhaust dyeing, there are again two type of processes HT and SF, which are High Temperature and Soft Flow respectively. The material which has to be sent for printing process has to go through the bleaching in HT or SF. The reason for using only this process its due to its better quality of bleaching over conventional. There would be no crease marks etc. The process of HT and SF starts as being cloth being fed into the system after the process either the cloth is squeezed in a squeezer or sent to Hydro Extractor which is relatively significantly slower.

After the bleaching process, here the cloth is sent to tumbler dryer where the softness of the material is improved significantly

3.8 ShearingShearing is a customer demand objective. In which the files on the cloth are straightened to customer’s delight. The process of machine works in such a way that the first cut is done pre-bleaching process. After the total bleaching process its sent to finishing cut for shearing after which its ready to be cut, stitched and packed.

The machine configurations at Feroze1888 H-23 can be elaborated through this table.

Dyeing and ProcessingEquipment Quantity

BleachingGreige Bin Piller 2

J-Box 2

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MCS 2Can Dryer 2

DyeingPad Steam and Bin

Piller 2

Pad Batch 2Washing Range and

Piller 1

HT 4SF 4

Hydro Extractor 2Squeezing machine 2

Finishing ProcessWetout 4

Loop Dryer 3Pentec Dryer 2

Shearing 2

3.9 PrintingPrinting is a process in which a desired shape is extracted onto the cloth or towel. In order to achieve printing of a desired geometry the cloth has to pass through following processes.

3.9.1 EngravingEngraving is a process in which a structure is printed onto LYLON frame. The Frame is made of aluminum. This frame is then stick with LYLON on which 4-5 layers of HCR-64 are coated. After which it is placed on an Inkjet and the geometry is printed onto the surface. Exposure of light onto the ink will result in removal of the printed area, leaving voids through which color can flow.

3.9.2 Piece PrintingIn Piece printing more labor is required since two labors are required to place the piece onto the machine. The printed material gone over to other industries. After printing it is sent to Steam Edger, then the cloth is washed and placed into Hydro Extractor afterwards. And finally, for finishing process it’s passed through tumbler dryer.

3.9.3 Continuous PrintingContinuous printing is faster thus higher production rate compared to patch printing. After the print the continuous roll is sent to Dryer, steam edger then finally into washer. Afterwards, its sent to steamer, washer, then softener chemical is added into the 10th chamber after which it is passed through Dryer and then into tumbler drier for finishing touch.

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3.10 CuttingThe continuous cloths or towels are meant to be in pieces thus they are cut into equal sizes and then sent to stitching.

3.11 StitchingThe material after being cut is sent for stitching, in which every edge is double stitched and then sent to packaging.

3.12 Packaging and TransportationDuring the packaging process the slip is added in the name of the customer and its location. After which the shipment is transported to the customer location.

3.13 RnD – Research and DevelopmentThe purpose of this department is to facilitate the buyers by providing them their demanded design. Research department has its own sampling or production machine used only for producing samples for the buyer if he wishes to initiate a purchase.

RnD has its own Printing, Dyeing, cutting and stitching department whose purpose is to meet the consumer or buyer’s standard and demand.

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4. Maintenance & Documentation Maintenance is essential requirement of any running machinery. Thus, a scheduled inspection and maintenance is an essential requirement of a Textile mill. In some cases, lack of maintenance might result in complete shutdown of production, aiding to heavy production loss.

There are following three types of maintenance,

Preventive Maintenance Breakdown Maintenance Shutdown Maintenance

4.1 Preventive MaintenancePreventative maintenance (or preventive maintenance) is maintenance that is regularly performed on a piece of equipment to lessen the likelihood of it failing. Preventative maintenance is performed while the equipment is still working, so that it does not break down unexpectedly.

Preventative maintenance is planned so that any required resources are available.

The maintenance is scheduled based on a time or usage trigger. A typical example of an asset with a time based preventative maintenance schedule is an air-conditioner which is serviced every year, before summer. A typical example of an asset with a usage based preventative maintenance schedule is a motor-vehicle which might be scheduled for service every 10,000km.

4.2 Breakdown MaintenanceBreakdown maintenance is maintenance performed on equipment that has broken down and is unusable. It is based on a breakdown maintenance trigger.

It may be either planned or it can be unplanned. An example of planned maintenance is run-to-failure maintenance, while examples of unplanned maintenance include corrective maintenance and reactive maintenance.

Breakdown maintenance can be more costly than preventative maintenance.

4.3 Shutdown MaintenanceSimply put, Shutdown Maintenance is maintenance that can only be performed while equipment is not in use. Shutting down machinery can be costly, but sometimes due to the nature of the defective part/machine, shutdown maintenance is the only viable maintenance procedure. Technicians will do all that they can to avoid a complete shutdown. In some industrial applications (power generation for example), a shutdown can mean enormous financial losses.

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4.4 Preventive Maintenance Procedure at Feroze1888 H-23Preventive Maintenance here takes place in the following order.

Scheduling maintenance on the Maintenance Log of individual equipment. Check List is prepared to be inspected LOTO Permit for equipment LOTO – Lockout Tagout Physically Maintenance performed Maintenance Report

5. Power HouseElectric power supply is an essential element of a textile industry. Lack of power and complete shutdown of few equipment may turn down the whole manufacturing process. At Feroze1888 Landhi H-25, the net power consumption per daily use is around 3.5MW. So mostly 3 out of 6 generators are fully functional while others are kept at standby.

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After the purchase of MTU 1.6MW Genset its fully operational with CAT Gensets. WAEKESHA Gas Genset and CUMMINS diesel Genset are kept at standby. The configuration of the generator units is given in the description below.

GeneratorsManufacturer Fuel Engine Config. Cooling System Power Output

MTU

Gas

V12 Radiator 1169kWV16 1560kW

WAEKESHA V12Cooling Tower

635kW

CAT V16 1005kWV16 975kW

CUMMINS Diesel V12 Radiator 1088kWI6 400kW

5.1 Waste Heat RecoveryThe Genset of CAT and MTU are connected to a Waste Heat Recovery System. The basic need of this system is due to very high exhaust temperature which is harmful to discard in the open environment. The exhaust temperature those temperature is around 450oC is directed towards the Boiler where it exchanges heat with the water converting it into steam. Then the flow gases are passed into the main stack where it gets in contact with the Economizer system and the flow gases which were around 150oC after heat exchange with the Feed Water heater that is the economizer exchanges heat and are left into the atmosphere at much lower temperature, which is environment friendly too. This is also an application of Clean Energy Technology.

Following is the Simple Process Flow diagrams.

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5.2 Flow Gases Block Diagram

5.3 Economizer and Feed Water Tank

The Razzak Associate and IME Boilers are Water Tube Waste heat recovery boilers. Both are separate systems. 2 IME Boilers are connected to an Dual CAT Genset instrument panel however one of them is replaced by MTU 1.2MW. The Razzak Associate Waste Heat recovery system is connected to the MTU 1.6MW Genset. The basic principle for the Heat Recovery process however is almost the same as mentioned in the Process Flow Diagrams.

Boiler Feed Water Tank

Economizer

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5.4 Jacket Water Heat RecoveryThis system is connected to the generators in order to receive high temperature water for the process. For example, for Bleaching process. The water is entered at ambient temperature into the heat exchangers where it leaves at 75-80oC.

The system is designed in such a manner that when hot processes water is needed the engine is cooled exchanging its heat with the process water and when process water is not a requirement generator exchanges its heat through water from Open Circuit cooling tower. In heat exchanger, the Coolant and the Water are well separated only transferring the heat from high temperature to low temperature.

5.5 Air Ventilation System – Power HouseGenerators require a good proper air ventilation system for their operations. This brings into place the use of Supply and Return Fans running at nearly 1500 RPM. The purpose of supply fan is to suck the air from the atmosphere into the room, while the return fan throws the air out. There is a proper Air Filter established on each of the supply fan in order to obstruct any foreign particles from striking the generator or destroying the running environment for the generators. There is a specified air flow and ventilation given by the OEMs which has to be maintained for safer operations.

There are currently 3 supply and 3 return fans continuously in operation.

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5.6 Cooling Tower SpecificationsCooling Tower

Tower Type Capacity Pumps ApplicationPower House

1Open

Circuit 125ton4x7.5HP

Jacket Water Cooling(Standby)

Power House 2

Open Circuit 200ton Jacket Water Cooling

(Operational)

Chiller Open Circuit 125ton 2x3.5HP Die Formation

Waste Water Treatment

Plant

Package Type 100ton 2 Waste Water Cooling after

Equalization Tank

5.7 Gas Turbine – GTGas turbine is another source of Power Generation. Gas turbines have a lot of application since they can be operated in a variety of environments. However, GT at Feroze1888 H-23 has been mostly dismantled due to its schedules major overhauling. Maintenance cost of the GT 3300kW gas turbine is a lot more hence it was more feasible to use MTU GENSET equipment instead.

There was also a Waste Heat Recovery System Setup with the GT which could produce a design capacity of 5ton of steam at 9bar or 900kPa.

5.8 LT and HT DistributionAfter the production of Electricity its distribution to the consuming equipment is the major hurdle. The generated potential on the generator side is 400V which is then fed to a Step-Up transformer to raise it to 11kV.

The need of Step Up is to reduce line losses and to improve the efficiency.

There are 2 Step Down and 1 Step Up transformer. The Step Up increases the Voltage from 400V to 11kV while the Step Down reduces the 11kV to 400V. after the Step down the electricity is available for the equipment.

There are Circuit Breakers Installed in the Power House to ensure safe operation of the equipment.

The Breaker Panels situated in Power House have the following specifications,

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LT Distribution System

Unit Circuit Breaker Specification (Amps)100 150 250 400 600

WWTP Change Over *

Reco A/C Department *

Weaving Sulzer

“Shade A”*

Weaving Sulzer

“Shade B”*

Terry Folding *Luwa A/C

Department *

Salvada Machine *

Warping and Sizing *

Chiller Plant *KDA Pump

and Boundaries

Light

*

HT,SF,GM Office, D&P and Turbine

Chiller

*

Half Bleach *Fire Boiler *Workshop and Pad Steam

*

RnD Light and Power

House Light*

Backside A/C *MCS

Machine *

RnD Lab *Loop Drier *RO Water *

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ReclaimOH & Fire

Pump *

MCS *Washer *Wet out *

Can Drier (New) *

Can Drier (Old) *

G-1 Department (MF Area)

*

J-Box *IT and Admin 300Amps*

Turbine Compressor and Gresham

Boiler

*

6. BoilersA boiler is a closed vessel in which water or other

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fluid is heated. The fluid does not necessarily boil. The heated or vaporized fluid exits the boiler for use in various processes or heating applications. The source of heat for a boiler is combustion of any of several fuels, such as wood, coal, oil, or natural gas. Electric steam boilers use resistance- or immersion-type heating elements. Nuclear fission is also used as a heat source for generating steam, either directly (BWR) or, in most cases, in specialized heat exchangers called "steam generators" (PWR). Heat recovery steam generators (HRSGs) use the heat rejected from other processes such as gas turbine.

In Feroze1888 Mills Landhi H-23 we see a variety in Boiler category. There exist both Fire Tube and Water Tube boilers.

6.1 Fire-tube boiler: Here, water partially fills a boiler barrel with a small volume left above to accommodate the steam (steam space). This is the type of boiler used in nearly all steam locomotives. The heat source is inside a furnace or firebox that has to be kept permanently surrounded by the water in order to maintain the temperature of the heating surface below the boiling point. The furnace can be situated at one end of a fire-tube which lengthens the path of the hot gases, thus augmenting the heating surface which can be further increased by making the gases reverse direction through a second parallel tube or a bundle of multiple tubes (two-pass or return flue boiler); alternatively, the gases may be taken along the sides and then beneath the boiler through flues (3-pass boiler). In case of a locomotive-type boiler, a boiler barrel extends from the firebox and the hot gases pass through a bundle of fire tubes inside the barrel which greatly increases the heating surface compared to a single tube and further improves heat transfer. Fire-tube boilers usually have a comparatively low rate of steam production, but high steam storage capacity. Fire-tube boilers mostly burn solid fuels, but are readily adaptable to those of the liquid or gas variety.

6.2 Water-tube boiler: In this type, tubes filled with water are arranged inside a furnace in a number of possible configurations. Often the water tubes connect large drums, the lower ones containing water and the upper one’s steam and water; in other cases, such as a mono-tube boiler, water is circulated by a pump through a succession of coils. This type generally gives high steam production rates, but less storage capacity than the above. Water tube boilers can be designed to exploit any heat source and are generally preferred in high-pressure applications since the high-pressure water/steam is contained within small diameter pipes which can withstand the pressure with a thinner wall.

Boiler Specifications at Feroze1888 H-23.

Boilers

OEM Quantity Type Capacity Operating Pressure

Design Pressure

Descon 1

Fire Tube

15ton

9bar 14barJohn Thompson 1 5ton

- 2 2tonIME Boilers 2 Waste Heat 850kg 8bar 12bar

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RecoveryRazzak Associates 1 1200kg 8bar 12bar

6.3 Flow Diagram for DESCON Boiler

In Boiler room, there are 2 Feed Water Tanks of 10 and 8 cubic meter for John Thompson and DESCON Boiler Respectively. And a Blowdown tank which drains the contaminated water from the bottom of the boiler.

Boiler Peripherals (DESCON & John Thompson)Equipment Quantity Capacity/Power

Feed Water Tank 2 10m3

8m3

Deaerator 2 -Feed Water Pump (DESCON) 2 22kW

Feed Water Pump (John Thompson) 2 9kW

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Boiler Safety and Set PointsSafety Quantity Set Point

Water Level Indicator 2 40%Safety Valve 2 10bar

Temperature Safety 2 215oC

7. Water TreatmentWater Treatment is an essential requirement of a textile Industry since there is a lot of millions of gallons of water being used and discarded. However, at feroze1888 H-23 the total consumption of water in approximately 0.3 million gallons daily. In order to meet water requirements large quantity of “Well Water” is being utilized and water is being recycled.

Wastewater treatment is a process used to convert wastewater - which is water no longer needed or suitable for its most recent use - into an effluent that can be either returned to the water cycle with minimal environmental issues or reused. The latter is

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called water reclamation and implies avoidance of disposal by use of treated wastewater effluent for various purposes. Treatment means removing impurities from water being treated; and some methods of treatment are applicable to both water and wastewater. The physical infrastructure used for wastewater treatment is called a wastewater treatment plant (WWTP)

Following Chart elaborates Water Consumption and Specs.

Water RequirementsType Well Water Waste Water

Capacity(induction) 0.2 million gallon 0.1 million gallonTreatment Method RO Plant WWTP + RO

Use Boiler Water and Bleaching (major)

Although disposal or reuse occurs after treatment, it must be considered first. Since disposal or reuse are the objectives of wastewater treatment, disposal or reuse options are the basis for treatment decisions. Acceptable impurity concentrations may vary with the type of use or location of disposal. Transportation costs often make acceptable impurity concentrations dependent upon location of disposal, but expensive treatment requirements may encourage selection of a disposal location on the basis of impurity concentrations.

7.1 Waste Water Treatment Plant Configuration H-23

Process of WWTP Feroze1888 H-23

Primary screening to contain heavy particles from reaching Equilization tank. Then water enters into the Equilization tank.

Purpose of equilization tank is to equalize the pH of the system and even the mixture.

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Also, to decrease the initial temperature up to 3-5oC. An Aerator Fan mixes the Waste Water.

Then water is pumped into the cooling tower to further decrease the temperature. Then water passes through the Drum Screen and enters into the Coagulation tank.

Lime and FeSO4 are added as coagulants. Then water enters into the Flocculation Tank. Where its mixed with a Polymer

Flocculant. Then Water enters into Primary Sedimentation tank.

Solids and non-polar liquids may be removed from wastewater by gravity when density differences are sufficient to overcome dispersion by turbulence. Gravity separation of solids is the primary treatment of sewage, where the unit process is called "primary settling tanks" or "primary sedimentation tanks". It is also widely used for the treatment of other wastewaters. Solids that are heavier than water will accumulate at the bottom of quiescent settling basins.

Water then enters into Distribution tanks and get divided evenly in both Aeration tanks. Water then enters the Aeration tank.

In an aerated basin system, the aerators provide two functions: they transfer air into the basins required by the biological oxidation reactions, and they provide the mixing required for dispersing the air and for contacting the reactants (that is, oxygen, wastewater and microbes). Typically, the floating surface aerators are rated to deliver the amount of air equivalent to 1.8 to 2.7 kg O2/kWh. However, they do not provide as good mixing as is normally achieved in activated sludge systems and therefore aerated basins do not achieve the same performance level as activated sludge units. In Feroze1888 H-23 the DO level is maintained at 2mg/m2.

Then water enters into the secondary sedimentation tank or Biological Sedimentation. The water then goes to Ultra Filtration plant for further purification.

NOTE: The sludge accumulated is first sent to Sludge Tank then into Sludge Conditioning Tank where it solidifies and is disposed in bags.

WWTPSite Quantity Capacity (m3)

Screen 2 -Equilization Tank 1 915Coagulation Tank 1 -Flocculation Tank 1 -

Primary Sedimentation Tank 1 169Distribution Tank 1 243

Aeration Tank 2 615Biological Sedimentation

Tank2 -

Sludge Tank 1 15Sludge Conditioning Tank 1 11.55

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7.2 Reverse Osmosis – ROIn industry, reverse osmosis removes minerals from boiler water at power plants. The water is distilled multiple times. It must be as pure as possible so it does not leave deposits on the machinery or cause corrosion. The deposits inside or outside the boiler tubes may result in underperformance of the boiler, bringing down its efficiency and resulting in poor steam production, hence poor power production at the turbine.

It is also used to clean effluent and brackish groundwater. The effluent in larger volumes should be treated in an effluent treatment plant first, and then the clear effluent is subjected to reverse osmosis system. Treatment cost is reduced significantly and membrane life of the reverse osmosis system is increased. The process of reverse osmosis can be used for the production of deionized water. Reverse osmosis process for water purification does not require thermal energy. Flow-through reverse osmosis systems can be regulated by high-pressure pumps. The recovery of purified water depends upon various factors, including membrane sizes, membrane pore size, temperature, operating pressure, and membrane surface area.

In Feroze1888 H-23 the Waste Water after UF is mixed with Well water after which it is stored and ready for RO. The TDS of Well Water and UF water is 3000-3500 and 1800-2500 respectively.

Specs. of RO Plant Feroze1888 H-23

RO PlantPlant 1 Plant 2

Membrane(OEM) KOCHCapacity 2 x 1.5 lac Gal 3 x 0.5 lac Gal

+1 x 2 lac Gal

Feed Water Pump 32 m3/hr -Pre-RO Storage Tank 75000 GalPost RO Storage Tank 2.25 lac GalProcess Delivery Tank 75000 Gal

Backwash Time 12 hrsUse Ro Polishing Plant RO Rejection Plant

Net Feed 40.41 m3/hrNet Product 28.41 m3/hr

Net Rejection 12 m3/hrTDS 1-3

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7.3 Process Diagram RO Plant Feroze1888 H-23

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8. HVAC – Heating Ventilation & Air CirculationIn a Textile Industry HVAC is a major department whose purpose is not to cool to air but to maintain a particular temperature and humidity level to ensure strength of threads on the looms. At Feroze1888 H-23 there are 171 looms continuously running. The ratio is 50 looms and 50 persons.The HVAC System at Feroze1888 H-23 Specs are as followed

HVAC SystemPlants Supply

Fan Return

FanShower Pump

Rotary Water Filter

Rotary Air Filter

Dust Collector

LUWA 6 2 2 2 1 1LUWARECO 4 1 2 1 1 1RECO

MANSTOCK 3 2 2 1 1 2

All the 5 Plants are divided into 6 compartments namely

Panel Room Shower Room Return Fan Room Air Rotary Room Element Room Dust Collector Room

8.1 HVAC Process Feroze1888 H-23 Fresh Air is ingested through atmosphere mixed with circulation air by the help of Return

Fans Water is circulated filtered and showered over the ingested air to increase the moisture

content in the shower room. Furthermore, there is always makeup water. The Moist Air is then forced into the room through supply fans. The Air then returns to the Dust Collector room where the air is purified before entering

the Return fan.

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8.2 HVAC – RECO Plant Process Flow

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9. Air Compressor RoomAn air compressor is a device that converts power (using an electric motor, diesel or gasoline engine, etc.) into potential energy stored in pressurized air (i.e., compressed air). By one of several methods, an air compressor forces more and more air into a storage tank, increasing the pressure. When tank pressure reaches its upper limit the air compressor shuts off.

There are numerous methods of air compression, divided into either positive-displacement or roto-dynamic types.

9.1 Positive displacement

Positive-displacement compressors work by forcing air into a chamber whose volume is decreased to compress the air. Common types of positive displacement compressors are,

Piston-type: air compressors use this principle by pumping air into an air chamber through the use of the constant motion of pistons. They use one-way valves to guide air into a cylinder chamber, where the air is compressed.

Rotary screw compressors: use positive-displacement compression by matching two helical screws that, when turned, guide air into a chamber, whose volume is decreased as the screws turn.

Vane compressors: use a slotted rotor with varied blade placement to guide air into a chamber and compress the volume. A type of compressor that delivers a fixed volume of air at high pressures.

9.2 Dynamic Displacement

Dynamic displacement air compressors include centrifugal compressors and axial compressors. In these types, a rotating component imparts its kinetic energy to the air which is eventually converted into pressure energy. These uses centrifugal force generated by a spinning impeller to accelerate and then decelerate captured air, which pressurizes it.

Pressurized Air is required during weaving to remove Dust blockage. At Feroze1888 H-23 the air pressure is maintained at 7bar.

The Specs of Air Compressor at Feroze1888 H-23 are

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Air CompressorOEM Model Quantity Operating Pressure

Fusheng SA22A 2 7Fusheng SA30A 1

Seize (Standby) SA220 2Atlas Copco GA55 1Atlas Copco GA110 1

Air Ingestion and Storage Process

Air passes through air filters and enters into the Compressors. Dryers Dry the air to remove any moisture. Clean air is then Fed into the Storage tank, ready to be delivered.

The capacity of storage tank is of 15min until the restore of standby supply of air.

10. Chiller and ApplicationA chiller is a machine that removes heat from a liquid via a vapor-compression or absorption refrigeration cycle. This liquid can then be circulated through a heat exchanger to cool equipment, or another process stream (such as air or process water). As a necessary by product, refrigeration creates waste heat that must be exhausted to ambient or, for greater efficiency, recovered for heating purposes.

The Chiller installed at Feroze1888 H-23 is of Vapor Compression System and Reciprocating Type. The Chiller here is used for dyes formation. Current vapor-compression chiller technology is based on the "reverse-Rankine" cycle known as vapor-compression. The minimum limit to the technology here is 7.5oC.

The Specs of the Chiller at Feroze1888 H-23 are,

ChillerChiller Type Vapor Compression System

Capacity 2 x 40tonCompressor Type Reciprocating System

Refrigerant PolyurethaneOperating Pressure 18bar

Pumps 2 (Condensor) x 5.5 kW2 (Chill Water Circulation) : 7.5kW(operational)+12.5kW(Standby)

Use Dyes Formation

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11. Internship Activities – Feroze1888 H-2311.1 Activity #1 – Generator repairingOur first activity at Feroze1888 H-23 started when the CAT 975kW Generator went out of order. The reason was the wear out Valve seats of the 3rd

number engine cylinder. The problem was diagnosed when at about 4:30 am in the night, the temperature sensor on the engine cylinder showed high temperature reading and that it must shutdown. The problem was analyzed and then the activity took place at 9:00 am in the morning.

The activity started on the shutdown engine by removing the screws over engine head and the head cap was removed. Afterwards the ignition transformer was removed over the cylinder head and then the sparkplug was removed and inspected for damage. Afterwards the cylinder head was removed also the pushrods and the cross over bridge (the CAT generator is a 4-valve operated engine configuration thus the purpose of bridge is to match the opening and closing timings). After the complete dismantle of cylinder head of 3rd piston cylinder it was inspected for damage. The exhaust valves and seats were found to be worn out. This required for the repairing of the cylinder head seats and the replacement for the exhaust valve.

After the activity, the engine was configured again and started. The engine shown no sign for further damage or faulty readings. However, it was about 2 days afterwards that the Throttling valve and its actuator started showing signs for a repair. Thus, again the activity was started and after dismantling the instrument the problem was rectified and the generator was placed into performance once more.

11.2 Activity #2 – Fire TrainingFire is the rapid oxidation of a material in the exothermic chemical process of combustion, releasing heat, light, and various reaction products.The triangle illustrates the three elements a fire needs to ignite: heat, fuel, and an oxidizing agent (usually oxygen). A fire naturally occurs when the elements are present and combined in the right mixture, meaning that fire is actually an event rather than a thing. A fire can be prevented or extinguished by removing any one of the elements in the fire triangle. For example, covering a fire with a fire blanket removes the oxygen part of the triangle and can extinguish a fire.Fire can be extinguished by removing any one of the elements of the fire triangle.

turning off the gas supply, which removes the fuel source;

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covering the flame completely, which smothers the flame as the combustion both uses the available oxidizer (the oxygen in the air) and displaces it from the area around the flame with CO2;

application of water, which removes heat from the fire faster than the fire can produce it.

Types of FireClass type Fuel

A SOLIDS such as paper, wood, plastic etcB FLAMMABLE LIQUIDS such as paraffin,

petrol, oil etcC FLAMMABLE GASES such as propane,

butane, methane etcD METALS such as aluminium, magnesium,

titanium etcE Fires involving ELECTRICAL APPARATUSF Cooking OIL & FAT etc

There are various types of Fire Extinguishers available in the market. The specific Fire Extinguishers and there purpose is given in the table as followed.

Fire ExtinguisherType Color Code Use

water Fire Extinguishers Red The cheapest and most widely used fire

extinguishers. Used for Class A fires. Not suitable for Class

B (Liquid) fires, or where electricity is involved.

Foam Fire Extinguishers Cream More expensive than water, but more versatile. Used for Classes A & B fires. Foam spray extinguishers are not

recommended for fires involving electricity, but are

safer than water if inadvertently sprayed onto

live electrical apparatusDry Powder Fire

ExtinguishersBlue Often termed the ‘multi-

purpose’ extinguisher, as it can be used on classes A, B & C fires. Best for running liquid fires (Class B). Will

efficiently extinguish Class C gas fires, BUT BEWARE, IT CAN BE DANGEROUS TO EXTINGUISH A GAS FIRE

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WITHOUT FIRST ISOLATING THE GAS

SUPPLY.  Special powders are available for class D

metal fires.CO2 Fire Extinguishers Black Often termed the ‘multi-

purpose’ extinguisher, as it can be used on classes A, B & C fires. Best for running liquid fires (Class B). Will

efficiently extinguish Class C gas fires, BUT BEWARE, IT CAN BE DANGEROUS TO EXTINGUISH A GAS FIRE

WITHOUT FIRST ISOLATING THE GAS

SUPPLY.  Special powders are available for class D

metal fires.

11.3 Activity #3 – Air CalculationsIn WAMATEX humidity is maintained as well as temperature for the looms, to maintain thread strength and to stop them from breaking frequently. In Air Calculation, the wind velocity at return and supply fan was measured on the site. The data collected was as followed.

WAMATEXFan Type

Quantity Fan Speed (RPM)

Air Velocity

Diameter (in)

Area (m2) Volume Flowrate

(m3/s)Supply

Fan4 1450 30.8 44 0.981 30.210x4=121

Return fan

4 1000 17.5 62 1.9478 34.086x4=136

More volume flow rate of return fan shows circulating as well as air from environment is send after humidification into the room, to compensate for the discarded air.

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12. Suggestions Power House – The CAT 975kW generator should be replaced or sent for complete

overhaul due to frequent forced shutdowns. Power House – WAUKESHA generators have obsolete technology; which aids to lower

fuel economy. Hence efficient generators like MTU should be adopted for better fuel Economy.

HVAC – The system can be improved to automatic system which will lower the human work load and improve work efficiency. The Automatic system can fine tune the Supply fans and return fans also the showering or steam ingestion, according to the humidity ratio.

D&P – The position for the Wetout or the Loop Dryer can be made better which can increase work efficiency. Since collecting the cloth after Wetout then dragging it to loop dryer for drying is a time and work consuming process.

Printing – The piecewise printing machine should be replaced with continuous printing for improved work efficiency.

13. ConclusionIt has been a great learning exposure at Feroze1888 – H-23. The technical staff shared their plentiful of practical and theoretical experience. Not only we managed to follow our internship plan but were able to find time to study and understand the whole Manufacturing Sequence. In the end I would like to thank Feroze1888 for providing us with an opportunity to be a part of Winter Internship Batch 2016.

14. Life GoalsI dream of pursuing my post graduate abroad as Mechanical Engineering. Furthermore, I plan to establish a carrier counseling system in Pakistan to help students meet their goals in life. I am a teacher and a student, I have speaking potential and I can speak for peace. If I ever got a chance, I would pursue my leisure as a public speaker.