Beruflich Dokumente
Kultur Dokumente
INDIAN INSTITUTE OF
MANAGEMENT LUCKNOW
SUMMER INTERNSHIP
PROJECT
DESIGN AND DEVELOPMENT OF HYDRAULIC
POWER PACK FOR LUMMUS BALER
Mr NILKANTHA K DOLE
SENIOR MANAGER MECHANICAL MAINTENANCE
PREFACE
ACKNOWLEDGEMENT
The satisfaction that accompanies the successful completion of
any task is incomplete without the mention of the people
whose ceaseless cooperation made it possible, whose constant
guidance and encouragement crown all the efforts with
success.
I am grateful to Reliance Management for giving me an
opportunity to enhance my skills as a mechanical engineer by
allowing me to join this esteemed organization as a summer
trainee.
I am highly obliged to Mr Muralidhara Rao, my Project Leader
and Mr Nilkantha K Dole, my Mentor, for their invaluable
guidance throughout my project.
I would also like to thank Mr Sanush Arthakad, Mr J P Mahale
and Mr Puneet Singh for all their valuable assistance in project
work.
Also my heartfelt thanks to Mr Ashok Pabbawar, Mr
Hanmantgad and Mr Aniket for providing me the necessary
congenial atmosphere and their support during the course of
my internship.
While working on this project I realized that a company like
Reliance is not only a store house of able engineers but also
proficient managers and that every project done over here
requires a true blend of technical and managerial skills.
Thanking all once again
AMAN GUPTA
CONTENTS
I PREFACE
II ACKNOWLEDGEMENT
III EXECUTIVE SUMMARY
1 INTRODUCTION
1.1 Ril Overview
1.2 Ril Patalganga Manufacturing Division Overview
1.3 PSF Plant Process
1.4 Drawing Process
1.5 Cutting Process
1.6 Packaging Process
4 MAINTENANCE
5 CALCULATIONS
5.1
5.2
Balers
5.3
5.4
EXECUTIVE SUMMARY
This summer internship is a part of my 7 th semester curriculum.
I was selected by Reliance for this summer internship and was
assigned a project at the Patalganga Site.
The title of me project was
INTRODUCTION
RIL OVERVIEW
The Reliance Group, founded by Dhirubhai H. Ambani (19322002), is Indias largest private sector enterprise, with
businesses in the energy and materials value chain. Groups
annual revenues are in excess of US$ 34 billion (as stated on
DETAILS
Total
Total
Total
Total
Total
Total
PRODUCTS
LOGISTICS
Naphtha/Kerosene is transported through pipeline from
BPCL, Mumbai using optical fibre cable for supervisory
control (SCADA)
Complex is well connected by road, located 7 kilometres
from National Highway.(NH4)
Nearest Railway Station (APTA) is 3 kilometres from the
site on Konkan railway track.
MANUFACTURING UNITS
The plant can be broadly divided into two manufacturing
divisions:
Petrochemical Division: This division comprises of PTA,
PX and LAB manufacturing plants.
Fibre Division: This division comprises of the PSF and
PFY manufacturing plants.
Petrochemical Division:
Plant
Purified Terephthalic
Acid
Para-Xylene
Process
Licenser
I . C . I .(U . K .)
Start
Date
Feb ,1998
Raw Material
Para-Xylene
U .O . P .(USA )
Nov , 1998
Naphtha
U .O . P .(USA )
Nov , 1987
Kerosenen
Paraffin
Process
Licenser
DuPont
Start
Date
Oct ,1982
PTA, MEG
DuPont
Mar , 1986
PTA, MEG
Fibre Division:
Plant
Polyester Filament
Yarn
Polyester Staple
Fiber
Raw Material
Polymerization
Spinning and Tow collection
Drawing, heat setting, crimpling and after treatment
Cutting and Baling
Drawing Process:
Draw machine (DM) or Draw Line (DL) is fundamentally an
arrangement of rotating equipment. There are sets of rollers
(modules) at different temperatures and speeds through which
spun polyester tow (bunch of millions of fibres) is passed. At
different stages water and finish solutions are applied and
removed from the polyester tow. When it comes out of the
machine, it had acquired some important fibre properties such
Next the puller rolls pull the tow and feed it into the
crimper assembly.
For regular or mid tenacity products the draw rope is
pulled directly by puller rollers from the second draw
module and fed to the crimper.
From the crimper, tow is distributed onto a relaxer belt
which passes the fibre through a controlled temperature
relaxer oven for drying.
Last section of oven is called cooling zone which reduces
the temperature of fibre.
After cooling, the rope band is pulled from the relaxer
belts by two pliable belts running in nip.
Then, the rope band from the puller belts falls into an
oscillating cutter box from there it is taken to the cutter.
CUTTING PROCESS:
In Lummus Baler, the tow is cut into required cut lengths in the
Lummus cutters. The cut fibre is then shifted from the cutter to
PACKAGING PROCESS:
The balers in PSF plant are the final processing units for the
ready product which is packed into bales weighing around 375
PARAMETERS
LUMMUS
AUTEFA
CAPACITY
PRODUCTS
BALE SIZE
300 TON
SEMI DULL,
TRILOBAL, SUPER
HIGH TENACITY
4 ft. X 3 ft. X 2 ft.
4
5
6
7
BALE WEIGHT
TOW DENIER
TOW FEED
TENSION
STAND
ARRANGEMENT
CUTTER REEL
MOUNTING
CUTTER BLADE
FIXING
5000 KN
SEMI DULL,
TRILOBAL, SUPER
HIGH TENACITY
1.27 m X .64 m X .
96 m
375 kg
2.6 million
220 m/min
POWER
CONTROLLED
8
9
10
11
HYDRAULIC
TANK
PUMP
SPECIFICATION
375 kg
1.6 million
220 m/min
POWER
CONTROLLED
BOLT MOUNTED
(1)
REEL HAS TO BE
REMOVED FROM
POSITION
2900 Lit.
VANE PUMP
T5ED
VOITH-IPH(internal
gear pump)
1600 Lit.
12
PISTON PUMP
P6P
BOX FILLING
GRAVITY FEED
INTO THE BOX
0
1
O
O
X
0
2
O
O
X
0
3
O
O
O
0
4
X
O
X
0
5
X
O
X
0
6
X
O
O
0
7
X
X
X
0
8
X
X
X
0
9
X
O
O
1
0
O
O
O
1
1
X
X
O
1
2
X
O
X
1
3
O
X
X
1
4
X
X
O
1
5
O
X
X
1
6
X
X
X
X
O
X
O
O
O
X
O
X
O
X
O
X
X
X
X
X
O
O
O
X
X
X
O
X
X
O
O
X
X
O
O
SEQUENCE OF MOTIONS
1) Bottom ram up
2) Top ram down
3) Top & bottom ram down
Prepress system
Main press system
Press Box Lifting system
Cooler-Filter unit
Prepress system
It is equivalent to the tramper arrangement in the Lummus
baler. The main difference is that in the Lummus Baler, the
tramper is driven by a motor through a chain and sprocket
arrangement, while in the Autefa Baler the tramper is operated
by a hydraulic cylinder.
Oil is supplied to the prepress circuit by the cover end pump of
the Vickers Flat-plate type Double Vane pump (90 lpm
Oil is supplied to the press box lifting circuit by the shaft end
pump of the Vickers Flat-plate type Double Vane pump (149
lpm discharge capacity). Theere are five SOVs provided to
control the operation of the Press Box Lifting cylinders and the
revolving unit lifting cylinders.
MAINTENANCE
Many changes have already been made in the existing system
to help in maintaining the system properly
New cooling system were installed in the Hydraulic pack of the
Baler as the heat given out by the hydraulic unit was so much
that it was quite difficult to even stay in the room where the
system is installed. The new cooling system has made it
possible to stand near the hydraulic system and perform
various tasks.
The pre-press or the Tramper system of the Baler two was
changed. Earlier the bulky chain and pulley mechanism was
being used, which was very prone to various faults and was
very heavy and its maintenance also required lot of power and
resources, which was replaced by a hydraulic system which is
THEO.
DISPL.
THEO.
DELIVERY
(RPM)
(ml/rev)
(GPM)
2000 PSI
3000 PSI
(HP)
(HP)
(HP)
1200
212
67.2
45.9
80.6
120.2
1800
212
100.8
68.3
122.7
181.6
2200
212
123.2
83.0
150.0
220.0
THEO.
DISPL.
THEO.
DELIVERY
(RPM)
(ml/rev)
(GPM)
2000 PSI
3000 PSI
(HP)
(HP)
(HP)
1200
143.6
45.0
28.5
54.9
82.3
1800
143.6
67.5
43.5
84.0
120.0
2200
143.6
82.5
53.2
102.9
152.7
Leakage at fittings
PROBABLE CAUSE
1) Seal Failure
2) Damaged Casting
3) Damaged or defective
seal b/w housing &
mounting cap
1) Cracked or damaged
flange or fittings
2) Damaged or defective
flange threads
3) Damaged or defective ORing seal
4) Burr on mating surfaces
Power source too small for
pump being used.
1) Pump does not prime
2) Wrong direction of shaft
rotation
3) Tank fluid level too low
4) Fluid inlet line or suction
strainer is choked
5) Air leak in suction line
6) Fluid viscosity too heavy
to pick up prime.
7) Broken pump shaft or
internal parts.
Pump not
delivering pressure
POSSIBLE REMEDY
1) Replace seal
2) Replace Casting
3) Replace seal
Noisy or erratic
operation
Seal failure
loading vanes
1) Air leak at inlet or suction 1) Check for leaks by
line
pouring system fluids
around joints and listen
for change in sound level.
Tighten as required.
2)
Check bolts for proper
2) Housing and mounting
torque
cap separation
3) Reset or clogged inlet
line or strainer
3) Clean strainer and
4) Excessive pump RPM
clogged lines
(cavitation)
5) Worn vane holdout pins
4) Provide power source that
or clogged oil feed holes
does not exceed max
in pins
pump RPM
6) Worn bearings
5) Disassemble as per the
instruction manual
6) Disassemble and replace
Decrease inlet pressure
TERM
ml/rev
GOLDCUP 6
98
GOLDCUP 7
119
PSI
PSI
RPM
GPM
5000
6000
3000
77.9
5000
6000
3000
94.2
GPM
13.9
13.9
PSI
PSI
SAE
SAE
lbs.
200
335.535
C-2 bolt
C-Spline or
key
175
200
335.535
C-2 bolt
C-Spline or
key
`
Possible
cause
Air in fluid
Cavitation in
pump or
motor
rotating
group
Misaligned
shaft
Mechanical
fault in pump
Erosion on barrel
ports and port
plates
High wear in pump
and motor
Air in fluid
Cavitation
Excessive
loads
Contaminant
particles in
fluid
Improper
fluid
Improper
repair
Unwanted
water in fluid
Heating of fluid
Excessive
pump
leakage
Relief valve
Heat
exchanger
reservoir
CALIBRATION/PRESSURE
CHECKING
OF
INDIVIDUAL SOLENOID VALVES AND RELATED
ABNORMALITIES
S.
NO.
S1
S2
S3
S4
S5
S6
S7
CHECKPOINT
PRESSURE
PROBLEM
SETTING/ RELATED TO
STATUS
ABNORMALIT
Y
Isolate all other solenoids
1100 PSI
Valve setting
and check pressure at X4
low
with top & bottom ram at
Pump pressure
bottom position
low
Isolate all other solenoids
2400 PSI
Valve setting
and check pressure at X4
low
with top & bottom ram at
Pump pressure
bottom position
low
Isolate all other solenoids
4200 PSI
Valve setting
and check pressure at X4
low
with top & bottom ram at
Pump pressure
bottom position
low
Isolate all other solenoids
1100 PSI
Valve setting
and check pressure at X5
low
with top & bottom ram at
Pump pressure
bottom position
low
Isolate all other solenoids
2400 PSI
Valve setting
and check pressure at X5
low
with top & bottom ram at
Pump pressure
bottom position
low
Isolate all other solenoids
4200 PSI
Valve setting
and check pressure at X5
low
with top & bottom ram at
Pump pressure
bottom position
low
a) Check whether top ram
Yes
S7 fails to
goes up
open
b) Check extrude pressure at 1200-1600
S8 fails to
X6 when top and bottom
PSI
open & S7
Yes
fails to close
S8 fails to
open
375-500
PSI
Valve setting
wrong
1500 PSI
Valve setting
wrong
Yes
Valve fails to
open
CALCULATIONS
Existing System
Power Consumption Cost:
From the collected data, the number of bales packed from 1 st
March, 2014 to 31st April, 2014, by different balers was
No. of
Bales
LUMMUS
Baler 1
6721
LUMMUS
Baler 2
6819
LUMMUS
Baler 3
6636
AUTEFA
Baler
8282
1) LUMMUS BALER:
Power consumed by motor: 250 HP = 186.5 KW
No. of hours working in a day: 21 hours
No. of days required: 9 days
No. of hours system runs: 9x21 = 189
Cost of electricity: 7.98 per unit
Total cost: 186.5x189x7.98 = 281283
2) AUTEFA BALER:
Power consumed by motor: 75 HP = 55.95 KW
No. of hours working in a day: 24 hours
No. of days required: 7 days
No. of hours system runs: 7x24 = 168
Cost of electricity: 7.98 per unit
Total cost: 55.95x168x7.98 = 75008
201
0
201
1
201
2
201
3
201
4
LUMMUS PUMPS
CHANGED
3
Therefore,
V = (7)2(1) = 153.9 in3
And as 1 in3 = 0.00433 US gallons so,
Volume of oil displace by 1 in movement of piston = 153.9 x
0.00433 = 0.6667 US gallons
Q x p
Pinput
Where,
m /sec
3
x p x (6894.76)
( 0 .0038
60 )
Q x p
=
x 0.00058
P input x 746
Where,
Pinput
in PSI
Pinput is the input power given to the pump in
HP
vane A is the efficiency of the shaft end of the vane type double
pump
Vane A =
Q x p
x 0.00058
Pinput
99 x 1000
x 0.00058
85
Vane A =0.675
vane B is the efficiency of the cap end of the vane type double
pump
Vane A =
Q x p
x 0.00058
Pinput
65 x 1000
x 0.00058
50
Vane B =0.652
Q x p
x 0.00058
Pinput
45 x 1000
x 0.00058
35
piston =0.745
81 GPM
212.5 GPM
212.5 GPM
TANK
BOTTOM RAM UP
The above mentioned flow rates are in accordance with the pressure required in the
existing system.
425 GPM
163 GPM
212.5 GPM
212.5 GPM
TANK
The above mentioned flow rates are in accordance with the pressure required in the
existing system.
240 GPM
92 GPM
92 GPM
240 GPM
212.5 GPM
TANK
As calculated above, while the top & bottom ram goes down,
34 gallons of oil is displaced by the each and the existing
system takes approximately 8 seconds in the process, so, the
34 x
The above mentioned flow rates are in accordance with the pressure required in the
existing system.
425 GPM
163 GPM
212.5 GPM
212.5 GPM
TANK
555 GPM
212.5 GPM
212.5 GPM
TANK
TOP RAM UP
As calculated above, while the top ram goes up, 106 gallons of
oil is displaced and the existing system takes approximately 20
seconds in the process, so, the flow rate required to move the
top ram up is
106 x 3 =
318 GPM
The above mentioned flow rates are in accordance with the pressure required in the
existing system.
46 GPM
120 GPM
120
GPM
212.5 GPM
TANK
RECOMMENDATIONS
REFERENCES