“SUMMER INTERNSHIP (OFFLINE) at NAYARA ENERGY

LIMITED”
By
PATEL KISHANKUMAR HITESHBHAI
20173105008

Under the guidance of

Guided by: Guided by (Industry guide if applicable)
Prof. Dolly Gandhi Mr. Paresh Bodar
Associative Professor Production Manager
Chem. Engg. Dept. Manufacturing Department
V.G.E.C. Chandkheda Dahej

A Report Submitted to
Chemical Engineering Department
in Partial Fulfillment of the Requirements for
the Bachelor Degree of Chemical Engineering

June- 2024

Vishwakarma Government Engineering College,

(Affiliated to Gujarat Technological University)
Nr. Visat three roads, Sabarmati-Koba highway, Chandkheda,
Ahmedabad, Gujarat, India-382424

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CERTIFICATE

This is to certify that the internshipentitled “Manufacturing of Polyos”has been carried out by
Asodariya Akshay M. (210170105007)for partial fulfillment ofBachelor of engineering degreein
chemical engineering to be awarded by Gujarat Technological University during the academic year
2023-24. This internship work has been carried out under my guidance and supervision and it is
upto my satisfaction.

Date:
Place: Chandkheda, Ahmedabad

Guided by: Guided by:-

Prof. Dolly Gandhi Mr. Paresh Bodar
Associative Professor Production Manager
Chem. Engg. Dept. Manufacturing Department
V.G.E.C. Chandkheda Dahej.

Dr. Femina J. Patel

Professor and Head,Chemical Engg. Dept.
VGEC, Chandkheda

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INTERNSHIP APPROVAL CERTIFICATE

This is to certify that internship work titled “Manufacturing of Polyols At Expanded Polymer
Systems Pvt. Ltd.”was carried out by Asodariya Akshay M. (210170105007)at Vishwakarma
Government Engineering College, Chandkheda (017) is approved for the for partial fulfillment
of Bachelor of engineering degreein Chemical Engineeringby Gujarat Technological University.

Date:

Place:VGEC, Chandkheda

External Examiner(s):

……………………… ………………………
.. ..

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UNERTAKING ABOUT ORIGINALITY OF WORK

We hereby certify that we are the sole authors of this internship report and that neither any part of
this report nor the whole of the report has been submitted for partial fulfillment of Bachelor of
engineering degree to any other University or Institution.
We certify that, to the best of our knowledge, the currentinternship report does not infringe upon
anyone’s copyright nor violate any proprietary rights and that any ideas, techniques, quotations, or
any other material from the work of other people included in my report, published or otherwise, are
fully acknowledged in accordance with the standard referencing practices. Furthermore, to the
extent that I have included copyrighted material that surpasses the bounds of fair dealing within the
meaning of the Indian Copyright (Amendment) Act 2012, We certify that we have obtained a
written permission from the copyright owner(s) to include such material(s) in the current report and
have included copies of such copyright clearances to my appendix.
We have checked the write up of the present thesis using anti-plagiarism database and it is in
allowable limit. Even though later on in case of any compliant pertaining of plagiarism, we are sole
responsible for the same and we understand that as per UGC norms, University can even revoke
Engineering degree conferred to the student submitting this report.

Date:

Place: Chandkheda, Ahmedabad

Signatures:

Student: Guide: Guide:

Asodariya Akshay Mayurbhai Prof. Dolly Gandhi Mr. Paresh Bodar
210170105007 Associative Professor Production Manager

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ACKNOWLEDGEMENT

It is a matter of extreme honor and privilege for me to offer my grateful acknowledgement to my

guideProf. Dolly Gandhi for providing a chance to work under their guidance and supervision.
I express my sincere appreciation and thanks my guide and co-guide for constant encouragement
and needful help during various stages of work. I am also thankful to the Chemical engineering
department and the institute for providing all kind of required resources.
I appreciate all my colleagues whose direct and indirect contribution helped me a lot to accomplish
this projects and who made the period of project more pleasant and fruitful. I would also like to
thank all the teaching and non-teaching staff for co-operating with me and providing valuable
advice which helped me in the completion of this internship project.
I would like to express my sincere thanks to Head of Department of Chemical Engineering Dr.
F.J.Patel for granting the permission to do work as project in summer internship.

With regards,
Asodariya Akshay M.
210170105007

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TABLE OF CONTENTS

Title Page………………………………………………………………………….………....i
Certificate………………………………………………………………………….……… .ii
Internshipapproval certificate…………………………………………………………....iii
Undertaking about originality of work…………………………………………………...iv
Acknowledgement…………………………………………………………………………..v
Table of Contents…………………………………………………………………………..vii
List of Figures…………………………………………………………………………..…viii
List of Tables…………………………………..……………………………………….…...x
Abstract…………………………………………………………………………………..…xi

CHAPTER1) INTRODUCTION…………………………………………………………..29
1.1) Company Profile………………………………………………………………………29
1.2) Raw Materials……………………...………………………………………………….31
1.3) Storage tank…………………………………………………………………………...34
1.4) Equipments……………………………………………………………………….…...35
1.5) Flow meters…………………………………………………………………………...39
CHAPTER 2) PROCESS ……………...…………………………………………………....40
2.1) Utilizes………………….. ……………………………………………………………40

CHAPTER 3) Calculations………….………………………………………………………42

CHAPTER 4) Quality Control……………………………………………………………..45

4.1) Efflutent treatment plant………………………………………………………………45

4.1) Process Safety…………………………………………………………………………46
4.1) 13 Elements Of Process Safety……………………………………………..…………47

CHAPTER 5) REFERNCES……………………………………………………………….51

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LIST OF FIGURES

FigureNo. Title of figures

1 Reactor(Polymeriser)
2 Filter press
3 Scrubber tank
4 Gear pump
5 Lobe pump
6 Air operated diaphragm (AOD)
7 Ball valve
8 NRV
9 Butterfly valve
10 Gate valve
11 Globe valve
12 Rotameter
13 Mass flow meter
14 Cooling tower

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ABSTRACT

Submitted by:
Asodariya Akshay M.
(210170105007)

Supervised by:

Guided by: Guided by:

Prof. Dolly Gandhi Mr. Paresh Bodar
Associative Professor Production Manager
Chem. Engg. Dept. Manufacturing Department
V.G.E.C. Chandkheda (017) Dahej

ABSTRACT:

My industrial internship (subject code: 3170001) is at Expanded Polymers Systems Pvt. LTD.,
industry situated at Dahej. There is production of Polyols in this industry. During my internship I
am going to obtain in plant training in Production department. I was taking my industrial training
under technical persons working with this industry. I was getting benefit of understanding practical
aspects of various operations, Reaction, process safety, and process utilities as well as process
control throughout this training. It was help me a lot to correlate theoretical knowledge of chemical
engineering principles with industrial applications on large scale operations. I was also getting
knowledge about construction and working of various process equipm

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CHAPTER 1

INTRODUCTION

Expanded Polymer Systems was founded as ‘Expanded Incorporation,’ in 1983, and its offices were
then located at Nandkishore Industrial Estate on Mahakali Caves Road in Andheri. Currently, its
production facilities are located in the Pawne Industrial Area, just 25 km from Mumbai city. It has a
second, much larger production & bulk storage facility in Dahej (a port in Gujarat), 40 km from
Bharuch, on the Mumbai-Delhi corridor.
They launched their industrial operations by blending the Polyols used in the rigid PU industry.
Their facility was upgraded in 1991, with in-house technology for manufacturing both Polyester and
Polyether based Polyols. This enabled them to offer a consistent quality of Polyol blends to the
industry and they soon succeeded in becoming a preferred supplier to top-end industries like
Refrigeration and General Insulation. This also enabled them to establish very strong brand equity
in the Middle East market.
Their chemicals’ business is well complimented with the marketing of Polyurethane Foam
processing equipment from Cannon of Italy. As its sole distributor in India, Expanded has supplied
the maximum number of PU Plants in the country. This venture has been augmented with Marketing
Agencies for Polyurethane & Plastic processing machinery from world-renowned companies.
Description of pilot plant and Line 1,2,3,7,8,9 are given below:
● Pilot Plant: This plant has a capacity of 1 MT/batch. The first scale up of all products
developed by the Research and Development division located at Navi Mumbai is done here
to optimize quality, consistency and engineering.
● Line 1: This plant is dedicated to the manufacture of rigid polyether polyols, and has the
capacity to produce 9000 MT/Annum.
● Line 2: This is the plant dedicated to the production of flexible polyether polyols of up to
6000 molecular weight, which includes HR, cell opener, and some PPG grades.
● Line 3: This plant is capable of producing every products of all in line combined with
capacity of 9000 MT/Annum Rigid polyether polyol.
● Line 7: This plant is producing soft polyol with the annual capacity of 9000 MT.
● Line 8: This plant also producing the soft polyol but it give best products out of all the other
line with the same capacity per annum.
● Line 9: In this line also soft polyol is produce with the same capacity per annum.
● Storage facility: Has a storage facility to store and preserve 100 m 3 of propylene oxide and
20 m3 of ethylene oxide with an additional approval and civil work of 100 m 3 propylene
oxide tank and 20 m3 ethylene oxide tank.

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● Bulk storage facility: The Company has put up a 3000 KL storage tank at GCPTCL with a 4
km pipeline from the jetty to the storage tank to unload the ship.
The products information is given below:
Polyether polyols:
Rigid: A range of polyether is manufactured using various starters such as sucrose, sorbitol, glycols,
pentaerythritol, ethylene diamine, triethylamine and their mixtures. These polyether polyols are
marketed under the brand name of EXAPOL. These are short chain polyether being used in rigid
polyurethane foam formulations.
Flexible: 3000 & 3500 MW ethylene oxide/ propylene oxide based polyols are manufactured at
Dahej Plant, and are being marketed as EXAFLEX.
Polyester polyols:
A wide range of aliphatic as well as aromatic polyester polyols are manufactured mainly from
dibasic acids and diols for varied polyurethane applications. This class of polyols is marketed under
the brand names EXPOL and BEXTER. Even while a large selection is available from standard
grades of polyester polyols, Expanded Polymer Systems takes pride in taking up development and
production of polyesters as per a customer’s specifications.
Amine based polyols:
These are fast curing amine based polyols for spray and reactive applications. These polyols are
marketed under the brand name EXAMOL QP.
Blended polyols and polyether systems:
A majority of the company’s own basic polyurethane raw materials are utilized to manufacture
tailor-made formulations for a wide variety of polyurethane applications.
Their system product portfolio covers many and varied cellular and non-cellular polyurethane
applications. Expanded Polymer Systems offers blended polyols under the brand names of
ECOPUF, PUFOL, PUFFLEX and ECOPFLEX.

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Raw materials

Sorbitol
Sorbitol, also known as glucitol, is a sugar alcohol with a sweet taste which the human body
metabolizes slowly. It can be obtained by reduction of glucose, changing the aldehyde group to
a hydroxyl group. Most sorbitol is made from corn syrup, but it is also found in apples, pears,
peaches, and prunes.
Physical State Solid
Colour white
Odour odourless
pH 6-7 for 70% soln.
Viscosity 110 cp @ 25C
Boiling Point 295 deg C
Freezing/Melting Point 75 deg C
Solubility in water 55% @ 25C
Specific Gravity/Density 1.489
Molecular Formula C6H14O6
Molecular Weight 182.0944

Glycerol:-
Glycerolalso called glycerine or glycerine is a simple polyol (sugar alcohol) compound. It is a
colourless, odourless, viscous liquid that is sweet-tasting and non-toxic. It is widely used in the food
industry as a sweetener and humectants and in pharmaceutical formulations. Glycerol has
three hydroxyl groups that are responsible for its solubility in water and its hygroscopic nature. The
glycerol backbone is central to all lipids known as triglycerides.
Physical state and appearance Liquid. (Viscous liquid)
Odour Mild
Taste Sweet.
Molecular Weight 92.09 g/mole
Colour Clear Colourless.

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Boiling Point 290°C (554°F)

Melting Point 19°C (66.2°F)
Specific Gravity 1.2636 (Water = 1)
Vapour Pressure 0 kPa (@ 20°C)
Vapour Density 3.17 (Air = 1)

Diethylene glycol (DEG):-

Diethylene glycol (DEG) is an organic compound with the formula (HOCH2CH2)2O. It is a
colorless, practically odourless, poisonous, and hygroscopic liquid with a sweetish taste.
It is miscible in water, alcohol, ether, acetone, and ethylene glycol.] DEG is a widely used solvent. It
can be a contaminant in consumer products; this has resulted in numerous epidemics of poisoning
since the early 20th century.
Physical state and appearance: Liquid. (Clear viscous liquid.)
Odour Odourless.
Taste Sweet.
Molecular Weight 106.12 g/mole
Colour Colourless.
Boiling Point 245.8°C (474.4°F)
Melting Point -8°C (17.6°F)
Specific Gravity 1.12 (Water = 1)
Vapour Pressure 0.01 mm of Hg (@ 20°C)
Vapor Density 3.66 (Air = 1)
Solubility Easily soluble in cold water, hot water,
methanol, diethyl ether.

Propylene oxide:-
Propylene oxide is an organic compound with the molecular formula CH3CHCH2O. This
colourless volatile liquid is produced on a large scale industrially, its major application being its use
for the production of polyether polyols for use in making polyurethaneplastics. It is a chiral epoxide,
although it is commonly used as a racemic mixture.

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Boiling Point 94°F (34.2°C)

Freezing Point -169°F (-111.7°C)
Specific Gravity 0.833 at 20°C (68°F)
Vapor Pressure 455 mm Hg at 20°C (68°F)
Vapor Density (Air=1) 2.0
Solubility in Water 39.5% 20°C (68°F)
Molecular Weight 58.08 grams/mole
Percent Volatile by Volume 100%
Appearance and Odor Clear, colorless liquid with asweet ether-like
odour.

Ethylene oxide:-
Ethylene oxide, properly called oxirane by IUPAC, is the organic compound with
the formula C2H4O. It is cyclic ether.
It is the simplest epoxide: a three-membered ring consisting of one oxygen atom and two carbon
atoms. Because of its special molecular structure, ethylene oxide easily participates in addition
reactions; e.g., opening its ring and thus easily polymerizing. Ethylene oxide
is isomeric with acetaldehyde and with vinyl alcohol.
Boiling Point 51.1°F (10.6°C)
Freezing Point -170.7°F (-112.6°C)
Specific Gravity 0.882 at 10°C (50°F)
Vapor Pressure 1310 mm Hg at 25°C (77°F)
Vapor Density (Air=1) 1.49
Solubility in Water 1000 g/L25°C (77°F)
Molecular Weight 44 grams/mole
Percent Volatile by Volume 100%
Appearance and Odour Clear, colorless liquid with asweet ether-like
odour.

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Storage tanks
Storage tank(ST) Material Capacity
1 Sorbitol 70% 20Kl
2 Glycerine 20Kl
3 DEG 50Kl
4 PH-322 20Kl
5 PE-380 20Kl
6 MDC 20Kl
7 IPA 10Kl
8 SOR-445N 20Kl
9 SUD-455 100Kl
10 RCO 15Kl
11 Polyol 100Kl
12 CAN 30Kl
13 EO 20Kl
14 PO 100Kl
15 Styrene 20Kl

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Equipment

Reactor (Polymeriser):-

Equipment in which chemical reaction takes place, is

known as Reactor. Here it is also known as polymeriser
because of production of polymers.

It is made from SS-304 material.

CAPACITY: 15 KL
Jacket is provided to reactor(jacketed reactor), which is
used for heating and cooling purpose.
Mostly, cooling inlet is at bottom and heating inlet is at top of jacketed reactor in order to good heat
transfer.
Safety valve is installed at top, which opens automatically to release excessive pressure when
pressure increases above set point. Rupture disc is also there for more safety.
Rupture disc is expensive compare to safety valve and only one time usable. Internal coil is
provided through which cooling of inside material can be done. Blade pitched turbine at 45 degree
angle and at bottom Anchor type agitator is there for mixing purpose with optimum power
consumption.

Filter press:-
A filter press is a tool used in separation processes, specifically in solid/liquid separation using the
principle of pressure drive, provided by a slurry pump.
The filter press is used in fixed-volume
and batch operations, which means that
the operation must be stopped to
discharge the filter cake before the next
batch can be started.
It contains a set of plates to provide a
series of chamber or compartments in
which solids may collect.

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The plates are covered with filter medium.Slurry is admitted to each compartment under pressure;
liquor passes through the filter medium and out a discharge pipe, leaving a wet cake of solids behind

Neutraliser:-

It is equipment in which PH of product is maintained in desired range.

CAPACITY: 15 KL
Helical type impeller along with blade is provided in neutraliser.Here, ortho phosphoric acid H3PO4
is used to decrease the PH and maintained at desired value while KOH is used to increase the PH
and maintained at desired value.

Stabiliser:-
This equipment is used to collect the product material.
Helical type impeller is provided in stabiliser.
CAPACITY: 15 KL

Scrubber tank:-
To dissolve the vapour into liquid solvent, scrubber tank is
used.Berl saddle type packing is used in scrubber tank it provides
surface area for mass transfer from vapour phase to liquid phase.
This operation is performed in counter current manner.
CAPACITY:1.2 KL

Condenser:-
Condensers are used to change vapour phase into liquid by contacting it with cooling water.
Condensers are in both position horizontal as well as vertical in operation.
Generally, Condensation is done on shell side while cooling medium is allocated on tube side.

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Pumps and valves:-

Pumps increase the mechanical energy of the liquid, increasing its velocity, pressure, or elevation.
In plant, gear pumps and lobe pumps are used which are capable to handle highly viscous liquid.
Strainer is provided in suction line of pump, it stops any large particle from fluid and protect the
impeller of pump.

Gear pump Lobe pump

Air operated diaphragm(AOD) type pumps and Dozing pumps

are also used in plant.
Gear and lobe pumps comes in Positive displacement type Rotary
pump category while AOD and Dozing pumps comes in Positive
displacement type RECIPROCATE pumps.
To control the flow of flowing fluid, different types of valves are
provided with different intense.

A ball valve is a quarter-turn shut-off valve that uses a rotary

ball to control the flow of gas, compressed air, and various
liquids. These valves allow the through-hole configuration to be
blocked, open, or partially open to regulate the flow of liquid or
gas.

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NRV(non-return valve) permits flow in one direction only. It is used

where back flow is not required.
Butterfly valve is also there in plant. Control valve can control the
fluid by different opening.

Control valve Butterfly valve

Gate valve, in fully open or fully close position, is used. It provides low pressure drop. Direction of
fluid is not changed when it passes through the GATE valve.
Globe valves are widely used for controlling flow.

Gate valve Globe valve

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Flow meters

Rotameter:-

It is variable area flow meter. Float is provided in glass tube

which changes its position as per the flow rate. Its position
indicates the flow rate of flowing fluid.
It is always use in vertical position and density of float must be
higher than the same of flowing fluid.

Coriolis meter(Mass flow meter):-

It is costlier flow meter amongst all type of flow meter. It

works on the principle of Coriolis force.
Its principle states that ‘fluid flowing through a tube,
vibrating at its natural frequency, generates a force that
slightly distorts the tube. This extremely small distortion,
picked up by sensors, is directly proportional to the mass
flow rate.’
It measures flow rate very accurately.

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Chapter 2
Utilities

Cooling towers:-

A cooling tower is a heat rejection device which

rejects waste heat to the atmosphere through the
cooling of a water stream to a lower temperature.
Cooling towers may either use the evaporation of water
to remove process heat and cool the working fluid.
There are total three cooling towers in plant from which
two are of mechanical induced type and one is of
mechanical forced draft type.
Water is falling down from top and a fan is provided at
the top of tower which throws the air on water and cools
the water so it can be reused.
Using fan, tower can decrease the temperature up to 4
degree C.

Boiler room
Boilers are used to generate steam from water and this steam is used in plant for heating purpose.
Six vertical Cochran type boilers and One Thermic Fluid Heater (THF) are in plant.
CAPACITY: 850 kg/hr
It is LDO(low density oil) fire boiler. Fire takes place at top of boiler.
Blower is used to supply the air for fire while LDO pump and water pump are there to supply LDO
and water. Water is circulated in internal coil.

Chilled water room

To cool the water, it is passed through the condensers. There are two condensers with four pass and
28 tubes.
Water is allocated on tube side while air to be condensed on shell side.

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Storage of liquid Nitrogen

Nitrogen is an inert gas so it is used here to increase the pressure of equipment.
Nitrogen has very low boiling point so to keep it in liquid form it is stored in high pressurise tank(8
kg/cm2).
Nitrogen tank is covered with jacket(cup in cup type) and insulated powder is placed in space
between jacket and tank so atmospheric effect does not affect the liquid nitrogen.

Diesel Generator set area

In case of unavailability of electricity, plant can run continue by using electricity generated by
DG(Diesel generator).
There are two DG set in plant. Its specifications are as follow:
CAPACITY: 160 KVA
AMPS: 222.6
Volts: 415
RPM: 1500

Air compressor
An 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.
The compressed air, then, is held in the tank until called into use. The energy contained in the
compressed air can be used for a variety of applications, utilizing the kinetic energy of the air as it is
released and the tank depressurizes. When tank pressure reaches its lower limit, the air compressor
turns on again and re-pressurizes the tank.

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CHAPTER 3

Calcuation

# Heat duty of Boiler:-

Given data:-
Capacity :- 850kg/hr
Sp. Heat :- 1kcal/kg °C
Latent heat of Vaporisation :- 540 kcal/kg
Temperature T1:- 100°C
T2:- 50°C
Q1=m ×C p × ∆ T

Q1=850 × 1× 50

kcal
Q1=42500
kg

Q2=m× λ

Q2=850 × 540

kcal
Q 2=459000
kg

Qtotal=Q1 +Q2

Qtotal=42500+459000

kcal
Qtotal=501500
kg

These, is total amount of heat produce in 850 capacity of boiler.

Heat Loss:-

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Q total
Q input =
Boiler efficency
501500
Q input =
0.8
kcal
Q input =626875
kg

Heat loss=Qinput −QOutput

Heat loss=626875−501500
125375
Heat loss=
850
kcal
Heat loss=147.5
kg

# Fuel consumption of Boiler:-

Given data (For, NG):-
Capacity :- 850kg/hr
Total heat output :- 590 kal/kg
Gross calorific value :- 9300 kcal/m3
590
Amount of NG= × 850
9300
3
m
Amount of NG=53.92 ≈ 54
hr

Given data (For, LDO):-

Capacity :- 850kg/hr
Total heat output :- 590 kal/kg
Gross calorific value :- 10600 kcal/m3
Density:- 790 kg/m3

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590
Amount of LDO= ×850
10600
3
m
Amount of LDO=47.311
hr
m
ρ=
v
47.311
v=
790
L
v=59.88 ≈ 60
hr

# Ton of Refrigeration :-
Given data:-
Discharge flow :- 242 m3/hr
Sp. Heat :- 1kcal/kg °C
Temp. Diff. :- 4°C
Efficiency :- 0.8
Discharge × 1000× sp .heat ×Temp . diff .
TR=
3026 × Efficieny

242 ×1000 ×1 × 4
TR=
3026 × 0.8

TR=399.8 ≈ 400

CHAPTER 4

Effluent treatment plant(ETP)

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Water from chemical plant contains chemical impurities, so it is necessary to remove

chemical content as much as possible from it before discharging.

For the same purpose, there is an ETP in which chemical impurities are reduced by
using several processes and chemicals.

Chemical contained water is collected in Holding tank.

Using pump, this water is discharged into neutraliser tank. Meter is provided to
measure the quantity of water. Lime and Alum are added in some known quantities
into neutraliser tank, which maintain PH of water around 7.

Then water from this tank is pumped into the primary settling tank. Sufficient time
is provided to water to settle the sludge in this tank.

Water is next moved into Aeration tank-1.Maida, DAP, Biozeme is added in this
tank. Using blower, air is introduced into this tank from bottom which promotes the
growth of bacteria.

Then water is discharged into secondary settling tank to settle the remaining sludge.

Water from this tank is transferred in Aeration tank-2. Same as above, Maida, DAP
etc., are added in less quantity compared to first aeration tank for the same purpose.

Then, water is discharged into final settling tank. Remaining all sludge is settled in
this tank.

Water from this tank is transferred into Intermediate tank.

Then this water is sent to the sand filter. Sand, colloids etc., are filtered in filter and
improved the quality of water.

In ETP, there are separately sludge settling tanks in which sludge is collected.

Pure water is used to pour the plants and for garden.

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To check the quality of final water, CHEMICAL OXYGEN DEMAND(COD)

parameter is used. It measures the chemical content in water in ppm(parts per million)
unit.

As per the rule of Gujarat pollution control board(GPCB), COD proportion must be
less than 100 ppm in final water.

PROCESS SAFETY

Process safety is a disciplined framework for managing the integrity of operating

systems and processes that handle hazardous substances. It relies on good design
principles, engineering and operating and maintenance practices. It deals with the
prevention and control of events that have the potential to release hazardous materials
and energy.

The terms ‘process safety’ and ‘asset integrity’ are both used throughout the
petroleum industry, often synonymously. For the oil and gas industry the emphasis of
process safety and asset integrity is to prevent unplanned releases which could result
in a major incident. A major incident is typically initiated by a hazardous release; it
may also result from a structural failure or loss of stability that escalates to become a
major incident.

13 ELEMENTS OF PROCESS SAFETY

1. EMPLOYEE PARTICIPATION

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Perhaps one of the most important

mandates, the employee participation
clause requires that employees—
including production and maintenance
staff—be involved in every aspect of
the PSM programs at their respective
worksites. They must also be
represented at the meetings where
PSM-related issues are discussed. OSHA requires employee participation to be
followed as written, so employers should create formal plans.

2. PROCESS SAFETY INFORMATION

According to OSHA’s PSM mandates, “The employer shall complete a compilation

of written process safety information before conducting any process safety hazard
analysis required by the standard.” In other words, all workers should be able to
access and understand the technical data regarding the HHC-related risks they face on
the job.

3. PROCESS HAZARD ANALYSIS

One of the most technical elements of PSM, Process Hazard Analysis requires that
engineers and maintenance leaders analyze the consequences of safety failures. These
analyses must be conducted in teams, and each team must include one person who is
“knowledgeable in the specific process hazard methodology being used.”

4. OPERATING PROCEDURES

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There are plenty of potential chemical hazards following turnarounds and emergency
shutdowns. OSHA inspectors want to see that companies have plans for keeping
everyone safe as they start back up.

5. TRAINING

Workers who carry out processes involving highly hazardous chemicals need to be
well-trained, and their training should have been accomplished through a competent
source, first-party or otherwise. Their training also needs to be well-
documented. Training management software makes it much easier to track this.

6. CONTRACTORS

Regular employees and contractors alike must be well-informed of the hazards they
face. Under the PSM National Emphasis Program, “The employer shall inform
contract employers of the known potential fire, explosion or toxic release hazards
related to the contractor’s work and the process.”

7. PRE-STARTUP SAFETY REVIEW

Are you reviewing your safety procedures every time a worksite starts back up? You
should be. OSHA expects employers to perform pre-startup safety reviews for both
new and modified facilities. This rule applies even if the procedural changes only
affect a single component or process.

8. MECHANICAL INTEGRITY

Periodic, documented inspections are required for several systems, including:

● Pressure vessels

● Storage tanks

● Piping systems
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● Ventilation systems

The employers or contractors conducting these inspections must not only be officially
trained, their testing procedures must follow “recognized and generally accepted good
engineering practices,” according to OSHA. In other words, your company must be
able to explain WHY your inspectors made their decisions

9. HOT WORK PERMIT

Every employer needs to issue permits to employees and contractors who weld or
perform other high-temperature work near covered processes. They also need to train
their personnel to post and file these permits when necessary.

10. MANAGEMENT OF CHANGE

Companies need standard procedures for managing changes to process chemicals,

technology, equipment and procedures. Each change also requires the following
considerations:

● The technical basis for the change.

● The impact of the change on worker safety and health.

● Necessary modifications to operating procedures.

● The necessary time period for the change.

● Authorization requirements for the proposed change.

11. INCIDENT INVESTIGATION

OSHA’s state standard calls for investigations for all incidents that result in—or
could have resulted in—a catastrophic highly hazardous chemical release. Because of
that ambiguous wording, cautious companies must keep every potential HHC-related
scenario in mind.
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12. EMERGENCY PLANNING AND RESPONSE

Even minor chemical releases can lead to major incidents. This element mandates
employers to create emergency plans for handling smaller HHC releases.

13. COMPLIANCE AUDITS

According to the PSM-NEP, “Employers shall certify that they have evaluated
compliance with the provisions of this section at least every three years to verify that
the procedures and practices developed under the standard are adequate and are being
followed.” This element also requires employers to retain at least their two most
recent audit reports.

Chapter 5

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References

 Mr. Presh Bodar January 2015, https://www.expanded.co.in/

 https://www.zoro.com/pipes-valves-fittings/c/33/?
gclid=1e6c39abfbc916e49f595f3573fbca98&gclid=gclid&msclkid=1e6c39abfbc916e49f595f3573fbc
a98&utm_source=bing&utm_medium=cpc&utm_campaign=ml_all_dyn_main_pmax_bing
%20medium%20ST%20skus
%20Plumbing&utm_term=www.zoro.com&utm_content=Plumbing&gclsrc=3p.ds

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