Grasim Industries Limited PDF

INTERNSHIP TRAINING
AT
GRASIM INDUSTRIES
LIMITED
CHEMICAL DIVISION, KARWAR
P.O. BINAGA -581307
January- February
2019
ALVA’S INSTITUTE OF
ENGINEERING AND TECHNOLOGY
MOODBIDRI-574225,
KARNATAKA
NAME : VIDYASHEESH PATEL

COURSE: MECHANICAL ENGINEERING
usn : 4AL15me088
ACKNOWLEDGEMENT
I am highly indebted to Mr. Om Prakash and Mechanical maintenance dept for
their guidance and constant supervision as well as for providing necessary
information regarding the training and also for their support in completing the
same. I would to like to express my gratitude towards my parents and the
members of GRASIM INDUSTRIES LIMITED for their kind cooperation and
encouragement which helped me in completion of this training.
I would like to express my special gratitude and thanks to the persons, officials
of industry for giving me such attention and time inspite of their busy schedules
and pre-occupations. I sincerely once again thank to all concerned for providing
me this unique opportunity and developing the Project report.
Dr. S K Bhat Mr Om Prakash

Head of H.R Manager of mechanical dept
TABLE OF CONTENTS
CHAPTER NO. DESCRIPTIONS PAGE NO.
CHAPTER 1 Introduction 1-2

CHAPTER 2 Safety rules 3-4
CHAPTER 3 Uses and applications 5-7
CHAPTER 4 Pumps 8-12
CHAPTER 5 Valves 13-18
CHAPTER 6 Cooling towers 19-21
CHAPTER 7 Lubrication and 22-24
lubricants
CHAPTER 8 Air compressors 25-27
CHAPTER 9 Boilers 28-32
CHAPTER 10 Welding 33-34
CHAPTER 11 Conclusion 35
CHAPTER NO 1
INTRODUCTION
The GRASIM INDUSTRIES LIMITED, BINGA, KARWAR, is mainly

engaged in the production of two chemicals- Caustic soda (NaOH) and
Phosphoric acid (H3PO4). The entire plant is divided into two divisions i.e.,
Phosphoric acid plant and Caustic soda plant. Hydrochloric acid and Hypo
are some of the byproducts which are produced. The company initially was
called BALLARPUR INDUSTRIES LIMITED. Later on the company
changed its title as THE SOLARIS CHEMTECH INDUSTRIES LIMITED.
Further this company was taken over by ADITYA BIRLA GROUP and was
named as GRASIM INDUSTRIES LIMITED, to make a strong base in the
southern region of India in manufacturing of Phosphoric acid and Caustic
soda.
The main objectives of this company are :
-To continuously improve the level of satisfaction of customers in its

targeted market segments.
-Protection of environment in all its activities and ensure a safe and healthy
working environment at this Karwar unit.
Aditya birla chemicals (India) Limited
-Supply of quality products meeting the customers‟ expectations and also

strictly sticking to the delivery schedules with pro-active customer
relationship.
-Planning and involvement of the people in the industry for the improvement
of quality , EMS and OH&S programs on a continuous basis. In this process
open communication with all the stakeholders on the progress of the industry
and also quality of the production.
-Documentation of the activities in the system for regular review and for
monitoring of the process in furtherance of taking corrective actions through
the trained personnel, if so required .
GRASIM INDUSTRIES LIMITED CHEMICAL DIVISION, KARWAR Page 2

CHAPTER NO 2
SAFETY INSTRUCTIONS
SAFETY RULES :
 You are responsible for your own safety and safety of others.
 Wear personal protective equipments necessary
 Always use equipments /tools/ machinery safely and properly
 Keep your work area clean.
 Wear appropriate and safe work clothing and footwear.
 Report any unsafe condition.
 Clean up spills immediately.
 Report all injuries.
 No alcohol and drugs to be used or allowed inside the company.
FIRE HAZARDS :
Fire mainly requires 3 things :
1. Combustible material
2. Heat
3. Oxygen
CHLORINE GAS LEAKAGE HAZARDS :

Chlorine is a toxic gas. Its weight is more than that of air so, it settles down
after travelling a certain distance and can travel further only with the aid of
wind. If there is any chlorine leakage, move in a direction perpendicular to
the direction of gas flow and assemble in assembly point.
RECENT TYPES OF FIRE & APPLIANCES

SUITABLE FOR USE AGAINST THEM
Class of Fuel / burnable Suitable type
fire materials of appliance
A Fires in ordinary Gas expelled water
combustibles[wood, type and antifreeze
vegetables, fibres , rubber , type extinguishers
plastic & other waste and water buckets.
materials].
B Fires in flammable liquids Mechanical foam ,
, paints , oil , grease , carbondioxide , dry
solvents &other liquid powder type
fuels. extinguishers.
C Fires and gaseous Chemical
substance under pressure extinguishers of
including liquefied gases. dry powder and
carbon dioxide
type.

CHAPTER NO 3
USES AND APPLICATIONS
CAUSTIC SODA :
 Demineralization: regeneration of ion exchangers.

 Drinking water production: partial water softening.
 Beverages: bottle-cleaning.
 Dairy: cleaning production installations.
 Pharmaceutical industry: various products, including sodium lactate
 Cooking oils and fats: refining and purification.

 Production of starches and derivatives.
 Petroleum industry: refining and desulfurization.
 Waste-water treatment: Ph-correction, flocculent enhancers.
 Steel production: ammonia recovery in cokes production .
PHOSPHORIC ACID :
 Food additive.
 Medical applications.
 As a solution for anodizing.
 As an external standard for phosphorus-31 nuclear magnetic

resonance (NMR).
 As a buffer agent in biology and chemistry. For example, a buffer

for high-performance liquid chromatography.
 As a chemical oxidizing agent for activated carbon production, as used in

the Wentworth process.
 As the electrolyte in phosphoric-acid fuel cells..
 As a Ph adjuster in cosmetics and skin-care products.
 Heated in micro fabrication to etch silicon nitride (Si3N4). It is highly

selective in etching Si3N4 instead of SiO2, silicon dioxide.
 As a cleaner by construction trades to remove mineral deposits,

cementitious smears, and hard-water stains.
 As a chelant in some household cleaners aimed at similar cleaning tasks.
HYDROCHLORIC ACID :
 Hydrochloric acid is used in the manufacturing of organic compounds

like dichloroethane and vinyl chloride, which is used to manufacture PVC
(Poly Vinyl Chloride).
 It is used to effectively regulate the Ph level of a wide variety of
manufacturing processes including the production of drinking water,
foods and pharmaceuticals.
 Hydrochloric acid is necessary to lower the Ph or total alkalinity of the
water in swimming pools to optimal levels for swimmers.
 This acid can be used in the salt purification process.
 It is used in a specific process to „pickle‟ steel. The process involves
removing rust and scale from a steel coil or sheet with the help of
a hydrochloric acid solution. .

 Hydrochloric acid is effectively used to regenerate ion exchangers.

 The production of inorganic compounds for water treatment can require
hydrochloric acid, including drinking water and wastewater.
 Hydrochloric acid is used in to facilitate oil well acidizing in North Sea
oil production.
 The food industry utilizes hydrochloric acid in the processing of various
additives like fructose, citric acid and hydrolyzed vegetable protein.
SODIUM HYPOCHLORITE :
Sodium hypochlorite is a chemical compound with the formula NaClO. It is

composed of a sodium cation (Na+) and a hypochlorite anion (ClO−); it may
also be viewed as the sodium salt of hypochlorous acid. When dissolved in
water it is commonly known as bleach or liquid bleach.[1] Sodium
hypochlorite is practically and chemically distinct from chlorine.[2] Sodium
hypochlorite is frequently used as a disinfectant or a bleaching agent. The
mixture of sodium peroxide (Na2O2) and hydrochloric acid, which react to
produce sodium hypochlorite is also termed as oxone.
Uses:
 Bleaching
 Cleaning
 Disinfection
 Deodorizing
 Water treatment
 Endodontics
 Nerve agent neutralization
 Reduction of skin damage

CHAPTER NO 4
PUMPS
 A pump is a device that moves fluids (liquids or gases), or

sometimes slurries, by mechanical action. Pumps can be classified into
three major groups according to the method they use to move the
fluid: direct lift, displacement, and gravity pumps.
 Pumps operate by some (typically reciprocating or rotary), and

consume energy to perform mechanical work by moving the fluid.
Pumps operate via many energy sources, including manual
operation, electricity, engines, or wind power, come in many sizes,
from microscopic for use in medical applications to large industrial
pumps.
Mechanical pumps serve in a wide range of applications such as pumping

water from wells, aquarium filtering, pond filtering and aeration, in
the car
industry for water-cooling and fuel injection, in the energy

industry for pumping oil and natural gas or for operating cooling towers. In
the medical industry, pumps are used for biochemical processes in
developing and manufacturing medicine, and as artificial replacements for
body parts, in particular the artificial heart and penile prosthesis.
 Single stage pump – When a casing contains only one revolving impeller, it
is called a single stage pump.
 Double/multi-stage pump – When a casing contains two or more revolving

impellers, it is called a double or multi-stage pump.
Classification of pumps :
Basically pumps are classified into 2 types :
1. Dynamic pumps.
2. Positive displacement pump.

Uses of pumps :
Industrial pumps are used for a wide range of applications. An industrial

pump is usually a heavy duty process pump used to move many different
types of products including water, chemicals, petroleum, wastewater, oil,
sludge, slurry etc. the types of pumps mainly used for industrial purposes
will be majorly centrifugal pumps or positive displacement pumps.
Centrifugal pumps:

Centrifugal pumps are used to transport fluids by the conversion of

rotational kinetic to the hydrodynamic energy of the fluid flow. The
rotational energy typically coms from an engine or electric motor. The fluid
enters the pump impeller along or near to the rotating axis and is accelerated
by the impeller, flowing radially outward into a diffuser or a volute
chamber(casing), from where it exits.
Fluids enters axially through eye of the casing, is caught up in the

impeller blades, and is whirled tangentially and radially outward until it
leaves through all circumferential parts of the impeller into the diffuser part
of the casing. The fluid gains both velocity and pressure while passing
through the impeller. The doughnut-shaped diffuser, or scroll, section of the
casing decelerates the flow and further increases the pressure. Here the water
is not pushed radially outward by centrifugal force, but rather by inertia , the
natural tendency of an object to continue in straight line when travelling
around a circle .
Dosing pump:

A dosing pump is a small, positive displacement pump.It is designed to

pump a very precise flow rate of a chemical or substance into either a
water, steam or gas flow. A dosing pump will deliver this flow rate of
chemical into the pipe or tank being dosed. Generally dosing pumps are set
up to inject a product into a water or fluid stream to cause a chemical or
physical reaction.

CHAPTER NO 5
VALVES AND ITS TYPES
A valve is a device that regulates, directs or controls the flow of a

fluid(gases, liquids, slurries) by opening, closing, or partially obstructing
various passageways.
DIFFERENT TYPES OF VALVES USED IN PLANT:
1) Ball valve:
A ball valve is a form of quarter-turn valve which uses a hollow,

perforated and pivoting ball to control flow through it. It is open when the
ball’s hole is in line with the flow and closed when it is pivoted 90-
degrees by the valve handle. The handle lies flat in alignment with the
flow when open, and is
perpendicular to it when closed, making for easy visual confirmation of the

valve‟s status. One disadvantage of a ball valve is that they trap water in the
center cavity while in the closed position. In the event of a freeze, the sides
can crack due to expansion of ice forming.
2) GLOBE VALVE:
A globe valve, different from ball valve, is a type of valve of valve

used for regulating flow in a pipeline, consisting of a movable disc-
type element and a stationary ring seat in a generally spherical body.

3) GATE VALVE
A gate valve, also known as a sluice valve, is a valve which opens by lifting
a round or rectangular gate/wedge out of a path of the fluid. The distinct
feature of a gate valve is the sealing surface between the gates and seats are
planar, so gate valves are often are used when a straight line flow of fluid
and minimum restriction is desire

4) NON-RETURN VALVE:
A non-return valve allows a medium(fluid) to flow in only one

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

5) BUTTERFLY VALVE:
A butterfly valve is a valve that isolates or regulates the flow of fluid. The
closing mechanism is a disk that rotates. Butterfly valves are generally
favoured because of their less cost, and are lighter weight so they need less
support. The disc is positioned in the centre of pipe.
6. DIAPHRAGM VALVE:

Diaphragm valve (membrane valve) consists of a valve body with two

or more ports, a diaphragm, and a “weir or saddle” or seat upon which
the diaphragm closes the valve, The valve body may be constructed
from plastic, metal, wood or other materials depending on the intended
use.
There are two main categories of a diaphragm valves: one type

seals over a weir” (saddle) and the other type seals over the seat. The weir
or saddle type is the most common in process applications and the seat
type is more commonly used in slurry applications to reduce blocking
issues but exists also as a process valve.
7. SAFETY VALVE:
A safety valve is a valve that acts as a fail-safe. An example of

safety valve is a pressure relief valve (PRV), which automatically
releases a substance from boiler, pressure vessel, or other system,
when the pressure or temperature exceeds preset limits.
CHAPTER NO 6
COOLING TOWERS
A cooling tower is a heat rejection device that 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 to near the wet-bulb air temperature or, in the
case of closed circuit dry cooling towers, rely solely on air to cool the
working fluid to near the dry-bulb air temperature.
Common applications include cooling the circulating water used

in refineries, petrochemical and other chemical plants, thermal power
stations and HVAC systems for cooling buildings. The classification is based
on the type of air induction into the tower: the main types of cooling towers
are natural draft and induced draft cooling towers.
Cooling towers vary in size from small roof-top units to very

large hyperboloid structures (as in the adjacent image) that can be up to 200
meters (660 ft) tall and 100 meters (330 ft) in diameter, or rectangular
structures that can be over 40 meters (130 ft) tall and 80 meters (260 ft) long.
The hyperboloid cooling towers are often associated with nuclear power
plants,[1] although they are also used in some coal-fired plants and to some
extent in some large chemical and other industrial plants. Although these
large towers are very prominent, the vast majority of cooling towers are
much smaller, including many units installed on or near buildings to
discharge heat from air conditioning
Classification of cooling towers :
 Natural draft cooling towers

As their name implies, natural draft cooling towers rely on
natural convection to circulate air throughout the tower, which
then cools the water. Air movement occurs due to differences in
density between the entering air and the internal air within the
tower. Warm, moist air, which is more dense than cool air, will
naturally rise through the tower, while the dry, cool air from
outside will fall, creating a constant cycle of air flow.
 Mechanical draft cooling towers

Unlike natural draft cooling towers, mechanical draft cooling towers

employ fans or other mechanics to circulate air through the tower. Common
fans used in these towers include propeller fans and centrifugal fans.
Mechanical draft towers are more effective than natural draft towers, and can
even be located inside a building when exhausted properly. However, they
consume more power than natural draft cooling towers and cost more to
operate as a result.
Cross flow towers and counter flow towers are the two types of mechanical
draft cooling towers:
1. Cross flow towers

In a crossflow tower, air flows horizontally through the cooling
tower‟s structure while hot water flows downward from distribution
basins. Crosslow towers can be as tall as counterblow towers, but
they‟re also more prone to freezing and are less efficient.
2. Counter flow towers

Counterflow towers move air upward through the tower while water
flows downward to cool the air. These towers are often more compact
in footprint than crossflow towers, and can save energy in the long
run.

CHAPTER NO 7
LUBRICATION
Lubrication is the process or technique employed to reduce friction between,
and wear of one or both, surfaces in proximity and moving relative to each
other, by interposing a substance called a lubricant in between them. The
lubricant can be a solid, (e.g. Molybdenum disulfide MoS2) a solid/liquid
dispersion, a liquid such a soil or water, a liquid-liquid dispersion (a grease)
or a gas.
With fluid lubricants the applied load is either carried by pressure generated
within the liquid due to the frictional viscous resistance to motion of the
lubricating fluid between the surfaces, or by the liquid being pumped under
pressure between the surfaces.
Lubrication can also describe the phenomenon where reduction of friction

occurs unintentionally, which can be hazardous such as hydroplaning on a
road.
The science of friction, lubrication and wear is called tribology.
Adequate lubrication allows smooth continuous operation of equipment,

reduces the rate of wear, and prevents excessive stresses or seizures
at bearings. When lubrication breaks down, components can rub
destructively against each other, causing heat, local welding, destructive
damage and failure.
LUBRICANTS:
A lubricant is a substance, usually organic, introduced to

reduce friction between surfaces in mutual contact, which ultimately reduces
the heat generated when the surfaces move. It may also have the function of
transmitting forces, transporting foreign particles, or heating or cooling the
surfaces. The property of reducing friction is known as lubricity.
In addition to industrial applications, lubricants are used for many other

purposes. Other uses include cooking (oils and fatsin use in frying pans, in
baking to prevent food sticking), bioapplications on humans (e.g. lubricants
for artificial joints), ultrasound examination, medical examinations.
Types of lubricants :
1. Solid lubricants.
2. Liquid lubricants
3. Semi-solid lubricants
 Solid Lubricants :
A solid lubricant is basically any solid material which can be placed

between two bearing surfaces and which will shear more easily under a
given load than the bearing materials themselves. The coefficient of
friction in dry lubrication is related to the shearing force and the bearing
load. Two primary property requirements are :
1. Material must be able to support applied load without significant
distortion, deformation or loss in strength.
2. Coefficient of friction and the rate of wear must be acceptably low.

 Liquid Lubricants:
There are two systems for oil classification. The SAE (Society of
Automotive Engineers) viscosity grade and the API (American
Petroleum Institute) classification that designates the type of engines
for which the oil was designed. The SAE viscosity grade is known as
the “W” number when classifying winter oils. In general, the lower the
first number, the better the oil performance in extremely cold
conditions. Conversely, the higher the second number the better the oil
protection at higher temperatures.
 Semi-Solid Lubricant : Grease
In layman‟s language Grease is: A black or yellow sticky mass used in the
bearings for lubrication purpose. Lubricating greases consist of lubricating
oils, often of quite low viscosity

CHAPTER NO 8
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 engineered upper limit the air compressor shuts off. The
compressed air, then, is held in the tank until called into use. [1] 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.
An air compressor must be differentiated from an air pump which merely

pumps air from one context (often the surrounding environment) into another
(such as an inflatable mattress, an aquarium, etc.). Air pumps do not contain
an air tank for storing pressurized air and are generally much slower, quieter,
and less expensive to own and operate than an air compressor.
Single stage compressor:
Each cylinder is fitted with suction and delivery valves. The suction filter is
connected at the middle of the cylinders. So that air can enter at both the
ends of the piston during the foerward and backward stroke. The piston is
moving in the cylinder, quantity of air sucked to the front side is compressed
to the required pressure when the piston travels to the front end cover and
similarly when the piston travels to the rare end cover.
Two stage compressor:
After compression, the air from the first stage cylinder passed through the
delivery valve to the water cooled heat exchanger provided in between the
first and second stage. Ther it is cooled very near to the atmospheric
temperature and is sucked by the second stage through the suction valves.
In the second stage the air is compressed again to the requires pressure and
enters to the delivery header connected to the second stage cylinder and then
to after cooler and then to the receiver.
Uses of compressors :

 Painting vehicles in an auto body shop

 Sanding in an auto body shop or in woodworking
 Making snow at ski hills or for entertainment uses
 Using pneumatic nail guns for roofing
 Providing dental and medical services
 Using pneumatic drills and hammers on construction sites
 Powering various air tools in an automotive repair shop

CHAPTER NO 9
Boilers
Boiler is a closed vessel which generates steam under pressure .
Based on heat transfer mode boilers are classified into two types :
1. FIRE TUBE BOILERS :

In a fire tube boiler the hot flue gases passes through the tubes and
water remain outside the tubes heat is transferred from inside the tube to
water
outside the tube. Fire tube boilers are usually preferred where the steam
pressure required is then about 30kg/cm2.
2.Water tube boiler:

In a water tube boiler, water circulates through tubes and heat source is
outside. Heat is transferred from outside . heat is transferred from outside the
tube to water to water inside the tube. Where large quantity of steam is
required at high pressure- water tube type boiler is preferred. In power plants
normally , high pressure water-tube type boilers are used where capacity
ranges from30-650 t/hr.
Feed water system: properly treated feed water first water comes to
equipment known as deaerator, where dissolved oxygen is removed. Feed
water is added as make up water to the condensate which is being circulated
back to the system . deaeration is done by heating up the water by auxillary
steam. This is a part of the sensible heat received in the cycle, which we can
compare with a temperature enthalpy curve.
From the deaerator, the feed water goed to the boiler feed pump, which
pumps the feed water at high pressure into the evaporator. But at this point
the temperature of the water is much less than saturation temperature and
evaporation would start.
So it is first taken into the economizer when it is subjected to economizer

heated feed water temperature enters the evaporator through the steam drum
where water will be circulated while getting evaporated. The water circulates
usually due to thermosyphon action and known as natural circulation.
Now heat from the hot flue gases is received by the riser, where streaming
takes place and therefore riser contains a mixture of water and steam,
whereas the down comer contains the denser water .due to density difference

in the two columns, circulation takes place in the evaporator. In some

evaporator system , where the geometry doesnot allw the natural circulation,
or where the density difference is less due to high pressure, the circulation
os maintained with a pump, which is called forced or assisted circulation
In the evaporator section, water receives the remaining amount of sensible

heat and total latent heat of evaporation and finally steam leaves the
evaporator from the steam drum and enters the superheater section.
The steam should be completely dry and saturated before it enters
superheater, otherwise , instead of raising temperatureof steam beyond
saturation temperature in the superheater , remaining water would first get
converted into steam and then only the temperature would rise . a number of
water separator are used in the steam drum to ensure that.
In the superheater , the temperature of steam is raised by further heating .

the final temperature is usually controlled by water spraying through
attemperator, which is placed before the final superheater .
The superheated steam then goes to the turbine which expand in the turbine
section and rotates the turbine blade . In some power plants, where multiple
pressure turbine section is available, the expanded steam which is at lower
pressure and temperature is further brought back to the boiler section .This
part is known as reheater and steam gets further superheated in this section.
Selection of boilers:
There are various factors that should be kept in mind before boiler
selection :
1. The working pressure and quality of steam required .

2. Steam generation rate.

3. Floor area available .
4. Accessibility and repair and inspection.
5. Comparative initial cost .
6. Erection facilities.
7. The fuel and water available.
8. Operating and maintaining cost
Terminologies used in boiler:
1. Shell: The shell of a boiler is made of one or more steel plates bent
into cylindrical form and are riveted or welded together. It is the
cylindrical portion of the body.
2. Furnace: It is the chamber just below the shell in which combustion

of fuel takes place. It is also called as fire box.
3. Mountings : mountings are external features that are included in them

without which a boiler cannot work properly like a stop valve, safety
valve ,water level guage , fusible plug, blow off cock, water level
indicators, pressure gauges etc.
4. Accessories: They are all the items which are included in boilers to
increase the efficiency of boilers. These are superheaters,
economizers, feed pump etc.
5. Water space and water steam: The volume of the shell is occupied
by the water is called water space. The entire shell excluding the water
and the tube is called steam space.

6. Foaming: Due to high surface tension of water there is formation of

steam bubbles on the surface of boiler water. This is called foaming.
7. Scale: Due to the dissolved salts and undesirable quantities in water, it

gets deposited on the walls of the tubes which provides resistance to
the heating of water. This is called scaling.
8. Refractory: These are fire bricks or plastic clay used for the lining
the combustion chamber. This is done so that the walls of the shell are
not damaged.
9. Lagging: The steam pipes and the shell of a boiler are wrapped with
asbestos or magnesia for insulation . This is done to minimize the loss
of heat due to radiation.
Applications of boliers:
 Boilers are used mainly in power plant for generating high pressure
steam to produce electricity.
 in cold countries hot water producing boilers are used for heating the
buildings.
 Boilers also find its application in textile industries for sizing and
bleaching, and many other industries like sugar mills and chemical
industries

CHAPTER NO 10
WELDING
Welding is a fabrication or sculptural process that joins materials,

usually metals or thermoplastics, by causing fusion, which is distinct from
lower temperature metal-joining techniques such as brazing and soldering,
which do not melt the base metal. In addition to melting the base metal, a
filler material is typically added to the joint to form a pool of molten material
(the weld pool) that cools to form a joint that is usually stronger than the
base material. Pressure may also be used in conjunction with heat, or by
itself, to produce a weld. Welding also requires a form of shield to protect
the filler metals or melted metals from being contaminated or oxidized
Some of the best known welding methods include:

 Oxy-fuel welding – also known as oxyacetylene welding or oxy welding,

uses fuel gases and oxygen to weld and cut metals.
 Shielded metal arc welding (SMAW) – also known as “stick welding” or
“electric welding”, uses an electrode that has flux around it to protect the
weld puddle. The electrode holder holds the electrode as it slowly melts
away. Slag protects the weld puddle from atmospheric contamination.
 Gas tungsten arc welding (GTAW) – also known as TIG (tungsten, inert
gas), uses a non-consumable tungsten electrode to produce the weld. The
weld area is protected from atmospheric contamination by an inert
shielding gas such as argon or helium.
 Gas metal arc welding (GMAW) – commonly termed MIG (metal, inert
gas), uses a wire feeding gun that feeds wire at an adjustable speed and
flows an argon-based shielding gas or a mix of argon and carbon
dioxide (CO2) over the weld puddle to protect it from atmospheric
contamination.
Uses of welding :
 Aerospace engineering
 Train and rail carriages
 Automotive industry and auto suppliers
 Electricals and electronics
 Domestic hardware
 Radiators and containers
 Medical instruments and supplies
 Nuclear equipment
 Food and beverage industry
 Other miscellaneous metal processing industries.

CHAPTER NO 11
CONCLUSION
As an undergraduate of the VisvesvarayaTechnological University, I would

like to say that this training program is an excellent opportunity for us to get
to the ground level and experience the things that we would have never
gained through going straight into a job. I am grateful to GRASIM
INDUSTRIES LIMITED for giving me this wonderful opportunity.
The main objective of the industrial training is to provide an opportunity to

undergraduates to identify, observe and practice how engineering is
applicable in the real industry. It is not only to get experience on technical
practices but also to observe management practices and to interact with
fellow workers. It is easy to work with sophisticated machines, but not with
people. The only chance that an undergraduate to have this experience is the
industrial training period. I learnt the way of work in an organization, the
importance of being punctual, maximum commitment, and team spirit.
I would like to thank everyone who were the part of my training and have
given me the maximum knowledge of working of an industry, handling the
man power force and also the social responsibility. I would also like to state
that this training has been a enlightening and I am grateful to all for guiding
me to complete my training successfully.

Grasim Industries Limited PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Grasim Industries Limited PDF

Uploaded by

Copyright:

Available Formats

INTERNSHIP TRAINING

NAME : VIDYASHEESH PATEL

Dr. S K Bhat Mr Om Prakash

CHAPTER NO. DESCRIPTIONS PAGE NO.

CHAPTER 1 Introduction 1-2

The GRASIM INDUSTRIES LIMITED, BINGA, KARWAR, is mainly

The main objectives of this company are :

-To continuously improve the level of satisfaction of customers in its

-Supply of quality products meeting the customers‟ expectations and also

GRASIM INDUSTRIES LIMITED CHEMICAL DIVISION, KARWAR Page 2

 Wear personal protective equipments necessary

 Always use equipments /tools/ machinery safely and properly

 Keep your work area clean.

 Wear appropriate and safe work clothing and footwear.

 Report any unsafe condition.

 Clean up spills immediately.

 Report all injuries.

 No alcohol and drugs to be used or allowed inside the company.

CHLORINE GAS LEAKAGE HAZARDS :

RECENT TYPES OF FIRE & APPLIANCES

GRASIM INDUSTRIES LIMITED CHEMICAL DIVISION, KARWAR Page 4

 Demineralization: regeneration of ion exchangers.

 Cooking oils and fats: refining and purification.

 As a solution for anodizing.

 As an external standard for phosphorus-31 nuclear magnetic

 As a buffer agent in biology and chemistry. For example, a buffer

 As a chemical oxidizing agent for activated carbon production, as used in

 As the electrolyte in phosphoric-acid fuel cells..

 As a Ph adjuster in cosmetics and skin-care products.

 Heated in micro fabrication to etch silicon nitride (Si3N4). It is highly

 As a cleaner by construction trades to remove mineral deposits,

 As a chelant in some household cleaners aimed at similar cleaning tasks.

 Hydrochloric acid is used in the manufacturing of organic compounds

GRASIM INDUSTRIES LIMITED CHEMICAL DIVISION, KARWAR Page 6

 Hydrochloric acid is effectively used to regenerate ion exchangers.

Sodium hypochlorite is a chemical compound with the formula NaClO. It is

GRASIM INDUSTRIES LIMITED CHEMICAL DIVISION, KARWAR Page 7

 A pump is a device that moves fluids (liquids or gases), or

 Pumps operate by some (typically reciprocating or rotary), and

Mechanical pumps serve in a wide range of applications such as pumping

industry for water-cooling and fuel injection, in the energy

 Double/multi-stage pump – When a casing contains two or more revolving

Basically pumps are classified into 2 types :

2. Positive displacement pump.

GRASIM INDUSTRIES LIMITED CHEMICAL DIVISION, KARWAR Page 9

Industrial pumps are used for a wide range of applications. An industrial

GRASIM INDUSTRIES LIMITED CHEMICAL DIVISION, KARWAR Page 10

Centrifugal pumps are used to transport fluids by the conversion of

Fluids enters axially through eye of the casing, is caught up in the

GRASIM INDUSTRIES LIMITED CHEMICAL DIVISION, KARWAR Page 11

A dosing pump is a small, positive displacement pump.It is designed to

GRASIM INDUSTRIES LIMITED CHEMICAL DIVISION, KARWAR Page 12

VALVES AND ITS TYPES

A valve is a device that regulates, directs or controls the flow of a

DIFFERENT TYPES OF VALVES USED IN PLANT:

A ball valve is a form of quarter-turn valve which uses a hollow,

perpendicular to it when closed, making for easy visual confirmation of the

A globe valve, different from ball valve, is a type of valve of valve

GRASIM INDUSTRIES LIMITED CHEMICAL DIVISION, KARWAR Page 14

GRASIM INDUSTRIES LIMITED CHEMICAL DIVISION, KARWAR Page 15

A non-return valve allows a medium(fluid) to flow in only one

GRASIM INDUSTRIES LIMITED CHEMICAL DIVISION, KARWAR Page 16

GRASIM INDUSTRIES LIMITED CHEMICAL DIVISION, KARWAR Page 17