CHAPTER-1

INTRODUCTION
This report describes the two months vocational summer training we have undergone during the
period 16 May 2017 to 16 July 2017 at Orient Paper Mill (OPM)-caustic soda unit, Amlai,
Madhya Pradesh.
OPM Caustic soda unit was set up in the year 1967 in the state of Madhya Pradesh. The unit is
situated on the west bank of river Sone at village Amlai in Shahdol district. The unit is located in
the centre of the country giving it easy access to all india markets. The unit is well connected by
rail having Amlai Railway Station on Bilaspur- Katni broad gauge railway section of South
Eastern Railways.
The company was incorporated as Hukumchand Mills (Calcutta) Ltd. on 25th Sept, 1919 and
originally carried on the business as a manufacturer of Jute goods with its plant at Naihati in
West Bengal. The company was subsequently acquired by the present promoters. The name of
the company was changed to Hukumchand Jute Mills Ltd. on 26th April 1967. The company
diversified into Chloro-Alkali business by setting up a plant for the manufacture of caustic soda
(with Mercury Cells) with a capacity of 30 tons per day at Amlai(Madhya Pradesh) to the 1965.
The companies name was changed to its present name Hukumchand Jute & Industries Ltd. on
30th May 1984.The company sold the Jute division in September, 1988, however, it continued to
export jute goods until 1994.HJI has been merged with GMMCO Limited on 1st April 1999 to
April 2009.It is a C.K.Birla Group Company.

Now this chemical plant operates as a chemical division of Orient Paper Mills Ltd. Since April,
2009.
At present HJI manufactures (NaOH) Caustic Soda of about 100 tons per day. Caustic soda is
manufactured in the ION EXCHANGE MEMBRANE PLANT unit. The other main units are
FUSION PLANT & CHLORINE PLANT.
The main product of the plant is Caustic Soda & bi-products are Hypo, Chlorine & HCl(Hydro
Chloric Acid).
Presently companys production capacity of caustic soda (NaOH) is 100-110-tons/ day. For this
caustic production, the chlorine produced will be 90.869 tons per day. HCL plant has full
capacity of 30 tons per day.

1.1 List of departments

Human resources department-
The main purpose of the department is to enhance the human resource which in turn termed as
Organization Development has been categorized as:
1. Traditional Development
2. Upgradation of Knowledge
3. Skill Development

Thus to look after the social care and modify the human resources
TOTAL STAFF: 136
TOTAL COMPANY LABOURS: 116+05
TOTAL CONTRACT LABOURS: 230

General Shift-
08:00 am to 12:00 noon
1:30pm TO 05:30 pm

Shift For Workers-

A SHIFT: 07:30 AM to 03:30 pm
B SHIFT: 03:30 PM to 11:30 pm
C SHIFT: 11:30 PM to 07:30 am

Shift For Staff-

06:00 am to 02:00 pm
02:00 pm to 10:00 pm
10:00 pm to 06:00 am

Security Department-
This department details the procedure for Access Control, Deployment of Guards and Patrols and
related duties, vigilance and anti-corruption activities, information and networking and
investigation of minor / major crimes.
The procedure is applicable for:
 Employees entering /exiting the gates
Guards and their deployment
Visitors system
Vehicular movements & records related to stores & items
Maintenance of records related to security dept.

Dispensary-
It provides 24 hours medical facility to the plant employees.

Sales Department-
The function of Sales department is to dispatch Caustic & Bi-products.
This department also maintains an input register of sales for maintaining the invoice.

Accounts Department-
Account department deals with every money related enquiry in the plant.This department
maintains the records of income, expenditure, assets, liabilities, profit & loss etc. It also prepares
Balance Sheet for every financial year.

Purchase Department-
Purchase department invites tenders from various parties as per indents received from various
departments for different process related items. After it makes order to appropriate party after
going through a detailed study of the ordered products/items in order to purchase the required
items.

QA & EP Department-
This department ensures testing of raw materials, intermediate & finished products of the plant.
This department also concerns with environmental protection. It takes necessary steps in order to
control the waste generated by the plant as per norms of environment protection.

E.D.P.(electro data processing) Department-

 E.D.P. manages all commercial, material management, store/purchase, sales, dispatch related
computer work and data processing and Local Area networking in the plant.

Civil Department-
This department deals with all types of construction work, all civil related project work, plant
labor requirements fulfillment, general plant house- keeping & cleaning work, colony area
maintenance work, drinking water supply management etc. for HJI. The labors have been
categorized into three grades as under :-
A 279 +PF +ESI +LEAVE +BONUS
B 220 TO 229 + PF +ESI +LEAVE +BONUS
C -144 + PF +ESI +LEAVE +BONUS

Safety Department-
Safety department works for safety of personnel & plant. It provides general safety wear like
helmets, safety goggles & P.P.Es.(Personnel protective Equipments) to the plant employees.
This department also organizes various seminars/meetings to keep up safety norms in the plant.

Electrical Department-
Electricity is one of the main raw materials for Chlor-alkali industry. In HJI-Division of Orient
Paper Mills, source of electricity is 132kV substation, which gets power from Chachai Thermal
Power Station. Electrical Department performs following functions:
To perform preventive & breakdown maintenance of Electrical equipments.
To keep equipments in safe & good operating condition for better operation of the plant.
Ensure availability of necessary resources at scheduled time at site.
Ensure proper precaution for safe working
Explain purpose, safety requirements and job description to maintenance team including
contract labors.
If testing and inspection results are not up to-desired level (due to lack of resources i.e.
time, spares etc.) and it is still safe to energize the Instrument, this can be done only after
Head of Department permission.
Arrange resources and plan another outage so that the equipments reliability & safety can
be ensured.
Ensure that equipment get in service without any trouble to ensure removal of men &
material from site.
Handover to the concern department.
 Instrumentation Department-
Aim of Instrumentation Dept. is to establish a system to keep instruments in safe & good
operating condition for better operation of the plant.
The main function of the department is to:
Calibration of Pressure gauge
Calibration of Temperature gauge
Calibration of Transmitter
Calibration of Control valve
Calibration of Process Controller

Mechanical Department-
The main purpose of Mechanical Department is to sustain the production of the company in a
better way maintaining all the mechanical equipments in healthy condition so that the plant
should be in a continuous form.
The various material used for piping-

Caustic nickel , MSRL , MS , PVC

Chlorine PVC, FRP
Dry chlorine MS
Chlorine (moist) - PVC+FRP, titanium.
Brine- Titanium, FRP, PVC+FRP, Rubber line
Depleted brine- alpolite
Feed brine- CPVC
Hydrogen MS
Hypo cast iron
Sulphuric acid (78%)- PVC+FRP
Sulphuric acid (98%)- MS
HCL PVC, FRP, PVC+FRP (32%)

Various types of valves using for controlling flow-:

Ball type
Butter fly
Diaphragm
Globe valve
Gate valve
 Plug valve
Non return valve

Various colors used for detection of line:-

Water- green
Hydrogen & H2SO4- red
Caustic blue
HCL & CL2- yellow
Brine grey

Various types of pumps using in chemical plant:-

To keep pumps operating successfully for long periods of time, several elements are
required. These elements include careful pump design selection proper installation, careful
operation; the ability to observe changes in performance over time, and in the event of a failure,
the capacity to thoroughly investigate the cause of the failure and take measures to prevent the
problem from recurring.
Pumps that are properly sized and dynamically balanced that sit on stable foundations with
good shaft alignment and with proper lubrication that operators start run and stop carefully and
that maintenance personnel observe for the appearance of unhealthy trends, usually never
experience a catastrophic failure.
The family of pumps comprises a large number of types based on application and
capabilities. The two major of pumps are dynamic and positive displacement.
Liquid is allowed to flow into the pump as the cavity on the suction side expands and the
liquid is forced out of the discharge as the cavity collapses. These principles applies to all types
of positive displacement pumps where the pump is a rotary lobe, gear within a gear, piston,
diaphragm, screw, progressing cavity, etc.

A positive displacement pump, unlike centrifugal pumps, will produce the same flow at a given
rpm no matter what the discharge pressure is a positive displacement pump cannot be operated
against a closed valve on the discharge side of the pump i.e. it does not have a shut off dead like
a centrifugal pump does
Raw Material Department-
The aim of the raw material department is to decide the accumulating place in the Salt Godown
after knowing the description, amount and analysis data of the raw salt and Select the raw salt so
that the quality of the raw salt used becomes as equally as possible.
Normally at HJI salt comes from three sources
Gandhi Dham
Sambhar Lake
Bharat Salt

Ion Exchance Membrane Cell-

The ion exchange membrane cell (IEM Cell) introduced in HJI in 1993, it is unique compact in
arrangement unlike mercury & diaphragm cells.
The process of manufacture of caustic soda and chlorine by Ion Exchange Membrane [IEM]
process consists of the following sections:
Primary brine
Secondary brine
Electrolysys
At present, there are total eight electrolyzers of CCM-408D*2 of monopolar type in two rows.
Each electrolyzer has two cells.
For electrolyzing D.C. current is required.
The AC current is converted to DC current in thyristor Rectifier then supplied to cell through
busbars at the bottom of the cell.

Chlorine Plant-
The chlorine gas coming out of the cells can be taken to any of the three-section i.e. Liquefaction
section. Hydrochloric acid section or Calcium hypochlorite section.
Normally 50-55% chlorine of IEM cell is taken to Hydrochloric acid section to produce mercury
free acid.

Caustic Fusion Plant-

Part of Caustic soda solution having 46 47 % concentration is transferred to Caustic soda
flaking section (or Caustic concentration unit).
The plant is designed for the concentration of caustic soda lye from 45% up-to 99% into
baggable flakes. The flakes are filled into open type plastic bags.
The flakes are filled into HDPE bags and sealed by stitching. These are then ready for dispatch to
consumers.
 CHAPTER-2
POWER SUPPLY SYSTEM
The plant is supplied with 11KV high tension overhead power lines from OPM 30MW
generating unit. A supply of 132KV substation which gets power from Chachai thermal power
plant, is kept as standby, to be used in case of blackout at the OPM end. The same power is used
to supply to the OPM feeder in case of failure of OPM turbine generator.
11KV supply is fed to the incoming feeder in the switch gear room, from where the power is
supplied to different units from the outgoing feeder through the circuit breakers connecting the
incoming and outgoing feeders for protection purpose. Switch gear room is equipped with
various metering and protection devices.
The power from 132KV line is received at one end of the switch yard and at the other end it is
converted to 11KV by a 15MVA transformer. The switch yard equipped with the following
devices-

Lightening arrester: A lightning arrester is a device used on electrical systems

and telecommunication systems to protect the insulation and conductors of the system
from the damaging effects of lightening.

Potential transformer: Voltage transformers (VT), also called potential transformers (PT),
are a parallel connected type of instrument transformer. They are designed to present
negligible load to the supply being measured and have an accurate voltage ratio and
phase relationship to enable accurate secondary connected metering.

Current transformer: A current transformer (CT) is a type of transformer that is used to

measure AC Current. It produces an alternating current (AC) in its secondary which is
proportional to the AC current in its primary. It has relay connected to it in series so that
it can detect faults and send signal to the circuit breaker.

Isolators: Isolator is a switch operated manually, which separate the circuit from the
power main and discharges the trapped charges in the circuit.

Circuit breaker: A circuit breaker is an automatically operated electrical switch designed

to protect an electrical circuit from damage caused by excess current, typically resulting
from an overload or short circuit. Its basic function is to interrupt current flow after a
fault is detected.