A Summer Internship Report

on

“MAINTENANCE AND MECHANICAL EQUIPMENTS”

Submitted to

Charotar University of Science & Technology (CHARUSAT)

Submitted by

NAME: DARSHAN SONI

(ID No. : 17ME094)

C. M. Department of Mechanical Engineering

Chandubhai S Patel Institute of Technology
Faculty of Technology & Engineering
Charotar University of Science and Technology, Changa

MAY 2019

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 Certificate

This is to certify that the Summer Internship Report entitled “MAINTENANCE AND
MECHANICAL EQUIPMENTS” submitted by Mr. Darshan Soni. (ID No. 17ME094) towards
the partial fulfillment of the requirement for the third year subject ME-349 Summer Internship-
1 at Charotar University of Science and Technology (CHARUSAT) is a record of the bona-fide
work carried out by him/her under my guidance and supervision. The work submitted, in my
opinion, has reached to a level required for being accepted for the examination.

Certified By

Prof. Vishal Mehta

Assistant Professor,
C. M. Dept of Mechanical Engineering,
Chandubhai S. Patel Institute of Technology,
Faculty of Technology & Engineering,
Charotar University of Science &
Technology, Changa

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sCopy of
Certificate
Received From
Company

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 A Summer Internship
Approval Sheet

The A Summer Internship Report entitled

“MAINTENANCE AND MECHANICAL EQUIPMENTS”

Submitted By
DARSHAN SONI(ID No. 17ME094)

As a partial fulfillment of the subject ME-349 Summer Internship -1

5th Semester
B. Tech (Mechanical Engineering)

Internal Examiner External Examiner

Date :

Place : Bayer Vapi Pvt. Ltd.

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 List of contents
Chapter topic
1 Introduction
1.1 Objective 6
1.2 Company history 6
1.3 5S System 7
1.4 Types of Maintenance 8

2 Mechanical Equipment
2.1 Pumps 11
2.2 Ejectors 16
2.3 Tanks 18
2.4 Gaskets 18
2.5 Reactors 19
2.6 Heat exchangers 25
2.7 Gear boxes 28
2.8 Mechanical seals 29
2.9 ANF 32
2.10 RVD 35
2.11 Columns 37
2.12 Centrifuges 40

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 1. INTRODUCTION

1.1 OBJECTIVE
Bayer Vapi Private Limited is engaged in the manufacture of active ingredients and its
intermediates for use in a wide array of agriculture and environment protection products. It is
also the single largest Synthetic Pyrethroids production facility in the world. Mastery over
complex chemistry, large-scale manufacturing capacities with full backward integration,
ability to manufacture custom-made grades of various products, international quality control
standards, highly successful R&D and excellent transport connectivity to any part of the world,
make Bayer Vapi a “Supplier of Choice” for many multinational agrochemical corporates in
India and abroad. Most of our Active Ingredients are produced using internally manufactured
intermediates, which are manufactured starting from generic chemicals. Nearly 80% of the
company’s production volumes are exported globally.
Bayer Vapi is a core manufacturing site for the Crop Science Division of Bayer globally and
is its exclusive manufacturing site for Synthetic Pyrethroids.

1.2 COMPANY HISTORY

1863: Company is founded by F. Bayer & J.F. Weskott in Wuppertal, Germany

1896: First wholly-owned subsidiary of Bayer in Asia “Farbenfabriken Bayer and Co. Ltd.” is
set-up in Mumbai
1958: Bayer establishes Bayer Agrochem Private Limited in India
1963: The name of Bayer Agrochem changes to Bayer (India) Limite
1969: The company commences operations of a major plant in Than
2001: Bayer acquires Aventis CropScience
2004: First Imidacloprid production facility outside Germany is inaugurated in Vapi
2005: Lanxess AG is spun off from the Bayer Group
2005: New nematicides plant is inaugurated in Ankleshwar
2006: Takeover of Schering AG, Berlin, Germany
2007: Bayer MaterialScience Polyurethane Systems House commences operations in Greater
Noida
2009: Bayer Technology Services opens its first office in India at Thane
2011: EcoCommercial Building is set up in Greater Noida as Bayer’s first emissions-neutral
office building in Asia
2011: Bayer Zydus Pharma is set up as a 50:50 joint venture between Bayer HealthCare and
Zydus Cadilla

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2011: Bayer MaterialScience inaugurates the Color Competence and Design Center in Greater
Noida
2011: Bayer MaterialScience inaugurates a new aromatic and aliphatic polyisocyanate (PIC)
manufacturing facility in India
2013: The Seeds business unit1 of Bayer CropScience opens a new Mustard Breeding Station
in Palwal, Haryana
2013: The Seeds business unit1 of Bayer CropScience opens a multi-crop breeding station in
Chandippa, near Hyderabad
2014: New Headquarters of Bayer in India inaugurated at Thane

1.3 5S SYSTEM
5S is a systematic form of visual management utilizing everything from floor tape to operations
manuals. It is not just about cleanliness or organization; it is also about maximizing efficiency
and profit. 5S is a framework that emphasizes the use of a specific mindset and tools to create
efficiency and value. It involves observing, analysing, collaborating, and searching for waste
and also involves the practice of removing waste
In English, the five S's are translated as Sort, Set in Order, Shine, Standardize, and Sustain.

Sort Sort through materials, keeping only the

essential items needed to complete tasks.
Set in order Ensure that all items are organized and each
item has a designated place.
Shine Proactive efforts to keep workplace areas
clean and orderly to ensure purpose-driven
work
Standard Create a set of standards for both
organization and processes
Sustain Sustain new practices and conduct audits to
maintain discipline

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 1.4 TYPES OF MAINTENANCE
Preventive Maintenance:
➢ Preventive maintenance is time-driven maintenance program.
➢ Maintenance tasks are based on elapsed time or hours of operation that are based on
statistical or historical data for specific types of plant equipment
➢ PM is a regular and systematic inspection, cleaning, and replacement of worn parts,
materials, and systems.
Predictive Maintenance:
➢ Predictive maintenance is a condition-driven preventive maintenance program.
➢ Predictive maintenance uses direct monitoring of the operating condition, efficiency,
heat distribution and other indicators to determine the actual mean-time-to-failure or
loss of efficiency that would be detrimental to plant operations for all critical systems
in the plant or facility
Reactive Maintenance:
➢ Reactive maintenance is just a breakdown maintenance
➢ React at the time of failure.
➢ The net result of this reactive type of maintenance management is higher maintenance
cost and lower availability of process machinery.
The major expenses associated with this type of maintenance management are:
➢ High spare parts inventory cost
➢ High overtime labor costs
➢ High machine downtime

➢ Low production availability

REQUIREMENT OF GENERATION OF PM PLAN
Identify the:
➢ Functions: Know about the function of equipment
➢ Functional failures : Identify possible failures
➢ Failure modes: Identify reasons of failures, “What are the events that cause each
failure?”
➢ Failure effects: Know about effects due to failure, “What happens when each failure
occurs?”

Preventive maintenance tasks must:

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 ➢ Aim at the failure process
➢ Be specific
➢ Measure or check for conditions against a standard
➢ Report the results

BENEFITS OF PM
➢ Elimination of approx. 33% to 50% of maintenance expenditures
➢ Elimination of unscheduled downtime caused by equipment or system failures
➢ Increased manpower utilization
➢ Increased capacity
➢ Increased useful life
➢ Fewer expensive and inconvenient repair
➢ Quick response on any breakdowns
➢ Reduce an overtime charge
➢ Extended equipment life

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2. MECHANICAL EQUIPMENTS

2.1 Pumps
Centrifugal pump
Self priming pump
Submersible pump
Multi stage pump
Positive Displacement Pumps
Reciprocating pump
Rotary pump
COMPONENTS
1. Suction nozzle
2. Volute Casing
3. Impeller
4. Discharge nozzle
5. Mechanical seal
6. Shaft
7. Adaptor
8. Bearing hosing
9. Bearing
10. Oil SEAL

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Working principle of centrifugal pump
➢ The centrifugal pump is a rot dynamic pump and works by creating kinetic energy.
➢ Its main component is the impeller, which is actually the driving force behind the
creation of kinetic energy.
➢ These are capable of discharging large amount of fluid being pumped.
➢ The impeller of the centrifugal pump is available in both straight vanes and curved
vanes to suit the pumping requirement as the case may be.
➢ The centrifugal pump is not a self-primed machine. It needs to be filled with liquid first
and then set to operate.
➢ There is another type of centrifugal pump available, which has two or more impellers
assembled with it. This type of the centrifugal pump is known as the multistage
centrifugal pump.
➢ The design structure although may differ. The impellers may use either a single shaft
to mount impellers over, or it may have different shafts as well.

➢ Impeller: The spinning part of the centrifugal pump.

➢ Eye of the impeller: The inlet of the impeller that allows fluid to enter into it.
➢ Vanes: The straight or curved blades of the impeller that exert force over the
fluid to make it move.

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 ➢ Discharge nozzle: The outlet through which fluid finally exits from the
impeller.
➢ Volute: The pump’s housing.
➢ Shaft
➢ Shaft sleeve
➢ Casing
➢ Casing wear ring

Types of Impeller

Closed semi-open open

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How Seal less pump work
A magnetic drive pump uses a balanced magnetic field to create the rotation of the fluid
impeller. Unlike a traditional centrifugal pump which has a direct drive connection between
impeller and motor, a mag-drive pump eliminates the direct drive mechanism and replaces it
with a magnetic field. An outer magnetic bell housing is mounted on the end of the pump shaft.
This outer bell is aligned on the outside of the rear casing. The pump impeller is connected to
a smaller magnet assembly and rides on an internal shaft and bushing assembly. (The liquid
end parts are all isolated within the fluid head of the pump without the need for a mechanical
seal.) The smaller magnet assembly is mounted within the center of the magnetic field of the
outer bell housing. Although these two magnet assemblies are separated by a fluid barrier, the
magnetic fields are aligned. When the pump motor is started the outer bell housing begins to
rotate. As the outer bell rotates, the rotating magnetic field effects the inner impeller magnet.
As the two magnets begin to turn together, the impeller begins turning and displacing fluid.
Now you know how it works.

Positive Displacement Pump

The positive displacement pumps can be divided in two main classes
• reciprocating
• Rotary

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The positive displacement principle applies whether the pump is a
• rotary lobe pump
• progressing cavity pump
• rotary gear pump
• piston pump
• diaphragm pump
• screw pump
• gear pump
• vane pump

Difference Between Centrifugal & Positive displacement Pump

Care of pumps
➢ Start seal cooling before start up of pump.
➢ After any maintenance work on pump check the rotation of motor .
➢ Check oil level of pump before start up of pump.
➢ Clean /Neutralize any chemical leakage spillage on pump body.
➢ Keep always pump dyke clean
➢ Ensure seal cooling water is going to general drain throw proper way.

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 ➢ Report any oil leakage and seal leakage immediately to responsible person.
➢ Report any abnormal noise /vibration to responsible person.

2.2 EJECTORS
Principle of Vacuum Ejector
The Venturi effect is a particular case of Bernoulli's principle. Fluid under high pressure is
converted into a high-velocity jet at the throat of the convergent-divergent nozzle which creates
a low pressure at that point. The low pressure draws the suction fluid into the convergent-
divergent nozzle where it mixes with the motive fluid.

Care of Ejectors
➢ Ejector jets are to be levelled and aligned during installation
➢ Proper supports are to be provided to each stage.
➢ Special care to be taken during installation of graphite ejector.
➢ Graphite ejectors are to be handled by trained person only.
➢ Close steam jet while ejectors are not in operation.
➢ Proper strainers are to be provided in pump suction

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Trouble shooting of ejector

Pump suction valve failed

No water in sump
No vacuum at dead end
Reverse rotation of pump
Pump impeller damaged
Water jet nozzle partially choked
steam jet nozzle partiallychoked
Vacuum line partially choked
Vacuum line punctured
Pump suction valve partially opened
Less vacuum at dead end as required Steam jet ejector steam line puncture
Steam line gasket leakage of steam jet ejector
Condensed solvent accumulated in vacuum line
Vacuum line NRV not operating propperly.
Low steam pressure
Ejector sump water temperature is more than required

2.3 TANKS
Care of Tanks
➢ Any leakage and spillage on tank is to be decontaminated /neutralize immediately, re-
paint immediately.
➢ Any Leakage of tank joints is to rectified as soon as possible
➢ Damaged insulation of insulated tank is to be repaired as soon as possible.
➢ After any maintenance work on tank ,Tank is to be pressure tested before use.

2.4 GASKETS
• A gasket is a mechanical seal which fills the space between two or more mating
surfaces, generally to prevent leakage from or into the joined objects while under
compression.
• Gasket material saves money by allowing less precise mating surfaces on machine parts
which can use gasket material to fill irregularities.
• Gaskets are commonly produced by cutting from sheet gasket materials.

2.5 REACTORS
Moc of Reactors
1. MS
2. SS (304,316,316L,Hastalloy)

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 3. MSTL,
4. MSRL
5. MSRLTL
6. MSLB
7. MSGC
8. MSGL

Components of reactor
1. Gear box.
2. Motor
3. Lantern stool
4. Top shaft
5. Bearing housing
6. Top shaft bearing
7. Mechanical seal
8. Pad plate
9. Bottom shaft.
10. Agitator blades
11. Guide bush
12. Guide bush housing
13. Baffle
14. Thermowell
15. Jacket/Limpet
Disassembly and assembling of reactor
1. Fix required capacity lifting and shifting prior to start the work.
2. Ensure all incoming lines are
3. Ensure Electrical isolation of Motor.
4. Empty out gearbox oil and Thermosyphon oil
5. Disconnect all thermosyphon and mechanical seal connection
6. Take vessel entry permit.
7. Do Required arrangement to open bottom shaft coupling bolts
8. Remove agitator blades.
9. Remove guide bush and guide bush housing.
10. Tie bottom shaft coupling with required capacity chain /rope
11. Open bottom shaft coupling bolts and lower down bottom shaft, remove shaft through
manhole.
12. Remove Gear box, motor ,Top shaft coupling
13. Tie top shaft with suitable chain and loose bearing housing and lower down top shaft

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 14. Remove lantern with bearing housing
15. Remove pad plate
16. Assembling will be in reverse way.

Disassembly and assembling of MSGL reactor

1. Fix required capacity lifting and shifting prior to start the work.
2. Ensure all incoming lines are blinded
3. Ensure Electrical isolation of Motor.
4. Empty out gearbox oil and Thermosyphon oil
5. Disconnect all thermosyphon and mechanical seal connection
6. Take vessel entry permit.
7. Ensure no metal parts like keys, wrist watch, spanner while taking vessel entry.
8. Lay rubber sheet and wooden planks firmly on agitator blades in triangle shape
9. Remove motor, gear box, lantern
10. Remove agitator coupling.
11. Loose seal lock and loose bearing housing check nut
12. Remove lantern with bearing housing
13. Remove Mechanical seal.
14. Do marking on COC
15. Do proper fixture for coc for lifting and pulling
16. Remove COC and take care agitator while lifting COC.
17. Remove agitator by expert and skilled riggers
18. Do assembling in reverse way.

Shimming of COC gasket

[Link] filler gauge and check the clearance circumferentially
[Link] thickness of shim required at every clearance
[Link] gasket
[Link] shimming
[Link] gasket and tight 4 COC bolts diagonally
[Link] check clearance by filler gauge
[Link] there is no clearance fix all bolts of COC

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[Link] opposite bolts simultaneously in clock wise direction.

Maintenance of reactor
[Link] guide bush and Guide bush housing
[Link] guide bush housing worn-out check thoroughness of bottom shaft and correct it and
rectify guide bush housing.
b. Only Guide bush worn out
Replace teflon guide bush.
[Link] Agitator blade bolts and coupling bolts.
a. Found loosen.:Use proper moc of bolt with check nuts,don’t use single nut.
3. Check Bearing housing.
[Link] housing grease observed dry/Thinner
Remove old grease and apply new grease
[Link] seal cooling flow
If there is no flow in outlet:clean/flush seal jacket./Thermosyphon coil
Change Thermosyphon oil if oil quality is not ok.
[Link] seal pot pressure all ways 1.5 times of Reactor pressure.
[Link] seal oil level half of glass indicator.
[Link] 20 w 40 oil in seal pot.
[Link] 320 no oil for worm and worm wheel tyoe gear box and use 220 no oil in planetary
gear box.
[Link] gear box oil half of gauge glass, during filling open gear box vent plug to remove air
inside gear box.
[Link] rotation of Reactor before handing over to production it should be clockwise
direction.
[Link] all rotating components are guarded and safety devices are properly fitted before
handing over to production.
[Link] every inside inspection of reactor do pressure test 1.5 times working pressure and
do retention test for one hour.
And do all direct contact nozzles,COC,manhole and bottom nozzle for soap solution test
14..During inside inspection of glass lined of doubt observed in glass then do spark test
maximum at 5KVA
[Link] not over tighten glass lined nozzles and use ss ring teflon env elope gasket.

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17 Use torque wrench to tight glass lined nozzles.
[Link] agitator seal installation maintain following parameters
Run out :Max 0.08MM
Square ness 0.04mm to 0.08mm
Conentricity:0.04mm to 0.08mm.
[Link] proper house keeping of besides reactor before handing over the reactor to
production.

Trouble shooting of reactors

[Link] coming from Reactor.
.Out side of reactor.
Observed carefully noise area (Motor,gearbox,agitator beaing housing,motor pully,Gear
box pully,Gear box coupling
[Link] belt if belt drive,check motor,if motor is ok refit belt and decouple gearbox
bottom couping,Then take trial to find the noise.
Inside surface of reactor:Open manhole and check the agitator (Loosen of coupling
bolts,blade bolts loosen,agitaor touching to thermowell,baffle due to loosening of coupling
[Link] materials inside the reactor that has came during charging or from incoming
[Link] damaged or guide bush damaged.
[Link] box motor rotating but agitator top shaft is not rotating.
[Link] box to agitator coupling bolts damaged/Gear box worm wheel damaged
[Link] tripping frequently.
[Link] load on agitator/Gear box motor alignment problem
[Link] worn out damaged
[Link] alignment
[Link] groove over sized

Care of Reactors
Before start up of Reactor.
❑ Check oil level of gear box.
❑ Check seal pot pressure .
❑ Check Thermosyphon pot oil level.
❑ Check seal cooling in let and out let pipe are in open condition.

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❑ Check rotation of agitator if Motor is newly replaced or after any major maintenance
work where motor is removed out side.
❑ Inspect Inside surface of reactor thoroughly throw view glass or man hole any
abnormality.
❑ Check bottom valve in close position
❑ Open jacket outlet valve first and then open inlet valve slowly.
❑ Ensure steam by pass valve in close position.
❑ Check condition of belt and belt guards
❑ Ensure all rotating parts are properly guarded
Any chemical leakage /spillage on reactor is to be cleaned immediately or decontaminated
in order avoid corrosion and damaged to reactor.
Any abnormal noise/vibration and oil leakage from gear box and mechanical seal is to be
reported to responsible person immediately.
Any insulation damaged either of reactor or utility lines are to be reported to responsible
person.
Completely flush jacket in every fort night to increase life of jacket where multi utility is
used.

2.6 HEAT EXCHANGERS

Heat exchanger is a mechanical equipment that transfer heat to motive fluid.
Moc of Heat exchanger.
[Link]
[Link].304
3.SS316
[Link] 316L
[Link]
Type of heat exchanger.
[Link] and tube heat exchanger
[Link] heat exchanger
[Link] heat exchanger

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Care of Heat exchangers
➢ first Open utility outlet valve and then slowly open in let valve to avoid sudden jerk.
This care is very important in case of graphite heat exchange other wise it may damaged
graphite block.
➢ Check insulation condition of heat exchangers.
➢ Ensure lock open of utility valve before starting of utility in let valve
➢ Immediately repair damaged insulation in order to avoid heat loss and condenser
external corrosion.

Trouble shooting of heat exchanger

[Link] coming in collection line.
A. Condenser tube puncture

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Open both side bonnet of heat exchanger,Apply utility in condenser jacket and check the
utility coming in which tube mark the tubes,Plug the puncture tubes and do hydro test 1.5
times of working pressure, if there is no leakage box up and hand over.
B Condenser tube sheet puncture: Take hot work and do welding at leakage area and do
hydro test at 1.5 times of working pressure,if there is no leakage hand over to production
deptt.
For graphite condenser cracked blockes are to be replaced if utility coming in collection
line .Soft rope /flat rope are to be used for joining two blocks.
Graphite condenser are to be dismantled /assembling to be done in up wright condition for
proper fitting
C. Pressure development in Reactor:
May condenser tube choked
Ice formation in condenser tube.
[Link] heat transfer
Scale in condenser jacket and tube.
Air lock in condenser jacket.

2.7 GEAR BOXES

Type of gear box.
[Link]

B. Planetary

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 C. In line

Care of Gear boxes.

➢ Check oil level of gear box before start up of gear box.
➢ Ensure gear box is of dust and dart free.
➢ Report to responsible person of any oil leakages .
➢ Report to responsible person for any abnormal noise.
➢ Report to responsible person for any abnormal rise in temperature of gear box body.

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 2.8 MECHANICAL SEALS
• Unbalanced – describes a seal design wherein
the sealing faces are exposed to the full
hydraulic pressure at the sealing chamber
without benefit of any predetermined
counterbalance measures. Its design
simplicity, cost and ability to handle a
moderate pressure range allows the
unbalanced seal to be used extensively in
pumping applications.
• Balanced – A mechanical seal design in which
the face contact area is counterbalanced to
reduce the amount of hydraulic faces. The
most common way of achieving balancing is
by providing a step in the shaft or sleeve, and
moving the seal face radially inward, thereby
reducing the hydraulic area under pressure.

Working principle of mechanical seal

➢ Mechanical seals are being used increasingly on fluid pumps to replace packed glands
and lip seals. Pumps with mechanical seals perform more efficiently and generally
perform more reliably for extended periods of time
➢ Mechanical seals are provided to prevent pumped fluids from leaking out along the
drive shafts. The controlled leakage path is between two flat surfaces associated with
the rotating shaft and the housing respectively. The leakage path gap varies as the
faces are subject to varying external loads which tend to move the faces relative to each
other.
➢ The mechanical seal requires a different shaft housing design arrangement compared to
that for the other type of seals because the seal is a more complicated arrangement and
the mechanical seal does not provide any support to the shaft.
➢ In order for the mechanical seal to perform over an extended time period with low
friction the faces are generally hydro dynamically lubricated. The fluid film will need
to carry substantial load. If the load becomes too high for the film surface contact will
take place with consequent bearing failure. This lubricating film is generally of the
order of 3 micrometers thick , or less. This thickness is critical to the required sealing
function. Mechanical seals often have one face of a suitable solid lubricant such that
the seal can still operate for a period without the fluid film.

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 Type of Mechanical seal
[Link] Mechanical seal. [Link] Mechanical seal

Care of Mechanical seal

• Avoid dry running of pump.
• Open seal cooling before start up of pump/Reactors
• Check T.S.S Pot pressure of pump/Reactor
• Check T.S.S Pot Oil level of Pump/Reactor
• Maintain shaft run out 0.08 mm

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 • For reactor shaft run out ,squre ness and
• Concentricity 0.08mm
• Clean all parts of mechanical seal thoroughly
• Before assembling.

2.9 ANF
Type of ANF
• Detachable type ANFs
• Non-Detachable type ANFs
Uses of Agitated Nutsche Filter
Agitator filters are mostly used in chemical plant for the process of the filtration of liquids
with a high solid content.
• Agitating / Washing of Solid Particles/powder/Slurry
• Drying process
• Re-suspending / Mixing of solid particles
• Filtrations
• Extraction
• Crystallizing

Main Part of ANFS

• Mono-block
• Bottom Disc with Perforated Plate, Sintered wire mesh & Filter cloth
• Discharge Valve
• Dust collector
• Agitator
• Gearbox with Motor
• Hydraulic Cylinders
• Hydraulic Power Pack
• Mechanical Seal

Operation Cycle of ANFD

• Filling & Charging :The first step involves the transferring of the product to be
filtered, usually an aqueous or solvent based solid/liquid slurry, from the primary
location (e.g. reactor) to the filter/dryer. The filter should be sized appropriately to
handle the solids volume that is being charged. A general rule of thumb to follow is
that the maximum solids height should be equal or less than the agitator stroke, typically
12 - 20 inches
• Filtering : The second step involves the use of pressure and/or vacuum to force liquid
through the solid bed and filter media. The process is stopped when solids are visible,

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 or can be continued until all the liquid is pushed out. There are various types of filter
media available in Nutsche filters – cloth, single layer metal screen, or multi-layer
sintered metal. The media should be determined based on the characteristics of the
slurry including particle size and shape, cake porosity, and compressibility (which are
all factors that, when taken into account with the filter media selected, will determine
filtration rate).
• Displacement Washing : fresh wash liquid is sprayed on top of the solid cake taking
care not to disturb the surface of the cake. The liquid is forced through with pressure
or vacuum. Displacement washing serves several purposes – it removes the liquid and
its impurities while keeping the cake intact and it replaces the previous liquid with fresh
liquid. There is also the opportunity prior to this step to try and close cracks if the cake
has any via smoothing.
• Reslurry Washing : As an additional washing option, a re-slurry washing can be
performed if additional extraction or dissolving of impurities is necessary. This is
executed by the addition of fresh wash liquid that is mixed with the solids. The agitator
is stopped and raised before filtering the wash liquid. The re-slurry process is also used
when a long contact time is needed between the wash fluid and the solids or the
displacement wash does not provide the required wash quality
• Smoothing: This next step may be used after any filtration or wash, especially after the
final wash, when gas is blown through the cake. The agitator is used to close cracks
and compress the cake to reduce residual moisture level. This function will help to
achieve uniform flow of liquid or gas through the filter cake, while helping to eliminate
liquid and gas channeling that reduces the efficiency of displacement washing and gas
blow through.
• Drying/Cooling :In most filter types, the solid must be evacuated into a second dryer
to complete the drying and subsequent cooling process. In Nutsche filter/dryers, the
two functions are combined and drying can take place in the same vessel. To
accomplish this, the vessel surfaces (including the wall, base, and agitator) are
heated. There are two types of drying that can be conducted – vacuum drying and
convection drying. The method used depends on the product behavior. Vacuum drying,
the most common method, involves a vacuum source, agitation, and dust filter. This
type of drying utilizes vacuum to reduce the temperature at which the solvent
evaporates, reducing the average drying temperature. During convection drying, hot,
pressurized gas (usually nitrogen) is blown down through solids and out of filtrate lines
(and even recirculated as necessary); this will eventually dry the solids. Convection
drying is unique to filter/dryers due to their porous filter plate. Unlike vacuum drying,
it does not require agitation. Whether vacuum or blow-through drying is selected, a
filter/dryer can allow you to get completely dry material out from your process, with
less than 0.1% final product moisture. At this point the vessel and product may need
to be cooled to an ambient temperature prior to discharge.
• Discharging: This final step is accomplished through the valve/port located on the
vessel sidewall. The agitator is slowly lowered as it rotates, effectively moving product
to the side discharge valve. There are certain applications where the desired product to
be discharged is not a dry solid. Nutsche filter/dryers are designed to facilitate flexible
discharge, which allows for wet solids, slurries, or even liquid to be discharged.

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 ANFD
• Check oil level of Hydraulic Power pack
• Use specified lubrication for Hydraulics & Gearbox
• Check gear box oil level.
• Check nitrogen pressure of Dry mechanical seal.
• Rectify any oil leakage from gear box, hydraulic cylinder.
• Remove liver of bottom disc hydraulic cylinder after filter cloth replacement.
• Detached bottom disc cylinder from body after filter cloth replacement.
• Check discharge valve sealing O ring in every batch
• Check ANF dust collector filter cloth in every six month.
• Keep ANF agitator up/down cylinder in down position when ANF is not used for
longer period.

2.10 RVD
Introduction
• Rotary vacuum dryers offer clean, simple and effective method of drying wet cake,
powder and even slurry.
• Labor and energy costs are minimal compared to tray dryers and product losses during
handling are also negligible.
• Additionally valuable organic solvents can be conveniently condensed and recovered
Working Principle
• The drying in a rotary vacuum dryer is a batch operation under vacuum.
• It is possible to dry heat sensitive materials at well below boiling points of water and
solvents.
• Drying time depends on material being dried, amount of solvent or water to be removed,
desired final moisture content, permissible jacket temperature etc.
• The dryer is available in sizes ranging from 100 liters to 20,000 liters gross volume.
The volume of wet material loaded into the dryer is usually restricted to 40-45% of
gross volume.

Rotary vacuum dryer :

• Give drying, mixing and breaking effects simultaneously.
• Wet cake or slurry is fed through charging door, while the agitator is rotating in
clockwise direction,
• Vacuum is applied in the dryer and heating media is circulated in the jacket.

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 • Evaporation of moisture takes place under vacuum and vapors passes through the dust
catcher into the condenser, where it is condensed and collected in the receiver.
• Dried material is discharged through discharge valve.
• This is a high efficiency dryer unit used for drying of wet cake product after filtration.
• RDPD can be used in drying process of various Pharmaceuticals, Intermediate
Compounds, Fine Chemicals, Chemicals, Agro Chemicals, Pesticides, Insecticides,
Dyes and Food Products

Main Part of RVD

• Mono-block
• Hollow Shaft
• Discharge Valve
• Dust collector
• Rotary Carbon
• Gearbox with Motor (Drive Assembly)
• Mechanical Seal

Check point for RVPD

• Check gear box oil level.
• Check nitrogen pressure of Dry mechanical seal.
• Check discharge valve sealing O ring in every batch
• Check RVPD dust collector filter cloth in every six month.
• Check Rotary Carbon Sealing
• Check leakage from Shaft & Gland

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 2.11 COLUMNS
Introduction to Distillation Column
• The purpose of distillation is to separate a liquid mixture into its components.
• Distillation is a process of separating the component substances from a liquid mixture
by selective evaporation and condensation. Distillation may result in essentially
complete separation (nearly pure components), or it may be a partial separation that
increases the concentration of selected components of the mixture

❑ Type of Distillation Column

Batch Process Column
In batch operation, the feed to the column is introduced batch-wise. That is, the column is
charged with a 'batch' and then the distillation process is carried out. When the desired task
is achieved, a next batch of feed is introduced.
Continuous Process Column
In contrast, continuous columns process a continuous feed stream. No interruptions occur
unless there is a problem with the column or surrounding process units. They are capable
of handling high throughputs and are the most common of the two types. We shall
concentrate only on this class of columns.
Type of Continuous Column
• binary column - feed contains only two components
• multi-component column - feed contains more than two components
• multi-product column - column has more than two product streams
• extractive distillation - where the extra feed appears in the bottom product stream
• azeotropic distillation - where the extra feed appears at the top product stream
• tray column - where trays of various designs are used to hold up the liquid to provide
better contact between vapour and liquid, hence better separation

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 • packed column - where instead of trays, 'packings' are used to enhance contact between
vapor and liquid

Basic Distillation Equipment & Operation

Main Components of Distillation Columns
Vertical shell: where the separation of liquid components is carried
• column internals: trays/plates,packings which are used to enhance component
separations
• Re-boiler: to provide the necessary vaporization for the distillation process
• Condenser: to cool and condense the vapor leaving the top of the column
• reflux drum: to hold the condensed vapor from the top of the column so that liquid
(reflux) can be recycled back to the column.

Parts of Column Internals

Trays and Plates
"trays" and "plates" are used interchangeably. There are many types of tray designs, but the
most common ones are :
A. Bubble cap trays B. Valve trays C. Sieve trays

THE PACKED TOWER

Column
• the packed tower is a vertical, steel column which contains 'Beds' of packing material
which are used to bring the rising vapors into intimate contact with falling liquid within
the tower. The heat added to the mixture before entering the tower partially vaporizes
the mixture and the vapors rise up the tower and begin to cool.
• The liquid falls towards the bottom of the tower. At the tower bottom, in general, more
heat is added to the liquid by a 'Reboiler' which may be steam heated or a fuel fired
furnace type. Ceramic Raschig Rings, Stainless Steel Pall Rings or Ceramic Saddles.

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 TRAY TYPE TOWER

2.12 CENTRIFUGES
Introduction
A centrifuge is a device that spins liquid samples at high speeds and thus creates a strong
centripetal force causing the denser materials to travel towards the bottom of the centrifuge
tube more rapidly than they would under the force of normal gravity. Types of centrifuges.

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 2.13 CONCLUSION
In conclusion, the Industrial training that I had gone through for 4 weeks at Bayer Vapi Pvt.
Ltd. Was very informative and instructive. It gave me lots of benefits and exposure which
enables me to enter the working environment. Through this training, I was able to gain insights
about the real industry working condition and practices, types of mechanical equipment and
maintenance. All of this valuable experience that I have gained wasn’t only acquired through
the direct involvement in task given but also through other aspect of the training such as work
observation, interaction with the staffs and local people.

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