TRAINING REPORT

ON

ELECTRONICS & COMMUNICATION

IN PARTIAL FULFILLMENT FOR THE DIPLOMA OF ELECTRONICS & COMMUNICATION AT

BALLARPUR INDUSTRIES LIMITED

Unit Shree Gopal, Yamuna Nagar.
Under Supervision of:Mr. J.K.GROVER (MGR. INSTT)

Submitted By:SUNNY DUBEY RAHUL GARG

PUNJAB POLYTECHNIC

LALRU MANDI PUNJAB

PREFACE
Practical training is an important part of theoretical studies. It covers all that remains uncovered in the classroom. It offers the student to exposure an invaluable treasure of experience. It offers an exposure to real practical of instruments & electronics in the industries. As we know that practical training plays an important role in future building of an individual. One can easily overcome the fear from that life in which he has to join a member after some time. Just theoretical knowledge is not sufficient for the success of an individual so one should have practical knowledge about each theory general life. The training greatly enhance our knowledge and provide good opportunities to blend our theoretical as well as

trainees get familiar with certain aspect of industries like shop floor management, production, process and industrial relation etc. I feel proud to get training at BALLARPUR INDUSTRIES LTD, YAMUNANAGAR that is one of the tops most paper manufacturing industries in India. I availed this opportunity in a very satisfactory manner and I have tried to cover whatever I came to know in this report.

ACKNOWLEDGEMENT
This report conveys my heartiest thanks to all those officers and employees of THAPAR GROUP who have given me their full cooperation and devoted their valuable time, for rendering me their needy services, guidelines during the course of imparting me practical training and with those sincere and precious help I have been able to complete my practical training successfully. I wish to express my sincere gratitude to Mr. J.K.GROVER (mgr. Instrumentation) for providing me the training facility. I wish to express my thanks to Mr. B.S. GILL, Mr. ROOP SINGH, Mr. B.CHAUDHARY , Mr. DIWAKAR (Dy mgr. Inst.) ,Mr.MAYANK JAIN, Mr.D.GHOSH, Mr.V.SHARMA and all the

INSTRUMENT DEPARTMENT for their precious co-operation and guidance during completion of this training. I also like to thank Mr. PANKAJ LOHAN and Mr. PRAKASH SHARMA(HR DEPTT) for their valuable support.

INTRODUCTION TO BILT
BALLARPUR
popularly known as BILT is efficiently managed, financially sound, and self sufficient and self made company is The flagship of the coveted THAPAR GROUPS.
The Thapar Group is one of the leading business houses in India. It has a turn over of Rest 5000/- Cores; BILT is one of the leading companies with in the Thapar Group.

INDUSTRIES

LIMITED,

The Thapar Group has a wide range of activities like paper, engineering, electronics, textiles, chemicals, glass, telecommunications, biotechnology, leather etc.
There are 54 companies and 84 plants under this group. Some of the main companies under this group are Crompton Greaves, K.C.T &

Bros. Limited, JCT Limited, BILT.

Ballarpur Industries Ltd. (BILT) promoted by LM Thapar, is

the leader in Indian paper industry with an annual production capacity of 460000 MT spread over in five manufacturing facilities produces ordinary and superior varieties of writing, printing and specialty papers etc. The company is also backwardly integrated with its Caustisoda/Chlorine manufacturing facility, which is a vital material consumed in the production process of paper.

BILT, which is originally incorporated in 1945 as Ballarpur Straw Board Mills, has changed its name in March 1946 to Ballarpur Paper and Straw Board Mills and again it was changed to the present name in Oct. 1975. Since then the company has grown to be a leader in paper industry by continuous expansion and modernization of its capacity and plant and strategic acquisitions. In 1969 the company has merged Shree Gopal Paper Mills with itself and the company which has acquired the Sinar Mass Pulp and Paper (India) Ltd. (now BILT Graphic Papers Ltd.) The company which was one of the most diversified companies in the pre-liberalization era of industrial licensing with interests in Paper, Chemicals has decided to focus on its core competence that is in paper and exit from its non-core businesses. First major steps on these lines were initiated in the year 1994-95 with hiving off the glass business. Thereafter the company sold its vanaspati and edible oils business in 1996-97. And in 1998, the chemical division of the company with its plant at Karwar, Karnataka and which has interests in Phosphates, Chlor Alkali and Bromine and Bromine Chemicals was spun of into a separate company that is Ballarpur Chemicals Ltd (now Solaris ChemTech Ltd). To complement its Restructuring and to enable it to emerge as a stronger and more competitive organization, the company is implementing a project involving modernization and expansion of capacity at its Units in Shree gopal, Ballarpur and

Sewa by 105000 TPA. The Project will be implemented in two

phases. In the first phase, the capacity expansion of 35000 TPA and 28000 TPA is planned over a two-year period from 2000-01 to 2002-03 for Units Sewa and Shree Gopal. In the second phase 42000 TPA of capacity is expected to come on stream at Unit Ballarpur by 200304. During the year 2001-02, the company has completed the up gradation of pulp mill at unit Sewa resulting in increase in capacity by 37 tones from the earlier 125 tones of unbleached pulp per day. The company has also completed the installation of a 2.4 meter wide blade coater at Unit Shree Gopal in FY2001-02. BILT entered into strategic alliance with Hansol of South Korea to provide world class blade coated paper to the Indian customer. it is the first company in the world to commercially exploit the fractionation of bamboo and has applied for the world patent for this process. It has also entered into direct retail distribution with the launch of A4 size, 100-sheet pack of Royal Executive Bond

Mr. Gautam Thapar, Managing Director of BILT, has been

associated with BILT since 1986 when joined the company as Shop floor Management Apprentice-Paper Mills and was instrumental in turning around BILT in the late 1990s.

BILT consists of Five Units:

1. 2. 3. 4. 5. Ballarpur Unit, Distt. Chandrapur, Maharastra. Shree Gopal, Yamuna Nagar, Haryana. Ashti, Maharastra. Bhigwan, Maharashtra Sewa, Orissa

INFRASTRUCTURE
Founder - Late Lala Karam Chand Thapar (1900-1962)

Consist of major industries such as paper, chemicals, glass, pulp, china clay, electronics etc.
Lala Karam Chand acquired Shree Gopal Paper Mill in 1936 as he already established himself as a coal king.

Shree Gopal Paper Mill earlier know as M/S Panjab Plup and Paper Company which was initially promoted by Foundation Company England, the mill was laid shut for 6 month and was ultimately auctioned. This unit consists of: Six paper machine machines. Two coating plants. Three finishing houses. Two power houses. One caustic soda plant.
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 New pulp mill. CHSR.

At present Unit - Shree Gopal is producing around 250 TPD of paper. Total Area - 206 Acers. Factory Area - 155 Acers. Colony Area - 51 Acers. Turnover - Rs 24-26 Crores / month. Manpower -: Managerial staff 230 Permanent workers 1560 Casual workers 740 Clerical 146

DEPARTMENTS:
The departments are categorized as

Administrative department
PDC People development and communication. Accounts Department. Material Department. Sales Department. Raw material Department. Traffic Department.

Process Department Mill

1. Pulp Mill 2. Machine House. 3. Coating Plant.

 Engineering Department
a. b. c. d. Electrical engineering. Mechanical Engineering Civil Engine Instrumentation Engineering e. Power House.

POWER HOUSE
This section of workshop undertakes the maintenance of: 1.

High pressure boilers No. 1,2 and 3(steam pr 85Kg/cm2)

2. ABL Recovery Boiler No. 4 3. JMW Recovery Boiler No. 5 4. Low Pr. Boiler No. 6 and 7 5. T.G Turbine 6. BTH Turbine 7. Black Liquor Evaporation Section 8. Chemical House

COATING PLANT
This section workshop undertakes the maintenance of: 1. Colour Kitchen 2. Coating Machine 3 Super Calendar 4 Rewinder 5 Laminating Machine No.1.2 and 3 6 Cutter 1&2 7 Wrapmatic Machine 8 Bundling Machine

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SPECIALITY SECTION
This section of workshop undertakes the maintenance of: 1 Paper Machine No. 5,6 and 7 2 Effluent Treatment Plant

PULP MILL SECTION

This section of workshop undertakes the maintenance of: 1. 2. New Pulp Mill New Chipper House

CLO2 PLANT
1. CLO2 section

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2. O2 section

3. SO2 section

4. Vapourizer section

PROCESS OF POWER PLANT

POWER HOUSE

In the Power House, electric power is generated to meet the demand of electrical energy for running the plant. The powerhouse can be divided into the following main sections:1. Water Treatment Plant (D.M Plant) 2. Coal fired boilers section 3. Recovery boilers section 4. Turbines section The detailed description of these sections is as follows: -

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1,Water Treatment Plant: In this plant, water is purified so as to make it usable for the boilers. The water, which comes from the pump house, has the hardness of approximately 200-250 and conductivity around 300-600 mho. This water with the help of feed pumps is fed to the reaction tank where it reacts with lime to remove the hardness of water. The reaction-taking place is: Ca (HCO3) 2 + Ca (OH) 2 CaCO3 + H2O

Precipitates settle down and water is collected from overflow in some adjacent tank. Now, the water is sent to the pressure filter, where calcium carbonate is taken as filter medium. After pressure filter, the hardness of water decreases to 5060. Now, this water is passed through the cation exchanger. In the cation exchanger, cationic impurities are removed. Cationic exchanger is charged with HCL every twenty-four hours. Then, the water flows to the De-gasser. Here, water is

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showered from the upper side and air is pumped from downwards. When the air strikes with water droplets, it takes the gas along with it. After this, the water goes to the weak Base Anion Exchanger, where strong anionic impurities are removed. The next is the Primary mixed bed, where the remaining cationic ND anionic impurities are removed. This water is now stored in the D.M tank. The condensates of steam are also brought to the same tank after passing through charcoal and iron filters. To ensure the required standard of de-mineralized water, the water is taken to the secondary mixed bed. Ammonia is dozed in this water so as to increase the pH to about 6.8-6.9. Now, this water is sent to the boilers for steam production.

2.Boiler section: The boiler section has two main parts: 1. Coal fired boilers 2. Recovery boilers 2.1.Coal fired boilers The coal-fired boilers are of two types: a) High pressure b) Medium pressure boilers

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Out of total seven boilers, Boiler No 1,2 and 3 are H.P. Boilers; Boiler No. 6 & 7 is M.P boilers and ABIL & JMW are the two recovery boilers. In the boiler, the steam is produced in the following manner. Water comes to the steam drum from the P.D.M tank. This tank is surrounded by steam line due to which inlet water temperature is approximately 48C. Here, morphine is dozed in the water, so as to laminate the pipes internally to increase the life of pipelines. The water is then taken to the Derator Tank. In the Derator Tank, water is showered from the upper side and steam is taken from the bottom side. This steam removes the air and increases the temperature of the feed-water. In the Derator Tank, hydrazine is dozed for the reaction with oxygen in the air. The reaction-taking place is: N2H4 + O2 N2 +2H2O The outlet temperature of water in the Dearator Tank is around 110C + 5C. From the Dearator Tank, water goes to the economizer. In the economizer, the heat of outgoing flue gases is used to increase the temperature of water from 105C to 235C (approx). The water from the economizer goes to the steam drum, where Na2PO4 is added to water so as to remove the silica left (if any) from the water. From steam drum, water through section lines goes to the mud drum. Precipitates of Na2PO4 and silica settle

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down and are drained off from the mud drum using CBD. Water from mud drum through sections lines goes to the furnace. In the furnace the temperature is around 1200-1400 deg C. This steam then goes to super heater zone. In this zone, there are two super heaters primary and secondary, an temperature is connected in between the primary and secondary super heater to control the temperature of out going steam by spraying pressurized water droplets. The steam produced is then connected in the header and then it is sent to the turbine section. 2.2.Recovery boilers The process of producing steam is same in recovery boiler as in the coal feed boilers. The difference lies in the combustion. In recovery boilers, the heat energy is recovered in boilers; heat energy is recovered from the wastage. The conc. black liquor from, evaporate section is taken and sprayed into the furnace by a nozzle of black liquor gun. As the black liquor falls into furnace at its ignition temp. The organic part of it i.e.-lignin burns to give heat energy and inorganic part i.e.- sodium salts are collected as smelt when dissolved in water is called weak white liquor or green liquor.

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Three Element Control Loop in The Boiler

Feed water flow This control loop is used to control the feed water flow. The feed water control systems, maintains the drum level at a manually set value by using both feed forward and feed backward control. The feed for a signal is the steam flow measurement, which manipulates the set point of feed water flow controller and therefore, manipulates the feed water flow to equal the rate of steam being withdrawn from the drum. The bias of the summing unit is such that during steady state conditions the output of the drum level controller does not affect the set point of the feed water flow controller. Since the liquid level process is subject to rapid load changes and is not self-regulating, feedback must be applied to eliminate drift. The feed back path is formed by the drum level
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signal from the drum level controller. This controller trims out the change in error during a load change or other transient variations in drum level.

Air Flow Control Loop The next very important control loop is the Air Flow Control Loop. It is required because in deficiency of air, there will not be proper burning of coal and in case, the air is present in excess, we have the heat loss. Thus in both cases there is an economical loss. So we have a control loop for air also. General Data of Boilers 1) H.P Boilers (no. 1, 2 & 3) Steam Pressure at output-86 kg/cm2 Steam Temperature at output-490deg celc. Steam producing capacity- 35-tones/ hr 2) Recovery boilers (ABIL & JMW) Steam pressure at output -46 kg/cm2 Steam temperature at output-400 deg celc.

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Steam producing capacity - 35-tones/ hr

4. Turbine section
There are two turbines of capacity 18 MW & 6 MW respectively (namely TG and BTH). Both the turbines are steam driven. The TG turbine uses steam at a pressure of 86 kg / cm2 And the BTH turbine uses the steam at the pressure of 46 kg/cm2. Generally, 4 tones of steam is used for the production of 1 MW of electrical energy as per approximate value. The process of producing electricity is same in both the turbines. The rotary blade of the turbine is set to motion by the steam pressure and hence the shaft of the turbine, which is coupled with the generator, rotates and produces electrical energy. Genral Data of Turbine:Inlet Steam Pressure: -86Kg/cm2 Inlet Steam Temp. :-( 490 +5deg.C) or (490 5deg.C) Steam pressure at first extraction: - 10Kg/cm2 Steam temp.at first extraction: - 270deg.C Steam pressure at second extraction: - 3Kg/cm2 Steam temp. At second extraction: -150deg.C-170deg.C Input RPM to gearbox: -8000 Output RPM to gearbox: -1500 For BTH Turbine: Inlet steam Pressure: -46Kg/cm2 Inlet Steam temp: - (490 + 5deg.C) or (490-5deg.C) Input RPM to gearbox: - 1500
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PULP MILL SECTION

Raw Materials & specifications Paper is made of pulp and pulp is made of fibers, which is obtained from various materials like grass, bagasse, wood & bamboo. Any material for pulp is selected on the basis of: 1. Ample supply 2. Available to pulp mill throughout the year. 3. High yield of quality fiber. 4. Should not deteriorate in storage. 5. Capable of being collected & stored in small area and transported, if necessary, at low cost 6. Cost of conversion to paper must be low. 7. Cellulose fiber must be of suitable size and character. 8. Location of paper mill must be close to the location of the raw material.
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9. It must make paper of sufficient quality to be competitive in the international market. 10. 11. It must be cheap. Must give good printability.

The ideal fiber for high-grade paper should be high in cellulose content and low in lignin content. The raw materials used in the paper industry are of two types: 1. AGRO BASED These are the short fibers. 1. Bagasse 2. Khal 3. Khar 4. Sabai grass 2. WOOD BASED 1. Bamboo 2. Eucalyptus 3.Veneer waste

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Chipper House

Introduction It is necessary to reduce the wood to chips for pulp manufacture in order that the cooking liquor may penetrate the wood quickly, completely easy to transport pneumatically or on belt conveyers, and to store. This operation is known as chipping and the machine used for cutting the wood into chips is known as chipper. Thus, chipping is a necessary operation but is also a drastic action, which caused fiber damage and effects pulp quality. Damage is caused when wood is subjected to compressive strain as a result of bending, twisting or compression. Screening Size The size of the acceptable chips after screening varies considerably. In sulphite process, the aim is to have an average chip length of about 20 mm but chips are present ranging from less than 10mm to over 35mm long. Shortening of the chip length tends

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to give better impregnation of the chips, it is not suitable to decrease the chip length too much, as a big number if the fibers will be shortened and thus the strength pf pulp decreases. Short chips also mean more fines and saw dust, higher power costs in chipping, a smaller percentage of long fibers in the pulp and reduced pulp yield.

New Pulp Mill

Introduction The New Pulp Mill has been set up recently to produce the indigenous pulp for paper machines of the unit. The setup of the mill was aimed at fulfilling the needs of paper machines numbers 4,5, and 7. New pulp mill has helped in becoming self-dependent in terms of pulp requirement. Chief raw materials used are eucalyptus, bamboo, wood scrap and poplar etc. The raw material is first chipped in the chipper house with the help of two venoclain drum type chippers, the wood/raw material is converted into small chips of size 1 * *1/4. After chipping operation the chips are cooked in the digesters where indirect heating of digesters is done with the help of white liquor and black liquor mixer. After proper cooking the cooked slurry is washed. At the brown stock we are using four washing stages working in counter current fashion.
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After adequate washing the pulp is bleached at four bleaching section the desired brightness of the pulp is obtained without degrading the quality of the pulp. Finally the pulp after cleaning operation through centri cleaners is stored in bleached high-density towers. This final pulp can be sent to corresponding paper machineries. Important steps in cooking or digesters control operations. Liquid Penetration To ensure reaction, it is important that all the fibers in the wood get their proper share of chemicals and heat. Now charging of liquor starts. First of all we start white liquor pump (white liquor contains NaOH+Na2S) and charge white liquor as per need when required quantity is charged, we close the respective liquor charging pump and charge the black liquor as per the required quantity. Digester Heating After this, digester cooking commences. It takes place in two ways: 1. Direct heating 2. Indirect heating The digesters in the NEW

PULP MILL are indirectly heated.

Indirect heating involves the circulation of cooking liquor through external heat exchangers with the aid of circulation pumps, which draw off cooking liquor through strainers in the digester walls and

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deliever, the heated cooking liquor at appropriate inlets. The following are the advantages of the indirect cooking system: 1.Uniformity of circulation through out the digester. 2.Uniformity of quality. 3.Increased yield. 4. Increased pulp strength. 5.Steam saving. For ideal cooking the following parameters should be checked: 1.Proper temperature - 165 deg. C 2.Cooking time - 90 Min (at 165 deg. C) (Total time 260 min.) 3. Pressure - 8Kg/cm2 Digester Blowing During the blowing of the pulp and black liquor go to the blow tank and blow condensed steam vapors to the accumulator tank having primary and secondary condensers, which are in operation till blow is finished. From accumulator tank condensed steam goes to heat exchanger through fiber filter to arrest any fibers going with the condensed vapors. In heat exchanger warm water is pumped from warm water tank and hot water goes to hot water tank, which is used in brown stock washing and bleaching stages. Brown Stock Washing It is the process in which the dissolved organic and in organic materials are removed from pulp by filtreation. Our objective should be to obtain most efficient washing by using minimum

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amount of water. For this purpose we have four washing stages operating in counter current fashion. A low consistency suspension pulp (1-2%)is spread into vat which contains rotating drum filter vaccum created is applied to drum which cause the slurry to thicken as the liquor filtrates through the surface of the drum, as drum cylinder rotates a sheet of pulp is formed on the pulp surface which passes through spray wash zone and then drying zone and finally it is discharged. Consistency Vaccum drum filter operates with 1% feed consistency and 11 14 % discharge consistency. Bleaching The unbleached pulp contain a large amount of lignin and some other impurities which have been left behind after cooking and it is essential to bleached these pulps to obtain brighter pulps without degradation of cellulose fibers. Thus the main aim of bleaching of pulps can be summarized as follows: 1.Removal of residual lignin left after cooking and destruction and solubilization of coloring matters. 2.Removal of objectional dirt particles in form of five specks in pulp. 3.Retention of strength properties of the unbleached pulp. 4.To obtain greater brightness at low cost.

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The following various types of chemical may be employed for the bleaching of pulp: 1. ClO2, Cl2 2. H2O2, Na2O2 3. So2, NaHSO3
4. O2

Washing Again washing is done to remove the liquid chlorine from the pulp. Refiner The pulp is refined in the refiner. We have to refine the pulp to make short fibered. Mixing Chest In the mixing chest pulp is mixed with Rosin, Alum, Ranipal and filler like Carbon black as per requirement of the paper. Machine Chest After mixing the pulp is transferred into machine chest where its consistency is maintained. The fibrous pulp from machine chest is taken into the head box; normally the consistency pf pulp at this stage is kept 1.5 to 2 percent .now the pulp is make to pass on through the wire pat where the considerable amount of water is taken out of the fibers and paper web moves ahead to the press part .At these stage web is pressed in between the press rolls to reduce the moisture contents of fiber .The press section has two parts: The first press The second press.
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Now the paper is taken on to the dryers for drying purpose. After passing through predryers an intermediate stage comes known as the size press where the sizing chemicals such as starch are added. Then after passing through the post dryers section paper goes towards the calendar .A calendar is to smooth and shine the paper .Now the paper is wrapped on the drum reel .At the final stage the paper contains moisture contents about 5-6%. After this the pulp is transferred to Specialty Department where required quality paper is made from this pulp.

SPECIALITY PLANT
In paper industry a raw material (pulp) is then brought into paper plant, technically called Specialty Paper Plant. The Specialty paper machines installed here make Executive bond, Sunlight bond and other high quality paper.

Machine No. 5: The pulp turns into a paper of required thickness after passing through a number of stages and number of sections: 1.

Hydra Pulper:-It is the main chamber of pulp. Here raw material rotates with the help of rotor. Here the backwater of process is added because it contains chemicals. If we want to change the color or quality from superior to inferior or vice versa, then fresh water is used.
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2.

Dump Chest: - The pulp comes into dump chest from hydra pulper. Here pulp is beaten accurately. Circulation Chest: - The function of this chest is to reduce pulp into smaller particles. Stock Refinery: - It removes impurities from the pulp and beat the pulp. Mixing Chest: - The mixing and machine chest further beat the pulp. Machine Refiner: - They remove remaining dust from the pulp. Constant Level Box: - It consists of two chambers, which give the level of the erkensater. Its level remains constant always. Open Screen: - It consists of a hollow type roller, which is covered by an iron net having equal no. of holes. It removes heavy dust particles. Head Box: - In this we detect weight of paper. In this fresh water, are mixed highly purified pulp and their ratio depend upon weight of paper.
9.

3.

4.

5.

6.

7.

8.

Wire Section: - In this the pulp moves on belt in the form of sheet.
10.

Press Section: - In this section vaccum pressure is applied on the sheet of paper to reduce the moisture content.
11.

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Dryers: - Here heated steam dryers absorb almost 100% of the moisture.
12.

Size Press: - In this section we smoothen the paper we smoothen the paper with the help of roller.
13. 14.

Drum Roll: - Final Bond paper rolls over this roll.

COATING PLANT
In This Plant we increase the shininess & Strength of a Paper. Colour Kitchen: Firstly, The coating material is made in a colour kitchen at suitable concentration of different chemicals.This Preperation is called Recipe and this can be made by Kaddy Mill. Chemicals Include Starch,Latex,Calcium Carbonate & several other resins which are imported from MALAYSIA & BRAZIL. Coaters: This Material goes to the three Coaters which coat this material on a paper at three stages. At each stage we find its moisture contents,thickness etc. by scanner. Super Calendar: From coater this paper reels goto Super Calendar to increase its Shinning by continuous rolling a Reel in a cylinders. Rewinder:

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After this paper goes to Rewinder where reel is packed more efficiently. Lamination Machine: If we want to make a laminated paper then we send the paper to lamination Machine in this two reels of paper from different ends are joined with a help of glue which is made of starch. If we need a paper for playing cards we put black die in glue so that we cant see what is written on opposite side. Now this laminated paper is dried by steam cylinders which are on a above side of lamination Machine. Cutters: After this paper goes to 2 Cutters to make a sheets of proper size. These paper reels are cut in form of sheets by pneumatic cutter which are carrying circular knife. Wrapmatic machine These sheets are go to Wrapmatic machine for bundling. This is specially designed Machine in which we have three grippers . We feed the paper in it either automatically or manually,which are picked by jaws like structure and through belt it pulled back where it is picked by gripper 1,we use cylinders for each gripper. Gripper1 forward this bundle of paper to gripper2 then gripper2 send it to gripper3 but before gripper 3 this bundle is covered by outer cover which comes here with the help of reel this is straighten by vaccum when bundlr reach near it ,this outer cover is cutted by a cutter.gripper3 picked this bundle one rodless cylinder is use to apply glue .it is pneumatic cylinder. We use brushes to increase smoothness in gluing .Then this bundle goes under the another glue nozzle to glue the sides.this glue is maintained on
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high temperature so that our glue not solidifythis is maintained by head & hose.this bundle move to different lifts the location of lifts is controlled by gate which in turn is controlled by cylinder. From there we move a paper to Finishing House.

Instrumentation
These days instrumentations very vital to modern industries . The use of instrumentation system is in power plant, process industries, automation, production machines,various control and safety devices etc.A device used directly or indirectly to measure or control a variable. The term includes primary elements, final control elements and electrical devices such as Annunciators, Switches, Push buttons. A collection of instruments which directly or indirectly observe measure and control the physical parameters (flow, temperature, pressure, level) or combination of these.

PARAMETERS OF INSTRUMENTATION
1). Pressure 2). Temperature 3). Level 4). Flow 5). Consistency
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6) . PH

761 CONTROLLER(Bells make)

The single station controller used in BILT is the 761 series station controller .The 761 station controllers is self contained microprocessor based controller having the standard proportional integral and derivatives function .The exact tuning method used in it does not use any arbitrary process model .Instead it takes microprocessor technology. To make controller adjustments based on the actual current process dynamics. The controller is equipped with an RS485 serial communication port. This controller has got all the configuration and operating parameters being stored in a non-volatile memory .During a power failure essential controller settings and last operating condition are saved indefinitely and no batteries are required for it. The input signals for the controller are: Current input: The controller can have up to four currents inputs .the input standard range is 4-20 ma into 240 ohm input range can changed to 1-5v dc by changing input. Thermocouple converter input: One 4-20 mA measurement signal from temperature transistor or equivalent using thermocouple is provided to the controller. RTD input:

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It is used for one input from 100 ohm platinum RTD for direct temperature measurement or two elements RTD for direct temperature measurement or two elements RTD for temperature difference input. Discrete input : The controller can have up to two contact or transistor switch input 5V DC nominal open circuit voltage 1mA maximum current. The output signal for the controller are: Control output signal: 4-20 mA DC into 500 ohm maximum standard non isolated output. Auxiliary Out put signal: It can be configured to transmit the measurement, setpoint, condition input or output 1 signal as a 1-5 V DC output signal into 2K Ohm minimum. Discrete input: The controller has two non isolated open collector transistor switch output .switch reading are 50 V DC maximum and 250 mA maximum. Transistor power : The standard controller can provide 25 V DC nominal field power to two 4-20 mA transmitters .power supply has 250 ohm limiting resistors at each transmitter connection. Its operating limit in terms of temperature is 5 and 50 C. The relative humidity limits are 5,95%.the supply voltage required is A.C supply voltage : 110V, 220V, 50 Hz. D.C supply voltage :
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24 V ,1 mA The resolution of the display is +-0.1% of the upper range value. The resolution of the bar graph is 2% of upper range value. Segmented graphic display indicates the set point, measurement and controller output .Each segment represents an incremental reading of 2% of span the set point is indicated by illumination of the single segment in the set point display. For measurement and controller output reading the segment illuminates to form a bar graph .The desired reading is selected by a selector key the function being displayed is identified by an illuminated dot located above the corresponding bar graph. The controller operates in one of the three following modes: NORMAL ,READ OR SET . In NORMAL operation the controller performs the usual controller function READ mode the operator can read the value or status of various control parameters . In SET mode the operator can change these parameters and can adjust them according to their requirement . The description of various keys of the controller is given below W/P : Depending on the configuration it permits the controller to used either as a workstation or panel controller. R/L : Depending on the configuration it permits the user to select remote or local set point . A/M Depending on the configuration it permits the operator to select automatic or manual controller. be

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TAG Used to go from normal to read mode and to return from any point in read or set mode to normal mode.

In normal operation used to change local set point ,output etc. in read or set mode used to change configuration settings and to sequence through parameters categories. ACK In normal mode used to acknowledge an alarm condition .in read or set mode used to step sequential through every parameter in structure SEL In normal mode used to move the bar graph identifier dot .in read or set mode returns display in minor incremental back through program structure.

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PROGRAMMABLE LOGIC CONTROL

The P.L.C stands for Programmable logic control .It is an industrial computer based system which performs discrete and continuous control function for a plant or factory automation .The first P.L.C was designed in 1968. Some of the points describing how a P.L.C is different from a computer are as follows:

Real Time Operation : The P.L.C is a real time operation system.

Environmental design : The P.L.C is much more suitable for the environmental conditions like heat, dust moisture electrical noise, interference etc. Programming language : The programming done in P.L.C is relay logic programming and also sometimes blocks oriented language.

Maintenance and troubleshooting : The P.L.C has got modular design and inbuilt diagnostic software due to which the maintenance and problem emerging are dealt with very easily.

The various P.L.C components are as follow:

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C.P.U Power supply I/O System Programming Unit Peripheral Devices

A brief description of these elements is given below: C.P.U: It stands for the central processing unit .It contains the processor which performs all the work required to be done for the process control .It act as the brain of the P.L.C it performs function which are given below: Logical operation: It performs the logical operations like AND, OR, NOT. Timers: The C.P.U can also provided the functions of a timer .It can provided on delay (the output will be produced after a certain delay pf applying the input),off delay (the switching off occurs after a delay of applying the switch off command .Pulse (high output when input is high and low output when input is low) and extended pulse (it has the same output as for the pulse but it completes its pulse time even when the input signal goes low. Counters: This function of C.P.U is used to count up as well as down. Flip-Flop:

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It is used to latch the signal.

Power supply: It is used to charge the various units (I/O system, peripherals & C.P.U) connected together to make a P.L.C it supplies the power at various levels as required by the units. I/O System: The input module is used to convert the various input signals which are in the form of 24V DC, 220V AC, which are understood by the C.P.U the output module does the work opposite to that of the input module it converts the 5V DC signal given by the C.P.U to 24 V DC 220 AC as realized by the other devices in the field. Programming Unit: The programming unit provide an inter face between the P.L.C and the user during the program development start-up and trouble shooting. The programming of P.L.C can inform by three ways: STL statement list Ladder logic diagram Control system flow The tools need are : Programmer Software The connector used for the purpose of connecting programmer & P.L.C is RS 232 it is 9 pin used for serial communication.
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Peripherals: The peripherals include communication cards and memory. The communication cards are used by C.P.U to send and receive the signal to and from various ends respectively. The memories used are ROM and RAM. To store the application and the executives program. Types: The P.L.C are of two types: Modular Non-Modular The modular type of P.L.C have each and every components fitted in such a way that it can be checked by taking it out but the non modular type of P.L.C have every thing fitted within & it can't be taken out in any way . Companies: There is a wide variety of P.L.C available in the market but most common trade names in P.L.C are : Siemens Messung Bhartiya Cutler Hammer Allen Bradely Telemecanique Cegelec Crompton Greaves Factors:

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The factors which are kept in mind while selecting a P.L.C: 1Number of inputs and outputs 2.Cost 3.Space available 4.Speed and scan time

How P.L.C Works The functionality of P.LC includes the following: Input updating Program execution Output updating The functioning of the P.L.C include firstly input updating it checks every input &updates the input value if it gas changed. Then it executes the program feed in already and then according to the values generated for a output it gives the output .The time taken in performing the above three functions is called the scan time.

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INSTRUMENTS USED IN BILT

1. Conductivity measuring instruments used in D.M. Plant. 2. pH measuring instruments used in D.M. Plant . 3. Flow measuring instruments installed at PDM tank, super heater, water inlet in steam drum and in turbine section. 4. Pressure measuring instruments installed at ID fan, FD fan, main steam pipe, derator tank and turbine section. 5. Temperature measuring instruments used in main steam line, derator tank, steam drum, furnaces and also in turbine section. 6. Level measuring instruments used in various drums and tanks used in this section. 7. Control valves are installed at different places in the whole powerhouse. 8. Speed measurement of rotational speed of shaft in turbine section. 9. 761 controller is used in every section of powerhouse.

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Control Valve
A control valve is a final control element in a running process. The change in the position or condition of the control valve varies with process parameters. In level, pressure, flow and temperature applications control valve can control the process according to the requirement .It consists of three parts: 1. ACTUATOR: It is a part of control valve, which apply the force on valve for controlling the process. It looks like piston, which can move up and down according to the requirement. The actuator is based upon the concept of pressure.
F = (P1 - P2) x A Where, P1-P2= Pressure difference A= Diaphragm area F= Force applied 2. VALVE: It is a part of control valve, which can be operated

with the actuators manually, and an actuator operates valve. It has many types : a) Butterfly valves b) Pilot valves c) Plug type valve
3.

POSITIONER: These are fast responding precision calibrated, force balance instrument providing accurate valve positioning.

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Flow Measurment
Flow Measurements are also important parameters to be measured. The flow rate of the flowing pulp gives an idea of the consistency of the pulp. The various flow meters, which are used in BILT, are: 1.

ROTAMETER: - It consists of a vertical tube with a tapered cone in which a float assumes a vertical position corresponding to each flow rate through the tube. The tube is made up of steel and float is of brass. It works on equation: -

Qv = CEA2/Zgpd ------e If Pd = Pressure is held constant then volume flow rate is directly proportional to orifice area.
2.

ORIFICE METER: - It consists of an orifice plate inserted in a pipeline cases an increase in flow velocity and a corresponding decrease in pressure. The Flow pattern shows an effective decrease in cross of flow beyond the orifice plate with the maximum velocity and minimum pressure. The plate may be concentric, eccentric or segmented.

3. VENTURI METER: - The basic design of a venturi tube comprises three sections viz the converging conical section at the upstream, cylindrical throat, diverging recovery outlet cone at the downstream. The inlet cone tapers down from the pipe area to the throat section of a smaller area to produce the necessary increase in velocity and decrease in pressure. The throat provides a point of the measurement of this decrease in pressure where flow rate is steady.

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Magnetic Flow Meter

The transmitter is based upon the principle of Faradays law of EMI according to which, when a conductor is moved in a magnetic field, a voltage is induced in the conductor.During the electromagnetic flow measurement, the fluid passes through a magnetic field applied normally perpendicular to the direction of liquid flow. The movement of liquid induces and electric voltage which is proportional to the average field velocity and therefore to the volume of flow. In the case of electromagnetic flow transmitter: U = K x B x D x V Instruments constant Strength of magnetic field Average velocity Pipe diameter

Where, K = B = V = D =

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Pneumatic Current to Pressure converter

The main principle behind this type of I/P converter is that a core is wounded by coil, which receives a standard input signal of 4-20 mA, and it converts this electrical signal into a pneumatic signal. According to Faradays Law when a coil is carrying a current, a strong magnetic field is produced around the coil. This magnetic field is used to attract the soft iron core, to which is attached a flapper and nozzle. The nozzle opening is governed by the amount of current through the coil. A strong signal, i.e. large current would bring the flapper closer to the nozzle and this is provided to a pneumatic relay which produces an output in range of 3-15 PSI which are linear with 4-20 mA input signal. This output is capable to operate the control valve. I/P transmitter is also known as current to pressure converter since it converts or transmits current signals into pressure signal. In control loops where control valves are used I/P converter are used to operate the control valve. The transmission of signal to current is required since controllers in control loops are current controlled. The controlled valve open and close according to a set point. The signal from the controller is electrical but nature of control valve is pneumatic. So I/P converters render the signal, which is suitable for control valve operation.

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Temperature Measuring Instruments

(A) Thermocouple:- Thermocouple is made up of two dissimilar wires joined at their measuring and forming the measuring junction and hot junction. A small voltage known as sees back voltage creates at another junction.i.e.cold junction. This voltage change in accordance with the temperature. The controller or monitor measures the small voltage and converts it into a temperature signal and controls the temperature of loop and tank.

(B) Resistance Temperature Detector (RTD): - RTDs are usually platinum wire, wound on a glass or a ceramic babbin and sealed with a coating of ceramic or glass. They can also be made by depositing platinum as a film .The electric resistance of RTD changes as a function of temperature. The circuit is similar to a wheat stone bridge .A constant current into the bridge produces an output voltage that varies with temperature. RTDs are generally more accurate and more stable over time than thermocouple.

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pH meter pH Meter :
It is a device which measures the pH of any liquid such as acid alkalies and water.

Introduction about pH :
pH is a chemical factor which denotes the acidity or alkalinity of a solution . The degree of acidity or alkalinity of an aqueous solution is determined by relative concentration of hydrogen and hydroxyl ions in that solution. When the hydrogen ion predominates the solution is acidic and when hydroxyl ion dominates it is alkaline .

Working of pH Meter:
Hydrogen ion concentration is measured on scale that ranges from 0-14. When the value on scale is 7.0 hydrogen ions and hydroxyl ions balance each other as in case of distilled water. When the pH value is more than 7.0 solution is alkaline and when the value is less than 7.0 the solution is acidic. The measurement is done by immersing a cell (pair of electrodes) into the solution to be measured and measuring the voltage developed across them .In the pH cell one of the electrode is reference electrode is at a potential regardless of the pH value of solution under test. The potential of the other electrode called measuring electrode is determined by pH value of solution. Thus the potential difference between the two electrodes depend upon the pH value of the solution.
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Now a days combination electrode is used thus eliminating the need of two electrodes .The combnation electrode is a delicate chemical transducer to be handled very carefully .The pH combination electrode generates the potential difference which is a function of the pH value of the solution being tested. This is amplified and calibrated and fed to digital voltmeter which is again suitably calibrated to read directly in pH.

Differential Pressure Transmitter

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Pressure Measurement:
The differential transmitter may be used for measuring liquid flow, level or other applications requiring accurate measurement of differential .The quality of measurement depends to a great extent on proper installation of the transmitter.

Construction of Differential Pressure Transmitter

A pressure transmitter consists of sensor element two metal pieces are separated by sensor element seal as a diaphragm .It has two states low and high oil is filled in it and this system is covered with an insulator. When we apply the pressure on its low or high side then the pressure flows through the middle diaphragm and the middle diaphragm offers capacitance effect due to two plates separated by an insulator. In this system insulator is diaphragm and conductive surface is the metal piece when oil is linked with the diaphragm. When pressure is applied then capacitance C2 increases and C1 decreases .It flows from high level than voltage will be developed across to terminals, which is differential pressure, so it called as differential pressure transmitter. The pressure transmitter has a variable capacitance-sensing element the - cell. The differential capacitance between the sensing diaphragm and capacitor plate is converted electronically to a two wire 4 20 mA DC signal.

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P = K1 x C1 - C2 ------------C1 + C2 P = Process pressure K1 = Constant C1 = Capacitance b/w high pressure side and sensing diaphragm C2 = Capacitance b/w low pressure side and sensing diaphragm

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Liquid Level Measurement

Differential pressure transmitter used for liquid level application measures hydrostatic pressure. The pressure is equal to liquid height above the tab multiplied by the specific gravity of the liquid. Pressure depends upon volume or vessel shape. Open Vessel: A pressure transmitter mounted near a tank bottom measure the pressure of liquid above. Make connections of the high-pressure side of the transmitter went the low. Closed Vessel (Wet Leg Condition): Pressure above a fluid affects the pressure measure at the bottom of a closed vessel. The liquid specific gravity multiplied by the liquid height plus the vessel pressure equals to the pressure at bottom of the vessel. To measure true level the vessel pressure must be subtracted from the vessel bottom pressure. To do this, make pressure tab at the top of the vessel and connect this to the low side of a differential pressure transmitter. Vessel pressure is equally applied to both the high and low side of transmitter. The resulting differential pressure is directly proportional to liquid height multiplied by liquid specific gravity.

I/P Transmitter
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Current to pressure transmitter accepts the electrical inputs signals and converts it into proportional pneumatic output. Typically 4 to 20 Ma is converted to 3 to 15 pounds per square inch (Psi).the most common application of this transmitter is to receive electrical signal from a controller and to produce a pneumatic output for operating a control valve positioner . It has a solid state pressure sensor that moniters the output pressure and is a part of electronic feedback network. The final assembly of a transmitter contains the electronic circuit board, pilot/actuator assembly and booster stage.

Elec stage

Mag actuator

Pilot stage

Booster stage

Valve actuator

Solid state press sensor

Electronic circuit
The input current signal is received by electronic circuit and compared to the output pressure from booster stage .a solid state pressure sensor used strain gauge this film technology. It can withstand loops of pressure w/o damage.

Magnetic actuator

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The electronic circuit control the level of current flowing through the actuator coil which is located in the pilot /actuator assembly. A change to the level of coil current is to made by electronic circuit when it senses a discrepancy between the pressure measured by the sensor and pressure required by the input signal. The actuator performs the task of converting electrical energy to motion.

Pilot stage
It contains two opposed fixed nozzle. It also contains the deflector which is moving element. The supply nozzle is connected to the supply air stream. The receiver nozzle captures the air stream and converts it back to pressure . the receiver nozzle pressure is the output pressure of the pilot stage. In order to vary the pilot output pressure the velocity stream is diverted away from the receiver nozzle. This accomplished by the deflector which is cylindrical aerodynamic body located between the two nozzle. In response to a change in actuator coil current, the deflector is repositioned between the nozzle. There is a linear relationship between the coil current and the pilot stage output pressure . the power of f or fail safe , the position of the top of the deflector is near to the centre of stream and results in zero pilot output pressure. As the coil is energized , the deflector is drawn out of the stream. maximum pilot output pressure results when the deflector has moved completely out of the stream. The deflector material is tungsten carbide and nozzle are 316 stainless steel. The nozzle has a large bore of 0.016 inches which provides good resistance to plugging.

Booster stage
The receiver nozzle pressure controls the booster stage which has a poppet valve design. An increase in the transducer output signal. A decrease in the receiver nozzle pressure positions the valving in

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the booster stage to allow the exhaust to occur, decreasing the output signal.

CONCLUSION
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It can be concluded that BILT is a modernized and well-equipped industry form every aspect whether it is manufacturing process or finishing process. During my training period, I got valuable knowledge regarding the most modern techniques used in Electronics & Instrumentation trade that is P.L.C & Microprocessors .My training also made me familiar with many machines & instruments used in industry. The management & employees are very helpful. I hope that the valuable knowledge I have gain here will help me in future.

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