Professional Documents
Culture Documents
Industrial Presentation
Industrial Presentation
on
Learning Exposure
Safety
Commercial
Crushing (oil mill & Chillex)
Soya prep
SEP
Refinery, Acid oil, lecithin
ETP
Quality Assurance
Packaging & warehouses
Utilities(RO, Boiler)
E&I
Maintenance
SAFETY
• Fire-hydrant system
Safety policies:
Line pressure: 7 kg/cm²
EHS, safety disciplinary, minimum PPE, policy
Jockey pump: 6 kg/cm²
Plant safety rules
Main pump: 5.5 kg/cm²
HRW Standards AND COMPLIANCE
• Fire extinguisher (A,B,C,BC, ABC)
PERMITS TO WORK SYSTEM
• Enablon (Incident reporting portal)
Height work, Hot work, Confined space Energy
isolation(LOTO) • 5W1H system
• Risk management: • 3 Assembly point
Job safety and environment analysis • Multi purpose gas detector:
Step1. Identify hazards LEL, H2S,CO, O2
Step2. Assess risks
Step3. Control risks
Step4. Review control measure
Hierarchy of control:
Elimination Most effective
Substitution
Engineering control
Administration
PPE Less effective
Risk reduction(ALARP)
Emergency management system (EMS)
COMMERCIAL
Storage*3
Quality parameter:
seed: Oil:
Kolhu 594
O/C: 40% FFA: 0.5%
FM: ≤ % Colour:
1st press Oil tank 1st +2nd press
M/C: % M&V: 0.27-0.33%
Allyl: 0.23-0.27%
2nd press Filter 3rd press
press
MOC:
O/C:9.5-10%, M/C:%,
3rd press
Storage FFA-%, Thickness:8mm
Dry cooler
tank Milling defect: 1.3%
SEP
CHILLEX
Capacity:100 TPD
Destoner*3
To SEP 45ºC
B
e Grader(8mm & 6mm)
g
fi
l Aspirator hull Cooker (60-70ºC)
t Cracker*2 (2mm gap)
separator RT-20-25 min
e
r
124 bag
e
Dust
MUSTARD SEP
Fine separator
Dust Safety
Intermediate miscella catcher boiler
tank (55-60ºC)
Economiser
Econflasher 250mmhg
Stripper 530mmhg
Recuperation unit
VD 700mmhg,108ºC
SEP PARAMETERS
Costing:
Material balance:
Cake: Parameter SEP MUSTARD
O/C: 9.83%, M/C: 9.34%, FM: 1.18% Power Consp. 19.51kwh
DOC: ROC: 1.2%, M/C: 10.39%, S/S:0.37%, FM: Unit rs 8.95
0.92%
Total 174.53rs/mt
Total cake: 1 MT Steam Consp. 0.25 mt/mt
Moisture: 93.4kg, oil: 98.3kg, FM: 11.8kg Unit rs 1598 rs/mt
Dry cake: 796.5kg Total 398.42 rs/mt
Net DOC processed: 911.2kg (91.12%) Soft Consp. 0.26kl/mt
Moisture:94.67kg oil: 12kg, FM: 9.2 kg, cooling
Unit rs 48.68 rs/kl
water
S/S: 3.7 kg Total 12.69 rs/mt
Dry DOC: 791.63kg Chemical Consp. 4.1 lt/mt
Gross oil production: 87.2kg Unit rs 52.93 rs/lt
MIV: 1.64 kg Total 216.78 rs/mt
Net oil production: 85.6kg Operating exp. 182.83 rs/mt
Magnetic strainer
Wet Gums Degummed oil
Micro filter 25 micron
To drying To storage
process Barrel filling (200 kg and 1 MT)
LECITHIN PARAMETER
Separator
PHE (60-65ºC)
2
H
3
P Knife mixture VD(660-670mmhg) Candle filter 5
O micron
4
Retention tank30-35mi NOT
BOT(100-110ºC)
PHE (50-55 ºC) PHE(95-100ºC)
C
a Candle filter
Bleachin
u
Knife mixture g earth Slurry mixer
s
ti
Dearator
c
Caustic RT() Bleacher (105-
115ºC), 600-
Deo section
Shell&tube80-85ºC 700mmhg
PHE (90-95ºC)
From dearator Capacity: 200 TPD (Soya)
105ºC
100 TPD (Mustard)
To VHE Oil processed in 200 TPD
PHE 224ºC
Solvent soya oil & degummed soya oil
VHF
Parameters:
Steam(260 252ºC
-270ºC) at
48- Deo stripper Para. Crude Neutr Bleach Refine
60kg/cm² oil al ed d oil
Deo tray
248ºC
Oil Oil
FFA 0 0 0
4 Stage
Fatty scrubber
vacuum s/s
51ºC Colour -
Cooling PHE
48ºC
P-
content
To fatty storage
Soap - -
ppm
Refinery calculation
Parameter:
Soap stock from
refinery Parameter Soya Mustard
15 5 jar/min (2 nozzle)
SOYABEAN JAR
(ADPRO) 5 8 jar/min (5 nozzle)
2 12 jar/min (5 nozzle)
POUCH 2* Setpack= 36ppm
1* Samarpan= 36ppm
Parison formation
Total heating 8 zone
Mould blowing Parameters:
Heating unit
3 sec (1 ltr)
IR lamp: 1500 watt
Clamping and stretching Heating Temp: 90-110ºC
Parameters:
Pre blow(6-8 kg/cm²) and final
blow (35-40 kg/cm²)
Type Weight Cost
(RS/Nos.)
Cooling (8-10ºC at 4 kg/cm²)
and ejection 200 ml 11 g 1.39
500 ml 14.5,16.5 g 1.70, 1.99
Oil filling and capping
1 ltr. 19.5, 24 g 2.36, 2.81
Final labelling and storage
WATER TREATMENT PLANT
Chemical:
Raw water storage HCL, PC191T, PC-98, N- 8130,NaCl
Total water cost:
Sand filter and softener
Typ RO Soft Soft Soft cooling
Row water storage for RO e water cooling water
water solvent
DMF refinery
Cost 78RS 31 RS 47 RS 47 RS
MCF*4 (0.5 micron) Quality parameter:
Degasser
Softener DM tank
BOILERS
Specification:
Capacity: Thermax: 22TPH and CVL: 8TP Boilers Capacit Heating W.P.
y S. area (kg/cm2)
H
Thermax TPH
Steam to coal ratio: 6.25
CVL H
Material of construction: High carbon al
loy steel. Thermosy
phon
Size of bed material: 2-4 mm. Thermosy lakh
Size of feed coal: up to 6 mm. phon (oil) kcal
Parameter Coal Ash
Coal Yard Capacity: 1500 MT for 22 TP specifications specification
H and 300 MT for 8 TPH. GCV kcal/kg Kcal/kg
High tension line:33KV Lathe, Drill, Shaper, Surface grinder, bench grinder.
low tension line: 433 V Tools: Pliers, screwdriver, wrench, spanner, hamme
rs, files, hacksaw, allen key, vernier callipers, etc.
Transformer: (3000, 2*2500, 1600)KVA
Lubricants, oils are used for hydraulics, pumps ,ge
Make: ABB, CG power ar box, etc.
DG: 2*500KVA(auto), 3*380KVA (manual) Arc and TIG welding are incorporated.
Made by: Sudhir( Gen:Kirloskar, Stamford PM module is followed for the maintenance.
engine: Cummins) Mechanical:
PCC & MCC panel Chiller: Prasad GWK=8(TR= 9.7,7,28.5,25.7)
VCB(4), ACB, CT, PT cooling refrigerant= R22
Solar plant: 540KW Daiken= 9.7 TR
Total panel: 1680 panel (1 panel=320 w) Compressors:
72 cell=1 panel Kaiser, Ingersoll Rand(294 CFM),
Instrument: PT,TT, Actuator, control valve AF compressor(132 CFM)
vaccum transmitter LT, etc.
PLC, SCADA (Siemens, GE)
TEST: ELCB, IR, megger, earth resistance
Suggestions & Action taken
In the mustard pouch packaging line the weight rejecter m/c design can be modified b
ecause of it the carton gets damaged.
In the 1lt pet bottle line at the case sealing section the time delay providing between t
wo carton can be increased due to which the carton can’t get damaged.
In the boiler section the ash which is collected at the bottom of APH, Cyclone and Beg
filter can be collected by pneumatic system by which it can be collected at the ash silo
for easy handling of ash.
In various plant units the stair toe guard is missing in almost every staircase which is ha
zardous in terms of safety and can cause tripping to the person. And hence they shall
be installed at all the required stairs.
Food safety needs to be improved in oil mill oil runway (nali) should be properly cover
ed. Pots being used to pour water into kolhu shouldn't be made of plastic.
Underground oil storage tanks shall have a secondary closing beneath the primary do
or and it should be of wire mesh with a small opening provided for dipping. It will ensu
re that not any larger foreign material gets into the oil tank during the opening of prim
ary doors.
Some instrument like pressure and temperature gouges not working in mustard SEP T
hey should be replaced so that process become more accurate.
In the oil mill the plastic jar should be avoided for putting water in kohlu, Instead of thi
s SS material bucket should be used.
Facilitating factors
Support from plant team.
Daily meetings.
Various training sessions happening in the plant.