Crescent Bahümán Limited

Internship Report

Tahir Abbas
Mechanical utilities
Engr. M Hasnain Ashraf
Assistant Manager Mechanical Utilities | Operations & Maintenance
Crescent Bahümán Limited (CBL)
DENIM TO THE CORE
Crescent Bahümán, Pakistan’s first vertically integrated denim facility was inaugurated in 1995. Since then,
CBL – as it’s lovingly known in the industry – has gone from strength to strength by creating an eco-friendly
environment that enables its most important resources, our people, to develop and deliver to the satisfaction
of our clientele.

Engineering Department
Engineering department of CBL is the backbone of the factory which runs every department. Whole
team of engineers working round the clock to make sure smoothness of every operation. They provide Gas,
Water, Compressed Air and Maintenance to departmental machinary as well. A little delay in the supply of
these things can cause a mojor loss.
Engineering department comprises of following:
• Electrical
• Power Generation & Boiler
• Mechanical

Mechanical Department
❖ Civil
❖ Mechanical Utilities
❖ Mechanical Workshop
❖ GWP
❖ Waste Water Treatment Plant

Mechanical Utilities (Mech. UTY)

▪
Raw Water
▪
Soft Water
▪
Hot water
▪
R/O Water
▪
Compressed Air
▪
LPG (Liquified Petroleum Gas)
▪
Waste Water Treatment Plant
▪
Boiler House (Maintenance)
1. Compressor Room Utility:
Compressor Room Utility is responsible to provide compressed air across the plant. It provides the
compressed air at 100 psi across the plant. Compressor Room Utility comprise of following compressors and
Compressed Air Dryer;
1. IR-Centac 1
2. IR-Centac 2
3. Ozen OSC 340u
4. IR-MH250
5. Kaeser DSD281
6. Ganzair S-90
7. IR-ML15
8. MKB 12500
IR Centac 1 & 2
MSG Centac centrifugal air compressors are the most efficient and reliable air compressors on the
market. Their packaged design makes them easy to install wherever needed. Every component of these
compressors is mounted, piped and wired for convenient, single-point air and electrical connection.
Specifications;
• 3-Stage Compressor
• RPM = 3000
• Water Cooled
• Centrifugal Air Compressor
• Status = Centac 1 (Offline) Centac 2 (Online)
• P3/P1 = 5.99
Parts of the Centac
➢ Motor
➢ Propellor
➢ Compressor Casing
➢ Eye
➢ Diffuser
➢ Inlet/Suction Valve
➢ Primary Filters
➢ Secondary Filters
➢ Exhaust
➢ Control Panel

Figure 1: Centac Compressor 2 and Control Unit

Working Principle:
❖ At the start-up, the air introduces from the suction section into the centrifugal compressor
passing through primary and secondary filters.
❖ After entering into the compressor, it strikes the impeller. This impeller has multiple radial
blades that rotate with the rotation of the impeller.
❖ As the air strikes the radial blades of the impeller, the air pushes by centrifugal force into the
center of the impeller.
 ❖ After striking, the impeller blades provide kinetic energy to the air; due to that, its speed
(velocity) increases.
❖ After passing through the impeller, the air enters into the diffuser area. This diffuser has
stationary vans. After entering into the diffuser area, the speed or velocity of the flow of the air
starts decreasing.
❖ According to Bernoulli’s principle, the velocity square is inversely proportional to pressure.
The volute casing or diffuser converts the increased velocity of the air into pressure energy
before the air is drawn into the impeller center.
❖ The compressor is cooled by water between stages.
❖ After each stage, Diameter of the cylinders decreases and density increases.

Ozen OSC 340U

Ozen Kompresor is innovative. It always uses up-to-date technologies in compliance with world
standards.
Specifictions:
― Direct-Coupled Screw Compressor
― Rotary Type Screw Compressor
― Single Stage Compressor
― Air Cooled Compressor
― Oil Lubricted
― RPM = 3000
― Flow rate (m3/min) = 42.8
― Status = Online
Parts:
― Motor
― Rotors
― Oil Separator
― Oil Tank
― Oil Filter
― Air Intake Filters
― Air Cooler

― Air End
― Exhaust
― Fan Motor and Fan
― Door Filters
― Control Panel

Working Principle:
❖ The oil injected rotary screw compressor is a positive displacement type compressor.
❖ A given quantity of air or gas is trapped in a compression chamber and the space that it occupies
is mechanically reduced, causing a corresponding rise in pressure prior to discharge.
❖ A rotary screw compressor has a pair of intermeshing rotors housed in a suitable casing to
produce compression.
❖ Referred to generally as a twin screw compressor each rotor comprises of a set of helical lobes
affixed to a shaft
❖ One rotor is called the male rotor and the other rotor is the female rotor. The number of lobes
on the male rotor, and the number of flutes on the female, will vary from one compressor
manufacturer to another. However, the female rotor will always have numerically more valleys
(flutes) than the male rotor lobes for better efficiency
❖ Male lobe acts like a continuous piston rolling down female flute which acts like a cylinder
trapping air and reducing space continuously.
❖ With the rotation, the leading strip of the male lobe reaches the contour of the female groove
and traps the air in the pocket previously formed.
❖ The air is moved down the female rotor groove and is compressed as the volume is reduced.
When the male rotor lobe reaches the end of the groove, the trapped air is discharged from the
air end.
❖ The oil performs four crucial functions:
o Cooling
o Lubrication
o Sealing
o Noise dissipation
GANZAIR Compressor

Specifications:

➢ Single Stage
➢ Rotary Type Compressor
➢ Air Cooled
➢ Oil Lubricated
➢ Capacity = 16.2 psi
➢ Max Pressure = 7.5 bar
➢ RPM = 3000
➢ Status = Online

Parts:

➢ Compressor
➢ Air Filter
➢ Oil Filter
➢ Oil Separated
➢ Motor
➢ Exhaust

IR-ML 15

Specifications:

➢ Single Stage
➢ Rotary Type Compressor
➢ Air Cooled
➢ Oil Lubricated
➢ RPM =3000
➢ Status: Online

Parts:

➢ Compressor
➢ Air Filter
➢ Oil Filter
➢ Oil Separated
➢ Motor
➢ Exhaust

KAESER DSD281

❖ Single Stage
❖ Rotary Type Compressor
❖ Air Cooled
❖ Oil Lubricated
❖ RPM =3000
❖ Capacity = 23.1
❖ Status = Online
Compressed Air Dryers

When gas is compressed, some of it condense and make air moist. To remove the moist from the
compressed air, this air is stored in the Receiving air then it is transferred to the dryers to make it moisture
free.

IR Air Dryers

Two Ingorsoll Rand (IR) and one Mikropor Refrigerated Dryers are working round the
clock to provide the moisture free compressed air.

Parts of the Air Dryer

• Compressor
• Condenser
• Liquid Receiver
• Filter Drier
• Expansion Valve
• Heat Exchanger
• Liquid Separator

Working Principle of Air Dryers

o Compressor compresses the refrigerant gas

o Condenser cools down the refrigerant temperature by using ambient air
o Liquid receiver makes sure that no gas goes to the expansion valve
o Filter drier dries moisture and filters solid particles in the refrigerant
o Expansion Valve reduces the pressure and temperature of the liquid refrigerant to 3°C
o Heat Exchanger cools the compressed air and evaporates the refrigerant to gas due to
heat transfer. The moisture in the air converts into the liquid and been removed from
the air dryer through a pipe.

Liquid Separator separates gas from liquid and only allows the gas vapors to be sucked by the compressor.
2. LPG (Liquified Petroleum Gas)
Natural Gas (NG) is provided by SNGPL (Sui Northern Gas Pipeline Limited) at 15 psi and required
at following departments:
• Power House
• Boiler
• Textile
• Dryers (GWP)

In case if the pressure of the NG drops, engineering department make sure to provide required
Pressurized gas, here LPG came into use. LPG is provided at 10-12 psi. LPG is being stored in bullet
tanks.

Unloading of LPG

• First, pressure is equalized between both tanks. Then compressor starts and it draws
vapors from the top of the storage tank through transfer pipe.
• The compressor compresses the vapor and increases the vapor pressure as it is pushed
into the bottom of the storage tank.
• As the differential pressure between the two tanks increases the liquefied gas begins to
flow from the transport to the storage tank. The liquid transfer process is now complete
• The compressor is turned off to begin the vapor recovery process the four-way valve is
reversed and other valves are opened or closed to facilitate the vapor recovery. The
compressor is starting and begins to draw the vapor from the transport cutting.
• The liquid yields the remaining liquid in the transport tank boils off during the recovery
process. The compressor compresses the vapor and increases the vapor pressure as it is
pushed into the bottom of the storage tank.
• Vapor recovery process is complete when the desired evacuation pressure is reached.
• This LPG is then converted in Vapors using Water Bath.
 Water Bath:
Water bath is used to convert LPG into its Vapors. Water Bath consists of following
components;
― Cylindrical Body
― Water-Glycol Solution
― Helical Tubes
― Control Unit (Aqua Gas WB 600V Ely Energy Inc.)
Working of Water Bath:
• Water-Glycol Sol. is being heated.
• When Temperature of the solution increases up to 150 °F, Inlet Solenoid Valve
Control by the Control Unit, is temperature sensitive, opens up and LPG flows
into the helical tubes dipped into the Water-Glycol Solution.
• Then LPG has been converted into its Vapors which is then store in the tank
with a pressure of 10-12 psi.
3. HVAC System:
To maintain a temperature in which workers as well as the machinery can work, engineering
department has installed Water Cooled York Chillers at the departments mentioned below;
― GWP
― Textiles
― Sewing
Parts of York Chillers;
➢ Motor
➢ Centrifugal Compressor
➢ Evaporator
➢ Condenser
➢ Oil Tank
➢ Oil Filter
➢ Oil Cooler

Working;
o Evaporator maintains the lower temperature and pressure. The refrigerant takes
away the heat of chilled water
o Compressor maintain the temperature and pressure difference of the system.
Refrigerant can bring the heat from evaporator to condenser. Here refrigerant is in
gaseous state having low Temperature and Pressure
o Impeller rotates at high speed, increase the speed of the refrigerant resulting
lowering the Pressure
o When it leaves the compressor, it has high pressure and high temperature.
 o Condenser high temperature and pressure refrigerant condenses here. Water from
Cooling Towers bring away the heat of the refrigerant. Flooded type condensers
are used here
o Now Saturated Liquid Refrigerant expands through Expansion Valve (Variable
Orifice Type) and lowering the temperature of the refrigerant. Now it has mixture
of liquid and vapors of refrigerant, which enters the Evaporator
4. Boiler House
Boiler house is responsible for producing and supplying steam across the required departments. There
are two Boilers being used for this purpose. Both boilers are;
― Type = Fire Tube Boilers
― Capacity = 15 tons/h
― Fuel = Dual Fuel Type but using Gas for boiling these days
Parts of the Boilers
❖ Force Draft Fans
❖ Combustion Chamber
❖ Superheater
❖ Reheater
❖ Boiler