SESHASAYEE PAPERS AND BOARDS LIMITED

INTERNSHIP REPORT

SESHASAYEE PAPERS AND BOARDS LIMITED

Submitted By

B. RUPANRAJ – 950714105074
S. DILIP KUMAR – 950714105308
G.M. JOSHUA JOTHIBALAN – 950714105032

6th to 13th Dec. 2017

Academic Year 2017-2018

Final year of Electrical and Electronics Department
Francis Xavier Engineering College, Tirunelveli

Internship Supervisor

Mr.A.KANNAN M.Tech
Manager – Electrical Department
Seshasayee Papers and Boards Limited
Tirunelveli Unit.
 SESHASAYEE PAPERS AND BOARDS LIMITED

ACKNOWLEDGMENTS

We are very thankful to SESHASAYEE PAPER AND BOARDS LIMITED for having given us the
opportunity to undertake our internship training at their prestigious organization. It was a very good learning
experience for us to have worked at this site as this company involved many projects, constructions and
challenges. We would like to convey our heartiest thanks to Mr.A.Kannan M.Tech, Manager – Electrical,
who guided and encouraged us through the internship and imparted in depth knowledge of the electrical
industry. We thank Dr.A.Gnana Saravanan,HOD/EEE and our well engaged staff Mr.A.Manikanda
Nadarajan, AP/EEE who arranged this internship. Also thanking those directed team members. Once again
we thank you all.

Regards,

B. Rupanraj
S. Dilip Kumar
G.M. Joshua Jodhibalan
Final year Of EEE Dept.
Francis Xavier Engineering College, Tirunelveli.

Date : 13th Dec. 2017

 SESHASAYEE PAPERS AND BOARDS LIMITED

MISSION OF THE INTERNSHIP

• To acknowledge the work culture, vision and mission, rules and regulations, safety measures,
quality control and assurance of products and method of paper production at the industry.
• To understand the processes carried out at their own thermal power plant.
• To know how the problems and maintenance taken into action at the plant.
• To experience the work environment, responsibilities of electrical department of whole industry.
• To practice with our experience from the laboratory to the real time machines.
• To get career guidance from well experienced industry experts.
• To match our needs to begin the preparation with the industry

INTRODUCTION:

Seshasayee Paper and Boards Limited (SPB), the flagship company belonging to 'ESVIN GROUP', operates an
integrated pulp, paper and paper board Mill at Mukkoodal Tirunelveli District , Tamilnadu, India that we were
under gone an internship training. The head of SPB that’s at Erode, that incorporated in June 1960, was
promoted by Seshasayee Brothers (Pvt) Limited in association with a foreign collaborator M/s Parsons and
Whittemore, South East Asia Inc., USA. After commencement of commercial production, having fulfilled
their performance guarantee obligations, the foreign collaborators withdrew in 1969. Main promoters of the
Company as on date are a group of companies belonging to the ESVIN group headed by Mr. N Gopalaratnam.
SPB commenced commercial production in December 1962, on commissioning a 20000 tpa integrated
facility, comprising a Pulp Mill and two Paper Machines (PM-1 and PM-2), capable of producing, writing,
printing, kraft and poster varieties of paper. The Plant capacity was expanded to 35000 tpa in 1967-68, by
modification of PM-2 and addition of a third Paper Machine (PM-3). The cost of the expansion scheme, at Rs
34 Millions, was part financed by All India Financial Institutions (Rs 31 Millions).In the second stage of
expansion, undertaken in 1976, capacity was enhanced to 55000 tpa, through addition of a 60 tpd new Paper
Machine (PM-4). Cost of the project, including cost of a Chemical Recovery Boiler and other facilities for
enhanced requirement of utilities, was estimated at Rs. 176 Millions. The same was part financed by term
loans from Institutions and Banks to the extent of Rs. 145 Millions and the balance out of internal
generation. SPB undertook various equipment balancing and modernisation programmes, since then, for
improving its operating efficiency, captive power generation capacity.
EXPORTS PERFORMANCE

SPB's exports are nearly 20% of its production and is a significant exporter in the Indian Paper Industry.
Due to its excellent export performance, SPB has been awarded 'Golden Export House' status.

ENVIRONMENTAL PROTECTION

The Company attaches paramount importance to the conservation and improvement of the environment.
In its efforts to improve the environmental protection measures, the Company has installed:
• Two Electro Static Precipitators for its Boilers to control dust emissions
• An Anaerobic lagoon for high BOD liquid effluents
• A Secondary Treatment System for liquid effluents and
• An Electro Static Precipitator and Cascade Evaporator to the Recovery Boiler.
These facilities will ensure sustained compliance by the Company of the pollution control norms
prescribed by the Pollution Control Authorities.
 SESHASAYEE PAPERS AND BOARDS LIMITED

WORK CULTURE
• Freedom to express ideas and support.
• Continuous learning and training.
• Transparency at work place.
• Quality in all aspects of work.
• Rewards based on performance and potential of individual.

PRODUCT RANGE
 SESHASAYEE PAPERS AND BOARDS LIMITED

MACHINES AND PRODUCTS

PRODUCT SPECIFICATIONS
 SESHASAYEE PAPERS AND BOARDS LIMITED

THERMAL POWER PLANT

• Steam Turbine capacity 6.6MW, running at 6847 RPM.

• AC Generator capacity 12MW, running at 1500 RPM with rotating field and stationary
armature principle.
• Four pole AC generator with brushless AC exciter.
• AC exciter used for excitation with stationary field and rotating armature principle.
• 110V DC supply given to the AC exciter.
• Excitation transformer connected to stationary armature of generator for step down from
11KV to 415V.
• Speed ratio between turbine and generator is 4.5 : 1
• Frequency matched by varying generator rotor speed.
• AFBC – Air Fluidised Bed Combustion boiler is used in the plant.
• Boiler handles 50 Tons per hour with 33kg/ms 2 Pressure.
• Furnace Fueled by Coal and saw dust mixture
• ESP – Electro Static Precipitator used to pollution control, has step up transformer for
stepup 450V to 40KV
• Excess steam flowed in to the paper machine unit for pulp drying purpose.
• Various pumps and motors used for flowing water and air.
• Bed material like sand particles is placed below the furnace for with standing high
temperature.
• Coal is stored on the coal yard, while in use the coal crushed into small particles by the
crusher and collected by funker.

SUBSTATION

• 110KV line supplied from Thullukkapatti station.

• Transformer used for step down 110KV to 11KV.
• Various distribution transformers are present in the overall plant.
• For protection isolaters , surge arrestors, PT’s, CT’s, circuit breakers are present before
the in line given to the transformer.
• OLTC and automatic tap changer are available for tuning the input voltage
• ONAN & ONAF Cooling methods are present.
• Breather is used for removing moisture from air while oil expansion.
• VSR – Vector surge relay is used for sensing phase distance, phase voltage. during line
losses it disconnects the bus coupler to protect turbine and generator.
• RPR – Reverse power relay is protect power generation from reverse back to EB in
order to protect reverse power.
• Apart from the above protections, difference protection relay, distance protection relay,
under voltage, over voltage, under current, over current relays also present.

DETAILS OF SUBSTATION TRANSFORMER

• 12500/16000 KVA
• Step down from 110KV to 11KV
• DELTA in primary, STAR in secondary side.
 SESHASAYEE PAPERS AND BOARDS LIMITED

• Dyn11 vector group

• Cooling type – ONAN, ONAF
• Core wt. 23100kg
• Winding wt. 12000kg
• Total oil in litres. 13800ltrs
• Total wt. 47400kg
• Transport wt. 38000kg
• Insulation level. LI 550 AC 230-/LI 75 AC 28
• No load loss. 15KW
• Load loss. 70KW

PAPER MACHINE PROCESS

• Pulping, to separate and clean the fibres

• Beating and refining the fibres
• Diluting to form a thin fibre slurry
• Suspended in solution
• Forming a web of fibres on a thin screen
• Pressing the web to increase the density of the material
• Drying to remove the remaining moisture
• Finishing, to provide a suitable surface for the intended end use as papers.

DE-INKING PLANT
• Deinking is the industrial process of removing printing ink from paperfibers of recycled
paper to make deinked pulp.

DE-INKING PROCESS

Sorting
Waste paper may contain a mixture of different paper types made of mixtures of different paperfibers. These
must be sorted before processed. Broke (paper waste from paper production) is normally used directly in
the papermachine.
• Office waste (OW)
• Old magazine papers (OMP)
• Old newsprint (ONP)
• Paperboard
• Corrugated fiberboard

Pulping
Pulpers are either batch, which uses a tub with a high shear rotor, or continuous, using a long, perforated
drum. Drum pulpers are very expensive but have the advantage of not breaking up contaminants, thus giving
cleaner end product.

The pulper chops the paper to smaller pieces; water and chemicals are added. Normally the pH is adjusted
to 8.5 - 10.0. Normal deinking chemicals are:
• pH control: sodium silicate or sodium hydroxide
 SESHASAYEE PAPERS AND BOARDS LIMITED

• Bleaching: hydrogen peroxide

• Calcium ion source: hard water, lime or calcium chloride
• Collector: fatty acid, fatty acid emulsion, fatty acid soap or organo-modified siloxane

Cleaning and screening

Centrifugal cleaning is spinning the pulp slurry in a cleaner, causing materials that are denser than pulp fibers
to move outward and be rejected. Screens, with either slots or holes, are used to remove contaminants that
are larger than pulp fibers.
Materials which are more difficult to remove include wax coatings on corrugated cartons and stickies, soft
rubbery particles which can make deposits and contaminate the recycled paper. Stickies can originate
from book bindings, hot melt adhesives, PSA adhesives from paper labels, laminating adhesives of reinforced
gummed tapes.

Deinking stage
In the deinking stage the goal is to release and remove the hydrophobic contaminants from the recycled
paper. The contaminants are mostly printing ink and stickies. Several processes are used, most commonly
flotation or washing.

Flotation deinking
Froth flotation was adapted from the flotation process used in the mining industry in the 1960s. It is the
most common deinking process in Europe used to recover recycled paper. Often most of the collector is
added to the inlet of the flotation. The process temperatures are normally in the range 45 - 55 °C. Air is
blown into the pulp suspension. The collector has affinity both to the ink particles and air bubbles, causing
them to attach. The air bubbles lift the ink to the surface and form a thick froth that can be removed.
Normally the setup is a two stage system with 3, 4 or 5 flotation cells in series.[9] Flotation deinking is very
effective in removing ink particles larger than about 10 µm.

Wash deinking
Wash deinking consists of a washing stage where dispersants are added to wash out the printing inks. When
the pulp slurry is dewatered (thickened), the medium to fine particles are washed out. This process is most
useful for removing particles smaller than about 30 µm, like water-based inks, fillers, coating particles, fines
and micro stickies. This process is more common when making deinked pulp for tissue. The processing
equipment are belt filters, pressure belt filters, disk filters and static filters. This stage is much more efficient
than normal washing / dewatering stages.

Combined washing and flotation

High quality deinking of office wastes and other printing papers often commonly uses a combination of
washing and flotation.

Enzymatic deinking
This method of deinking uses industrial or food grade enzymes in conjunction with flotation deinking to aid
in the removal of inks in recycling mills. More efficient removal of ink increases fiber yield, decreases dirt
count, and increases paper brightness. Often the use of enzymatic deinking helps mills reduce their bleach
usage or use cheaper furnish.

Other deinking processes

Dissolved air flotation (DAF) is used by some mills in the deinking stage and will remove some ink and filler
(ash); however, it is mainly used to clarify the process water.
 SESHASAYEE PAPERS AND BOARDS LIMITED

Washing / dewatering
Washing / dewatering (thickening) is a filtration process. Small particles (< 5 µm) are removed by passing
water through the pulp.

Bleaching
If white paper is desired, bleaching uses peroxides or hydrosulfites to increase the brightness of the pulp.
The bleaching methods are similar for mechanical pulp, but the goal is to make the fiber brighter.

Papermaking
The deinked fiber is made into a new paper product in the same way that virgin wood fiber, see papermaking.

Byproducts
The unusable material left over, mainly ink, plastics, filler and short fibers, is called sludge. The sludge is
buried in a landfill, burned to create energy at the paper mill or used as a fertilizer by local farmers.

RESULTS OF INTERNSHIP
• As a power plant operator we should be careful, attentive, and persistent. They must be able to
concentrate on a task, such as monitoring the temperature of plant equipments, over a period
of time without being distracted.
• We should monitor complex controls and intricate machinery to ensure that everything is
operating properly.
• We must use precise and repeated motions when working in a control room.
• We should be familiar with how to operate, repair, and maintain equipment.
• We understands the functions inside of the substation and its associated equipments to protect
it from various impacts of natural and man made activities.
 SESHASAYEE PAPERS AND BOARDS LIMITED

CONCLUSION
It was a wonderful experience at Seshasayee Papers and Boards Limited in Mukkoodal. Tirunelveli.
We gained a lot of experiences, insights regarding almost every aspect of site. The friendly welcome from
all the employees in appreciating, sharing their experience and giving their peace of wisdom which they
gained in long journey of work. We are very much thankful for the facility especially a quality lunch for
10rs and some employees helped in pickup and drop us to the organization. We hope this experience
will surely help us in our future and in shaping our career.

ANNEXES