Internship Report Anser Shakeel(Internee)

InterLoop Limited

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Index

Sr. no. Contents Page no. 1 Acknowledgement 2 2 Introduction 3 3 HD-III overview 5 4 Knitting 12 5 Toe Closing 13 6 Processing 14 7 Finishing 15 8 Engineering 17 9 Conclusions 26

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ACKNOWLEDGEMENTS

I am very thankful to Interloop Limited for having given me the opportunity to undertake my

summer internship at their Hosiery Division 3 (HD-03), Lahore. It was a very good learning

experience for me to work at this division as this division involved many practices and

challenges. I would like to convey my heartiest thanks to Mr. Faraz Mehmood, Sr. Officer. HD-

03. I would also like to give my heart-felt thanks to Mr. Abdul Hanan, D.m of finance

department HD-03and Mr. Ejaz, Mr. Tanvir, Mr. Usman, and Mr. Nadeem auditor HD-03 who

guided and encouraged me all through the summer internship and parted in-depth knowledge

of the Finance department activities Also, I like to thanks Mr. Zeeshan, Mr. Musawar and Mr.

Monam who helped me whenever I needed help. Last but not the least I would like to thanks

Mr. Sajid HD-03, for being so helpful throughout this internship.

Name: Ansar Shakeel

Dated: 24-08-2013

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Introduction

Interloop started out in 1992 with just 10 knitting machines, now has 3500 machines and a

workforce of more than 14000. Interloop Limited has transformed itself into SOUTH ASIA'S

largest Socks Manufacturer and Exporter offering the highest quality socks at a level of service

unknown in our industry. It is located in Pakistan's Industrial hub Faisalabad; also known as

the "Manchester of Pakistan". Interloop is an integral part of this business community,

continuously striving to revolutionize business practices in this region. Interloop has 1 plant in

Bangladesh and also in Lahore.

Capacity

Knitting per month 2.5 Million dozens

Dyeing per month 2.7 Million dozens

Packing per month 2.7 Million dozens

Minimum order qty. 2,500 dozens( variable as per terms)

Minimum Lead time 45-60 days after approvals Short lead time possible for repeats

It is one of the very few firms in Pakistan with an impressive Social Responsibility Portfolio, realizing that a commitment to sustainability in all areas of commercial activity endorse the long term interests of a business.

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HD-III overview

Finance This is the main department of the InterLoop which makes the whole purchases in the

organization. Financing is also included in this department. There are 7 employees in

fianc department which do different activities related to their work or assigned to

them. There is a process of purchasing any good.

o Requisition:

First of all requisition is made of any good or thing which is not available in the

store and required by the staff members or employees. Any employees who

require any thing (yarn, cotton, ploy bag etc) tell to their head department and

head of the department sent a request thru mail to the finance department.

In finance department there is a employee who will receive this mail sent by

head of that person and make a not approved quotation of required thing. This

not quotation is checked or audit by the other person, who compare the prices of

current bill with the past. If there is a great difference in the goods rate then he

attach a comparative statement and sent it to the head department to make sure

that he allow buying this thing at new rate. In this way requisition end to its

process.

o Purchase order (PO):

After the completion of requisition. PO is made against the vendor from whom

InterLoop want to purchase the goods. This PO is approved by the head of the

department or Head of the plant to make sure that this thing is required by the

Organization not by the person for his personal use and sent it to the vendor to

deliver the goods as soon as possible. Vendor also checks the signature of the

head of the company to check that they really required this thing.

o Gate entry:

Vendor sends the goods to the organization and when goods arrive at the gate of

the organization. Security makes a gate entry of goods to make a proper record

that these things are entering in the factory.

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o Inspection and audit:

After entering in the factory, they are being transferred to the store to make the

inspection of the things. First of all they check that these are the really things

which were required by the staff. Then they check the quality of the goods that

they are of good quality or not. They physically count the goods to check its

quantity. Auditor makes the whole audit of the goods. Quantity, quality etc and

then finally goods receipt note (GRN) is made.

o Goods receipt note :

After making the audit, GRN is made. Its a proper format of recording n

maintaining the record of the goods received. This record is make save in their

computers to make sure that these goods have been delivered. After this, Finance

department check the GRN and made correct recording of the goods and save

the record of the goods on their computer.

All the GRNs is send to the HD-I Faisalabad. Email is also send to the HD-I that

having the information about the GRNs send by the finance department.

o Store rejection note:

When goods are being checked in the store. If they are not according to the

expected quality then goods is send back to the vendor with the store rejection

note. This note is consist of reason that why goods are rejected. And this rejection

note is attached to the GRN to do not make a payment of rejected goods.

o Bills payment:

After making the record, Finance department make a voucher of goods amount

and sent it to the auditor to check or make audit of the voucher. After auditing

work flow is completed and Cheque is made against the vendor to do the

payment of the goods purchased.

o Dispatch report:

This report is being made on daily basis. In this finance department sent the mail

to HD-I that is consist of the information of the GRNs that are send to them.

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o Debit note:

When the purchaser returns the goods to the seller the Purchaser sends a Debit

Note to the seller (i.e. the purchaser debits the seller in his books i.e. Purchasers

Books)

o Credit note:

The Seller sends a Credit Note to the purchaser (i.e. the seller credits the

Purchaser in his Books i.e. Sellers Books).

Support Services

o Human Resource:

InterLoop has been able to recruit the best professionals, who have taken the

Company to the new heights. Their HR philosophy is based on the belief that

they can increase overall Human Capital by improving the following:

Intellectual Capital: Processes which will improve specialized knowledge, skills, tacit knowledge, and imagination of our people.

Emotional Capital: Developing a culture which breeds self confidence, ambition, and courage. Developing Leadership capabilities and encouraging team based environment is an essential ingredient.

Social Capital: Leveraging social contacts for business and personal gains, strengthening networks of our people with outside world, trustworthiness etc. are the hallmark of this process.

It has a strong people development process, which enable us to plan career paths for our

executives. It also helps us to identify areas of improvement for further training by

developing a gap analysis. The assessments are done continuously so that our people

are ready to face the ever increasing challenges of the Corporate World.

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o Admin

Office administration includes planning work assignments for staff, supervising

staff, and requesting new office equipment and repairs on existing equipment.

Office administrators also handle duties such as customer service, payroll, and

implementing department policies and changes. They also discuss performance

problems with employees and work with higher management to hire new

employees or fire current employees

o IT

The IT department controls the networking in the InterLoop. All the senior staff

has think pro which are all connected by a server. This department controls all

the activities on the internet performing by the employees. The emails are

Director

Deputy General Manger

Sr. Manager Manager

General Manger

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scanned before they reach to the employees server think pro system. In this way

all the computers are free from hacking and viruses.

o Security

The security of the InterLoop is much tight. There is a strict check and balance in

the goods which are coming or going of the InterLoop. They check every

employee having any illegal thing which is not being allowed by the

organization. Everywhere security cameras are installed to reduce the risk of any

terrorist activity to minimum. Security guards are well trained and do their duty

as a responsible person.

o EHS

Interloop is committed to operate in a manner that reduces the EHS risks to all its

stake-holders. It continuously reviews its processes and makes improvements

that reduce the EHS risks. It tries to protect and conserve the environment and

devotes adequate resources that are required to achieve this goal.

Interloop invests in equipment that conserve energy, make workplace safe and

reduce risks to the environment.

Interloop will arrange to develop and implement EHS Standards that conform to

National / International Standards. It will arrange to impart proper training to

its workforce for implementing these standards. Line Managers are responsible

to maintain EHS Standards. However, a dedicated EHS Department has been

established to facilitate and train the Line Managers in implementing EHS

Standards.

Interloop has successfully qualified and received relevant EHS Certifications like

ISO 14001:2004 and OHSAS 18001:2007 for its facilities. Interloop complies with

all relevant EHS Standards, as required by law. A continuous review of EHS

issues is ensured through internal audits and efforts are made to improve the

system.

Environment

Keeping in view the climatic changing scenarios of the World, Interloop

Management is very much concerned to put in their best for the

conservation of environment to make this globe a worth living place.

Nijhuis Water Technology from Netherlands was engaged to install

Waste Water Treatment Plant for Interloop Limited. First Effluent

Treatment Plant of the Company was operational in 2005 with a capacity

of 100m3/hr. In 2007, with the increasing demands of business, another

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Waste Water Treatment Plant with a capacity of 120m3/hr. was set up in

cooperation with Joseph Igly Italia, an Italy based company dealing in

water technology.

The effluents from these Water Treatment Plants are being monitored by

the Scientists from "National Institute for Biotechnology & Genetic

Engineering (NIBGE, www.nibge.org)". To make a contribution in

bringing "Green Revolution", plantation has been carried out on

experimental basis with NIBGE since 2007. This plantation is irrigated

from treated water. The Company intends to intensify this exercise on a

larger scale as soon as the desired results are obtained.

A comprehensive plan was carved out in 2007 to meet the legal

requirements regarding air pollution. Emissions from all sources were

calculated throughout the facility in management with SGS Pakistan.

All sorts of wastages are segregated from manufacturing processes into

recyclables and non-recyclables. Wood is recycled within the facility. 17.8

Tons of Wood has been recycled in 2009.

Health and safety:

Interloop Limited is exemplary as far as Health and Safety issues

are concerned. The Company has standardized itself in line with

the National Laws of Pakistan and requirements of our valuable

customers/stakeholders.

A comprehensive Occupational Health and Safety Management

System are in compliance with recently revised Standard of

OHSAS 18001:2007.

Management has intensively invested in Health and Safety related

issues. All manufacturing areas are equipped with Fire Alarm

System compatible with British Standards. Keeping in view the

dual safety of employees and the environment, four Auto

Chemical Dispensing Systems with Italian Technology have been

setup in place to avoid human interaction with the chemicals and

land contamination. Management is keen to train the employees

effectively and efficiently in their respective service areas. The

initial focus was to impart training according to local laws and

various customers requirements, yet to the fact, the existing

training programs are over and above these necessities.

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Use of Personal Protective Equipment and Safety Devices according to the site activities

o Ear Protection Ear plugs are provided at the sites working with high sound levels.

o Eye Protection The workers carrying out grinding, cutting and welding works are provided with safety goggles and face shield.

o Hand Protection Cotton and rubber gloves are provided to the workers for their hands protection.

Supply Chain Logistics

o Raw material store:

It is the store where all the purchased raw material(cotton, thread) is kept in the store.

o Accessory store:

All the goods related to the packing to finishing department are kept in accessory store. Like

poly bags, Polystyrene bags.

o Chemical store:

This store is linked with the processing department and all the chemicals which

are being purchased or itself made by the InterLoop in their organization are

kept in it.

o Spare store:

All the things which does not come under the head of any store or extra thing are

kept in spare store. Like food, steam pipes etc.

o Waste store:

All the wastage of the InterLoop is kept in the waste store, like burned rice husk,

waste of socks and waste of carton.

o Finished goods store:

All the socks that are ready to deliver are kept in this store and there is very tight

security here.

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o Fair Price Shop: This project aims to reduce the cost of living for Company's employees by

providing certain articles of daily use at very cheap rates. All workers can

purchase necessities of life on a quota base determined by the Managing

Committee. The shop includes items like Cooking Oil, Sugar, Tea, Detergent,

Wheat Flour and Company Products etc.

Knitting

The Knitting Plant is made up of 2300 Fully Computerized Machines from Lonati,

Sangiacomo, Matec and Uniplet from 72 needles to 168 needles. We feature:

72N Single Cylinder (for Infant/Toddler) 84N Single Cylinder (for children sizes) 84N Single Cylinder (5 heavy gauge) 108-120N Single Cylinder 132N Single Cylinder 144N Single Cylinder 168N Single Cylinder 84N Double Cylinder (heavy gauge for casual socks) 168N Double Cylinder

They have wide range of Machine diameters which include 3.25, 3.50, 3.75, 4.00, 4.50 & 5.00 inch and wide range of needle selections.

Gauge 24 72, 84, 108 & 120 needles Gauge 36 120, 132, 144, 156 & 168 needles

Interloop's Knitting Team comprises of highly skilled and trained professionals including qualified engineers. Interloop has also established a Technical Training Centre to provide trained manpower for its on going expansion programs. This work force is being continuously trained through Training Courses in Italy and training on job by Italian and Local Experts.

Interloop's fleet of 2300 Knitting Machines is being continuously updated with latest

state-of-the-art equipment. Interloop has massive knitting capacity, spread over several

specialized areas.

Toe closing: Toe-Closing is a very important and sensitive operation of the socks making process.

Interloop is currently operating a very large Linking Section with the help of

Computerized Linking Machines and is able to offer the finest quality toe-close. It also

has Lin-Toe System on 40 sets of 108N Machines.

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Machine Type Qty

Roso/Conti Complete 110

Over Lock 10

Hand Linking 33

Flat Lock 06

Elastic Sewing 04

Lock Stitch 03

Processing: Interloop is well aware of the World's day by day changing trends and demands.

Interloop is already one step ahead and operating a complete Wet Processing Unit with

the help of latest equipments and techniques, and is capable of meeting all desired

standards of the clients. Interloop can offer almost all types of colors to the customers on

competitive rates with the help of the Processing Department.

Machine Type Qty

Rotary dyeing machines 60

Hydro-Extractors 8

Tumble Dryers 24

Sample Dyeing/Bleaching 04

HT Rotary Dyeing machines 02

Processing Capacity Per Month

Process Tons Dozens

Dyeing/Bleaching 1,300 2,700,000

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Quality assurance The Laboratory was set up to cater the requirements of Quality Assurance of production processes like Spinning, Knitting, Processing , Boarding and Packing of Interloop Limited. Now it performs tests, within the scope of its accreditation on products manufactured by Interloop Limited (Socks, Ecru yarns and Dyed yarns). It ensures that the products comply with the Company's own stringent guidelines and as per International Standards. The tests are done as per various International Standards like ISO / AATCC / ASTM / BS and validated through in-house methods. The tests are conducted under standard environmental conditions.Interloop pleases to announce that by the grace of Almighty Allah it has received the prestigious ISO/IEC-17025 Certificate of Accreditation from Pakistan National Accreditation Council (PNAC), Ministry of Science and Technology, Government of Pakistan. QA Lab of Interloop Limited has received the globally recognized accreditation for its Textile Testing. This milestone is seen as a major endorsement of the Quality of Testing performed at this World Class facility. The Laboratory was set up to cater the requirements of Quality Assurance of production processes like Spinning, Knitting, Processing , Boarding and Packing of Interloop Limited. Now it performs tests, within the scope of its accreditation on products manufactured by Interloop Limited (Socks, Ecru yarns and Dyed yarns). It ensures that the products comply with the Company's own stringent guidelines and as per International Standards. The tests are d one as per various International Standards like ISO / AATCC / ASTM / BS and validated through in-house methods. The tests are conducted under standard environmental conditions. Maintenance and improvement in the quality of our product (Socks) and our Quality Management System is the corner stone of our Quality Policy. Interloop established a Quality Assurance Department, which is operating with more than 380 Experts and Qualified work force and this Department is the most important for Interloop Interloop Limited established in 1992, has set up a separate and independent Quality Assurance Department (QAD). This Department has been functioning since 1997 and ensures that Quality Standards are maintained and customers requirements are fully met.

The Process Consists Of

Inspection and Testing of incoming material Inspection and Verification of correct issuance of materials and accessories against

requirement Independent in-line Inspection at every stage of the product manufacturing e.g. Knitting

, Linking , Processing , Boarding , Finishing / Packaging Final Inspection before Delivery

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Finishing:

Interloop has both, human and technical skills to offer all types of packaging services to its clients, while the accessories have been sourced from the World's best resources, locally as well as from Hong Kong/China etc. Interloop has a special facility to keep huge stocks of accessories in order to offer more efficient and quick deliveries to its customers.

Machines

Steam Boarding (Ghibili) 33

Electric Boarding 122

Thread cutting Machines 48

Heat transfer machines 04

Needle detector (Cintex) 02

Capacity

Packing capacity per month 2,700,000 dozen pairs

Packing capacity per day 90,000 dozen pairs

Number of employees in Packaging/Finishing 2,700

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Engineering

Chillers The absorption chiller is planted in InterLoop. The mechanism is explained below

Absorption Chillers:

An absorption chiller is a chiller that uses a heat source (e.g., solar, kerosene-fueled flame, waste

heat from factories or district heating systems) to provide the energy needed to drive the

cooling system.

There are two types of absorption chillers

1- Water-Ammonia chiller

2- Water-Li Br chiller

Water-Li Br Chiller

In water-lithium bromide vapor absorption refrigeration system, water is used as the refrigerant

while lithium bromide (Li Br) is used as the absorbent.

Process Cycle:

The heat is supplied to the refrigerant water and absorbent lithium bromide solution in the

generator from the steam or hot water. Due to heating water gets vaporized and it moves to the

condenser, where it gets cooled. As water refrigerant moves further in the refrigeration piping

and though nozzles, it pressure reduces and so also the temperature. This water refrigerant then

enters the evaporator where it produces the cooling effect.

Lithium bromide on the other hand, leaves the generator and reenters the absorber for

absorbing water refrigerant. Water as the refrigerant enters the evaporator at very low pressure

and temperature. Since very low pressure is maintained inside the evaporator the water exists

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in the partial liquid state and partial vapor state. This water refrigerant absorbs the heat from

the substance to be chilled and gets fully evaporated. It then enters the absorber.

In the absorber concentrated solution of lithium bromide is already available. Since water is

highly soluble in lithium bromide, solution of water-lithium bromide is formed. This solution is

pumped by the pump to the generator.

Applications:

The water-lithium bromide vapor absorption system is used in a number of air conditioning

applications. This system is useful for the applications where the temperature required is more

than 32 degree F.

Ammonia-Water Absorption Chiller:

The working of ammonia-water absorption refrigeration system is based on the simple vapor

absorption refrigeration system. In this system ammonia is used as the refrigerant and water is

used as the absorbent.

Process Cycle:

The Cycle is shown below.

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Ammonia vapor is extracted from the NH3 strong solution at high pressure in the generator by

an external heating source. In the rectifier, the water vapor which carried with ammonia is

removed and only the dried ammonia gas enters into the condenser, where its condensed.

The pressure and temperature of cooled NH3 solution is then reduced by a throttle valve below

the temperature of the evaporator. The NH3 refrigerant at low temperature enters the

evaporator and absorbs the required heat from it, then leaves it as saturated vapor.

The low pressure NH3 vapor is then passed to the absorber, where its absorbed by the NH3

weak solution which is sprayed also in the absorber as shown in Fig. After absorbing NH3

vapor by the weak NH3 solution (aquaammonia), the weak NH3 solution becomes strong

solution and then it is pumped to the generator passing through the heat exchanger.

In the pump, the pressure of the strong solution increases to generator pressure. In the heat

exchanger, heat form the high temperature weak NH3 solution is absorbed by the strong NH3

solution coming from the absorber.

As NH3 vapor comes out of the generator, the solution in it becomes weak. The weak high

temperature NH3 solution from the generator is then passed through the throttle valve to the

heat exchanger. The pressure of the liquid is reduced by the throttle valve to the absorber

pressure

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Air handling units An air handler, or air handling unit (often abbreviated to AHU), is a device used to condition

and circulate air as part of a heating, ventilating, and air-conditioning (HVAC) system. Usually,

an air handler is a large metal box containing a blower, heating and/or cooling elements filter

racks or chambers, sound attenuators, and dampers. Air handlers usually connect to duct work

that distributes the conditioned air through the building, and returns it to the AHU. Sometimes

AHUs discharge (supply) and admit (return) air directly to and from the space served, without

ductwork.

Small air handlers, for local use, are called terminal units, and may only include an air filter, coil, and blower; these simple terminal units are called blower coils or fan coil unit. A larger air handler that conditions 100% outside air, and no re circulated air, is known as a makeup air unit (MAU). An air handler designed for outdoor use, typically on roofs, is known as a packaged unit (PU) or rooftop unit (RTU)

Compressors

Pressure Generation: Compression

The pressure exerted by a confined gas results from rapid and repeated bombardment of the container walls by the enormous number of gas molecules present. The pressure can be increased by increasing the number or force of the collisions. Increasing the temperature does this by speeding up the molecules (Charles' Law). Another way is to increase the average number of molecules in a given volume. This is compression. It can be done by either decreasing the volume (Boyle's Law) or increasing the amount of gas. Liquids and solids can be compressed only with difficulty. But gases are easily compressed because their molecules are relatively far apart and move freely and randomly within a confined space.

Compression decreases the volume available to each molecule. This means that each particle has a shorter distance to travel before colliding with another particle or the wall. Thus, proportionately more collisions occur in a given span of time, resulting in a higher pressure.

Why do we need compressed air? The importance of compressed air is often over looked, but in reality it plays a vital part in most modern manufacturing processes and modern civilization. Although we may not realize it most

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products we use today could simply not be made without compressed air. Compressed air accounts for about 10% of the global energy used in industry today.

Compressed Air is clean, safe, simple and efficient. There are no dangerous exhaust fumes or other harmful by products when compressed air is used as a utility. It is a non-combustible, non-polluting utility.

Uses of Compressed air:

In industry, compressed air is so widely used that it is often regarded as the fourth utility, after

electricity, natural gas and water. However, compressed air is more expensive than the other

three utilities when evaluated on a per unit energy delivered basis.

Compressed air is used for many purposes, including:

Pneumatics, the use of pressurized gases to do work

Pneumatic post, using capsules to move paper and small goods through tubes.

Air tools

HVAC control systems

Vehicle propulsion

Energy storage

Air brakes, including:

railway braking systems

road vehicle braking systems

Scuba diving, for breathing and to inflate buoyancy devices

Refrigeration using a vortex tube

Gas dusters for cleaning electronic components that cannot be cleaned with water

Air-start systems in engines

Ammunition propulsion in:

Air guns

Airsoft equipment

Paintball equipment

Air Compressors: Basic Operation

An air compressor operates by converting mechanical energy into pneumatic energy via compression. The input energy could come from a drive motor, gasoline engine, or power takeoff.

Modern compressors use pistons, vanes, and other pumping mechanisms to draw air from the atmosphere, compress it, and discharge it into a receiver or pressure system.

Rotary Compressors

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They are commonly used to replace piston compressors where large volumes of high pressure

air are needed, either for large industrial applications or to operate high-power air tools such

as jackhammers.

The gas compression process of a rotary screw is a continuous sweeping motion, so there is very

little pulsation or surging of flow, as occurs with piston compressors.

In a rotary compressor the air is compressed by the rotating action of a roller inside a cylinder. The roller rotates eccentrically (off-center) around a shaft so that part of the roller is always in contact with the inside wall of the cylinder. A spring-mounted blade is always rubbing against the roller. The two points of contact create two sealed areas of continuously variable volume inside the cylinder. At a certain point in the rotation of the roller, the intake port is exposed and a quantity of air is sucked into the cylinder, filling one of the sealed areas. As the roller continues to rotate the volume of the area the air occupies is reduced and the air is compressed. When the exhaust valve is exposed, the high-pressure air forces the exhaust valve to open and the air is released. Rotary compressors are very efficient because the actions of taking in air and compressing air occur simultaneously.

Multistage Compression Compression may be accomplished in one or more stages. That is, air can be compressed once or several times before it reaches the compressor outlet and is delivered to the system devices. Each stage provides a proportional increase in the output pressure. Positive displacement compressors have the advantage of providing relatively large pressure changes in a single stage, and very large pressure changes in a few stages. However, the pressure output of non-positive displacement compressors can also be raised by staging. Single Stage - Fig. 3 is another way of illustrating how the compression process is carried out in a single pass through a pumping chamber. This piston-type compressor has two cylinders, but the compression action occurs in a single stage. The cylinders are connected in parallel between the atmosphere and the discharge manifold. The normal maximum pressure rating for single-stage compressors is about 100 psig. Operation above this level increases the heat of compression (caused by leakage and recompression) to levels that could harm the compressor and the overall system.

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Multiple Stage-In multiple-stage compression, the gas moves from one chamber to another. This sequential action provides the final pressure. For general utility and process purposes, two-stage compression is usually justified when the compression ratio (Rc) exceeds six. When Rc exceeds 20, compression is usually accomplished in three stages. To put this in pressure units, the upper limit for utility two-stage compressors is between 280 and 300 psig. A gauge pressure of 500 psi has an RC value of 35. Some multistage compressors eliminate the problem of increased heat of compression above 100 psig. This is done by:

Compressing the air to an intermediate pressure in the large-diameter low-pressure cylinder.

Removing a portion of the heat of compression before the air is fed to the next stage (this is known as "intercooling" and is normally done by an air-cooled or water-cooled heat exchanger).

Further compressing the air to final pressure in a smaller high-pressure cylinder. As Fig. 20 shows, these two cylinders are connected in series through the intercooler (compare with Fig. 19). Intercooling greatly decreases both the total temperature rise of the compressed air and the amount of work required for its compression. But the added cost of an intercooler cannot always be justified on a small compressor. Some two-stage compressors have three cylinders: two low-pressure cylinders connected to one high-pressure cylinder through an intercooler.

Lubrication and Exhaust Air Quality Contamination in the air can affect many applications. A laboratory process, for example, powered by compressed air may be extremely sensitive to moisture, oil, or dust particles. Or in such places as food processing plants, even the air exhausted from the pneumatic system may have to be entirely free of oil vapor and contaminants. A variety of filters, generally expensive, have been developed to solve such problems.

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An alternative is to use oil-less air compressor.

Oil-Less Compressors - Compressors designed with "dry" self-lubricating materials, such as graphite or Teflon, produce oil-free air both in the line and at the exhaust. They effectively eliminate the presence of air/oil vapors in applications where even a very fine oil mist can cause contamination, stains, deterioration, or a safety hazard. Oil-less pneumatic systems are particularly useful in the food, textile, paper, pharmaceutical, and chemical industries. And since no maintenance lubrication is required, these units can be mounted in the best, rather than the easiest to reach, location.

Oil-Lubricated Compressors - if, for some reason, an oil less air compressor is not practical in an application where contamination is prohibited, then an oil-lubricated unit must be used and equipped with appropriate filters to remove the oil after the air is compressed. In an oil-lubricated compressor, a thin film of oil is maintained between the walls of the pumping chamber and the pistons, vanes or other moving parts. Siphon or wick-type lubricators are used in light-duty operations. Pressure type lubricators are used in heavy-duty or continuous-duty applications. In general, oil-lubricated compressors have higher pressure ratings than oil-free compressors. They also run cooler and may therefore have longer service lives. The relative value of these factors versus the convenience of inherently oil-free operation dictates whether oil-less or an oil-lubricated compressor should be used.

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Boilers

Packaged Boiler: The packaged boiler is so called because it comes as a complete package. Once delivered to site, it requires only the steam, water pipe work, fuel supply and electrical connections to be made for it to become operational. Package boilers are generally of shell type with fire tube design so as to achieve high heat transfer rates by both radiation and convection Bureau of Energy Efficiency.

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The features of package boilers are:

Small combustion space and high heat release rate resulting in faster evaporation.

Large number of small diameter tubes leading to good convective heat transfer.

Forced or induced draft systems resulting in good combustion efficiency.

Number of passes resulting in better overall heat transfer.

Higher thermal efficiency levels compared with other boilers.

CONTINUOUS-FLOW RICE HUSK GASIFIER FOR SMALL-SCALE:

Rice husk gasification can now be done in a continuous mode with the latest design of a continuous-flow down-draft rice husk gasifier. Instead of using a dual reactor, continuous firing can be achieved using a single reactor. With this development, a more convenient and lower cost rice husk technology can be made available to people who wish to use rice husks as fuel as a replacement for the high-cost LPG fuel. The gasifier has the following components: a 0.25-m diameter by 110- cm high single reactor where rice husk is gasified using limited amount of air for combustion; a -sack capacity feeding hopper situated directly above the reactor that feeds rice husks by gravity mode; a char chamber positioned directly beneath the reactor used to hold burnt rice husks and also served as an exit duct for combustible gases to the burner; a char separator attached to the char chamber for cleaning the gas leaving the reactor before the gas enters the burner; and an air injector positioned beneath the char chamber to gradually remove the char from the chamber pneumatically through a cyclone separator. A 2-inch electric blower supplies the air needed for gasification and a 2-inch electric motor drives the pneumatic conveyor. Gasification of rice husks in this gasifier is accomplished in a downdraft mode. Rice husks are fed at the top of the reactor and are burned at its bottom. Air is introduced into the bed of rice husks from the top of the reactor and moves downward through the fire zone. Fire zone is maintained by gradually removing the char from the char chamber employing a jet-type pneumatic conveyor installed right beneath the reactor. The gas generated in the reactor during gasification is directed to the burner passing through the momentum separator. Char is separated from the gas by a 30-cm diameter cylindrical shape momentum separator. The gas produced is burned either in a jet-type, a gas pipe-type, or a drum-type burner. The air that is used to convey the char is also used to cool the reactor at the same time. At the end of the conveyor is a cyclone separator to separate the char from air. A water container is provided at the bottom of the cyclone to immediately cool the hot char that is leaving the reactor. Performance testing and evaluation showed that the gasifier can be successfully operated in a continuous mode. Firing of the reactor can be start-up evenly by using only few pieces of paperand by sprinkling kerosene at the bottom of the fuel bed. Once spontaneous combustion of fuel is attained, combustible gases are generated. Tests have shown that the gasifier consumes rice husk fuel at an average rate of 8.3 kg per hour. The amount of air used to gasify rice husk was measured at 13.2 m3/hr giving an equivalence ratio for the gasifier reactor of 0.4 The temperature of the gas leaving the reactor using a type k thermocouple wire thermometer was measured at 117 to 205C whereas the air used to cool the reactor and, at the same time, used to convey the char was measured at 50 to 87C. The computed specific gasification rate of the reactor is 169.2 kg/hr-m2. Based on the airflow and the cross-sectional area of the reactor, the computed superficial velocity of gas in the fuel bed is at 7.5 cm/min. The pneumatic conveyor operates well at a char-to-air ratio of 16.5 and for a terminal velocity of air inside the duct pipe of 11.5 m/s. Based on the energy generated from the gas and the energy available

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from the fuel, the overall efficiency of the gasifier is 63%. And, the computed power output is 19 kW. The gasifier can be used to supply combustible gases and effectively burns fuel either in a jettype, pipe-type, or drum-type gasifier burner. The char that is produced from the gasifier is completely black (40% of rice husk), which is good for soil conditioning. The cost of the gasifier is P35,000.00 per unit (1 US$ = 55 PHP). It requires a single person to attend its entire operation. Operating the gasifier entails a total electric power consumption of 0.4 kW. The computed payback period is less than 1 year when compared with LPG burner. The continuous-flow rice husk gasifier is of more advantage than the dual reactor rice husk gasifier primarily in terms of current investment cost. Instead of using two reactors, only one reactor is used which means lesser material cost. Other features of the continuous-flow rice husk gasifier are: (1) It is convenient to operate in which reloading of rice husk and unloading of char are eliminated; (2) It saves space since it has only one reactor; and (3) The size of the reactor can be scaled up or down, depending on the requirement of the client.

Conclusions

InterLoop has a dynamic environment with strong relationship amongst the employees. It normally prefers individual task outcomes, and evaluates the performance of its employees to identify the training and development needs, performance rewards and employees correction. Its production rate is quite high. This is due to the hard work and dedication of the employees. The engineering department makes sure that the machines are working properly, EHS department makes sure the safety of environment and workers while QA makes sure that the product is according to the standards. It was a good experience for me to learn about Purchasing, Financing, Working on ERP project oracle and excel. I enjoyed my time here in InterLoop.