A

INTERNSHIP PROJECTAT

ELANTAS BECK INDIA LTD.

Submitted by

LUHARIYA ANJALI J.

In partial fulfilment for the award of the degree of

BACHELOR OF TECHNOLOGY

In

CHEMICAL ENGINEERING

DHARMSINH DESAI UNIVERSITY, NADIAD

INTRODUCTION Chapter 1

1.1 About Elantas

With a worldwide network of production facilities, we can supply

customers locally wherever they are. The ELANTAS group comprises 7
companies and 12 production sites over the globe. ELANTAS Beck India
Limited.

ELANTAS BECK INDIA LIMITED is a Public Company, who was

incorporated 66 Year(s) 9 Month(s) 1 Day(s) ago on dated 15-Mar-1956 .
ELANTAS BECK INDIA LIMITED is classified as Non-govt company
and is registered at Registrar of Companies located in ROC-PUNE.
Ankleshwar Unit manufactures a wide range of specialty chemicals in the
electrical insulation and construction industries.

1.2 History of Elantas

Incorporated in Mar.'56 Dr Beck & Company (India) was promoted by

Mahindra & Mahindra in collaboration with Dr Beck & Company
Germany. It went public in 1961. The company has collaboration with
BASF Lacke and Farben Germany to manufacture paints at Satara.
BASF Germany which had the controlling interest in the company with
a stake of 51% sold its stake to Schenectady International Inc. USA. on
1st Jan.'98. The company has it manufacturing facilities at Pune
Ankleshwar and also has its regional offices located at Bangalore,
Kolkata, New Delhi & Mumbai etc.
Dr Beck & Company (India) has developed over the years one of the
finest and widest ranges of synthetic insulations for the Indian industry.
These ranges include wire enamels varnishes epoxy and unsaturated
polyester resins to meet the needs of various sectors like the private
government and PSUs such as defence railways telecommunications
heavy electricals etc.

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 Company has requisite permission from the Govt. of India & RBI for
Schenectady (India) Holding Ltd (SIHL) a wholly own subsidiary of
Schenectady International Inc USA acquired 51% of the Equity Capital of
the Company from BASF Group. SIHL made an offer to acquired further
6.16% f the equity of the Company the total holding of SIHL to 57.16%.
Company has received the ISO-14001 Environment Management System
Certification from RWTUV Germany.
With the Acquisition of majority shareholding of the Company by the
Schenectady Group the name of the company has changed to
'Schenectady-Beck India Ltd'. The Hon'ble High Court Mumbai has
approved scheme of amalgamation of Schenectady India Ltd. with the
company. The name of the company has been changed during the year
2003 from Schenectady-Beck India Ltd to Beck India Ltd. During 2005
the companies production capacity of Wire enamels & Impregnating
varnishes expanded from 8000 MT to 9500 MT. Synthetic Resins capacity
stood at 4500 MT.

1.3 Objectives & Principles of Elantas

Elantas aim to act on their own responsibility to ensure that their

products and working methods do not harm people or the environment.
The need to strive for economic success must not under any circumstances
prevent action in this direction which is prescribed by law or which they
consider to be important. Hence they want to create secure jobs and good
working conditions for the employees. To this end ALTANA Electrical
Insulation has defined group-wide environmental and safety standards.
These standards are based mainly on the Responsible Care initiative of the
chemical industry.

ELANTAS attaches great importance to uniform, group-wide

compliance with environmental and safety standards. To this end all
companies and subsidiaries worldwide are committed to comply with the
general principles contained in our Principles and Objectives and those
arising from the Responsible Care initiative.

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1.4 Company Product

Elantas customers benefit from their comprehensive product portfolio

and appreciate reliability and strong technical expertise.

1. Wire Enamels,

2. Impregnating Materials,

3. Casting & Potting Materials,

4. Flexible Electrical Insulation Materials,

5. Materials for Electronic Protection,

6. Materials for Tooling & Composites,

7. Specialty & Industrial Coatings,

8. Printed Electronic Products.

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DEPARTMENT

Elantas Beck India, Ankleshwar site work with many different departments. The
Admin block (Management), Environment, Occupational Health & Safety department,
Production/manufacturing department, Corporate Social responsibility Initiatives,
QC/QM department, Logistics Department, etc.

Quality, Environment, Occupational Health & Safety Department

ELANTAS Beck India Ltd, manufacturer of speciality chemicals is committed

to continually improve its customer satisfaction, environment, health and safety
performance and comply with all its legal obligations. It is the responsibility of
both management and its employees to achieve a high level of QEHS
performance through instituting adequate processes and measurement systems:

In pursuit of our belief and commitment, we shall strive to:

• Incorporate QEHS considerations at all key stages of our business operations.

• Achieve consistent quality of our products and services

• Conserve natural resources and protect the environment

• Provide all employees with a safe and healthy workplace by implementing

measures to prevent work related injury and ill health

• Provide our employees, distributors and customers with the information

necessary to handle and manage our products safely and thereby reduce
hazards and OH&S risks

• Increase employees and contractors’ awareness of this policy and provide

necessary training for improving QEHS performance

• Build a strong culture of team work through consultation and participation

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 PRODUCT

1. Wire Enamel

Electrical motors, generators and transformers function on the basis of

electromagnetic induction. The rotational or linear movement of such electrical
rotary equipment is caused by electromagnetic fields induced by current flow
through copper/aluminum wires and coils, and their mutual repulsion forces.

For a safe and stable operation of such rotary equipment, the copper or
aluminum wire is concentrically coated with multiple insulating layers of a
so-called wire enamel varnish, prior to the winding process. This wire coat
prevents short circuits and other electrical failures potentially resulting in
the loss of the electromagnetic fields and machine breakdowns.

Depending on the end-use application, wire enamels provide high

thermal resistance, strong mechanical stability, superior flexibility and
chemical/moisture resistance, which all supports a long service life of the
insulation.

ELANTAS is offering a high-performing range of enamels for the use as

magnet wire coatings. Our chemistries include Polyester, THEIC-modified
Polyester (PE), Polyesterimide (PEI), Polyamideimide (PAI), Polyimid (PI),
Polyamide (PA), Polyurethanes (PU), Polyvinylformal (PVF) and Nylon.

The ELANTAS portfolio comprises enamels especially designed for

various wire grades such as copper and aluminum wires, fine wires, medium
wires, heavy round wires and shaped wires. We provide solutions for both
horizontal and vertical enameling technologies, as well as different coating
builds from single layer to multiple layer application. Our product range
covers varnishes delivering special requirements such as corona resistance
properties, solder ability and oil resistance, among many others. In addition,
we guarantee superior compatibility with most impregnation varnishes, in
particular, the ELANTAS impregnation varnishes.

Through the global ELANTAS production infrastructure, with eight

manufacturing sites across the globe, we stand for the highest quality and
most stable supply chains. We offer a broad product portfolio globally
fulfilling the international standards of the industries but also provide
regional qualities that meet local demands.

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 2. Insulating Varnish

Excellent insulation material performance is critical wherever electrical

components have to operate and it is even more so under extreme conditions.

The application conditions for any piece of electrical equipment can be

extreme. It is therefore vitally important that insulation systems for motors,
generators and transformers are designed around the most critical
conditions. The right selection of insulating components including Flexible
Electrical Insulation for the various voltages and temperature classes is
paramount to the integrity of the electrical equipment.

Flexible Electrical Insulation layers protect insulated wires from coming

into contact with steel cores, hold wires in place, and provide a phase-to-
phase barrier. To protect the conductor and insulation structure against
mechanical, electrical, environmental and thermal stress, the whole winding
is then consolidated using a compatible resin system. Typical Flexible
Electrical Insulation applications are slot liners, phase insulations, wedges
and slot closures.

Withstanding extreme constant stresses – mechanical, thermal, chemical

and electrical – is a fundamental prerequisite that every insulation material
must meet. However, when it comes to Flexible Electrical Insulation,
ELANTAS goes beyond that and utilizes its extensive knowledge in
applications and its patented foundation for polyamideimide wire enamels
to develop an entirely new technology: advanced PAI layer technology.

2.1. Product Capacity

Product capacity: 9500 MT (9500000 Kg)

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2.2. MSDS

Each and every material have their own MSDS. All the component MSDS has 16
sections. Common Sections of MSDS are as follows.

Section 1: Identification of the substance/mixture and of the

company/undertaking.

Section 2: Hazardous identifications

Section 3: Composition/information on ingredients.

Section 4: First aid measures.

Section 5: Firefighting measures.

Section 6: Accidental release measures

Section 7: Handling and storage

Section 8: Exposure control/personal protection

Section 9: Physical and chemical properties

Section 10: Stability and reactivity

Section 11: toxicological information

Section 12: Ecological information

Section 13: Disposal consideration

Section 14: Transport information

Section 15: Regulatory information

Section 16: Other information

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SAFETY, HEALTH AND ENVIRONMENT

3.1. Introduction

a) Safety is the state of being “safe”, the condition of being protected against
physical, social, spiritual, financial, political, emotional, occupational,
psychological, education, or other types of consequences of failure, damage,
error, accident, harm or any other event which could be considered non
desirable. This can take the form of being protected from the event or from
exposure to something that causes health or economical loss. It can include
protection of people or of possessions.

b) No industry can afford to neglect the fundamentals of safety in design and

operation of its plant and machinery. It is important that all the people
responsible for management and operation of any industry should have a good
knowledge of industrial safety.

c) “Safe use of man, material and, machine by safe systems and method of work
so as to achieve zero accidents which results in higher productivity.

d) Accident: An accident is unplanned/ unexpected events which interfere or

interrupts with the planned process of work and results in personal injury.

3.2. Basic Rules

• No smoking
• No electronic items allowed in the industry without special permission
• Photography is strictly prohibited
• Personal protective equipments are compulsory.
• Only walk on the showed footpath
• Watch out for big vehicles in the blind spot convex mirrors. Let them pass
and then cross the road
• Speed limit 10km/hr
• Do not enter in restricted area.

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3.3. Emergency siren code

Testing Siren rings till 1 minutes continuously

Plant Alert Siren rings until plant safety

representativearrives on the lace.

On site emergency Siren rings continuously 10s to 2min

Off-site emergency Siren rings 10s to 15 min

All clear (on site) Siren rings continuously for 2 min

All clear (off site) Siren rings continuously for 3min

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3.4. Pre-start-up Safety review

• One of the fundamental tolls for managing change is the pre start-up
safety review (PSSR). A PSSR consists of a checklist of items to be
thoroughly verified before a process begins or restart in order to ensure that
potential hazards have been properly addressed.

• The aim of PSSR is to prevent serious injury from the hazard of stored
energy as a result of the failure of a pressure system or one off its component
parts.

• The team required for PSSR consists of representatives from the

followingdepartments:

e) Process
f) Mechanical
g) Electrical
h) Project
i) Instrumentation
j) Safety

It consists of verification of:

• Fire and explosion safety

• Electrical safety
• Machine and equipment safety
• Industrial hygiene
• Safety training
• Interlocks and alarms
• Field safety
• Relief devices

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3.5. Fire and Fire triangle

Generally, in industries explosions and fires have more possibility to happen

because sometimes untrained workers are allowed to operate or else the event
is simultaneous like increase of pressure inside the boiler.

I. Flash point: The minimum temperature at which fluid gets converted t

into vapor is called flashpoint.

II. Lower explosive limit (LEL): The lower explosive limit (LEL) is the
lowest concentration of a gas or vapor that will burn in the air.

III. Upper explosive limit (UEL): The highest concentration of a gas or

vapor above which a flame will nor spread in the presence of anignition
source.

IV. Flammable range: The concentration of gas between lower and upper
explosive limit.

V. Permissible Explosive limit (PEL): PEL is a regulatory limit on the

amount or concentration of a substance in the air.

VI. Threshold limit value (TLV): PEL is a regulatory limit on the amount
or concentration of a substance in the air.

VII. Short term exposure limit (STEL): A short term explosive limit is the
acceptable average exposure over a short period time, usually 15 min as
long as the time weighted average is not exceeded.

VIII. Acute toxicity: Acute toxicity describes the adverse effects of a

substance that result either from a single exposure or from multiple
exposures in a short period of time.

IX. Chronic toxicity: Chronic toxicity is the development of adverse effects

as the result of long-term exposure to a toxicant or other stressor.

X. Excursion limit: The OSHA standard fibre per cubic centimetre worker
exposure limit to asbestos, averaged over a sampling period of thirty
minutes.

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Fire Triangle:

The fire triangle or combustion triangle is a simple model for understanding the
necessary for most fires.

The triangle illustrates the three elements a fire needs to ignite: heat, fuel and an
oxidizing agent (usually oxygen). A fire naturally occurs when the elements arepresent
and combined in the right mixture. A fire can be prevented or extinguished by removing
any one of the elements in the fire triangle.

• Oxygen is approximately 20% of the atmosphere.

• There has to be an initial source of heat to ignite the fire
• Fuel such as paper, wood or flammable substances.

Fig: 3.5.1 Fire triangle

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Types of fires:

CLASS MATERIAL EXTINGUISHERS

A Wood, paper, fabric Water

B Flammable liquids Foam

C Burning gases Carbon dioxide

D Combustible metal Dry chemical powder

E Electrical equipment Carbon dioxide

F Unsaturated cooling oil Carbon dioxide

Table: 3.5 Types of fire

Techniques to stop fire:

• Cooling: By reducing temperature of surrounding

• Smothering: By removing oxygen from fire.
• Starving: By removing the fuel in the vicinity of fire.

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NFPA Diamond

Fig: 3.5.2 NFPA Diamond

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3.6. Plant safety

• Electrical safety: High voltage electricity is required to automize a

chemical plant. So electrical safety should be given priority.

• Some methods of shock protection are:

a. Isolation: To limit the forces transmitted to the surroundings of the

equipment in which shock originates.

b. Limitation: To stop providing power to the origin of shock.

c. Low voltage: Use earth leakage circuit breakers to avoid high voltage.

d. Double insulation: For thick wires use highly durable insulation

material.

e. Earthing: Earthing is used to protect you from an electric shock. It

does this by providing a path for a fault current to flow to earth.

Fig: 3.7.1 Site safety

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PERSONAL PROTECTIVE EQUIPMENT (PPE):

• Personal protective equipment, commonly referred to as “PPE”, is equipment

worn to minimize exposure to hazard that cause serious workplace injuries and
illnesses. These injuries and illnesses may result from contact with chemical,
radiological, physical, electrical, mechanical, or another workplace hazard.

• PPE ma include items such as gloves, safety glasses and shoes, earplugs or
muffs, hard hats, respirators or coveralls.

Fig: 3.7.2 PPE

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List of PPE used in an industry:

Non-Respiratory Respiratory
Safety Helmet Dust mask
Safety goggles ½ mask
Ear plug Bubble hood mask
Hand gloves: Powdered Air purifying
Sharp object-Kevlar gloves Respirator
Solvent handling-Neoprene
Normal work-Rubber gloves
Hot work-Leather gloves

Safety shoes Supplied Airline Respirator

Safety Harness Self-controlled breathing apparatus
(SCBA):
1. Open circuit
2. Closed circuit

Protective clothes

Table: 3.7 PPE

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