Internship Report for Electrical Enginee PDF

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2012 Nishat Mills LTD Submitted by : Muhammad Gulraiz Ahmed NFC Institute Of Engineering & Fertilizer Research Faisalabad (affiliated with UET LHR)

[INTERNSHIP REPORT] Electrical Engineering (power)

In the name of ALLAH The Gracious and The Benevolent

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Acknowledgements First of all the whole praise to ALMIGHTY ALLAH, the creator of the universe and anything in this universe. He made us super creature, blessed us to accomplish this work. We are very thankful to Allah Almighty, Who has provided us such an opportunity to gain knowledge in Ibrahim Fibers Limited. It was a great experience to do internship over here. We learnt many things practically which we have learnt theoretically earlier. We also pay our gratitude to the Almighty for enabling us to complete this Internship Report within due course of time. Words are very few to express enormous humble obligations to our affectionate Parents for their prayers and strong determination to enabling me to achieve this job. We would like to thank all the administration engineers, operators and officials for helping us and for their kind behavior.

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Introduction Nishat Group billion (US$ 5 billion), it ranks amongst the top five business houses of Pakistan. The group has strong presence in three most important business sectors of the region namely Textiles, Cement and Financial Services. In addition, the Group also has reasonable market share in Insurance (Adamjee and Security General), Power Generation, Paper products ( Nishat Shoaiba Paper Mills) and Aviation ( Phonix Aviation). It also has the distinction of being one of the largest players in each sector. The Group has a remarkable position in the market as good as any multinationals operating locally in terms of its quality of products, services and management skills.Nishat Group is one of the leading and most diversified business groups in South East Asia with fixed/ current assets of over Rs.300

Executive Summary Nishat has grown from a cotton export house into the premier business group of Pakistan with 5 listed companies, concentrating on 4 core businesses; Textiles, Cement, Banking and Power Generation. Today, Nishat is considered to be at par with multinationals operating locally in terms of its quality products and management skills. I recently have done my internship in Nishat Mills Limited, in which I got training from each of its department. The internship basically revolved around the product knowledge training. The system, the style of working & the commitment of the employees in NML is really exemplary. The difference between the success & failure is doing things right and doing things nearly right, & NML has always tried for success & that is why it is known to be one of the leading organizations in Pakistan. Irrespective of all these positive points of Nishat Mills Limited, I have 3

noticed a few areas where the improvement can really increase the efficiency of NML. In this report I have given a very brief review of what I have seen during our internship I have mentioned all these as I have made an internship as according to the schedule. I also mentioned about the Textile industry in Pakistan and vision of its industry. Then I have done a detailed SWOT analysis as well as PEST Analysis. Then I have discussed about my learning in the whole internship that is all about the Textile Terminologies and process of the productions. I have made it possible to write each and every thing that I have learnt there. I have all my practical efforts in the form of this manuscript that’s the asset for my future career.

Vision Statement To transform the Company into a modern and dynamic yarn, cloth and processed cloth and finished product manufacturing Company that is fully equipped to play a meaningful role on sustainable basis in the economy of Pakistan. To transform the Company into a modern and dynamic power generating Company that is fully equipped to play a meaningful role on sustainable basis in the economy of Pakistan.

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Mission Statement To provide quality products to customers and explore new markets to promote/expand sales of the Company through good governance and foster a sound and dynamic team, so as to achieve optimum prices of products of the Company for sustainable and equitable growth and prosperity of the Company.

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Company Profile Nishat Mills Limited is the flagship company of Nishat Group. It was established in 1951. It is one of the most modern, largest vertically integrated textile company in Pakistan. Nishat Mills Limited has 198,120 spindles, 655 Toyota air jet looms. The Company also has the most modern textile dyeing and processing units, 2 stitching units for home texitle, one stitching unit for garments and Power Generation facilities with a capacity of 89 MW. The Company’s total export for the year 2011 was Rs. 36.015 billion (US$ 416 million). Due to the application of prudent management policies, consolidation of operations, a strong balance sheet and an effective marketing strategy, the growth trend is expected to continue in the years to come. The Company's production facilities comprise of spinning, weaving, processing, stitching and power generation.

Quality Policy We work together as a team for implementation and continual improvement of total quality system in order to achieve satisfaction of our internal and external customers.

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Board of Directors As on April 05, 2012 1 2 3 4 5 6 7

Mian Umer Mansha Mian Hassan Mansha Mr. Khalid Qadeer Qureshi Mr. Muhammad Azam Syed Zahid Hussain Ms. Nabiha Shahnawaz Cheema Mr. Maqsood Ahmad

Director/CEO/Chairman Director Director Director Director (Nominee NIT) Director Director

Power Generation (MESSAGE FROM CEO) Mobilizing and generating affordable and environment-friendly energy resources is one of the key challengers for any nation in today's world. Today the top priority for Pakistan is Energy and Power Generation. Presently, Out of around 162 million population only 65-70% has access to electricity. To Enter into power generation business is one of the diversified decision of Nishat Group with the vision to enhance its Investment into Energy Sector. Nishat Power Ltd. (NPL) a public limited company was incorporated in February 2007 under the Companies Ordinance for setting up power plant under the Power Policy 2002 on Build, Own and Operate ("BOO") basis. Its a 200 MW Combined Cycle Power Plant based on Reciprocating Engine Technology. The 7

primary fuel of the Plant is Residual Furnace Oil ("RFO") and its uninterrupted supply is guaranteed by SHELL Pakistan. The Plant Configuration is eleven (11) proven Engine sets of type 18v46 manufactured by WARTSILA of Finland and eleven (11) generating sets, One (1) Heat Recovery Steam Turbine with generator.As per the Power Purchase Agreement, the NTDC has contracted to purchase the total net generation capacity of 195.26 MW produced by NPL for a period of 25 years at US cents 12.1253 per KWh. As the plant will operate on residual furnace oil, a Fuel Supply Agreement ("FSA") has been signed between the Company and Shell Pakistan Limited for a period of ten years after the commencement of commercial production.The entire plant, machinery and equipment required for the project has been procured from Wartsila Finland Oy. Whereas, Wartsila Pakistan (Private) limited has been appointed for the construction, erection, installation testing and commissioning of the entire project. We have also awarded Wartsila Pakistan an Operations & Maintenance Contract for our Plant.The total cost of the project including interest during the construction period is around PkR17.704 billion.

Major Consideration of the Project were: The Project would offer significant relief locally in the transmission system of Lahore, as it would bypass long transmission lines and potential stepdown transformer bottlenecks. There is currently no significant power generation inside this area The plant generation would be consumed very close to the generation site, thus also reducing substantial transmission losses The Project has been finalized and commissioned on a fast-track basis within 18 months as a power generation plant based on reciprocating engine single fuel RFO fired technology It is hoped that NPL's power project, the RFO based power plant under Power Policy 2002, shall serve as role model for others to follow. 8

Safety Precautions In order to avoid the hazards on the plant, company train their employees for the Safe handling and operation of materials and units installed on plant. So for this company follow following steps:

Authorization Even a small mistake on the plant can cause a serious damage so MMM (man, machine, material) is very important.

nting out and also some

crossing the roads and also tanks with explosive materials are present at different places and anything hitting them may cause a serious danger. workers and as a result, their work may be ignored. for every unit some guider is provided for the specific period of time and we are not allowed to go in any area according to our desire. other to prevent injury of workers. computer control systems to prevent the tripping of systems as they are very sensitive.

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water in that area is of very high conductivity. for the workers. material for the safe handling and storage of the materials. ded for the safe operations.

overcoming fire. Safety Measures: Safety measures are activities and precautions taken to improve safety, i.e. reduce risk related to human health. Common safety measures include: o Root cause analysis to identify causes of a system failure and correct deficiencies. o Visual examination for dangerous situations such as emergency exits blocked because they are being used as storage areas. o Visual examination for flaws such as cracks, peeling, loose connections. o Chemical analysis o X-ray analysis to see inside a sealed object such as a weld, a cement wall or an airplane outer skin. o Destructive testing of samples o Stress testing subjects a person or product to stresses in excess of those the person or product is designed to handle, to determining the "breaking point". 10

o Safety margins/Safety factors. For instance, a product rated to never be required to handle more than 200 pounds might be designed to fail under at least 400 pounds, a safety factor of two. Higher numbers are used in more sensitive applications such as medical or transit safety. o Implementation of standard protocols and procedures so that activities are conducted in a known way. o Training of employees, vendors, product users o Instruction manuals explaining how to use a product or perform an activity o Instructional videos demonstrating proper use of products o Examination of activities by specialists to minimize physical stress or increase productivity o Government regulation so suppliers know what standards their product is expected to meet. o Industry regulation so suppliers know what level of quality is expected. Industry regulation is often imposed to avoid potential government regulation. o Self-imposed regulation of various types. o Statements of Ethics by industry organizations or an individual company so its employees know what is expected of them. o Drug testing of employees, etc. o Physical examinations to determine whether a person has a physical condition that would create a problem. o Periodic evaluations of employees, departments, etc. o Geological surveys to determine whether land or water sources are polluted, how firm the ground is at a potential building site, etc.

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Different Safety Signs Safety signs are used for indication of the hazard involved while carrying out the certain action. They are very helpful in for the subject as they give clear guideline about the hazard that one could face at the site where they are erected. Some different safety signs are:

In safety there is a rule of triple M.  Man safety  Machine safety  Material safety Man safety In safety the first thing is man safety. Man safety is one of the important things between the rules of safety. Man safety means how to safe man in working area (plant).Mask, safeguard, gloves etc are provided for safety. Also no use of mobile

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Machine safety Machine safety is also important. The trouble shoot, maintenance of temperature is the important one. No use of mobile near to machine because safety of tripping and matching of frequency.

Material safety The safety of material is also important. The thing like sand is safe according to its way of safety. Other things like PTA, MEG are store according to its conditions.

Power Distribution The feeder lines are fed to the panels situated there which are connected to each other with bus couplers along with VCB breakers. From there, these lines are fed to Transformer Room where the voltage is stepped down from 11KVA to 415V. The lines from the transformers are fed to LVD Room in the form of bus wires. The bus wires are fed to the panels in LVD Room where the panels are connected in the form of Ring Main System along with Power Factor Control and ACCB Breakers for safety purpose. From there, the power is supplied further as per requirement.

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MCC Room The purpose of this room is to control the speed of the motors hence controlling the output of the SPG/DL-1 section. The speed is controlled through inverters which in turn are controlled through PLCs via Control Room. The explanation of different terms and the equipment mentioned above will be explained after giving the summary of each section. MCC is the motor control centre which is controlling the all the motors and pumps connected in the specific area. In MCC room the panels which are controlling the Motors parameters the technology which is using in MCC room is the one of the modern technology which the inverters based. The inverter work is converts the voltage waves into one form to the other. The main two inverters are using in the MCC room of polyester plant are the following: AC to AC inverters DC to AC inverters The main purpose of the invertors is that many motors which are using in the plant are proportional to the frequency and the power we having the frequency of 50 Hz so that by using invertors we can vary the frequency of the power given to the motor. We known t the speed is directly proportional to the frequency we apply.

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UTILITIES Soft Water Fresh raw water is pumped from ground and is transported to the water plant. In plant they are further pumped to gravel bed in a closed vessel. Small portions of Hydro-chloric acid (HCl) are added to the filtered water kill bacteria and to lower pH value. Then it passes through bag filter which consists of series of fibers to deposit gravel on them. The water that passes the laboratory test is termed as Soft water, and this is the major production of plant. The soft water produced is then decarbonised. Decarbonisation is a process in which air is pumped into water to remove carbon content. Daemon Water The soft water is passed through the bed of mixed cation and anion bed and it become demineralised. Daemon water is then stored in another vessel (4010-V05). Daemon water is used in chilled water circuit, boiler house etc. Drinking Water Soft water from the storage vessel and some small amount of raw water is passed through the bed of calcium hydrolit. Drinking water produced is then stored in drinking vessel.

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Boilers Boiler house have 3 boilers. All boilers are of fire tube types having three passes and a super heater. Water is accumulated in the shell and it surrounds the tubes. Fire is passed through first pass where combustion take place, from first pass end it enters the second pass from behind, leave the second pass from front and the fire rises to the super heater then it enters the third pass, exhaust gases leave the boiler at boiler rear face to the exhaust chimney erected outside the boiler house. There are basically two types of boilers:  Fire tube boiler  Water tube boiler Fire tube boiler The name fire tube is very descriptive. The fire, or hot flue gases from the burner, is channeled through tubes that are surrounded by the fluid to be heated. The body of the boiler is the pressure vessel and contains the fluid. In most cases this fluid is water that will be circulated for heating purposes or converted to steam for process use. Every set of tubes that the flue gas travels through, before it makes a turn, is considered a "pass". So a three-pass boiler will have three sets of tubes with the stack outlet located on the rear of the boiler. Fire tube Boilers are:     

Relatively inexpensive Easy to clean Compact in size Available in sizes from 600,000 btu/hr to 50,000,000 btu/hr Easy to replace tubes 16

 Well suited for space heating and industrial process applications

Disadvantages of Fire tube Boilers include:  Not suitable for high pressure applications 250 psig and above  Limitation for high capacity steam generation Three pass Fire tube boilers are used in the IFL. There are 3 fire tube boilers are used in IFL. One is stand by while 2 are in operation.

Water Tube Boiler A Water tube design is the exact opposite of a fire tube. Here the water flows through the tubes and are incased in a furnace in which the burner fires into. These tubes are connected to a steam drum and a mud drum. The water is heated and steam is produced in the upper drum. Large steam users are better suited for the Water tube design. The industrial watertube boiler typically produces steam or hot water primarily for industrial process applications, and is used less frequently for heating applications.

Water tube Boilers are:  Available in sizes that are far greater than the fire tube design. Up to several million pounds per hour of steam.  Able to handle higher pressures up to 5,000 psig  Recover faster than their fire tube cousin 17

 Have the ability to reach very high temperatures

Disadvantages of the Water tube design include:    

High initial capital cost Cleaning is more difficult due to the design No commonality between tubes Physical size may be an issue

Fuel for boiler:  Natural gas (mostly used)  Furnace oil (stand by) The steam at 25 bar pressure is then divided in to 3 different pressures  25-bar , 10-bar , 6-bar

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Parts Of Boiler:

Evaporator – A liquid vapor refrigerant mixture enters the evaporator at state point 1. Liquid refrigerant is vaporized to state point 2 as it absorbs heat from the system cooling load.The vaporized refrigerant flows into the compressor first stage.

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Compressor first stage – Refrigerant vapor is drawn from the evaporator into the first stage compressor. The first stage impeller accelerates the vapor increasing its temperature and pressure to state point 3. Compressor second stage – Refrigerant vapor leaving the first stage compressor is mixed with cooler refrigerant vapor from the economizer. This mixing lowers the enthalpy of the vapor entering the second stage. The second stage impeller accelerates the vapor, further increasing its temperature and pressure to state point 4. Condenser – Refrigerant vapor enters the condenser where the system cooling load and heat of compression are rejected to the condenser water circuit. This heat rejection cools and condenses the refrigerant vapor to a liquid up to point 5. Economizer and refrigerant orifice system – Liquid refrigerant leaving the condenser at state point 5 flows through the first orifice and enters the economizer to flash a small amount of refrigerant a an intermediate pressure labeled P1. Flashing some liquid refrigerant cools the remaining liquid to state point 8. Another benefit of flashing refrigerant is to increase the total evaporator Refrigeration Effect from RE’ to RE. The economi...