PAKISTAN STEEL

Internship Report
Submitted to: In charge (HRD)
Submitted by: riaz kaim khani
Technology: Industrial Electronics
No of wees: Four weeks
!"ted: 08-07- to 0!-08-
#ni$ersity: Institute "# Industrial
Electronics Engineering
$I was on internshi% under letter & HRD'I()'08'!0
PRE%A&E:
It is reall* a +alua,le asset #or us to ha+e internshi% training at
(-.I/)-0 /)EE12 In this %rocess o# learning and e3%eriencing
we not onl* went through electrical technolog*4 ,ut also an
understanding in ac5uiring o# electrical e5ui%ments which
going to harness all the correlating com%onents4 which in #act is
making o# modern industrial estate2
/%eciall* more so in the case o# a newl* de+elo%ing and
emerging state like (akistan4 whose tremendous headwa* in
this 6eld is lia,le to #oster all round de+elo%ments in lie s%heres
o# socioeconomic de+elo%ment in the %resent era wherein we
are %lanning to enter the realm o# !
st
centur* with a ,ig ,ang2
)he +ital o%%ortunit* was ,ene6cial #or #urtherance in the
%ro#essional 6elds7 ena,le us toward4 accelerating %ro#essional
e3%ertise allowing us to engage on 8o, training4 #or which we
are so highl* inde,ted2
)his re%ort is ,ased on the %lant training at in di9erent %lants
o# (akistan /teel %ro+iding necessar* knowledge #or carr*ing
out +arious kinds o# electrical maintenance and re%air work2
)he training o# *oung engineers consists o# not onl* in
%re%aring them to skill#ull* and install4 o%erate4 ser+ice4 and
re%air di9erent electrical e5ui%ments ,ut also %re%ared them to
ena,le to go a,out it in mentall* alert and intelligent manner2
)he o,8ecti+e to write this internshi% re%ort is to su%%l* a
meaning#ul material not onl* #or the students who ha+e
com%leted this training4 ,ut it will also hel% to introduce the
training %ur%ose #or the #uture corners in %lant2
-n un#orgetta,le e3%erience o# +ast dimensions4 ,ringing us
more closel* to each other4 de+elo%ing4 national cohesion and
solidarit*4 which alwa*s ,e cherishing and radiating a %articular
glo,e o# ha%%iness and ,rilliance2
(age : !
A&KN'(LE!)E*ENT
I am +er* thank#ul #rom the core o# our heart to
;hairman (akistan /teel #or %ro+iding us o%%ortunit* #or
training whose intelligent wise and sound leadershi%
con+erted the man %ower into a winning com,ination
,* con+erting the industr* into goldmine2
I am also thank#ul to <r2 =ousu# -*u,4 D*2 <anager (I())
HRD #or his %recious ad+ice and #or the great amount o#
encouragement and coo%eration4 so that I ha+e
success#ull* com%leted m* internshi% training at
(akistan /teel and learned a lot and also <r2 Imtiaz D*2
<anager ()((-)>/) who hel%ed us in connecting our
theoretical and %ractical knowledge and also <r2 0adir
Hussain zaidi De%ut* <anager (/<D) and <r2
<uhammad -kram De%ut* <anager (;R< Electrical
/ection)
I wish to e3%ress m* dee% grate#ulness to all a,o+e
mentioned %ersonals #or their consideration and
su%er+ision7 it was a memora,le time in (akistan /teel
due to their kind concern2
(age : ?
(age : @
+, )ener"l Inform"tion:
+,+ Introduction: (akistan /teel <ills ;or%oration ((A)) 1)D
was #ounded on ?0 th Decem,er4 B7?2 )he #oundation stone was laid ,*
/haheed Cul65ar -li >hutto4 (rime <inister o# (akistan at that time2
(akistan /teel is strategicall* located @0km south east o# .arachi in close
+icinit* to %ort <uhammed >in Dasim2 (akistan /teel is a costal site which
lies on the 0ational Highwa* and is linked to the railwa* network2 /%read
o+er an area o# 84E00 acres (!B s5uare miles) with 04?B0 acres #or the
main %lant4 8070 acres #or the townshi% and !00 acres #or the water
reser+oir (akistan /teel is (akistanFs largest industrial com%le34
com%rising com%onent units num,ering more than !02
Due to its remarka,le 5ualit* management it has ,een accredited in I/"
B004 @004 70!G4 /- 8000 and "H/-/ 8002 It has a (roduction
;a%acit* o# 2 <illion )on o# /teel E3%anda,le u% to ?20 <illion )on %er
annum2 <ain (roduct %re%ared ,* (akistan /teel is ;oke4 (ig Iron4 >illets4
;old Rolled /heets4 Hot Rolled /heets4 and Hal+anized /heets2
+,- .istory:
-#ter inde%endence in B@7/ it did not take long #or (akistan to come to
the realization that %rogressi+e industrial and economical de+elo%ment
would ,e im%ossi,le without thecause serious set,acks to the countr*
along with an e3tortionatel* high im%ort ,ill which would ,e im%ossi,le to
su%%ort2
)he initial idea #or a domestic iron and steel mill was %ut #orward in the
6rst 6+e *ear %lan o# (akistan (BGG - BE0)2 De,ates o+er the
manu#acturing %rocess4 su%%l* sources o# the re5uisite machiner* and raw
materials4 %lant site4 domestic ore +ersus im%orted ore4 ownershi%
%attern4 %roduct mi3 and a,o+e all #oreign 6nancing credit ke%t the %ro8ect
on hold #or a considera,le time2
In BE8 ,esides other #actors4 it was considered ,* the Ho+ernment o#
(akistan that a ,asic steel industr* should ,e esta,lished in the %u,lic
sector4 as %u,lic s%onsorshi% o# the %ro8ect would ena,le integrated
de+elo%ment o# the steel industr* in the countr*2 In light o# this4 the
go+ernment decided that the .arachi /teel (ro8ect should ,e s%onsored in
the %u,lic sector #or which a se%arate ;or%oration under the ;om%anies
-ct ,e #ormed2 -s a result on the !nd o# Iul*4 BE8 (akistan /teel <ills
;or%oration was setu% as a %ri+ate limited com%an* in the %u,lic sector in
accordance to the ;om%anies -ct o# B?4 with the o,8ecti+e to esta,lish
and run steel mills at .arachi and other %laces in (akistan2
(age : G
In Ianuar*4 BEB4 (akistan /teel concluded an agreement with A'" )ia8%ro
e3%ort o# the then J//R #or the %re%aration o# a #easi,ilit* re%ort into the
esta,lishment o# a steel mill at .arachi2 /u,se5uentl* in Ianuar*4 B7
(akistan and the J//R signed an agreement under which the latter
agreed to %ro+ide techno-6nancial assistance #or the construction o# a
coastal ,ased integrated steel mill at .arachi2
)he #oundation stone #or this gigantic %ro8ect was laid on the ?0th o#
Decem,er4 B7? ,* the then (rime <inister <r2 Cul65ar -li >hutto2 )he
mammoth construction and erection work o# the integrated steel mill4
ne+er e3%erienced ,e#ore in the countr*4 was carried out ,* a consortium
o# (akistani construction com%anies under the su%er+ision o# /o+iet
e3%erts22
-ugust4 B8G with the ;oke "+ens and >* (roducts (lant coming online
6rst and the Hal+anizing Jnit last2 ;ommissioning o# >last Furnace
0um,er on the @th o# -ugust4 B8 marked (akistanFs entr* into the
elite clu, o# iron and steel %roducing nations2 )he %ro8ect was com%leted
at a ca%ital cost o# Rs2 !@4700 million2 )he com%letion o# the steel mill was
#ormall* launched ,* Heneral Cia-Jl-Ha5 the then (resident o# (akistan on
the Gth o# Ianuar* B8G2
)oda* (akistan /teel is the countr*Fs largest industrial undertaking ha+ing
a %roduction ca%acit* o# 2 million tons o# steel2 )he enormous
dimensions o# the %ro8ect can ,e +isualized #rom the construction in%uts
which in+ol+ed the use o# 2!B million cu,ic meters o# concrete4 G270
million cu,ic meters o# earth work (second to )ar,ela Dam)4 ??04000 tons
o# machiner*4 steel structures and electrical e5ui%ment2 Its unloading and
con+e*or s*stem at (ort Dasim is the third largest in the world and its
industrial water reser+oir with a ca%acit* o# 0 million gallons %er da* is
the largest in -sia2 - !2Gkm long sea water channel connects the sea
water circulation s*stem to the %lant site with a consum%tion o# !E
million gallons o# sea water %er da*2
)he a,o+e 6gures illustrate the massi+e ci+il works4 intricate erections4
installations o# so%histicated electrical and mechanical e5ui%ment2 Kith
the com%letion o# (akistan /teel4 the local contractors gained the
technical a,ilit* till then unknown4 which the*
+,0 1ision "nd *ission
)o ,ecome a leading steel com%an* in /outh -sia committed to ser+e
stakeholders ,* o9ering 5ualit* %roducts through inno+ati+e and cost
e9ecti+e manner in en+ironmental #riendl* conditions2
(akistan /teel is committed to ,e leading in steel industr* ,*L
Hreater res%onse to consumer needs
High em%hasis on %roducti+it* and 5ualit*
(age : E
Facing challenges o# #ree market econom*
Ensuring #air rate o# return o# in+estment
De+elo%ing human resources and moti+ating em%lo*ees through
e5uita,le dis%ensation
/a#e working and en+ironmental #riendl* conditions
<inimizing and rec*cling wastes
Ful6lling social o,ligations
Im%ro+ing cor%orate image through %er#ormance
2. THERMAL POWER PLANT
AND TURBO BLOWER
STATION
(age : 7
-, Therm"l Power St"tion:
Heneration o# Electric (ower is the +er* 6rst ste% to meet the demands o#
energ*2 Electrical energ* is generated at +arious +oltage le+els4 which are
E .A4 2G .A to a ma3imum o# !G .A2 In (akistan4 the energ* is generated
at a +oltage le+el o# 2G.A mostl*2
(akistan /teel generates electrical energ* using )hermal Energ*2 )hermal
(ower (lants %roduce %ower through heat energ*2 In such %ower %lants oil4
gas4 diesel and coal are used to %roduce heat and intimatel* steam is
%roduced to rotate the ,lades o# tur,ine2
(akistan /teelMs )hermal (ower (lant com%rises o# ? )ur,o generators
each with a generating ca%acit* o# GG<K with a com,ined ca%acit* o#
EG<K2 )wo o# the generators are under o%eration while the third is #or
stand,* o%eration2)(( is a utilit* %lant4 installed to utilize the waste #rom
di9erent %lants at (akistan /teel <ills2 It utilizes the ,last #urnace gas4 a
waste #rom I<D4 coke o+en gas and coal tar gas4 a waste o# ;">( #or the
generation o# steam which is to %roduce electrical energ* #rom the
generators2 It is di+ided into di9erent sections2
-,+ Sections of Power Pl"nt:
2 Kater chemical )reatment (lant (K;)()
!2 >oiler /ection
?2 )ur,ine section
@2 <ain /witch Hear Room (</HR)
G2 )ur,o >lower /tation ()>/)2
-,- ("ter &hemic"l Tre"tment Pl"nt: ;ertain water
5ualities are necessar* #or steam generation at steam generators2 )o
ac5uire these 5ualities4 water is treated chemicall* and mechanicall* at
K;)(2 )reatment c*cle is as #ollowsL

i2 Drinking water (#rom .en8har 1ake)
ii2 ;oagulation (#or the remo+al o# dissol+ed %articles #rom water
using clari6ers and adding ;a("H)! N Fe/"@)
(age : 8
iii2 <echanical Filtration( to remo+e sus%ended solid %articles #rom
water)
i+2 (rimar* ;ation E3changers(where water is treated #or remo+ing
hardness4 i2e2 0a4 <g and ;a with the hel% o# resin)
+2 (rimar* anion E3changers (#or remo+ing chlorine4 silica and
nitrates #rom water)
+i2 De ;ar,onizers (to remo+e e3cessi+e dissol+ed gases #rom
water)
+ii2 /econdar* ;ation N -nion E3changers(the same %rocess
re%eated to a+oid an* risk o# hardness)
"+erall ca%acit* o# K;)( #or de mineralized water %roduction is !G0
tons'hr2 It also controls the su%%l* o# ammonia and h*drogen h*dride to
steam generator section to maintain water 5ualit*2
-,0 2oiler Section: /team #or tur,ines and other %lant
%rocesses is generated in #our units o# /team generator section2 Each unit
generates !!0 tons'hr su%erheated steam o# 00 kgF'cm! N G?G-G@0 2
-ll are water tu,e natural circulation +ertical ,oiler units and use >2F4 ;"4
;oal )ar and 0atural Has as #uel in ,urners2 )heir common su%%l* duct
com,ines the steam generated ,* all units and su%%lies it to all tur,ines2
;onstruction "+er+iewL Each unit consists o# the #ollowing ma8or %arts2
2 >oiler Drum ( with @! c*clones in u%%er hal# and @! down comer
in lower hal#4 %ro+ided with ! steam strainers and steam lines in
u%%er %ortion4 with lower hal# #urther di+ided into /alt* N ;lean
sections)
!2 Furnace ;ham,er2
?2 Induced Dra#t Fan N Forced Dra#t Fan2
@2 Regenerati+e -ir Heater ()em%erature o# air coming #rom R-H is
!E0O ;2
/ome other com%onents used in #eed water N steam c*cle are
(age : B
2 Dearators (two dearators o# 2! -)- N E -)- are installed that work
under tur,ine section2 Ideal tem% to remo+e ma3 o3*gen is E0O ;
and the ca%acit* o# dearator is E ton'hr2
!2 Feed (um%( <ultistage %um% with 0 im%ellers4 rotates at !EB0 r%m
and its dri+ing motor is ! <K while it sucks the #eed water at E -)-
,e#ore su%%l*ing to ,oiler drum +ia Feed Jnit)
?2 H( N 1( Heaters2
-,3 Turbine Section: It is the %rime mo+er o# the generator2
"ut o# ? %rime mo+ers4 )H is dou,le c*linder tur,ine with !8 stages
while other two are singe c*linder with !! stages2 -ll are com%ound t*%e
tur,ines (Im%ulse-Reaction com,ination) with single Pow condensing
design o%erating in a close c*cle2 )o control and regulate the s%eed o#
tur,ines4 s%ring loaded go+erning s*stem is installed2 Four regulator*
+al+es are %ro+ided #or steam distri,ution to tur,ine and a main sto%
+al+e #or steam inlet2 /hell and tu,e t*%e condenser with an e8ector
s*stem is also %ro+ided with it2 "il tank cooler4 starting N D; oil %um%s
are installed2 Each tur,ine has ? H( N ? 1( Heaters2
)hree tur,ines are installed each #or a ca%acit* o# GG <K and #or
this4 the* utilize !!0 tons'hr steam o# B0kgF'cm! at a tem% o# G?G-G@0O ;2
/team enters the tur,ines +ia regulating +al+es and during its %assage
#rom im%ulse and reaction stages4 it gi+es its energ* to tur,ines in the
#orm o# its motion and tem% N %ressure o# steam dro%s to 02G kgF'cm!
and G0-E0O ;2 <a3imum %ressure dro% occurs at 6rst stage called ;urtis
Kheel causing the tur,ine to initiall* rotate at @ r%m with a gradual
increase to G00 r%m and then !00 r%m #ollowed ,* !G00 r%m to a
ma3imum o# ?000 r%m2 )he mo+ement o# tur,ine sha#t is trans#erred to
generator sha#t which is electricall* magnetized2 -s it rotates4 it cuts the
magnetic Pu34 and em# is induced in the stator winding which is then
trans%orted to </HR2 Di9erent electronic %ressure gauges4 thermo
cou%les4 indicators and %rotection de+ices are installed to a+oid an*
irregularit* and accident2
)he generators are h*drogen cooled owing to its good s%eci6c heat2
)ENRAT'R SPE&I%I&ATI'NSL
)*%eL )> ?Q-GG-!7?4 2G .A /tator ;urrentL ?@E0 -
Rated /%eedL ?000 r%m Rotor ;urrentL !80 -
Rated Fre5uenc*L G0 HC (ower FactorL 028
(age : 0
(hase ;onnectionsL =-= H*drogen Rated (ressureL BE .(a
Rated (owerL E87G0 .A-
<-DE I0 J//R in 882
-,4 *"in Switch )e"r Regul"tor: Energ* generated
through tur,ine is trans%orted to </HR s*stem through ,us,ars4 which
then distri,utes this energ* through its distri,ution s*stem2 )he whole
s*stem consists o# ste% u%' ste% down trans#ormers4 circuit ,reakers and
rela* %rotection s*stems2 </HR ste%s u% energ* to .A and ste%s down
to E .A and su%%l* them to desired locations2 )his s*stem is s*nchronized
with .E/; #or ma3imum relia,ilit* to sustain ra%id load Puctuations2 "n
main lines4 Has circuit ,reakers are used and on internal lines4 oil ,reakers
are used while +acuum ,reakers are rarel* used2
In order to s*nchronize two %ower s*stems such as )(( N .E/;4 the
#ollowing re5uirements should ,e metL
1. )he rms line +oltage o# two s*stems must ,e the same2
2. )he two s*stems should ha+e the same %hase se5uence2
3. )he %hase angle ,etween RaM %hases o# the two s*stems
should ,e e5ual (the di9erence ,etween the %hase angle
should not e3ceed G, otherwise the system might experience a
huge surge causing it to trip)
4. The frequency of oncoming generator should e slightly higher than the
running system.
)he </HR includes a total o# !? #eeding units (#eeders) with D; ,acku% #or
the whole s*stem in case o# emergenc*2 )here are three t*%es o# D;
,acku%s which are ,eing used to tri% o9 the s*stem in case a #ault*
condition occurs2 "ne t*%e includes a Kard-1eonard /*stem (/*nchronous
motor- D; generator set)4 the second one consists o# ?0 units o# ! +olts
D; ,atteries (each in series) and the other one is )rickle ;harger2
)he #ollowing e5ui%ments are installed in the switch*ard (where
s*nchronization takes %lace) ne3t to </HRL
2 )wo E? <A-4 ?!'2G'E2E .A4 =-!"! (ower )rans#ormers2
!2 -u3iliar* ;om%onentsL <eters4 ;urrent trans#ormers4 (otential
trans#ormers2
(age :
?2 ;ontrol ;om%onentsL Isolators4 ;ircuit >reakers4 >us ;ou%lers2
@2 (rotection ;om%onentsL Fuses4 Rela*s4 Earthing4 1ightening
-rrestors2
G2 /ta,ilit* ;om%onentsL )a% ;hangers4 -uto Re-closers4 ;hange o+er
/witches4 Aoltage Regulators (shunt ca%acitors4 shunt reactors4
static A-R com%ensators
)heir /%eci6cations are shown in the 6gure ,elowL
(age : !
(age : ?
-,5 Turbo 2lower St"tion: It is installed to ensure consistent
su%%l* o# air to the ,last #urnace o# Iron making de%artment2 ;entri#ugal
;om%ressors sucks air #rom atmos%here and su%%l* com%ressed air to >F2
;om%ressors take their dri+e #rom steam tur,ines2 - total o# ? units are
installed4 the tur,ine o# each unit is ! stage and o# ! <K ca%acit* and
re5uire ?0 .gF'cm! at @00O ; and the 5uantit* o# steam re5uired is !G-@0
tons'hr2 )he s%eed range o# tur,ines is !E00-?@00 r%m while working
range is !700-?!00 r%m2 )he @ stage com%ressor allows the air Pow
ranging #rom 7G0-!E00 m?'min at a %ressure o# ?2G .g F'inch!2 -ir
su%%lied to >F called ;old >last is at a tem% o# 7B-!0O ;2 E5ui%ments
used at station are
2 "il ;ooler
!2 "il (um%
?2 -ir 6lters
(age : @
3. ENGINEERING LAB
Proportion of real power in total or apparent power is called power factor
How to amplify mechanical power? Using gears
Electrical power is stored using capacitors and batteries
Mechanical power is stored using springs
Control are of two types:
i. Auto control automation!
ii. Manual control
3.1 AUTOMATION:
Automation is a techni"ue in which any process going to complete according to
set point without help of human resources# and going on continuously
3.2 MANUAL CONTROL:
Manual control is a techni"ue in which any process going to complete according
to set point with help of human resources# and going on continuously.
3.3 INDUSTRIAL PRIMARY
3.3.1 SENSORS/TRANSDUCERS:
$. %ibration transducer
&. 'emperature transducer
(. Pressure transducer
). *e+el transducer
,. -low transducer
3.3.2 Device Use !"# T$e Me%s&#e'e() O* Te'+e#%)&#e:
$. -or low temperature ./)..
o
C!# we use thermometer
&. -or moderate temperature )../0..
o
C!# we use 1'2s
(. -or high temperature up to $3..
o
C!# we use thermocouples
(age : G
3., THERMOCOUPLE-s
3.,.1 WOR.ING PRINCIPLE:
4hen two different metal wires are welded at one end and left open at the other
end# then heated# after that mili +olts are produced at the open end. 'wo
commonly used materials for thermocouple are platinum and rhodium.
3.,.2 RTD-s:
1esistance temperature dependent
'hermo resistor changes the ohmic +alue
3.,.3 Di**e#e(ce //0 +#i'%#1 2 sec"(%#1 i(s)#&'e()s:
PRIMARY INSTRUMENTS:
'hose instruments which are mounted on or near the process# i.e. the
instruments which senses a signal and beha+es as input de+ice.
SECONDARY INSTRUMENTS:
'hose instruments which are mounted in control room# i.e. the instruments
which produce an output in response of input signal
3.,., E3AMPLE O! AUTOMATION O! BLAST
!URNACE:
5y means of con+eyer belt# iron ore is dropped into the blast furnace which is
surrounded by glass.
(age : E
4hen the material is melted properly then a hole is made by drill machine to
collect molten iron. After the collection of molten iron# the hole is again filled
by means of mud gun.
4e sense the temperature of blast furnace by thermocouples which gi+e output
in mili+olts# and then this signal is gi+en to indicator6recorder for displaying on
graph paper. 7t is then sent to controller which performs the desired operations#
and then output is gi+en to starter which regulates the motor through +al+e.
3.4 TYPES O! SWITCHING:
3.4.1 THERMAL SWITCHING:
'hermal switching occurs due to temperature change# it includes# bi
metallic strip which bends due to increase in temperature and hence
brea8 the contact.
3.4.2 PROTECTION SWITCHING:
Protection switching occurs due to drastic current flow short circuit!
3.4.3 WAY O! TROUBLESHOTING:
-irstly we 8now that from where and how much supply is to be gi+en#
secondly from where input is applied# last from where output is
collected. Enter the circuit and trouble shot each component
se"uentially
(age : 7