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REPORT - 2014
Mechanical Section
National Engineering Services Pakistan-NESPAK
6/27/2014
Prepared by:
Danial Sohail ME-089
Muhammad Bilal Javaid ME-120
Syed Irfan Ali ME-076
Sagar P. Jesrani ME-122
Zohaib Azhar Mallick ME-178
All praise to ALMIGHTY ALLAH, the creator of the universe and all
thing 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 National
Engineering Services Pakistan (NESPAK). It was a great experience of
getting trained 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.
We would like to thank all staff, especially Mr. Saeed Ahmed Soomro,
for helping us and for their kind behavior towards us throughout our
internship. We acknowledge that we were unable to learn this much on
our own.
Thank you!
With warm regards;
Danial Sohail
Muhammad Bilal Javaid
Syed Irfan Ali
Sagar P. Jesrani
Zohaib Azhar Mallick
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Table of Contents
Executive Summary ....................................................................................................................................... I
Lifts / Elevators ............................................................................................................................................. 1
Types of Lifts ................................................................................................................................... 2
Advantages and Disadvantages of Different Types of Elevator ....................................................... 3
Components of Elevator System ...................................................................................................... 4
Elements of Lift Design .................................................................................................................... 7
Famous Lift Manufacturers .............................................................................................................. 8
Visit to NICL Elevator System ........................................................................................................... 9
Fuel Storage Tanks ..................................................................................................................................... 10
Orientation of Storage Tanks ......................................................................................................... 11
Basic Components of Storage Tanks .............................................................................................. 13
Fuel Storage Tank Designing .......................................................................................................... 14
Designing of 10000 Liter Fuel Storage Tank................................................................................... 15
Fire Suppression System ............................................................................................................................ 16
Classes of Fire................................................................................................................................. 17
Fire Ingredients .............................................................................................................................. 17
Fire Suppression Techniques ......................................................................................................... 18
Fire Suppression Using Gases ........................................................................................................ 19
HVAC ........................................................................................................................................................... 21
Goal of an HVAC System ................................................................................................................ 22
Components of an HVAC System ................................................................................................... 23
Split Air Conditioner System .......................................................................................................... 24
Packaged Air Conditioner............................................................................................................... 25
Cooling Tower Technology............................................................................................................. 27
Chillers ........................................................................................................................................... 29
Air Handling Units .......................................................................................................................... 30
Pumps ............................................................................................................................................ 32
Positive Displacement Pumps ........................................................................................... 32
Kinetic Pumps ................................................................................................................... 38
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Welding Techniques ................................................................................................................................... 41
Gas Welding ................................................................................................................................... 42
Arc Welding .................................................................................................................................... 42
Shielded Metal Arc Welding .......................................................................................................... 43
Gas Shielded Arc Welding .............................................................................................................. 43
Weld Joints ..................................................................................................................................... 44
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Preface
Internship is one of the keys for understanding more deeply the concepts
learned from formal education by going through practical practices
adapted by industries. And this rationale brought us to National
Engineering Services Pakistan NESPAK.
During our internship we have learned a lot about building services and
HVAC systems. Every topic from crust to core was explained to us and
this report is an overview of what we learned. Information in this report
is gathered from different sources like instruction manual, project
proposals, online websites and notes provided by instructors.
This document gives reader an insight of design techniques for lifts,
storage tanks, and HVAC systems along with introduction to
international standards. Interactive visuals provide an ease to reader for
understanding cyclic process and dont let reader to get bored as
traditional technical text does.
We have tried our best to eliminate all mistakes and misrepresentation of
facts but since its natural for humans to make mistakes, so we ask your
pardon in advance for any such mistake.
Thank you!
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Executive Summary
Introduction:
During our internship at Mechanical Section NESPAK, we have gone through a lot
of stuff related to Building Services and HVAC system. We have studied and
discovered functioning of lifts, designing of fuel storage tanks, fire suppression
systems, welding techniques, HVAC systems and components, pumps and
Window and Split air conditioning systems.
Following is a brief topic wise detail of subjects we have studied during our
internship.
Lifts / Elevators:
Starting from basic types of lifts, area of application, advantages, disadvantages of
each type, our study have been extended to techniques of lift selection for
residential buildings, offices and medical facilities. Also visit to N.I.C.L building
Elevator system gave us an insight of working procedure of elevators.
HVAC:
NESPAK has its expertise in designing HVAC systems for residential buildings,
offices, medical facilities. During our posting in HVAC systems we have learned a
lot about HVAC system, from the main reason for employing HVAC to goals
HVAC should be accomplished, we have learned about components found in every
HVAC system along with types of air conditioning systems for better
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understanding of working of each component. Not just study of systems but also
the study of their governing refrigeration cycle gave us an insight of purpose of
each component. Special attention was given to study of pumps because it has its
application not only in HVAC but also in Waste Water Treatment, Fuel
transportation, Industrial purposes. Therefore we have studied all pump types and
area of their application.
Welding Techniques:
Welding is most used method for making parts in industry, from seamless pipes to
chases of cars, most structures are joined by weld. Welding techniques includes
preparation of work piece before welding, pre heating of work piece and
electrodes. Welding techniques also includes selection of appropriate welding
mechanism according to application and purpose of weld.
Conclusion:
Internship at NESPAK is one of most knowledgeable period in our professional
lives. We have learned a lot here, all staff specially engineers helped us throughout
our internship and we hope that this knowledge we are taking from here will help
us throughout our life.
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LIFTS / ELEVATORS
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Nowadays buildings are becoming taller and taller to confine large population into
a small piece of land, but access to floors above ground is inconvenient if done by
staircase because they are both time consuming and tiring, therefore lifts and
escalators are employed for transporting people from one floor to another.
Types of Lifts
Lifts are of two types
Traction Lifts
Hydraulic Lifts
Traction lift:
Works on the principle of pulling whereas hydraulic powered lifts works by
lifting through pushing action. In traction lifts pulling is done by electric motors
which rotate the pulley over which wire controls the motion of lift
corresponding to motion of balancing weights.
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Traction Lifts:
They can lift up to greater heights.
They have greater speeds
They are more costly than hydraulic elevators.
Elevator Car:
Elevator Car is the vehicle that travels between the different elevators stops
carrying passengers and/or goods, it is usually a heavy steel frame surrounding
a cage of metal and wood panels.
Shaft:
A vertical shaft in a building that gives passage to elevator to travel from floor
to floor
Guides:
Guides provide ways for traveling of cabin and counterweight and avoid
unnecessary vibration, providing a fixed path.
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Counter weight:
Counterweight balances the elevator car and provides an ease in functioning of
lifts. Initially during no load condition counter weight is equal to weight of
elevator car and then 50% weight of total lifting capacity of lift is added in
counterweights.
Machine Room:
Machine room consists of different components necessary for elevator system.
These include:
PCBs for controlling actions and reactions of lifts during a lift call.
Motor drive which gives power to lift car.
Governor and brake lever: as ELD (emergency landing device)
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Governor:
It is an independent device which in case of failures acts and applies brakes
on guides to stop lift immediately.
Buffer:
Buffer is a device used to absorb kinetic energy. Buffers are places at the
bottom of shaft at certain depth below floor, in case if cables supporting lifts
cuts off and lift fall then elevator car falls onto buffer and it reduces much of
its speed before striking ground.
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Not only speed, lifting capacity is important but elevator car appearance is
important if installed in corporate buildings and shopping malls, so
manufacturer pays special attention to its appearance and sometimes to
bring more fantasy capsule lifts are installed.
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FUEL STORAGE
TANKS
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Tanks are manufactured having storage capacity from few hundred liters for small
residential building to thousands of gallons for storing fuel for generators and
HVAC chillers in skyscrapers.
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Shell:
It covers majority of storage capacity of tank. It is simply a cylindrical shell
with dished ends to store any kind of liquid.
Dished Ends:
Dished ends closes shell opening so fuel can be confined in it, it is made dished
shape so forces developing on its surface will be distributed on a larger area
thus reducing its effect.
Air Vent:
Air vent is placed at top of tank on higher side of slope to prevent air trap.
Operating Valves:
Operation valves present in fuel storage tanks include:
Inlet/input valve
Outlet/output valve
Drainage valve
Lifting Lug:
It helps lifting tank during installation and other maintenance operations.
Manhole:
It is a provision/space for workers to enter tank for cleaning and maintenance
purposes.
Level Indicator:
It is a glass tube whose one end is linked to tanks bottom and other end to tank
tops, it indicates fuel level in tank.
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FIRE SUPPRESSION
SYSTEM
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From above given statistics we can understand the necessity of firefighting. These
fires are caused when the temperature rises and crosses flash point of surrounding
material. In order to deal with fire effectively and to avoid any major loss Fire
Suppression Systems are adapted. These automated system fights with fire until
firefighting crew arrives to deal with it. It uses fire extinguishing material like
foams, water and gases depending upon surrounding area and cause of fire.
Classes of Fires:
Fires are divided into four basic classes depending on material which causes
initiation of fire and each fire class has its own coping strategy. Four classes
of fires are:
Fire Ingredients:
Fire Triangle also known as combustion triangle tells us about necessary
ingredients of fires. The triangle illustrates the three elements a fire needs to
ignite: heat, fuel, and oxygen. A fire naturally occurs when the elements are
present and combined in the right mixture. And a fire can be prevented and
extinguished by any of these elements. And this is what a fire extinguisher /
fire suppression system do. Different types of system attacks on different
ingredient like water attacks heat whereas gas based suppression system
attacks on oxidizing agent.
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A separated pressurized piping system is required for halon based system and
is more costly than water sprinkler system.
Many organizations with such firefighting systems conduct fire drill regularly
to keep their staff prepared for any future happening.
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HVAC
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H- Heating
V- Ventilation
AC- Air-conditioning.
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Furnace:
The furnace pushes the cold or hot air outward into the ducts that run through
every room in the building. Throughout the ducts, there are vents that allow the
warm or cool air to pass into rooms and change their interior temperature. The
furnace unit is typically fairly large, requiring its own space within a building.
Heat Exchangers:
When the furnace is activated by the thermostat, the heat exchanger begins to
function as well. Air is sucked into the heat exchanger, either from the outside
or from a separate duct that pulls cool air out of the buildings rooms then heats
it before pushing it back out into the ductwork.
Evaporator Coil:
Evaporator coils performs the opposite function of the heat exchanger. It
supplies chilled air which is forced through ducts when required.
Condensing Unit:
In this unit, refrigerant liquid exchanges heat with air outside and cools. It is
then transmitted to the evaporator coil where it can be distributed throughout
the home.
Refrigerant Lines:
Refrigerant lines are series of tubes that contains refrigerant and transmits it
from the condensing unit to the evaporator coil and back.
Thermostat:
The thermostat controls the function of the furnace. A thermostat is usually
positioned somewhere within the building where it can easily discern
temperature and remain accessible to users. If the air in the room or building is
too cold, the heat exchanger kicks in and blows heat through the vents. If the
room is too warm, the condensing unit and evaporator coil start to function, and
the air conditioning system sends cool air throughout the building or to one
particular section of the building.
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Ducts:
Heating ducts are put in during the construction of a home or a building. They
are often run through the ceiling. In each room, at least one rectangular opening
is cut into the duct so that a vent or vents can be installed.
Vents
Vents are usually rectangular in shape. They are placed in the ceiling, with their
edges corresponding to the opening in the duct above. As warm or cool air
pours through the ducts, vents allow it to disperse into the rooms below.
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For an air conditioning system to operate with economy, the refrigerant must be
used repeatedly. For this reason, all air conditioners use the same cycle of
compression, condensation, expansion, and evaporation in a closed circuit. The
same refrigerant is used to move the heat from one area, to cool this area, and to
expel this heat in another area.
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Depending on the type of the cooling system used in these systems, the
packaged air conditioners are divided into two types;
Packaged Air Conditioner with water cooled condenser
Packaged Air Conditioner with air cooled condensers
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Cooling towers can be classified on the basis of the type of air induction into
the tower. The main types of cooling towers are;
Induced draft cooling towers
Natural draft cooling towers
Induced Draft:
An induced draft cooling tower is provided with a top mounted fan that
induces atmospheric air to flow up through the tower, as warm water falls
downward. An induced draft tower may have only spray nozzles for water
break up or it may be filled with various slat and deck arrangements.
Natural Draft:
The natural draft cooling tower is designed to cool water by means of air
moving through the tower at the low velocities prevalent in open spaces
during the summer. Natural draft towers are constructed of cypress or red
wood and have numerous wooden decks of splash bars installed at regular
intervals from bottom to the top. Warm water from the condenser is flooded
or sprayed over the distributing deck and flows by gravity to the water
collecting basin.
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Chillers:
A chiller is a machine that removes heat from a liquid via a vapor-compression
or absorption refrigeration cycle. This liquid can then be circulated through a
heat exchanger to cool air or equipment as required. As a necessary byproduct,
refrigeration creates waste heat that must be exhausted to ambient or for greater
efficiency, recovered for heating purposes. Concerns in design and selection of
chillers include performance, efficiency, maintenance, and product life cycle
environmental impact.
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Absorption Chillers:
Absorption chillers uses heat to vaporize a working fluid (usually either
ammonia or lithium bromide)
Single Effect Absorption use a single generator & condenser.
Double Effect Absorption use two generators/concentrators and
condensers, one at a lower temperature and the other at a higher temperature.
It is more efficient than the single effect, but it must use a higher
temperature heat source.
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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 units. A larger air handler that conditions 100% outside air, and
dont re-circulate 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).
An air handling unit; air flow is from the right to left in this case. Some
AHU components shown are
1 Supply duct
2 Fan compartment
3 Vibration isolator ('flex joint')
4 Heating and/or cooling coil
5 Filter compartment
6 Mixed (re circulated + outside) air duct
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Pumps:
The storage of liquids is necessary for their usage. It is also necessary that the
liquids from the storage tanks may easily approach the places where they are to
be used. To make sure that the liquid approach its target easily with the required
flow rate, pumps are used. The basic purpose of pumps is to maintain the flow
by keep on injecting kinetic energy in it, because the liquid loses its flow with
the passage of time because of the friction in the pipes and viscous forces.
Different type of pumps has different usage but there are only 2 basic type of
pumps which are:
Positive Displacement Pumps
Kinetic Pumps
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Diaphragm Pumps:
The diaphragm pumps or pneumatic diaphragm pumps use a flexible
diaphragm to trap and discharge the liquid rather using piston/plunger. It
also works on reciprocating action but the discharge and suction is with
the help of a diaphragm. The diaphragm may be of rubber, thermoplastic
or Teflon.
Single Rotor:
If the rotary pump uses a single rotor than it is single rotor rotary pump.
Vane Pump:
It is positive displacement pump in which there is a vane that is mounted on
a rotor. The rotor and the stator are not concentric so the liquid is pressurized
near the outlet where the area decreases. It consists of following
components;
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Stator
Rotor
Vanes
Spring
Piston Pumps:
In case of rotary piston pumps there are several piston connected with
the rotor instead of diaphragms. The rotor shaft is eccentric with stator
center line as a result of which the piston moves in axial direction and
pushes the liquid out of the pump.
The pump uses an elastomer rotating member with enlarged vane tips that
form a pumping chamber in conjunction with a casing when the rotor is
placed with the shaft centered in the substantially circular casing that
incorporates an eccentric section. Discharge forcing action is accomplished
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as the vane bends in the eccentric section, effectively squeezing liquid from
the discharge chamber.
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Gear Pumps:
Gear pumps are also widely used in chemical installations to pump high
viscosity fluids. They work on the principle that as the gears rotate they
separate on the intake side of the pump, creating a void and suction which is
filled by fluid. The fluid is carried by the gears to the discharge side of the
pump, where the meshing of the gears displaces the fluid.
Lobe Pumps:
Lobe pumps are used in a variety of industries including pulp and paper,
chemical, food, beverage, pharmaceutical, and biotechnology. They are
popular in these diverse industries because they offer superb sanitary
qualities, high efficiency, reliability, corrosion resistance and good clean-in-
place and steam-in-place (CIP/SIP) characteristics. There are lobes present
inside the goosing of the pump which while rotating traps the liquid and
discharges the pressurized liquid.
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Kinetic Pumps:
Kinetic pumps can be divided into two classes, centrifugal and peripheral.
In kinetic pumps a velocity is imparted to the fluid. Most of this velocity head is
then converted to pressure head. The disadvantage of these pumps is that, if
head increases at the outlet than it cant give the desired flow.
Kinetic pumps are classified into two main branches namely:
Centrifugal pumps.
Peripheral pumps.
Centrifugal Pumps:
Centrifugal pumps are those pumps which work on the centrifugal action of
the rotor. As the rotor rotates the impeller applies centrifugal forces on the
liquid in contact with it. The housing is made in such a way that inner area is
not constant throughout.as the area decreases pressure increases near the
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discharge this area increases and the pressure head of the liquid converts into
the velocity head.
Radial Flow:
These pumps totally on the centrifugal action and discharges the liquid in the
radial.
Mixed Flow:
These pumps are normally used in multistage where one impeller discharges
the pressurized liquid to the other and so on.The final discharge is obtained in
the radial direction. As the flow is both in the radial and axial direction
therefore it is known as mixed flow.
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Peripheral Pumps:
The Peripheral pump is a niche product between the Displacement and the
Centrifugal pump, in which the medium is pumped in a Peripheral channel.
Following are the types of peripheral pumps;
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WELDING
TECHNIQUES
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The most common types of welding are oxyfuel gas welding (OFW), arc welding
(AW), and resistance welding (RW). As a Steelworker, your primary concern
is gas and arc welding. The primary difference between these two processes is the
method used to generate the heat.
.
Gas Welding
One of the most popular welding methods uses a gas flame as a source of heat. In
the oxy-fuel gas welding process, heat is produced by burning a combustible gas,
such as MAPP (methylacetylene-propadiene)or acetylene, mixed with oxygen.
Arc Welding
Arc welding is a process that uses an electric arc to join the metals being welded. A
distinct advantage of arc welding over gas welding is the concentration of heat.
In gas welding the flame spreads over a large area, sometimes causing heat
distortion. The concentration of heat, characteristic of arc welding, is an advantage
because less heat spread reduces buckling and warping.
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Weld Joints
The weld joint is where two or more metal parts are joined by welding. The five
basic types of weld joints are;
Butt joint- used to join two members aligned in the same plane.
Corner joint- used to join two members located at right angles to each other.
Tee joint- used to join two members located at right angles to each other.
Lap joint- made by lapping one piece of metal over another.
Edge joint- used to join the edges of two or more members lying in the same
plane.
Corner and tee joints are used to join two members located at right angles to
each other.
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