ACKNOWLEDGEMENT

We were able to accomplish this journey by the grace of Allah Almighty and His guidance. We are also
very thankful to IBRAHIM FIBRE LTD GROUP for providing the interactive environment with the area
managers that really helped us in learning and exploring the things practically.
http://www.clipconverter.cc/download/VVpJTQPH/260591446/

Preface:
In this report we have comprehended every process and technique used in the departments we
visited during our four weeks internship at IFL. Weve divided this report into five parts. In First part
we have given information regarding the history and setup of IBRAHIM GROUP OF COMPANIES. In
the second part we have discussed Polymer process. Third part deals with the spinning draw lines,
Bailer and cutter. The fourth part concerns us with the utilities. While the fifth past deals with the
Auxiliary and (chemical & textile) lab.
LIST OF CONTENTS
ACKNOWLEDGEMENT .................................................................................................................... 1
PREFACE .............................................................................................................................................. 2
INTRODUCTION ................................................................................................................................. 5
IBRAHIM FIBERS LIMITED ............................................................................................................ 6
IFL (PP) -1 .......................................................................................................................................... 6
IFL (PP) -2 .......................................................................................................................................... 7
IFL (PP) -3 .......................................................................................................................................... 7
Textile plants ....................................................................................................................................... 7
PG -1 (power generation plant): .......................................................................................................... 7
Orientation plan ................................................................................................................................... 8
UTILITY (UTY).................................................................................................................................... 9
PTA & MEG Handling Unit ............................................................................................................... 9
Chiller ............................................................................................................................................... 11
Water Treatment plant ...................................................................................................................... 13
Boiler ................................................................................................................................................ 13
Cooling Tower .................................................................................................................................. 15
HTM Heater ...................................................................................................................................... 15
Gas Turbine ....................................................................................................................................... 16
POLYMER .................................................................................................................................. 17
Paste Tank ......................................................................................................................................... 18
Screw Pump ...................................................................................................................................... 18
ES-I reactor ....................................................................................................................................... 18
ES-II reactor ...................................................................................................................................... 18
Process Column ................................................................................................................................ 19
PP-I ....19
PP-II .................................................................................................................................................. 19
Scraper Condenser ............................................................................................................................ 20
Pre-polymer Filter ............................................................................................................................. 20
PDR. .................................................................................................................................................. 20
Product Filter .................................................................................................................................... 20
SPINNING AND DRAW LINE ................................................................................................... 21
Spinning Unit: ...................................................................................................................................
21
What is Spinning: .............................................................................................................................. 21
Polymer Melt Flow: .......................................................................................................................... 22
Spin Pumps: ...................................................................................................................................... 23

Spin Pack: ......................................................................................................................................... 24

Ring Oiler: ........................................................................................................................................ 24
Sunflower Wheel: ............................................................................................................................. 24
Draw Line/ Fiber Line: ................................................................................................................ 25
Crimping Mechanism: ...................................................................................................................... 27
Cutting Operation: ............................................................................................................................ 28
Bailer:... ............................................................................................................................................. 29
A/C system: ....................................................................................................................................... 29
Maintenance Work in Spinning and Draw Line: .............................................................................. 29
MECHANICAL WORKSHOP ................................................................................................... 31
Machining Shop: ............................................................................................................................... 31
Insulation, Cladding & Ducting: ....................................................................................................... 33
Welding: ............................................................................................................................................ 33
Rigging Shop: ................................................................................................................................... 34
Painting Shop: ................................................................................................................................... 34
Carpenter Shop: ................................................................................................................................ 35
POWER GENERATION I (PG - I) ............................................................................................. 36
Diesel Engine Cycle: ......................................................................................................................... 36
Engine Operation Processes: ............................................................................................................. 37
Engine Specifications: ...................................................................................................................... 37
Cooling Towers: ................................................................................................................................ 37
HRSG (Heat Recovery Steam Generator): ....................................................................................... 38
Maintenance Work at PG 1 Plant: .................................................................................................. 38
500 hours ........................................................................................................................................... 38
1000 hours ......................................................................................................................................... 38
2500 hours ......................................................................................................................................... 38
Major Overhauling (MOH) ............................................................................................................... 39
INTERNSHIP ASSIGNMENTS .................................................................................................. 39
Vibration Analysis of Draw Frame II Machine..40
Determining Torque in the roller of Draw Frame II Machine...54
CONCLUSION
INTRODUCTION:
The group started with a cloth trading business in the industrial city of Faisalabad. Late Haji Sheikh
Mohammad Ibrahim, founder of the Ibrahim Group. What is known in business today as Ibrahim
Group with diversified business interests from Spinning to PSF, Financial Institutions to Banking and
Energy, started off as a mere cloth trading agency just half a century ago.
In the mid 50s the group was taken over by Sheikh Mukhtar Ahmad, It was then that he took an
initiative of adding yarn trading in the business that set a milestone for the future progress. it did not
take long before the group was widely reputed and respected in marketing of cotton and blended
yarns. Backed by this good will and experience in marketing, in 1980, manufacturing of own blended
yarn was initiated by establishment of Ibrahim Textile Mills Limited. With long term considerations
and a simple principle of no compromise on quality two more textile spinning companies; A.A.
Textiles Limited in 1982 and Zainab Textile Mills Limited in 1987 were established. A power
generation Company Ibrahim Energy Limited was incorporated in 1991 to improve the efficiency of
the existing manufacturing companies. All these manufacturing companies have now been merged
into Ibrahim Fibers Limited.
The Group established a leasing company; Ibrahim Leasing Limited. Upon declaration of the
privatization policy by Government of Pakistan, Ibrahim Group together with other leading groups
participated in the bidding to acquire controlling shares of Muslim Commercial Bank Limited. Under
the scheme of reconstruction proposed by State Bank of Pakistan, Consortium of Ibrahim Leasing
Limited, Ibrahim Group and its sponsors acquired more than 75% of the shareholding of Allied Bank
of Pakistan Limited. Management and control of the Bank was handed over to Ibrahim Group on
August 19, 2004. At present Ibrahim Group is holding more than 80% shareholding of this bank. One
of the top five banks of Pakistan, Allied Bank has more than 742 branches across the country with
7,139 employees and financial assets of Pak Rupees 234 billion. After the acquisition of the bank
Ibrahim Leasing Limited has been merged into Allied Bank limited. The strength of the group today
stands manifold with entrepreneurial skills and visionary leadership of Sheikh Mukhtar Ahmed
added with fresh concepts and professional skills of Mohammad Naeem Mukhtar who has done his
MBA from the University of Wales, Cardiff, UK. and Mohammad Waseem Mukhtar who has done
his Bachelor in Computer Science and Masters in Total Quality Management (TQM) from the
University of Glam organ, Wales, UK .
Departments
Different Departments work and cooperate with each other to run Ibrahim fibers limited smoothly
and efficiently:
HR/Admin
Production(process)
Engineering-maintenance
Purchase departments
Imports departments
IT
Civil
Finance
Sales and marketing
Raw material & Poly
process
 PTA & MEG Handling Unit
Pure Terephthalic Acid (PTA) and Monoethylene Glycol (MEG) are the key ingredients to make
polyester fibre. These are the starting materials which react under specific conditions and
catalyst in polymer section to give molten polyester. Both of these reactants are handled
differently as described below:
1. PTA Handling Unit
PTA is brought in plant in the form of powder. It is in shipped in two form i.e. Bags and
container. Both have different charging method.

Conveyer
Storage
Container Bin Silo
tank

Compressed nitrogen

Containers are directly offloaded on the bin silos from where it is transferred to storage tank
with the help of compressed nitrogen gas. Nitrogen gas is used for transportation because it is
inert and would not react with PTA.

Charging of PTA through bags is done by the system in which hoist carries two bags at a time and
discharge them through the vibrating screens in order to remove the oversized or agglomerated
particles. It takes 5 to 7 min to charge one bag into the bin silo. Then from Bin silo PTA powder is
carried to storage tank with the help of compressed nitrogen gas

Storage
Bin silo tank
Container Hoist
Conveyer
Vibrating screens

Compressed nitrogen
 2. MEG Handling
MEG is shipped from Karachi in the form of liquid. Before shipment, a series of tests are
performed at Port Qasim IFL plant to check the quality of MEG i.e.

1. Dip test

2. Temperature Test
3. Density Test
4. Moisture content Test etc. (less than 1%)
5. Color test
It is brought to polyester plant in tanks where it is pumped to storage tank through filters with
the aid of centrifugal pump and flexible pipe. Each storage tank has a capacity of 2000 tons,
each is provided by breathing valve (which are provided to maintain pressure on stored MEG).
It can both intake and breathe out vapors according to requirement.

To processing section

Container Filter Storage

tank