Abdul Basit Internship Report On EBRAHIM TEXTILE MILLS On ELECTRICAL ENGINEERING

 

 

INTERNSHIP REPORT B.E (ELECTRICAL ENGINEERING)

Submitted to

DEAN OF ELECTRICAL ENGINEERING DEPARTMENT Dr. Seema Ansari By

S.M Abdul Basit Imam- (18268) B.E ELECTRICAL (Specialization in Electronics)

COLLEGE of ENGINEERING and SCIENCES

INSTITUTE of BUSINESS MANAGEMENT March, 2019 

 

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Name: S.M Abdul Basit Imam  ID No: 20152-18268 Program: BE Electrical Major Field: Electronics

1.1. 

Organization where internship was served: Ebrahim Textile Mills (ETM)

1.2. 

Duration: From February 12, 2019 to April 5th, 2019

1.3.

Report based on (Tick) Option 1 _____________ _____________ Option 2 ______________ ______________

1.4.

Due date of the report April 20th, 2019  (2 weeks after the successful completion of internship)

1.5. Report submitted on  ______________________  ___________ ______________________ ______________________ ______________________ ___________ 1.6.

Delayed by N/A days (If applicable)

1.7.

Reasons for delay N/A (If applicable)

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Contents

2.

ELECTRICAL ENGINEERING DEPARTMENT DEPARTMENT ............................................ ............................................................ ................ 5

2.1.

Power House ............................................ .................................................................. ............................................ ............................................. ........................... .... 5

2.2.

Energy Measurement Alternatives Alternatives ............................................ ................................................................... ...................................... ............... 6

2.3.

Power Generation Generation Engines Engines .......................................... ................................................................ ............................................ .............................. ........ 7

2.4.

Jenbacher (J (J –  .................................................................. ............................................ ...................................... ................ 7  –  320): ............................................

2.4.1.

How A Gas Engine Works? ........................................... .................................................................. ............................................. ......................7

2.4.2.

Working Description: .......................................... ................................................................ ............................................ .................................. ............ 8

2.4.3.

The Engine Can Be Powered By Various Types Types of Trash: ......................................... .........................................8

2.4.4.

Simple Logic: ........................................... ................................................................. ............................................ ............................................. .......................8

2.5.

Cooling Tower: ............................................ .................................................................. ............................................ ............................................. .......................8

2.5.1.

Losses in the Cooling Tower: ............................................ ................................................................... ......................................... ..................9

2.5.1.1.

Loss of Evaporation: ............................................ .................................................................. ............................................ .............................. ........ 9

2.5.1.2.

Loss of Drift: ........................................... .................................................................. ............................................. ......................................... ...................9

2.5.1.3.

Blow-Down Losses: ............................................ .................................................................. ............................................ .............................. ........ 9

2.6.

Main Unit: ............................................ ................................................................... ............................................. ............................................. ............................ ..... 10

2.6.1.

Voltage Indication Unit: .......................................... ................................................................ ............................................ ............................ ...... 11

2.6.2.

Earth Fault Indication:............................................. ................................................................... ............................................ ............................ ...... 11

2.6.3.

Short Circuit Indication: .......................................... ................................................................ ............................................ ............................ ...... 11

2.6.4.

Pressure Switch: .......................................... ................................................................. ............................................. ....................................... .................11

2.7.

Pad Steam Machine: ........................................... ................................................................. ............................................ .................................... .............. 11

2.7.1.

Different Sections of Pad Steam Machine: .......................................... ............................................................... .....................11

2.7.1.1.

Fabric inlet: ........................................... ................................................................. ............................................ ........................................... .....................11

2.7.1.2.

Steamer: ............................................ .................................................................. ............................................ ............................................. ......................... .. 12

2.7.1.3.

Washing Unit: .......................................... ................................................................. ............................................. ....................................... .................12

2.7.1.4.

Oxidation: ............................................. ................................................................... ............................................ ........................................... .....................12

2.7.1.5.

Neutralizing Unit: ............................................ .................................................................. ............................................ ................................ .......... 12

2.7.1.6.

Dryer: ............................................ ................................................................... ............................................. ............................................. ............................ ..... 12

2.7.1.7.

Cooling Roller: ............................................ .................................................................. ............................................ .................................... .............. 13

2.7.1.8.

Fabric Outlet: ........................................... .................................................................. ............................................. ....................................... .................13

2.7.2.

Flow Chart of Pad Steam: .......................................... ................................................................ ............................................ ......................... ... 14   3

 

2.8.

Sanforizing Machine: .......................................... ................................................................ ............................................ .................................... .............. 15

2.9.

Computer Numerical Control Printing Machine: ........................................... ......................................................... .............. 15

3.

FUNCTIONS OF THE DEPARTMENT ............................................. .................................................................... ............................ ..... 16

3.1.

Workshop: ............................................ ................................................................... ............................................. ............................................. ............................ ..... 16

3.2.

Service Department:................................................ Department:...................................................................... ............................................ ................................ .......... 16

3.3. Work Done Done in the Department: Department: .......................................... ................................................................. ........................................... ....................16 3.3.1. Observation and Inspection: ........................................... .................................................................. ........................................... ....................16 3.3.2.

Complaints and Checkups: ......................................... ............................................................... ............................................. ......................... .. 17

3.3.3.

General Working and Learnings: .......................................... ................................................................. .................................... ............. 17

4. THEORIES LEARNED IN ACADEMICS AND THEIR APPLICATION DURING INTERNSHIP: ............................................. ................................................................... ............................................ ............................................ ................................ .......... 18 4.1.

Department: Electrical Engineering Engineering Department ............................................ .......................................................... .............. 18

4.2.

Theories / concepts concepts I learned in IoBM / which you saw being applied applied ........................ ........................ 18

4.3.

Any New Theories/Concepts Theories/Concepts Learned: ............................................. .................................................................... ............................ ..... 18

4.4. 4.5.

Working Experience: .......................................... ................................................................ ............................................ .................................... .............. 18 Conclusion: .......................................... ................................................................. ............................................. ............................................. ............................ ..... 19

4.6.

Recommendations:.......................................... ................................................................. ............................................. ....................................... .................19

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2. 

ELECTRICAL ENGINEERING DEPARTMENT

Department: Electrical Engineering Department. Department.  Supervisor’s Name: M. Junaid  Designation: Senior Electronic Engineer  Duration: 2 months 

I was wasaaappointed to the Department of Electrical Engineering at Ibrahim Textile Company. My things to do consist in monitoring, verifying and verifying machines and turbines and  performing day by day technical verifications of both machines and turbines. I have assisted a ssisted technicians in the development department and I additionally accompanied them on visits to the turbine after receiving the attractive safety precautions. Ebrahim Textile Mills these days is able to method and convert extra than 70 million meters of material per year in clothes and garments. Ebrahim Textile Mills provides a vast range of coordinated concepts in bedding, bedspreads, etc. In addition, it also produces formal and informal clothes for men, women and youth that have exclusive fabrics and designs in line with world trends.

2.1.  Power House Ebrahim Textile Mills is geared up with ultra-modern machinery. It houses one of the biggest cloth processing amenities in the country and can meet the diverse wants of its clients anywhere in the world with its internal services for ginning, spinning, weaving and export of garments and merchandise made of the exceptional quality. Ebrahim Textile Mills has mounted a 12.6 MW natural gas strength technology facility, with warmness exchanger and waste warmness steam boilers for its operations. Ebrahim Textile Mills attaches a fundamental importance to operations that respect the environment. It is the first textile employer in Pakistan to install a wastewater treatment plant that separates quite a number impurities from wastewater and received certifications for environmentally pleasant products.   5

 

2.2.  Energy Measurement Alternatives One of the most full-size choices used whilst executing a work like this, is which electric  power necessities strategy to apply. Just as was highlighted, the usual approach for noncommercial power calculation was once by means of the use of electro-mechanical Ferraris disk meters, these types of meters validated fantastic achievements for a length that had now not noticed strong country electricity calculation systems. 30 years beyond, you can locate quite a number electric electricity strategies to calculate strength which is not simply lesser in  price but additionally way extra unique (simply no shifting components). In the vicinity of  power calculation, calculati on, there is without a doubt a vast variety variet y of a number of implementations i mplementations to successfully dimension power. The calculations in the back of this fashionable will be as follow:

P=

×   √ 2

In which P is power in watts, V is voltage, I is current in ampere together with E is energy in  joules. stepsT Tfor Tthree threeT T phase  phaseT Tmotors ThreeTsteps ThreeT PhaseT Phase T1:T 1:TDetermine DetermineT Tthe theT Tinput inputT Tpower:

VT×TIT×TPF PFT T×√ 3   1000

PiT=T ThreeT TPhase PhaseT T power Tin inT TKW PiT PiT=TThree

RMST TVoltage, Voltage,T Tmean meanT Tline lineT Tto toT Tline lineT Tof Tthree threeT T phases VT=TRMS IT=TRMS RMST Tcurrent, current,T Tmean meanT Tof Tthree threeT T phases. PFT=T power Tfactor Tas PFT asT Tdecimal.

T2TDetermine DetermineT Tthe theT TRated RatedT TPower: PhaseT Phase

hpT T×T Pr T=Thp

0.7457   

InputT T power TatT atTfull fullT Trated ratedT Tload loadT Tin inT TKW Pr T=TInput HpT=THorse HpT HorseT TPower T    6

 

EfficiencyT TatT atTfull fullT Tload nr T=TEfficiency T3TPercentage PercentageT TLoad: PhaseT Phase

T=T LoadT Load

 T×T100 

LoadT Load T=Toutput outputT T power measuredT Tthree threeT T phase  phaseT T power PiT PiT=Tmeasured inputT T power Pr T=Tinput

2.3.  Power Generation Engines Ebrahim Textile Mills (ETM) electricity house uses two engines to generate electricity. They each are gas engines. The first engine is named Caterpillar (CAT  –   G3516-B) it generates 1110 KW and the second one is JENBACHER (J  –  320).   320). It generates 1064 KW. Both has 1500 RPM. Similarly, it doesn’t run on full strength generation capability due to the thing of strength loss and over load. It generates an average of seven hundred KW respectively. Both the engines are synchronized with K-electric to grant higher response and forestall breakdowns and shutdowns.

2.4.  Jenbacher (J  –  320):  320): A quite environment friendly electricity supply succesful of feeding herbal gas, agricultural waste and even garbage in landfills.

2.4.1.  How A Gas Engine Works? Just as wind turbines work. 1.  Suck 2.  Squeeze 3.  Bang 4.  Blow It has three similar steps but the fourth step is different, it has:   7

 

1.  Suck 2.  Squeeze 3.  Bang 4.  Twist And the reason is you’re not wanting to create thrust you’re wanting you’re wanting to create talk.

2.4.2.  Working Description: We usually use turbochargers to blow compressed air into the piston cavity, then the plunger goes toward the top of the cavity, causing the pressure and then the strike. Therefore, these engines usually ignite a spark plug that ignites the fuel and becomes a lot of pressure, a lot of heat that drives the piston down and then manages the crankshaft, which is the speed of torsion.

2.4.3.  The Engine Can Be Powered By Various Types of Trash: Any waste that has the capacity and biological content that can be digested to convert it into methane or can be used as a burnable gas. But, it can come from a source where it is simply thrown away.

2.4.4.  Simple Logic: Where there are humans, there is waste. With this garbage there is a gas, we are this gas. It's like a circle of energy.

2.5.  Cooling Tower: The water will be sprayed from the pinnacle of the cooling tower, the place the central flow fans pull the air from both facets of the cooling tower and discharge it to the pinnacle of the cooling tower (thus, the pass flow). The air, which is nevertheless now not saturated with steam, is in contact with the water spray and turns it from liquid to vapor through which the touchy heat is converted to latent heat because the water temperature drops to the temperature of the wet lamp.   8

 

Part of the cooling water evaporates through absorbing the latent warmness of the water, thus reducing its temperature. An correctly sized cooling tower can cool incoming water to temperatures up to three ° C greater than the ambient temperature of the moist bulb. Relative humidity of ambient air is an vital determinant factor. The fan forces or forces the air via the cooling tower the place the water falls through the compressed warmth transfer fluid. Operating costs are high, however they are simple and rapid to build. intermitt ent with the flow of water.   The airflow can be parallel or intermittent



  Biocides and chemicals are needed to eliminate bacterial overgrowth and harmful



scales while reducing performance.

2.5.1.  Losses in the Cooling Tower: The loss of water in the cooling tower is due to three exclusive motives and must be compensated during the operation. Makeup ratio in present day towers about 1%.

2.5.1.1. 

Loss of Evaporation:

A Part of the water evaporates, which creates a cooling effect. It relies upon on the ambient temperature, the relative humidity or the ambient temperature.

2.5.1.2. 

Loss of Drift:

The water particles had been drawn into the circulating air. Drift eliminators and unique sketch have substantially reduced this problem. In present day towers, this ought to represent 0.02% of the water flow.

2.5.1.3. 

Blow-Down Losses:

Evaporated water leaves behind salts, which accumulate over time and increase TDS levels. This requires being purged from time to time. This constitutes a loss that ought to be recovered.

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2.6.  Main Unit: The main unit consists of an input charger and one or extra output chargers. The enter is a vacuum circuit breaker or an SF6 circuit breaker with disconnect or and a floor switch. The cost cutoff change is nothing extra than an isolator that can shut down the circuit at some stage in over charging. The nominal voltage of the main unit is generally 24 kV. The enlarge of the nominal voltage is due to an amplify in the stress of the insulating gas. The fundamental unit is used in a secondary distribution system. It is in general used for uninterrupted strength supply. By its side, it also protects its transformer from the secondary facet of occasional transient currents. There are essentially 4 characteristics in the most important unit, namely:

i.  ii. 

Voltage indication unit Earth fault indication

iii. 

Short circuit indication

iv. 

Pressure switch

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2.6.1.  Voltage Indication Unit: This installation is in a very intrinsical cable bushing that enables to verify the presence or absence of voltage within the cable, through junction rectifier voltage indicators put in on the front panel of the unit..

2.6.2.  Earth Fault Indication: This provides a sign of a ground fault current within the television. This makes it easier to isolate the fault location and quickly restore the facility supply through healthy sections..

2.6.3.  Short Circuit Indication: This provides an indication of a ground fault current in the cable system. This makes it easier to isolate the fault location and quickly restore the power source through healthy sections.

2.6.4.  Pressure Switch: This is used for the warning of gas overpressure or low pressure in a distant location. l ocation.

2.7.  Pad Steam Machine: Pad-Steam dyeing is a non-stop dyeing procedure in which the open-width material is packed with dye and then sprayed. Pad Steam is an supreme machine for the reactive dyeing of cotton and its collective fabrics.

2.7.1.  Different Sections of Pad Steam Machine:

2.7.1.1. 

Fabric inlet:

From the thermosol, the material is introduced into the body of water of the buffer externalcombustion engine. Once the material passes over a free roll, AN entrance roll and a receptacle. Here may be a compensator management to regulate to manage} the dimension entry of the material and control the speed of the material.   11

 

2.7.1.2. 

Steamer:

In the pad steam machine, the chemical filler passes through the vaporizer to connect. It consists of 2 cameras. This space is heated with steam and also the temperature is around a hundred to one zero five ºC. Here, the materials bear rolls. The length of the vaporizer is ninety meters and also the material stays here for regarding one.5 minutes.

2.7.1.3. 

Washing Unit:

After spraying, the dye is fastened on the material. Now, unbound dyes area unit washed away. Here, the new and cold wash is performed in several rooms. The cold wash temperature is regarding forty ° C and within the cold wash temperature it's regarding ninety to a hundred ° C. There area unit eight wash units. Wherever one and eight area unit the cold wash unit and 2-7 area unit the new wash unit.

2.7.1.4. 

Oxidation:

In this step, the leuco compound of the vat color is alter and reborn to its original color and soluble kind. This oxidization is caused by part element. this can be typically wiped out second laundry unit.

2.7.1.5. 

Neutralizing Unit:

After laundry, neutralization is performed to regulate the pH of the merchandise. It's done by carboxylic acid. For reagents, only 1 neutralization chamber is employed once laundry. Here, chemical reaction isn't needed.

2.7.1.6. 

Dryer:

In the Pad external-combustion engine, the two-stage vertical cylinder appliance is employed for correct drying. the material passes over the surface of the cylinder and dries. This appliance is heated with steam. The temperature temperat ure is concerning 120-140 ° C.

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2.7.1.7. 

Cooling Roller:

After drying during a roll appliance, it's necessary to chill. Therefore, the material is passed on the cooling roller. It’s a chrome steel roller through that cold water is passed. passed.  

2.7.1.8. 

Fabric Outlet:

Finally, the fabric is passed on a couple of cylinders and wrapped during a dispenser. If the shade is sweet, it'll be prepared for finishing.

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2.7.2.  Flow Chart of Pad Steam:

Fabric inlet ↓  Color truf

(Room temp. for  –  – CPS,  CPS, R/C, W/W) ↓  Padder

(2.6-2-2.6) bar ↓ 

Steaming Unit

(103-105’C) (103105’C)  

↓  Cold water tank ↓  Cold wash-1

40’C   40’C

600L

3 bar

↓  Hot wash-2

90-100’C 90100’C  

600L

3 bar

600L

3 bar

1200L

3 bar

1200L

3 bar

600L

3 bar

600L

3 bar

600L

3 bar

↓  Hot wash-3

90-100’C 90100’C   ↓ 

Hot wash-4

90-100’C 90100’C   ↓ 

Hot wash-5

90-100’C 90100’C   ↓ 

Hot wash-6

90-100’C 90100’C   ↓ 

Hot wash-7

90-100’C 90100’C   ↓ 

Cold wash-8

40’C   40’C ↓ 

Dry chamber

(120- 150’C) 150’C)   ↓ 

Fabric outlet

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2.8.  Sanforizing Machine: It is how to increase, shrink and stabilize the length and breadth of the material before cutting and production, to scale back the contraction that will occur once laundry. l aundry. During the remotion method, the fabric is inserted into the Sanforizing machine wherever it's treated with water or steam to push shrinkage, then pressing on a hot elastic device to relax and pull the fibers. Rotary roller Press a rubber cowl against another heated roller. during this manner, the quilt is podlike concisely and extended sideways, then relax to its natural thickness. the aim of this method could be a material that doesn't shrink greatly throughout  production, cutting, ironing, and stitching or once exploitation ready-made garments and laundry them.

2.9.  Computer Numerical Control Printing Machine: CNC could be a method utilized in the producing sector involving the utilization of computers to manage machine tools. Tools which will be controlled during this approach embody lathes, mills, routers and mills.CNC edge machines take a collection of solids (such as metal or wood) and use sharp rotating tools or cutters to get rid of all uncalled-for elements.CNC could be a quicker answer than three-dimensional printing. CNC machines will operate twenty four hours daily, provided they're properly maintained. A project which will need one-hour CNC process are going to be resembling a 3D printer which will take hours to induce the ultimate product as a result of it should build the merchandise la layer yer with a layer.

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3. 

FUNCTIONS OF THE DEPARTMENT

3.1.  Workshop: The function of this department is to carry out maintenance operations on the various machines which are installed by the company.

3.2.  Service Department: The function of this sector is to send service ser vice teams to different llocations ocations where the products are installed and the site needs to be repaired or repaired on site. The service team sends its staff to these sites and is completed after the work files have been completed.

3.3.  Work Done in the Department:

3.3.1.  Observation and Inspection: During our time in Ebrahim Textile Mills (ETM) we did the following tasks:

  Alternator service.



  Assembling and disassembling VFD.



  Calibrated multiple machines (Sanforizer, Narrow Standard, and Pad Steam).



  Assisting engineers with electronic and electrical components.





  Observation of GIS (gas insulated substation) Hall.   Inspection of power unit.



  Making survey of PLC panels.



  Checking the charging current and voltmeter.



  Working operations of cooling tower.



  Inspection of syringing machine.



  Inspection of thermo pole machine.



  Lab work



  Observe the oil testing process Jenbacher and CAT engines.



  Assisting engineers in the new plant.



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3.3.2.  Complaints and Checkups: I have performed all the the tasks within the oversight of Senior Engineer Engineer M. Junaid. I have reviewed several of the complaints. These machines are: slim customary, Syringing, and Thermo pole, Pad Steam, VFD and Sanforizer. Sanforiz er. I even have done the given work  by creating factors and so place it on the PLC package when calculative the mechanical meter for each machine, label them in an exceedingly timely manner and eliminate the trouble. Moreover, in engineering lab I have performed task to run a VFD machine by taking commands from the manual.

3.3.3.  General Working and Learnings: 

  Safety precautions.   Daily and weekly basis checklists.



  Physical inspections of cable compartments.



  Performing plant analysis.



  Checking the wiring and connections.



  Detecting and diagnosing problems.



  Assisting engineers and technicians in finding solutions to problems.



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4. 

THEORIES LEARNED IN ACADEMICS AND THEIR APPLICATION DURING INTERNSHIP:

4.1.  Department: Electrical Engineering Department

4.2.  Theories / concepts I learned in IoBM / which you saw being applied While working in this department we applied the following theories / concepts. concepts .

  The course Electrical Machines was applicable on generators and motors



  Methods in Business Writing (Report writing).



  Industrial Control Electronics (Automation, PLC based programming).



  Electrical Machines (Motor Control and Limit Switches).



  Digital Signal Processing (Fourier Transform).



  Circuit wiring (Linear Circuit Analysis/ Linear Control Systems/ Network



Analysis)

  Planning, Organizing and Controlling (Principles of Management).



  Budgeting (Engineering Economics)



4.3.  Any New Theories/Concepts Learned:   Situation handling.



  Single Line Diagram



  Designing a system.



  Circuit Breaker



4.4.  Working Experience: Before post I knew several theories and dealing principles of power mechanism and connected instrumentations however from internship I gained sensible data regarding power system engineering and its equipment. Here, I invariably tried to relate my tutorial courses with sensible participation of power generation method. Beside I conjointly two-faced some sensible issues that wasn't tutored in my tutorial courses. My communication talent conjointly   18

 

improved through communication with completely different pedagogue. Therefore, I created sensible achievements with my industrial coaching which can facilitate facil itate ME in my future.

4.5.  Conclusion: A lot of expertise in Ebrahim Textile Mills was attain once a protracted amount of study in education. throughout my post I came to grasp that however the various activities manifest itself, what the procedures are? Overall Ebrahim textile mills making progress according to needs of modern age. Using high  productive machinery to compete with others. Managers of every department is well educated, having ton of expertise and convergent thinker. The management is professionally qualified and toughened. The Ebrahim Textile Mills ought to encourage their staffs by providing simple facilities like transportation, mess facility and allowance. Eye-catching pay packages are sources of their motivation. Outstanding quality goods (yarn and cloth) are shaped in Ebrahim Textile Mills. The demand of Ebrahim Textile Mill’s products is growing with the passage of period. The firm should multiply its ability as soon as possible to fulfil the demands of their clients.

4.6.  Recommendations: Some recommendations are given below for the students to do their internship program in a  better way. More theoretical data regarding power generation, protection system, and power equipment’s ought to be learnt before going for this program. thus students should complete the connected courses to their situation before entering into this program. Taking the courses before the internship course helps the scholars perceive the subject far better.

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