KML Power Plant Internship Report
KML Power Plant Internship Report
KML Power Plant Internship Report
The University of Lahore is one of the leading universities of the country. The University Electrical
Engineering is the heart of this University. This institute is rendering invaluable services to the
nation Pakistan by producing outstanding graduate engineers who have aims to change the world.
We ourselves feel proud as being a part of that superb University and of our teachers because of
their excellent style of teaching and vast knowledge, as well as their scholastic approach. Preparing
students to face the world confidently and courageously, The University of Lahore arranges an
internship Programs during summer vacations. The purpose of this program is to give practical
exposure to our field of studies. It is also helpful for understanding the organizational environment
and to deal with the professionals. For that, we joined Kohinoor Dying Mills Limited, which is
one of the largest textiles Export Company in Pakistan. During our internship span of 45 days we
got chance to work in the electrical departments of Kohinoor Dying Mills. .
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ACKNOWLEDGMENT
None, however great can lay claim to absolute originality in any branch of knowledge. No one
can deny it. Everyone is indebted to their precursors in the particular field in which they are
working. We are indebted to many individuals within our branch of knowledge and outside it. At
first, we are grateful to Almighty ALLAH, The most Beneficent and Merciful, Who gave us mind
to think and all physical abilities to work out problems and obstacles faced in life, and for giving
us enough courage and commitment to complete this internship successfully. At Kohinoor Dying
Mills, we found people very cooperative. During our internship we learnt a lot and found it as an
excellent learning place. We are very thankful to Mr Mujahid (HR Electrical), Mr.Iftikhar, Mr
Ashfaq Mr Yaseen and Mr Munaaf and others colleagues. Who allowed us to work under their
supervision. At this place I would also like to thank Ms. Mumtaz Zia (Manager HR Dying) for her
guidance and warm support throughout the internship period.
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Introduction of Organization
Kohinoor textile mills has grown from a cotton export house into the premier business group of
Pakistan with 5 listed companies, concentrating on 3 core businesses; Textiles, Cement and Power
Generation. Today, K.M.L is considered to be at par with multinationals operating locally in terms
of its quality products and management skills.
I recently have done my internship in Kohinoor Dying Mills, in which I got training from its
Electrical Department. The internship basically revolved around the employee relation with the
organization. The system, the style of working &the commitment of the employees in KDM is
really an example. The difference between the success & failure is doing things right and doing
things nearly right, & KDM has always tried for success & that is why it is known to be one of the
leading organizations in Pakistan.
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Organization chart:
An organization chart (often called organization chart, org chart, is a diagram that show the
structure of an organization and the relationship and relative ranks of its parts and position/ job.
The term is also used for similar diagram, for example one is showing is different elements of a
field of knowledge or a group of language.
Plant Manager
Shift Incharge
Muster Station 1 Muster Station Muster Station 3 Muster Station 4 Muster Station 5
Maint supervisor Assit maint Lab 1: All KGL admin 1: all decanting
mech/maint mech engr/shift incharge/weigh staff and both Lab
supervisor engr or shift bridge staff
2: O & M office
elect/manager supervisor attendant/boiler
staff all mech & 3: all time office
elect/ERO/ engr
2: ALL Elect staff elect opr staff & security office
2: All Mech staff
Fire Party
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A BRIEF DESCRIPTION OF DEPARTMENTS OF ORGANIZATION
Kohinoor Mills Limited with its state-of-the-art facilities spread over an area of 103 acres is located
at 8th KM Manga Raiwind Road near provincial capital city Lahore.
Kohinoor Mills Limited is one of the largest vertically integrated textile manufacturers, started its
successful journey back in 1949. The company has achieved annual sales of US$ 140 million to
customers based in Americas, Europe, Africa, Australia and Asia.
We have diversified products and engaged in manufacturing of Greige and Dyed Fabrics exported
to major brands and retail chains.
Kohinoor Mills Limited has employed a highly qualified and technically trained workforce of 1500
people working as a closely knitted family based on corporate culture, values and beliefs. Our team
is capable of taking on challenges for fulfilling every work related task with dynamism and
dedicated efforts.
Kohinoor has two main division which is the back bone of industry.
1. Weaving division
2. Dying division
1. Weaving division
Weaving is the flagship Division of Kohinoor Mills Ltd, commenced Production in year 1990 with
48 SulzerRuti looms.
Weaving Division currently operates 174 high speed, state of the art air-jet looms including Picanol
Omni + and Toyota Euro Tech. We also have specialized dobby and jacquard machines in narrow
and wider widths. Back process consists of warping and sizing machines from Benninger and we
also have sectional warper to handle synthetic warps and dyed yarns. Weaving Division's
production capacity is around 30 million linear meters per annum.
Weaving Division's product range includes loom state fabrics of various textures such as plain,
canvas, twills, drills, sateens, specialized design fabrics with dobby and jacquard weaves. We are
fully equipped and capable to deliver yarn dyed products with any number of colors in the warp
and up to 6 colors in the weft for both Home and apparel fabrics.
Weaving Division has a dedicated product Development department too, with specialist designers
who are capable not only to replicate customer's designs but also create and develop new designs
for export and local markets.
2. Dying division
Kohinoor Dying is renowned throughout the world for its remarkable dyed fabrics. Special finishes
like Teflon's, soil release, stain repellant, water repellant, fire retardant, Nanotex, anti-microbial,
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pre-cure and post cure are produced on regular basis. Kohinoor dying is using all the Oekotex
certified dyes and chemicals for its products. Kohinoor Dying is also processing organic cotton
fabrics to meet the changing needs of its customers.
Dying Division started production in June 2002. Top of the line European Machinery is capable
of producing 30 million meters per annum of Cotton and Cotton Blended Finished Fabrics.
Company Profile
Dying Division started production in June 2002. Top of the line European Machinery is capable
of producing 30 million meters per annum of Cotton and Cotton Blended Finished Fabrics.
Today the customer base starting from the Oceania's to America's buy fabrics to be used for High
street Fashion, casual, sportswear and work wear. Venture with French Company SaicVelcorex
from the last six years has given a competitive edge on other mills in Asia in terms of fabrication,
Hand feels and special finishes.
Well established planning, quality assurance and online quality control systems ensure to deliver
the right product to the customers on time. Today the top customers are LEVI's, GAP, OLD
NAVY, BANANA REPUBLIC, PERRY ELIS, A&F, COLUMBIA SPORTS, ANN TAYLOR,
JC PENNY, WALMART, VF, ZARA, COLLINS and TEMA.
Kohinoor Dying is renowned throughout the world for its remarkable dyed fabrics. Special finishes
like Teflon's, soil release, stain repellant, water repellant, fire retardant, Nanotex, anti-microbial,
pre-cure and post cure are produced on regular basis. Kohinoor dying is using all the Oekotex
certified dyes and chemicals for its products. Kohinoor Dying is also processing organic cotton
fabrics to meet the changing needs of its customers.
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Layout Of KGL
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Field area of Training:
Electrical Room:
In electrical room we are connected with both circuit breaker and electric panels of control
diesel generator. That is the section which we control all the system of industry in this
section we learn how to maintain the wiring and connection with each other
Diesel Engine Section:
In this section they have 3 Diesel engines Of (NIGATA) 3 Gas Engine (CATERPILLER)
and 1 Gas Turbine (Turbo-mach TBM-T70) are used in industry.
Each diesel engine generates 6 MW
Each Gas engine generate 2 MW
Gas Turbine generate 8 MW
Total Production is 32 MW
Description:
“An internal-combustion engine in which heat produced by the compression of air in the cylinder
is used to ignite the fuel’’
In other words
“An electric generator is a device that converts mechanical energy obtained from an external
source into electrical energy as the output”.
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The types of diesel engine are...
I Type ( they are used in above discussed industry)
V Type
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(1) Engine:
The engine is the source of the input mechanical energy to the generator. The size of the engine
is directly proportional to the maximum power output the generator can supply. There are several
factors that you need to keep in mind while assessing the engine of your generator. The
manufacturer of the engine should be consulted to obtain full engine operation specifications and
maintenance schedules.
(A) Type of Fuel Used: – Generator engines operate on a variety of fuels such as diesel, gasoline,
propane (in liquefied or gaseous form), or natural gas. Smaller engines usually operate on
gasoline while larger engines run on diesel, liquid propane, propane gas, or natural gas. Certain
engines can also operate on a dual feed of both diesel and gas in a bi-fuel operation mode.
Advantages of four strokes engine (Diesel engine):
More efficiency and less fuel consumption then a two stroke engine.
More effective lubrication.
Low heat stress and better cooling.
Scavenging pumps not necessary.
(2) Alternator:
Figure 5: Alternator
The alternator, also known as the ‘genhead’, is the part of the generator that produces the
electrical output from the mechanical input supplied by the engine. It contains an assembly of
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stationary and moving parts encased in housing. The components work together to cause relative
movement between the magnetic and electric fields, which in turn generates electricity.
(A) Stator – This is the stationary component. It contains a set of electrical conductors wound in
coils over an iron core.
(b) Rotor / Armature – This is the moving component that produces a rotating magnetic field in
any one of the following three ways:
(i) By induction – These are known as brushless alternators and are usually used in large
generators.
(ii) By permanent magnets – This is common in small alternator units.
(iii) By using an exciter – An exciter is a small source of direct current (DC) that energizes the
rotor through an assembly of conducting slip rings and brushes.
The rotor generates a moving magnetic field around the stator, which induces a voltage
difference between the windings of the stator. This produces the alternating current (AC) output
of the generator.
The following are the factors that you need to keep in mind while assessing the alternator of a
generator:
(a) Metal versus Plastic Housing: An all-metal design ensures durability of the alternator.
Plastic housings get deformed with time and cause the moving parts of the alternator to be
exposed. This increases wear and tear and more importantly, is hazardous to the user.
(b) Ball Bearings versus Needle Bearings: – Ball bearings are preferred and last longer.
(c) Brushless Design: – An alternator that does not use brushes requires less maintenance and
also produces cleaner power.
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The fuel tank usually has sufficient capacity to keep the generator operational for 6 to 8 hours on
an average. In the case of small generator units, the fuel tank is a part of the generator’s skid base
or is mounted on top of the generator frame. For commercial applications, it may be necessary to
erect and install an external fuel tank. All such installations are subject to the approval of the
City Planning Division. Click the following link for further details regarding fuel tanks for
generators.
Common features of the fuel system include the following:
(a) Pipe connection from fuel tank to engine – The supply line directs fuel from the tank to the
engine and the return line directs fuel from the engine to the tank.
(b) Ventilation pipe for fuel tank – The fuel tank has a ventilation pipe to prevent the build-up
of pressure or vacuum during refilling and drainage of the tank. When you refill the fuel tank,
ensure metal-to-metal contact between the filler nozzle and the fuel tank to avoid sparks.
(c) Overflow connection from fuel tank to the drain pipe – This is required so that any
overflow during refilling of the tank does not cause spillage of the liquid on the generator set.
(d) Fuel pump – This transfers fuel from the main storage tank to the day tank. The fuel pump is
typically electrically operated.
(e) Fuel Water Separator / Fuel Filter – This separates water and foreign matter from the
liquid fuel to protect other components of the generator from corrosion and contamination.
(f) Fuel Injector – This atomizes the liquid fuel and sprays the required amount of fuel into the
combustion chamber of the engine.
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Figure 7: Air intake Indoor and outdoor system
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above. Hydrogen is sometimes used as a coolant for the stator windings of large generator units
since it is more efficient at absorbing heat than other coolants. Hydrogen removes heat from the
generator and transfers it through a heat exchanger into a secondary cooling circuit that contains
de-mineralized water as a coolant. This is why very large generators and small power plants often
have large cooling towers next to them. For all other common applications, both residential and
industrial, a standard radiator and fan is mounted on the generator and works as the primary cooling
system.
It is essential to check the coolant levels of the generator on a daily basis. The cooling system and
raw water pump should be flushed after every 600 hours and the heat exchanger should be cleaned
after every 2,400 hours of generator operation. The generator should be placed in an open and
ventilated area that has adequate supply of fresh air. The National Electric Code (NEC) mandates
that a minimum space of 3 feet should be allowed on all sides of the generator to ensure free flow
of cooling air.
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Figure 10: Purifier
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The start function of a generator is battery-operated. The battery charger keeps the generator
battery charged by supplying it with a precise ‘float’ voltage. If the float voltage is very low, the
battery will remain undercharged. If the float voltage is very high, it will shorten the life of the
battery. Battery chargers are usually made of stainless steel to prevent corrosion. They are also
fully automatic and do not require any adjustments to be made or any settings to be changed. The
DC output voltage of the battery charger is set at 2.33 Volts per cell, which is the precise float
voltage for lead acid batteries. The battery charger has an isolated DC voltage output that does
interfere with the normal functioning of the generator.
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“That is used to lubricate the each and every part of the diesel engine this is the process in
industry is called turning”
Turbo-charger
Description
Turbocharger, or turbo is a turbine-driven forced device that increases an internal combustion
engine’s efficiency and power output by forcing extra air into the combustion chamber.
Auxiliary room:
Fuel oil secondary filter.
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Figure 14: Filter
Description
Fuel oil secondary filter is used to filter the fuel oil used in the engine to produce energy.
Strainer
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Viscosity control
Purifier
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Figure 18: Purifier meter
Description
Used to purify the oil.
Air Compressor
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Backup battery: A backup battery provides power to a system when the primary source of
power is unavailable. Backup batteries range from small single cells to retain clock time and date
in computers, up to large battery room facilities that power uninterruptible power supply systems
for large data centers. Small backup batteries may be primary cells; rechargeable backup batteries
are kept charged by the prime power supply.
Examples
Power Stations
Power failure in a power station that produces electricity would result in a blackout situation that
would cause irreparable damage to equipment such as the turbine-generator. The safety of power
station employees is a major concern during an unscheduled power outage at a power plant. A
bank of large station backup batteries are used to power uninterruptible power supplies as well as
directly power emergency oil pumps for up to 8 hours while normal power is being restored to the
power station.
Battery room:
A battery room is a room in a facility used to house batteries for backup or uninterruptible
power systems.
Battery rooms are found in telecommunication central offices, and to provide standby
power to computing equipment in datacenters.
Batteries provide direct current (DC) electricity, which may be used directly by some types
of equipment, or which may be converted to alternating current (AC) by uninterruptible
power supply (UPS) equipment.
The batteries may provide power for minutes, hours or days depending on the electrical
system design, although most commonly the batteries power the UPS during brief electric
utility outages lasting only seconds. Battery rooms were used to segregate the fumes and
corrosive chemicals of wet cell batteries from the operating equipment; a separate room
also allowed better control of temperature and ventilation for the batteries.
Blower Room:
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That place where a machine for supplying air at a moderate pressure, as a supply forced draft or
supercharge and scavenge diesel engine
Chimney:
Boiler side:
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Decanting area:
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Gas turbine and Caterpillar Gas Engine:
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Safety Precautions:
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Types of Fire
Muster Stations:
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Schedule of internship
Duration Department
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Description of equipment/tools and techniques/implementation:
1: Electrical Room
An electrical room is a room or space in a building dedicated to electrical equipment. The size of
the electrical equipment is usually proportional to the size of the building. Large building may
have a main electrical room and subsidiary electrical room. Electrical equipment may be for power
distribution equipment, or for communication equipment.
Electrical room typically house of the following
Electric switchboard:
Is a device that directs electricity from one or more source of power supply or several smaller
region of usage. It is assembly of one or more panel, each which contain switch that allow
electricity to be redirect.
Distribution board:
Is also known as (panel board or breaker panel) is a component of an electricity supply system
which divide an electrical power feed into subsidiary circuit while providing a protective fuse or
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circuit breaker for each circuit in a common enclosure . Normally a main switch and in recent
boards one or more residual current device (RCD) residual current breaker with over current
protective (RCBO)
Distribution board also referred as:
Breaker panel
Circuit breaker panel
Consumer unit or CU
Electrical panel
Service panel
Circuit breaker:
Is an automatically operated electrical switched to protect electrical circuit from damage, is basic
function is to detect a fault in condition and interrupt current flow , There few types or circuit
breakers are use in domestic, commercial, and industrial.
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(2) MCCB (Molded case circuit breaker):
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Temperature transistor
This device is designed to support all common RTDs, thermocouples, resistance and mili volt-
sensors.
Setup is quick and easy with the transmitter-modem and SIPROM T software.
Unique user-friendly details are implemented: Without opening the 4-20mA loop, the output
current can read directly with a millimeter.
This device is fitted in the steel case as shown above.
PT100
A platinum resistance temperature detector (RTD) Pt100 is a device with a typical resistance
of 100 Ω at 0°C (it is called Pt100).
It changes resistance value as its temperature changes following a positive slope (resistance
increases when temperature is increasing).
They have been used for many years to measure temperature in laboratory and industrial
processes, and have developed a reputation for accuracy, repeatability, and stability.
A RTD can typically measure temperatures up to 850 °C. The relationship between resistance and
temperature is relatively linear as shown below for a sample 100 Ω.
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Figure 38: ECR panels
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Useful points for new interns
Good internships are difficult to get your hands on. Once you’ve secured one, it’s important to
make the most of your short time in the company.
Whether you need help with interviews, networking with your new colleagues, or advice on
expanding your workload, take a look at these tips to make sure you can be selected for, and take
advantage of, a brilliant internship opportunity.
Apply:
The interview:
Preparation:
It’s important to make sure you are well prepared for the first day.
19. Remember that the first day, and probably the first week, will be a shock to the system.
20. Understand that being new in the office is always tough, but as long as you focus on working
hard and being polite, you will soon fit into the team.
21. Use your introductory meeting with your supervisor to agree on the focus of your internship
and the opportunities you’ll be given.
22. Try and go for coffee or have short meetings with the people you will be coming into contact
with—this not only helps you to feel at home, but it will also give others the perception that you
are approachable and eager to learn from them.
23. Attend as many meetings as possible to get exposure to the right people and issues.
24. Don’t be afraid to ask as many questions as you need to; it’s always better to ask how to do
something instead of doing it wrong.
25. Always ask for honest feedback from your colleagues and supervisor. You’re in an internship
to learn; asking others to offer advice on your development points will help you to improve.
26. be polite to everyone you work with. You never know what you might need from them next
week.
27. Keep hard copies of feedback you receive and good work you do as an intern. It will be
useful to return to once the internship is over.
28. Always take notes when you’re given instructions—it will help to prevent silly mistakes.
29. Don’t be downhearted if you feel some of the work you’re given is below your intelligence
level. You still have to prove yourself and maintaining a good attitude at all times is important.
30. be innovative. Look for opportunities to prove yourself as a useful asset to the company; this
could be by designing a social networking page or reorganizing the filing system.
31. Produce a short presentation to show someone senior if you can get 15 minutes of that
person’s time. Show him or her an idea you have for the company.
37. Book exit meetings with your supervisor and key contacts.
38. Get a written reference listing your achievements and take contact details of anyone you
think could help you in your future career.
39. Thank colleagues who have offered time and advice.
40. Don’t forget to take a few cakes in for your last day in the office. Everybody loves cake.
41. Ask for feedback covering your whole internship and learning points that can help you
develop in the future (this is the most important objective for your last few days).
42. Don’t ignore this feedback—use it to consider how you work in your next role and to book
onto courses that will help you to develop.
Follow up:
43. Write your own report of your internship; it will jog your memory if you need to think of
useful experiences at work as examples for interviews in the future.
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44. Keep in contact with someone particularly inspiring that you met during your placement; ask
that person to be your mentor.
45. Keep in touch with other members of the team by email and ask them to let you know of any
job opportunities or freelance work that might be coming up.
46. Use your contacts to keep your finger on the pulse of your chosen industry—this can be
difficult once you return to the world of study or a job outside the area you’re aiming for.
47. Ask your supervisor for a written report that can be used as a quick job reference in the
future.
Most importantly:
48. Never give up. Internships can be tough, especially for people who have not previously
worked in an office.
49. Don’t be afraid to ask for advice from colleagues, your supervisor, and others outside work.
50. Try to relax and remain professional while milking your internship for all the development
opportunities it offers. View it as a vocational learning experience.
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Suggestions/Recommendations
Help interns be successful from the very beginning by having a workspace set up for
Them before they arrive if feasible. This allows them to get started right away and
Assures them that you expect them to be an integral part of the organization.
Assign projects that are challenging and valuable to your organization – consider the
Level of experience, education and motivation that students possess. Offer pre-
Professional tasks (less than 50% clerical work). It is helpful to set goals and put them in
Writing. Be sure to define what you want to see from the interns by the end of the
Internship.
Compile a list of secondary tasks for times when interns finish their assignments ahead
Of schedule.
Meet regularly with the intern to answer questions and to give guidance and feedback.
It can be frustrating and counterproductive for interns if they feel they are interrupting
You. Having a set time to discuss their work will increase efficiency and productivity.
Consider interns as “real” employees and teach them about the values of the company.
It is critical that they go through an orientation and be given written policies if available.
It benefits the organization if they have a realistic view of the workplace.
Keep them in the organizational loop through emails, memos or staff meetings.
Occasionally, surprise the students with “perks” such as a coffee card, paid parking, or
Include them in office outings such as baseball games or picnics, etc. This helps them
Feel like a part of the organization and can boost morale.
Ask students if there are specific areas they would like to learn. When possible, arrange
“Personal learning opportunities” for one-on-one discussions with company executives
And key customers to help them begin building their professional network.
When possible, provide professional networking opportunities to help students gain
Additional insights into this career and also increase future employment contacts.
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Conclusion
In review this internship has been an excellent and rewarding experience. I have been able to meet
and network with so many people that I am sure will be able to help me with opportunities in the
future. One main thing that I have learned through this internship is time management skills as
well as self-motivation. When I first started I did not think that I was going to be able to make my
self-sit in an office for five hours a day, five days a week. Once I realized what I had to do I
Organized my day and work so that I was not overlapping or wasting my hours. I learned that I
needed to be organized and have questions ready for when it was the correct time to get Feedback.
From this internship and time management I had to learn how to motivate myself through being in
the office for so many hoursI will for sure want to work with this company and I am still keeping
my Options open for new Opportunities. I enjoy this line of work, I will continue to work hard in
my position and Hope to continue to learn about the industry and meet new people in future. This
was an excellent Experience for me.
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