D.G Khan Cement Company Limited (D G K C C), a unit of Nishat Group, is a second largest cement manufacturing unit in Pakistan with a production capacity of 5500-ton clinker per day. It has country wide distribution network and its product are preferred on projects of nationally repute both locally and internationally due to the unparalleled and consistent quantity. It is list on all the Stock Exchanges of Pakistan.

1. Internship Report
Submitted by:
Muhammad Haseeb Ahsan<16F-8351>
Department of Electrical Engineering
FAST-National University of Computer and Emerging Sciences CFD Campus
August, 2018

2. Contents
INTERNSHIP TRAINING SHEDULE:...................................................................................................3
INTRODUCTION: .....................................................................................................................................3
NISHAT GROUP: ......................................................................................................................................3
POWER PLANTS.......................................................................................................................................4
C.F.P.P:........................................................................................................................................................4
INTRODUCTION: .....................................................................................................................................4
WORKING:.................................................................................................................................................5
COAL CYCLE PROCESS: ...................................................................................................................5
WATER CYCLE PROCESS:................................................................................................................5
OVERALL WORKING:............................................................................................................................6
MAJOR PARTS: ........................................................................................................................................6
TRANSFORMER:..................................................................................................................................6
MOTORS AND FANS: ..........................................................................................................................6
TURBINE:...............................................................................................................................................7
GENERATOR: .......................................................................................................................................7
EMERGENCY GENERATORS:..........................................................................................................7
POWER UNIT:...........................................................................................................................................8
INTRODUCTION: .....................................................................................................................................8
WORKING:.................................................................................................................................................8
MAJOR PARTS: ........................................................................................................................................9
TRANSFORMER:..................................................................................................................................9
GENERATOR: .......................................................................................................................................9
W.H.R.P.P: ................................................................................................................................................10
INTRODUCTION: ...................................................................................................................................10
WORKING:...............................................................................................................................................10
MAJOR PARTS: ......................................................................................................................................11
BOILERS: .............................................................................................................................................11
PH (PRE-HEATER) BOILER: .......................................................................................................11
AQCH (AIR QUENCH CONTROL) BOILER:............................................................................12
KILN:.....................................................................................................................................................13
CONCLUSION:........................................................................................................................................13

3. INTERNSHIP TRAINING SHEDULE:
➢ C.F.P.P. (Coal Fired Power Plant)
➢ Power Unit.
➢ W.H.R.P.P. (Waste Heat Recovery Power Plant)
INTRODUCTION:
D.G Khan Cement Company Limited (D G K C C), a unit of Nishat Group, is a second
largest cement manufacturing unit in Pakistan with a production capacity of 5500-ton
clinker per day. It has country wide distribution network and its product are preferred on
projects of nationally repute both locally and internationally due to the unparalleled and
consistent quantity. It is list on all the Stock Exchanges of Pakistan.
D G K C C was established under the management control of State Cement Cooperation
of Pakistan Limited (SCCP) in 1987. DGKCC started its commercial production in 1986
with 2000 tons per day (TPD) clinker based on dry processes Technology. Plant and
Machinery was supplied by UBE industries of Japan.
NISHAT GROUP:
Nishat Group is one of the leading and most diversified business groups in South East Asia.
With assets over PRs. 300 Billion. It ranked amongst the Top five business houses of
Pakistan. The group has strong presence in three most important business sectors of the
region namely Textiles, cement and Financial Services. In addition, the group has also
interest in Insurance, Power Generation, Paper Products and Aviation. It also has the
distinction of being one of the largest players in each sector. The Group is considered at
per with multinationals operating locally in terms of quality of product and services and
management skills.

4. POWER PLANTS
Names MW (Mega Watts) KV (Kilo Volts) Fuel
CFPP 30MW 6.3KV COAL
Power Unit 26.3MW 6.3KV GAS
WHRPP 10.4MW 6.3KV HOT AIR GASSES
C.F.P.P:
INTRODUCTION:
C.F.P.P basically known as Coal Fired Power Plant. It has a Capacity of 30 MW and
Voltages of 6.3KV. It runs with the fuel of Coal which burns in boiler to produce steam
and this team is used to run the turbine blades for generation. There are three major things
which processes as per cycle to generate electricity. Block diagram shows all the three
processes in a systematic way.
Basically, CFPP is divided into some areas. There are Four Areas of CFPP named TG Area,
Boiler Area, Coal Mill Area, F.D.G Area (Flew Gas Desulfurization).

5. WORKING:
There are Two types of Cycles which process in all the CFPP plant. These Cycles are:
➢ Coal Cycle Process.
➢ Water Cycle Process.
COAL CYCLE PROCESS:
First of all, Coal is imported from a Foreign country named South Africa. It is then saved
into a coal shed 0-meter Area. It is a random shaped coal. The imported coal is almost from
500mm to 100mm.
There are eight Convere Belts which are used to take the coal to its coal mill Area from
BC1 to BC8. Each Convere Belt has a Gear box in which coal is shifted from one belt to
another. After the coal shed area, the coal is then shifted into the crusher building for
crushing to a particular size of 90mm per coal. It is then saved in the form of Stacker
(Pilings) and then Reclaimer is used to remove the layers of piling of crushed coal and
shifted it to the BC7.
In theBC7 & BC8 portion, there is a magnetic separator which is used to attract the metal
from the crushed coal to filter it into the pure coal. Now coal is then feeded into the coal
feeder through Hub for storage purpose only. This coal is then taken to the Grinder (as per
requirement) to grind it into a powder form. After the powdered form, the coal is taken to
the Boiler for Combustion and produce steam. This is the process of coal from imported
shed Area to the Boiler Area.
WATER CYCLE PROCESS:
First of all, Water is taken from the lake outside the Cement Factory. It is then
demineralized into the DEMI Area. There are three Methods used to demineralize the
water. These Methods are:
➢ Reverse Osmosis Method.
➢ Chemical using Method.
➢ Salt using Method.
The demineralized water is then stored into a storage tank for usage. There are almost 6
pre-Heaters used to heat the water as per requirements. These Heaters re:
➢ LP Heaters.
➢ HP Heaters.
➢ LT Heaters.
➢ HT Heaters.
The Heated water has a temperature of almost 150°C. It is then stored into a Deaerator.
After the Deaerator, the heated water is then taken to the Furnace Area of the Boiler to
evaporate it into the steam form. The steam has now a temperature of 545°C. This is then
taken to the Turbine to generate Electricity.

6. OVERALL WORKING:
The Working process of Coal and Water ends at a Boiler portion where the coal is fired
and the water is converted into the steam. The steam is then taken to the Turbine. Basically,
Turbine has 11 blades which are used to run with the pressures of steam.8 blades are a
High-Pressure Blades and 3 blades are a Low-Pressure Blades. Turbine has a 3000r.p.m
coupled directly with the Generator and exciter to produce Electricity of 30MW and 6.3KV
constant. The steam is then collected at the hot well and then shifted to the Condenser with
the help of condensating pumps to convert it into the water again for reuse. The condenser
is the water tube type condenser in which water is in the tube and steam or fire is outside
the tube. This water is then circulated to the Boiler with the help of feed water pumps to
use it again.
MAJOR PARTS:
Following are the major parts which are being used in the CFPP Plant. These parts are:
TRANSFORMER:
A Device which transfer Electrical power from one circuit to another to another
circuit without changing the frequency is known as TRANSFORMER.
There are Total nine transformers which are being used in the CFPP Plant. All the
transformers are STEP DOWN transformers. These transformers have their own
type with the specific purpose. The name and their types are given below:
Name Type KV(kilo
volts)
Ratings
(KVA)
Total
Nanjing Daqo Oil Type 660V 3150KVA 2
Yanghzhong
Zhongdian
Dry type 440V 2500KVA 5
MOTORS AND FANS:
A Device which converts Electrical Energy into Mechanical Energy is known as
MOTOR.
There are at least 14 motors and fans are used in the CFPP whole Plant.
Name Rated Power Rated
Voltage
R.P.M Connection Total
I.D Fan 220KW 400V 1480 Delta 2
F.D Fan 220KW 400V 1480 Delta 2

7. Ceiling Air
Fan
55KW 400V 1480 Delta 2
Primary Air
Fan
220KW 400V 1480 Delta 2
Circulating
Water Pump
88KW 400V 1480 Y 4
Feed Water
Pump
800KW 6.3KV 3000 Y 2
TURBINE:
A Machine which is used to generate the Electricity with the help of coupled generators.
The turbine has the following parameters:
Name Rated
Power
Rated
Temp.
R.P.M Rated
Pressure
Blades Company
Steam
Turbine
30MW 535°C 3000 9.6MPas 11 HangZou
Chinen
GENERATOR:
A Device or Machine which converts Mechanical energy into Electrical Energy. The
Generator has the following parameters:
Name Rated Power Rated
Voltages
R.P.M Rated
Current
Company
Coupled
Generator
30MW 6.3KV 3000 3436.6A HangZou
Hanfa
EMERGENCY GENERATORS:
A Device or Machine which converts Mechanical energy into Electrical Energy. The
Generator has the following parameters:
Name Rated Power Rated
Voltages
R.P.M Rated
Current
Phase
Diesel
Generator
800KW 6.3KV 1500 916A 3

8. POWER UNIT:
INTRODUCTION:
Power Unit is basically a Gas Power station which has 3 Gas engines which is used to
produce Electricity. It has a Capacity of 26.3 MW and Voltages of 6.3KV. It runs with the
fuel of Gas which burns in cylinders of engines to produce combustion process and this
process is used to generate electricity with the help of generator and exciter. There are three
major things which processes as per cycle to generate electricity.
There is also a Diesel Generator Engines which were used to produce electricity but now
it is going to shift at Karachi main HUB Station. These Engines have a capacity of 5.79MW
each. And a rated voltage of 6,6KV each. If we include these engines, then whole power
unit have a capacity of almost 44MW and 6.3KV.
WORKING:
Working of this power plant is very simple as it has only a gas engine which works with
the help of gas as a fuel and creates electricity. It has three WARTSILA Gas Engines of a
capacity of 8.79MW each. It has a Model no. 20V34SG and made in Japan Toyodonkey.
Firstly, the Gas is taken from the Compressor which has a Gas Regulating Unit. Then this
Gas is used in the engines to generate electricity. This gas is taken to the Cylinders of the
Gas Engines.
There are at least 20 cylinders in engine which are in like V shape. These cylinders are
divided into two sides (10 per each side). A side and B side. Each cylinder contains an
ignition Gun separately to burn the gas for combustion and also a PLC card of CCM10
(Cylinder Control Module) in each cylinder. After the Combustion, it produces force which
is used by the generator to generate electricity. The generator is coupled with the same
shaft and Exciter is also coupled for the generation of electricity.
There are at least 20 sensors which are used to sense the temperature of gas a combusted
fire. These sensors are connected with the PLC through CCM10 card to sense periodically
by the users. Corena 46 oil is used in the generators to run smoothly with the exciter.

9. MAJOR PARTS:
Following are the major parts which are being used in the Power Unit. These parts are:
TRANSFORMER:
A Device which transfer Electrical power from one circuit to another to another
circuit without changing the frequency is known as transformer.
There are Total nine transformers which are being used in the CFPP Plant. All the
transformers are step down transformers. These transformers have their own type
with the specific purpose.
GENERATOR:
A Device or Machine which converts Mechanical energy into Electrical Energy. The
Generator has the following parameters:
Name Rated Power Rated
Voltages
R.P.M Rated
Current
Company
AVK
Generator
8.79MW 6.3KV 3000 1000A AVK

10. W.H.R.P.P:
INTRODUCTION:
W.H.R.P.P basically known as Waste Heat Recovery Power Plant. It has a Capacity of
10.4 MW and Voltages of 6.3KV. It runs with the fuel of Hot air gasses which burns in
boiler to produce steam and this team is used to run the turbine blades for generation. There
are three major things which processes as per cycle to generate electricity.
Basically, WHRPP is divided into some areas. There are Three major Areas of WHRPP
named PH Area, Kiln Area and AQC (Air Quench Control) Area.
WORKING:
The working of this power plant is basically on the waste of heat of the cement mill area.
This cement heat is reused to produce electricity in the form of hot air gasses as a fuel.
First of all, the process of this power plant starts from the Raw material portion of the
Cement factory. The cement in the Raw material portion is in the powder form. The cement
is then taken to the pre-heater which heats the cement inti 350°C.
There is also a water cycle process in the WHRPP which is used as a steam in turbine
blades. The cycle starts from the flasher which is formally known as a storage tank of water.
With the help of Feed water pumps, the water is then shifted to the economize from the
flasher. The economizer has three basic stages.
➢ PH-2 Steam Drum
➢ AQC-2 Steam Drum
➢ Flasher.
PH-2 Boiler has vertical tubes in it so, a circulating water pump is used to flow the water
in these tubes. Then it is collected in the generator portion and then in the super heater
portion of the boiler to convert it into a dry saturated steam. Then it is collected in the Main
steam line.
AQC-2 Boiler has horizontal tubes in it so, no circulating pump is used in it as the water
flows with the help of Gravity. Then it is collected in the generator portion and then in the
super heater portion of the boiler to convert it into a dry saturated steam. Then it is collected
in the Main steam line.
After all the steam is collected in the steam line, the pressure of the steam is 1.88MPas and
temp is almost 365°C. The steam is then go through the MSV (Main Steam Valve) and

11. with the help of governor, the steam is taken to the Turbine Blades. Turbine has 11 blades
which are used to run with the pressures of steam.8 blades are a High-Pressure Blades and
3 blades are a Low-Pressure Blades. Turbine has a 3000r.p.m coupled directly with the
Generator and exciter to produce Electricity of 30MW and 6.3KV constant. The steam is
then collected at the hot well and then shifted to the Condenser with the help of
condensating pumps to convert it into the water again for reuse. The condenser is the water
tube type condenser in which water is in the tube and steam or fire is outside the tube. This
water is then circulated to the Boiler with the help of feed water pumps to use it again.
MAJOR PARTS:
Following are the major parts which are being used in the WHRPP. These parts are:
BOILERS:
There are almost 4 boilers used in the WHRPP. These boilers have their own type and
their own purpose. These are:
➢ PH (Pre-Heater) Boiler.
➢ AQC (Air Quench Control) Boiler.
PH (PRE-HEATER) BOILER:
Pre-heater Boiler usually a common water tube boiler which is used to boil the water into
steam and then this steam is used to generate electricity with the help of turbine blades.
Pre-heater Boiler can be categorized into two different portions. These are:
➢ Super Heater portion.
➢ Generator portion.
In Generator portion, the Hot water is circulated to burn the water into steam but it has
some moisture in it. So, in Super heater portion, the steam is converted into super saturated
steam with no moisture in it and it is then collected in the steam drum.

12. AQCH (AIR QUENCH CONTROL) BOILER:
AQC Boiler usually a common water tube boiler which is used to boil the water into steam
and then this steam is used to generate electricity with the help of turbine blades. Pre-heater
Boiler can be categorized into three different portions. These are:
➢ Super Heater portion.
➢ Generator portion.
➢ Economizer.
In Generator portion, the Hot water is circulated to burn the water into steam but it has
some moisture in it. So, in Super heater portion, the steam is converted into super saturated
steam with no moisture in it and it is then collected in the economizer and then in the steam
drum. Following Diagram and table shows the capacity and temp ratings of each Boiler.
Name Rated Temp. Rated Pres. Ton per Hour
AQC-1 350°C 1.88MPas 8.7
AQC-2 350°C 1.88MPas 13.4
PH-1 365°C 1.88MPas 12.2
PH-2 365°C 1,88MPas 20.7

13. KILN:
Kiln is basically a roller which has high temperature. in this plant, heat cannot be wasted but it
can be recovered.
There are two kilns in this WHRPP, Kiln 1 and kiln 2. It has a temp of 1300°C. This diagram
shows the structure of kiln.
CONCLUSION:
Electricity is one of the most important things in our daily life. It is one of the essential
components in almost every field of life. By doing this internship, I am able to know the
basics and works of machines used in the power plants and know how to deal with it if
any problem occurs. This helps me a lot in my career life.